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This entry was posted on September 23, 1999 by
Fuel Storage TheEpicenter.com.

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also sine wave AC power as well.

CUSTOMER REVIEWS Then again, it might not cost as much as you might think to
build your ideal system if you already have one of the key
components.

Erik P You might be one of those DIY-ers who might have a spare
October 28, 2017 engine sitting around and could use it to drive a generator
Great company to do b head without needing to purchase an expensive and
with. Competitive price
dedicated AC generator system. In some cases it could be
shipping.
less expensive to purchase the generator head and reuse an
engine from something else that you no longer have a need
for, or only need for a few months each year.

A good example would be a person who has a pressure

washer sitting around that has a large engine, possibly a high
quality and expensive one like a Honda. In that case you
could remove the pump assembly from your washer and
attach a generator head when needed in the winter, and in
the spring you could remove the generator head and
reattach the pressure washer pump assembly.

A better case could be made for

building a multipurpose power
generation system because it is not
something that you can currently buy.
In this application you might need to
charge of bank of batteries as an
example at the same time as having
some AC power available. In this application the same engine
can direct drive a generator head while belt driving an
alternator for DC charging purposes.

In general, when someone wants to charge a bank of

batteries there's often excess horsepower available which
could be used to run an AC generator head at the same time.
Or on the other hand, you might need AC power to make
repairs around the house with power tools, or you might
need to run the microwave, refrigerator or something, and
would like to charge your batteries at the same time.

Shown here at the left is a prototype of a project I'm

experimenting with for my own use.

The AC generator head is direct coupled to the Tecumseh 8

HP motor, and has a belt driven 12 volt alternator mounted
to our Horizontal generator bracket which is attached to the
motor. To get the full rated output of 6,000 W peak from the
generator head, this particular motor is under powered. To
develop the full rated output power from this head, the
engine should really be a 10 HP model like the HM100, or
better yet an 11 HP model for a bit more headroom. Of
course running an alternator exclusively on this engine is an
example of overkill but the combination of the lower output
of AC at the same time as DC is available makes for a fairly
e cient use of fuel and resources.

In my application, I don't require more than 2500 watts of AC

power which would normally require about a 5 HP engine.
The remaining 3 horse power can be devoted to the DC
charging subsystem using the attached alternator.

Here is another view where you can see the direct drive and the
belt drive components.
Let's take a look
at what's really
required to
make this
generator head
produce AC
power for speci c output current levels.

For full power, an 11 HP motor is speci ed by the

manufacturer but other motors could be used if you do not
violate the general rules outlined below. Trying to draw more
power than shown below using an under rated engine
horsepower rating will result in the generator producing an
AC voltage lower than the speci ed output. In some cases
this could cause a "brown out" condition which could result
in electrical damage to the devices being powered. Special
precautions should be taken to ensure that the example
horsepower ratings and output power or levels below are
not violated.

Engine size required (for

AC generator output example purpose)

6000W peak, 5000W continuous 11 Horse power

(full rated AC output, no DC)

5000W peak, 4000W continuous 8 Horse power

3000W peak, 2500W continuous 5 Horse power

So, if you are using an 8 HP motor with this AC generator

head and can insure you never will use more than say
2500W of AC power, then there is enough horse power left
to be able to belt drive a 12 volt alternator running at say 40
amps (14.4 volts x 40 amps = 576 Watts) with some head
room when belt driven o the same shaft.

Although the manufacturer speci cally states that to develop

the full rated output an engine size equivalent to eleven
horsepower is required, smaller versions of this generator
head produce lower continuous ratings shown in the table
and require less horsepower. We have extrapolated the data
shown from the speci cations for the smaller generator
heads, and although the larger 6000W peak head has more
mass in the rotor, we would realistically expect that it doesn't
require that much additional power to spin the rotor
especially since sealed ball bearings are used on both ends
of the head.

I guess what I'm trying to say is that if you can guarantee that
you would never try to pull too much AC from the generator
head, then even a small engine will not bog down and there
would be extra horsepower available for other uses like
running an alternator as shown in the prototype.

So, let's discuss some of the issues

Typical Gas engines rate their horse power at 3600
RPM.
If the motor is used at speeds
below that rating, the engine
does not develop full rated
output torque and horse
power.

