Dock Lines - Thought Solicitation
 

On Thu, 4 Feb 2010 13:37:14 -0800 (PST), Tim
wrote:

Good news this morning on the alternator. *It came back repaired and
working. *


Great! I was wondering what ever came of that episode. What kind of a
unit is it? a Powerline or Lestek? Just guessing,. Those makers
specialize in extremely high output units in automotive
configurations.

I'm not sure who actually made the alternator but it is based on a
Delco CS-144 (large case, 2 inch foot), and then beefed up with heavy
duty stator windings and extra diodes:

http://www.alternatorparts.com/Extreme%20Duty%20Dual%20Rectifier%20CS-144%20type.htm

It was supposed to be good for 200+ amps but I was never able to get
more than about 150 out of it before the voltage started sagging off.
The local guy here replaced the stator coils with whatever he had on
hand, nothing special it appears, and it now looks like it is good for
about 110 amps or so. I'm OK with that as long as it is durable. The
stock Delco that they use in Chevy pickups and Suburbans is rated at
124 amps but the local NAPA place couldn't get one in a reasonable
time.

Dock Lines - Thought Solicitation
 

On Feb 4, 4:15*pm, Wayne.B wrote:
On Thu, 4 Feb 2010 13:37:14 -0800 (PST), Tim
wrote:

Good news this morning on the alternator. *It came back repaired and
working. *

Great! I was wondering what ever came of that episode. *What kind of a
unit is it? a Powerline or Lestek? Just guessing,. Those makers
specialize in extremely high output units in automotive
configurations.

I'm not sure who actually made the alternator but it is based on a
Delco CS-144 (large case, 2 inch foot), and then beefed up with heavy
duty stator windings and extra diodes:

http://www.alternatorparts.com/Extreme%20Duty%20Dual%20Rectifier%20CS...

It was supposed to be good for 200+ amps but I was never able to get
more than about 150 out of it before the voltage started sagging off.
The local guy here replaced the stator coils with whatever he had on
hand, nothing special it appears, and it now looks like it is good for
about 110 amps or so. *I'm OK with that as long as it is durable. *The
stock Delco that they use in Chevy pickups and Suburbans is rated at
124 amps but the local NAPA place couldn't get one in a reasonable
time.


Wayne, if your alternator is modified to a 'self-exciting' or 'one-
wire' system, that's possibly where your problem was. it seems that
regardless of brand, the SE volt regulators are known to have a
voltage drop where you can't get a good full load out of the unit. or
you need a slightly smaller alt. pulley. (too small is harsh on the
belts, though)

Those items might explain the 150a. before the voltage drop. Or the
builder isn't accurate with their rating claim.

Dock Lines - Thought Solicitation
 

On Thu, 4 Feb 2010 15:51:04 -0800 (PST), Tim
wrote:

It was supposed to be good for 200+ amps but I was never able to get
more than about 150 out of it before the voltage started sagging off.
The local guy here replaced the stator coils with whatever he had on
hand, nothing special it appears, and it now looks like it is good for
about 110 amps or so. *I'm OK with that as long as it is durable. *The
stock Delco that they use in Chevy pickups and Suburbans is rated at
124 amps but the local NAPA place couldn't get one in a reasonable
time.


Wayne, if your alternator is modified to a 'self-exciting' or 'one-
wire' system, that's possibly where your problem was. it seems that
regardless of brand, the SE volt regulators are known to have a
voltage drop where you can't get a good full load out of the unit. or
you need a slightly smaller alt. pulley. (too small is harsh on the
belts, though)

Those items might explain the 150a. before the voltage drop. Or the
builder isn't accurate with their rating claim.

Tim, you raise an interesting issue because it is in fact a self
exciting, internally regulated alternator. On the other hand it
failed prematurely even running at less than rated output so it's
entirely possible that I'll eventually need to bite the bullet and
spend the big bucks for an industrial strength J-180 type with
external regulation. I'll have to re-engineer the mounting bracket on
the engines however to do that.

I think my pulley size is OK because it does reach a point where
increasing the engine RPM no longer increases the alternator output.
I'm running dual Gates XL belts and they seem to be holding up pretty
well.

Dock Lines - Thought Solicitation
 

On Feb 4, 7:35*pm, Wayne.B wrote:
On Thu, 4 Feb 2010 15:51:04 -0800 (PST), Tim
wrote:



It was supposed to be good for 200+ amps but I was never able to get
more than about 150 out of it before the voltage started sagging off.
The local guy here replaced the stator coils with whatever he had on
hand, nothing special it appears, and it now looks like it is good for
about 110 amps or so. *I'm OK with that as long as it is durable. *The
stock Delco that they use in Chevy pickups and Suburbans is rated at
124 amps but the local NAPA place couldn't get one in a reasonable
time.

Wayne, if your alternator is modified to a 'self-exciting' or 'one-
wire' system, that's possibly where your problem was. it seems that
regardless of brand, the SE volt regulators are known to have a
voltage drop where you can't get a good full load out of the unit. or
you need a slightly smaller alt. pulley. (too small is harsh on the
belts, though)

Those items *might explain the 150a. before the voltage drop. *Or the
builder isn't accurate with their rating claim.

Tim, you raise an interesting issue because it is in fact a self
exciting, internally regulated alternator. * On the other hand it
failed prematurely even running at less than rated output so it's
entirely possible that I'll eventually need to bite the bullet and
spend the big bucks for an industrial strength J-180 type with
external regulation. *I'll have to re-engineer the mounting bracket on
the engines however to do that.

I think my pulley size is OK because it does reach a point where
increasing the engine RPM no longer increases the alternator output.
I'm running dual Gates XL belts and they seem to be holding up pretty
well.

If that's thee case I'm sure it blew a diode and probably burned the
Stator. Wayne, can you run an exciter wire for a regulator connector
plug? actually any key operated 12'v hot source would do. That is,
excluding the starter solenoid switch.

No need to go with a J-mount. We can go with that same CS 144 design
and take it up to a respectable standard 160a rating on full load with
about a 185a. max. 14.7 volt, with a drop to a minimum of 13.9v at
full amp output.

not hard to do. but still need a key ign. source.

Dock Lines - Thought Solicitation
 

On Thu, 4 Feb 2010 17:55:57 -0800 (PST), Tim
wrote:

No need to go with a J-mount. We can go with that same CS 144 design
and take it up to a respectable standard 160a rating on full load with
about a 185a. max. 14.7 volt, with a drop to a minimum of 13.9v at
full amp output.

not hard to do. but still need a key ign. source.

Something like that might be interesting although I'd prefer a
regulated voltage of 14.2 to prevent cooking the batteries too badly.
We are talking about more or less continuous operating conditions,
sometimes for 48+ hours non-stop, and I need an alternator that can
run reliably in that kind of environment at close to full power.
Ambient temperatures are on the toasty side also with the alternators
literally inches away from the blocks which are at 180 degrees.

The engines each have an on/off switch which I could trace out and tap
into if need be, although I'd rather not.