Author Topic: TDI as generator (Read 5962 times)

aidan · « **on:** March 23, 2008, 10:27:38 am »

any thoughts on an ahu mtdi as generator on wvo, needing to run 1500rpm/50Hz 24/7?

I see dynos of tdis running about 30bhp at this rpm, or 22kw.

It would run on a 11mm mtdi pump, probably 205s if needed, smaller turbo (thinking K35 off corsa 1.3, c2 1.4 or renault 1.5) as i think a gt15 would be a bit slow boosting at 1500rpm. I think maybe this setup could give 40bhp/29.4kw at 1500rpm?

I think though that maximum needed would only ever be maybe 10kw peak for a few hours a day dropping to maybe 1-2kw 50% of the time, and maybe only 500w for 30% of the time.

Needs to run WVO, I suggest running all day to keep the wvo warm and circulating. maybe doesn't need a turbo?

snakemaster · « **Reply #1 on:** March 23, 2008, 11:07:37 am »

i think a sdi would be beter for this, if the engine runs at 1500rpm with very little load for a long time it will glase the bores, a 1.6 d would do the same job and cheaper to get , my 2pence worth

aidan · « **Reply #2 on:** March 23, 2008, 11:20:11 am »

Thats pretty much what I thought, though I already have the ahu block (no head) and the mtdi pump.
I could probably just put a tdi head on and run no turbo, I was just concerned about smoke with a sudden load, but I guess its not actually much load for the engine.

hillfolk'r · « **Reply #3 on:** March 26, 2008, 08:13:58 pm »

Quote from: "snakemaster"

i think a sdi would be beter for this, if the engine runs at 1500rpm with very little load for a long time it will glase the bores, a 1.6 d would do the same job and cheaper to get , my 2pence worth

gens run at basically 2 speeds
if you have a 4 pole rotor,itll run at 1800,or 1500 for 60,or 50 hz
if you have a 2 pole rotor,itll run at 3600,or 3000 for 60,or 50 hz

if you can figure your hp out at 1500,then you can size a gen to your engine
you wont glaze bores etc,,but i bet you will have to drastically reduce your turbo size so itll spool at 1500
a tdi would rock the house
from my gen experience,im thinking you could run a 15kw,maybe a 20kw gen ,,,,probably 15 if you are lucky
basically 746 watts = 1hp
or,1kw(1000watts) is "about" 1.3hp
its nice having a 4 pole rotor gen,cause the engine runs nice and slow,3600rpms suck too loud

food for thought
a kohler standby gen i can think of is a 10kw unit that uses a ford 1.3(same family as the old ford fiesta)
of course if you get a 2 pole rotor,you can run it faster,and get more hp to run a bigger gen

IMO,a tdi could do a 10kw gen not too badly at all
and gen control modules for auto start(and crank disconnect) are cheap for around 300$ or less

just gotta adapt the engine to bolt to the gen

heres some gen pics

this is an 80 kw onan with a ford 460 on LP and turboed
it runs 1800 rpm

15kw katolight with a nissan 2.4 engine(1800rpm)

stay with 1500rpm for less noise

aidan · « **Reply #4 on:** March 27, 2008, 01:42:56 pm »

Its definitely a tdi I want for this, a 1.6d would need a metal HG putting on it, a 1.9d/td would need the crank pulley sorted and the tdi is more economical and more easily available.

Wasn't intending on an auto changeover as it'd be the only source of power rather than back up.

Just need to find a decent alternator for it, 12kw seems a commonly available size, and i'm sure it must be better for the engine to only put out around that power so it can be maxed out occasionally than to have it make 20kw and never go past 50%

shortysclimbin · « **Reply #5 on:** March 28, 2008, 08:32:13 am »

hillfolk'r that gave me flash backs to work!

I would agree with everything you said. And.. I would add I would suggest enclosing the unit to reduce noise and to offer better cooling through the system. I would suspet the tdi motor also wouldnt mind driving the fan right off the acc belt either...

jtanguay · « **Reply #6 on:** March 28, 2008, 03:45:02 pm »

Quote from: "aidan"

Its definitely a tdi I want for this, a 1.6d would need a metal HG putting on it, a 1.9d/td would need the crank pulley sorted and the tdi is more economical and more easily available.

Wasn't intending on an auto changeover as it'd be the only source of power rather than back up.

Just need to find a decent alternator for it, 12kw seems a commonly available size, and i'm sure it must be better for the engine to only put out around that power so it can be maxed out occasionally than to have it make 20kw and never go past 50%

the 1.9 crank issue is due in part to the alternator putting back force onto the crank pulley. in time the back force eventually hammers the crank enough to make it loose and then bam. i doubt that the crank issue would happen when running it as a generator. unless you're constantly changing rpm's like someone driving in town.

Tintin · « **Reply #7 on:** March 28, 2008, 07:01:28 pm »

The most important thing with this project is the engine speed controller for industrial application, when the engine needs power, that take a mechanism to allow more fueling to keep a steady RPM, like a lawnmower engine, (brigg & stratton)

A stock 4BT pump with a modified throttle spring, ''softer spring'' to regulate the engine at a steady 1500rpm at full throttle.

A conventional pump at 1500RPM (1/4 throttle) do not give enough fuel to produce a good power, the dyno you see It is at full throttle.

aidan · « **Reply #8 on:** March 29, 2008, 09:19:50 am »

I know it goes against what i've already said, but what about this one?

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1&item=260224771208&ssPageName=STRK:MEWA:IT&ih=016

Looks like a 60bhp td by the sticker and plate, but it runs at 3000rpm. Assuming this is a 1.6, what would the consumption be compared to a tdi at 1500 rpm?