However, running an engine

at a lower RPM increases fuel
e ciency and decreases wear
and tear so there are always trade o s.
 You should also note that these
rotates in counter clock wise
direction as viewed from the
output shaft side of the
motor. This is something that
will come up again!

Because most engines are

rated at 3600 RPM, you will
note that many generator heads are also designed to be
rotated at 3600 RPM.

If you attempt to run the AC

generator head a speeds
below the rated RPM of 3600
in this case, the AC output
voltage will not be 120 volts,
but will be a lower value.
Some equipment you intend
to power may be more forgiving about the lower voltage,
some equipment might be damaged, so it is critical that you
spin the generator at the correct RPM.
More discussion on setting the RPM of the engine and
generator head can be found in the next section.

You will also want to note that the generator heads shaft
needs to rotate in a clockwise direction as viewed from the
shaft side of the generator head. So, place the shafts facing
each other and guess what? Both the motor and the
generator head rotate in the correct directions. This allows
for direct driving the generator head by using a shaft
coupler.

Now, let's talk about Connecting the Motor to

the Generator Head
Q: How do you direct drive a
generator head with an
engine?
A: Direct drive shaft coupler
assembly.
To connect the output shaft of a motor
to a generator head input shaft (or
anything else), a special shaft coupler
is required. Basically, three pieces are
needed.

Select a coupler half that is the correct

size to t the motor shaft (or driving shaft size), then select a
coupler half that is the correct size for
the generator head (or Driven shaft
size).

Then the two shaft couplers are joined

using what is called a spider.

Notice that the shaft couplers each have 3 ngers and the
spider has 6 slots. The three ngers from the motor side t
into three of the spider slots, and the three ngers from the
generator side coupler t into the other three slots on the
spider. This coupler assembly allows for several degrees of
misalignment between the two shafts and protect the
bearings from seeing side loads that would result from
misalignment.

These couplers are available in a bunch of sizes. Several sizes

are available at TheEpicenter.com.

Q: When you're building your own AC generator using a

gas engine and an AC generator head, how do you set up
the combination so that the system produces the correct
output voltage, and turns the generator head at the
correct speed?
A: There are two approaches that can be taken:
Measure the AC voltage to adjust the
engine RPM.

This AC volt meter plugs directly into

any AC outlet and displays the
measured voltage without the need to
use a hand held DVM and jam probes
into an AC outlet. The meter features a
built-in AC plug on the back side.

Voltages within the standard 115 to 125 volts range are

highlighted in green indicating acceptable voltage
parameters. Voltages out side of those ranges are indicated
in red. This meter provides an easy to read indication of the
generator output voltage.
Measure the engine RPM with an
inductive Tachometer, and also know
when to change the oil!
This device allows you to monitor and
set the engine rpm such that it rotates
at the speci ed RPM required by the
generator head. This is an RPM
(revolutions per minute) meter or tachometer. It inductively
connects to the spark plug wire and senses the rate at which
the spark plug res over a given time period. The resultant
measurement is displayed in revolutions per minute. The
engine rpm can then be adjusted until the speci ed RPM of
the generator head is achieved. If the RPM is adjusted to the
manufacturers speci cation for the generator head, the
rated output of the generator would then be 120/240 volts
depending on the construction and speci cations of the AC
generator head.

The unit shown also keeps a running total of engine usage

and display the number of hours and minutes the engine has
operated. While the engine produce a Spark, the RPM is
displayed. Once the engine stops running the total time the
engine has operated in terms of hours and minutes is
displayed. One thing to note about this Tac is that the hour
meter can not be reset. However the cumulative run time
displayed is extremely useful in deciding when you need to
perform regular maintenance such as oil changes.

Engines that don't turn at 3600 RPM

Q: What if I have an engine that doesn't turn at 3600
RPM? Can a generator head like this be used somehow?
A: Yes! But it's a bit more complicated.

Belt Drive Con guration

This generator head is designed with dual ball bearings to

allow belt drive applications.

In this con guration, the generator bearings see a high side

load and not all generator heads are built with the required
bearings to handle this side load. However, the generator
head we use is designed to handle the job.

Here is how you would gure out what size pulleys to use:
Ratio of RPM = Ratio of pulley size

In more detail:
Engine RPM / Generator RPM = Generator pulley size /
Engine Pulley size.

So, knowing the generator needs to rotate at 3600 RPM, next

de ne what speed the engine needs to run at. This ratio will
determine the ratio of pulleys required.

Let's say for example that the engine is a Diesel that needs to
run at 1800 RPM for full rated torque. Then plug the values
into the equation and you get:

1800 RPM / 3600 RPM = 1/2 = Generator pulley size / Engine

Pulley size.

So, what ever size pulley is selected for the generator, the
engine pulley size must be 2 times that size.

The selection of pulley size is also complicated by the fact

that not all pulleys are available in all shaft diameters. And,
the outside diameter of pulley sizes is not always the
e ective diameter when using one style of belt as opposed
to using another style of belt. Since belts of di erent styles
ride higher or lower in the groove of the pulley, the e ective
diameter of the pulley can change if another type of belt is
used, but the e ect is seen on both pulleys so the ratio of
pulley size is still applicable for most applications.

If you are unable to de ne a pair of pulleys that are

standard, available and give you the exact ratio, then there
are three choices:
1. You could use what is called a "variable pitch" pulley,
which is a pulley that allows the width of the groove to be
adjusted. They are very specialized and a bit expensive. Since
the belt is a xed width, adjusting the width of the "variable
pitch" pulley causes the belt to ride higher or lower in the
groove, thus e ectively adjusting the "pitch diameter" of the
pulley. I mention this only for academic reasons (so some
smart ass out there doesn't beat me to the punch) because
the other choices below are simpler.

2. Use the pair that give you the least ratio error, and then
adjust the throttle of the engine to compensate. This method
can not be performed by simply using a tachometer without
doing some computations to correct the tac reading. A better
choice would be to use a volt meter and adjust the throttle
until 120 volts output from the generator is achieved.

3. You could use an intermediate shaft and a combination of

two pulley ratios. This option is only needed in EXTREME
cases where the ratio is such that no combinations come
close, or you don't have access to pulleys that t one of your
shafts. I'm not going to discuss this much as it gets a bit
complicated, but there is an example of an intermediate
shaft being used below.

We put together the table below to help you nd pulley sizes

that are considered standard in the industry. We don't stock
all these sizes but can special order one for you if you can't
nd one locally that ts your need. The cells marked with "X"
indicate that a pulley is available in the combination of shaft
and diameter. Cells that are blank (or black depending on
your browser) indicate that a pulley is not typically available
in that combination of shaft size and diameter.

Notice that the "pulley size" shown below is the outside

diameter. The actual pitch diameter depends on what belt is
used. For example if an "A" style belt is used, they ride down
in the groove such that you can subtract 0.25" from the size
shown.

Shaft size

Pulley size 1/2 inch 5/8 inch 3/4 inch 7/8 inch 1 inch

1.75 X X - - -

2.00 X X X - -

2.20 X X X - -

2.50 X X X X -

2.80 X X X X -

3.05 - X - X -

3.45 X X X X -

3.75 X X X X X

3.95 X X X X X

4.25 - - - X -

4.45 X X X X X

4.75 - - - X -

4.95 X X X X X

5.25 - - - X -

5.45 X X X X X

5.75 - - - X -

5.93 - X X X X

6.25 - - - X -

6.93 - X X X X

7.93 - X X X X

8.93 - X X X X

9.93 - - X X X

10.93 - - X X X

11.93 - - - X X

13.25 - - - - X

14.16 - - - X X

Here is a practical example of using intermediate shaft

and dual pulley arrangement
In the example shown, I was attempting to convert an
induction motor into a generator (that's something that is
outlined in the booklet "alternator secrets"). The motor on
 the left is a one
hoarse power
motor which
turns at 3,450
rpm when
powered with 120
VAC and the
motor to the right
is an induction motor that runs normally at 1725 rpm.

For testing purposes, I wanted to use the motor on the left to

spin the motor on the right at the correct speed so but I
could test the conversion of the induction motor, and verify
the output voltage. However, the motor on the right had a
very small pulley which was frozen on the shaft and there
was no way to remove it. My original plan was to remove the
pulley and put a multi step pulley on both motors so I could
achieve the gear reduction from a 3450 rpm driving motor
through one belt to the 1725 rpm motor. That would require
having a pulley one-half the size on the faster motor as the
pulley size on the slower motor. Like I said, I couldn't get the
pulley o the motor on the right.

So, what I ended up doing was to drive the motor on the

right through an intermediate shaft which had a multi step
pulley on it. The two pulleys were of equal size so the speed
on the intermediate shaft would be exactly the same as the
speed of the motor on the right side. Next I placed a multi
step pulley on the motor which normally turns at 3,450 rpm
(the left motor) and belt drove that to a pulley groove on the
intermediate shaft that was twice the size. So for each
revolution of the motor on the left, the intermediate shaft
would rotate 1/2 of a revolution which would cause the gear
reduction from the left motor to the right motor to be exactly
one-half. Thus, when the motor on the left rotated at 3450
rpm the motor on the right would rotate at 1725 rpm.

Let's pretend that I could have installed the correct size

pulley on both motors in the rst place. And lets pretend the
motor on the left is a gas engine and the motor on the right
is a generator head. Then, the situation is best shown with
an equation:

Ratio of RPM = Ratio of pulley size

In more detail: Engine RPM / Generator RPM = Generator

pulley size / Engine Pulley size.

Knowing that I needed the engine to run at 3450 rpm and

the generator to run at 1725 rpm, then... 3450 RPM / 1725
RPM = 2
Then say I've got a 2" pulley that ts the engine side, that
means that the generator side needs to be twice as large, or
4".

Let's Take Another Belt Drive, for example

Here is an old Onan AC generator
head. This beast needs to rotate
at 1800 rpm to deliver 120/240
volts AC. Most of the small
gasoline engines you'll nd have
their rated horsepower output
speci ed at 3600 rpm. Knowing
that the engine rpm must be at
3600 to develop full horsepower
and also knowing that the Onan generator head needs to
rotated 1800 rpm it becomes obvious that we can't just
direct drive this particular generator with a gasoline engine.
Some form of speed reduction is required.

For this application the same formula applies and is shown

below:

Engine RPM / Generator RPM = Generator pulley size /

Engine Pulley size.

Knowing that we would need the engine to run at 3600 RPM,

and the generator to run at 1800 rpm, then... 3600 RPM /
1800 RPM = 2

Since I had a 3" pulley already for the engine, I needed to

determine the pulley size that would be correct or the
generator shaft. Again, from the above equation:

2 = Generator pulley size / 3"

So, the Generator pulley size would need to be 6".

Wiring it up
The advantage of using the AC generator head in this project
is that the AC connectors are pre wired to connectors on the
back of the head. There are two connectors, one for 120 volt
and one for 220 volt, each having two outlets.

One 120 volt Duplex (two outlets) 20A Receptacle, 5-20R

One 240 volt Duplex (two outlets) 15A Receptacle, 6-15R
The DC section can be wired several ways depending on
what type of alternator is selected.

The wiring depends on which alternator you choose. All

three alternator types are shown.

Do not wire the alternator unless you are sure about what
 type you are using. If you make a mistake in the selection of
the alternator or wiring diagram you run a very high risk of
damaging your battery, electronic devices, or worse yet
causing personal injury! Consult a parts professional for
additional information!

This article is intended for educational purposes only. No

guarantees are expressed or implied as to the accuracy of
information presented here! Consult with an automotive
wiring expert before attempting to carry out any wiring.

One nal note: If you are using an alternator that requires an

external switch, you will need to turn o the switch prior to
attempting to start the generator. Once the motor is running,
the switch can be set to the on position.

Special parts used in many of our power

related tips are available here at
TheEpicenter.com!
Parts needed for the Horizontal Shaft Generator Project
Parts needed for the Vertical Shaft Generator Project
Parts needed for the Direct Drive Generator Project

This entry was posted in Generators & Emergency Power,

ARTICLES & TIPS on September 23, 1999 by
TheEpicenter.com.

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