Portable L2 charging

[stevon 0]

Portable charging at L2. After getting stuck and towed 300 yards to my friends house decided I needed a portable emergency charge solution on board the car, sort of a spare tire which is another project. Looking for portable generators at 240 volt the list gets short here in America. Found one, a Pramac S2800 http://www.zoro.com/pramac-portable-generator-rated-watts2400-160cc-s2800/i/G8491594/?utm_source=google_shopping&utm_medium=organic&utm_campaign=Google_Shopping_Feed&KW3&gclid=CJmWyN-13cUCFQ8waQod5pwAhg&gclsrc=aw.ds

Desc:

Portable Generator, Rated Watts 2400, 160cc

by PRAMAC

Technical Specifications

Zoro #: G8491594 | Mfr #: S2800

Fuel Tank Capacity: 0.45 gal. Fuel Type: Gasoline

Run Time Hour Meter: No Cylinder Material: Cast Iron

Engine Alternator: Mecc alte Outlets: (1) 120V 5-20R

Voltage: 120 Engine Size: 160cc

Standards: EPA Height: 16-5/8"

Warranty: 3 Month Commercial Use Sound Level dB: 74

Run Time @ Full Load: 2 hr./Tank Run Time @ 1/2 Load: 2.6 hr./Tank

Circuit Breaker: Yes Width: 14-3/8"

Engine Brand: Subaru Engine HP: 6

Length: 21-3/4" Full Power Switch: No

Low Oil Shut Down: Yes Surge Watts: 2800

Rated Watts: 2400 Starter Type: Recoil

Amps @ 120/240V: 20/10 amps

Air Cleaner Type: Paper

Item: Portable Generator Zoro Number: G8491594

Mfr Number: S2800

Product Description

Portable Generator, Rated Watts 2400, Surge Watts 2800, Engine Brand Subaru, Voltage 120, 20/10 Amps @ 120/240V, Circuit Breaker Yes, Engine Size 160cc, Engine Alternator Mecc Alte, 2 hr./Tank Run Time @ Full Load, 2.6 hr./Tank Run Time @ 1/2 Load, Sound Level dB 74, Engine HP 6, 0.45 gal. Fuel Tank Capacity, Recoil Starter Type, Air Cleaner Type Paper, Low Oil Shut Down Yes, Length 21-3/4 In., Width 14-3/8 In., Height 16-5/8 In., Full Power Switch No, Gasoline Fuel Type, Outlets (1) 120V 5-20R

Some modifications were needed for my application, Unit arrives set up tor 120 volt only with both coil outputs tied together on a 1 pole 20A circuit breaker.

Removed the 20 amp circuit breaker and separated the generator coil outputs then rewired for 240 volt output. (see Mecc Alte diagram)

Picked up a double pole circuit breaker: http://www.ebay.com/itm/201185736018?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Then added a right angle cable clamp from the hardware store to the back cover with a L14-20 female plug and some cable.

http://stevon.myevblog.com/wp-admin/upload.php

My calculations of load being 8 amps@ 240 volt + 1920 watts total. purchased a portable EVSE charging station kit http://store.openevse.com/products/openevse-30a-standard-charge-station-combo

(clear cover my modification)

It accepts available input voltage from 100 to 250 volts, switches upon detecting voltage and communicates via the SAE J1772-2001 standard protocol through the J177 cable. EVSE charger sets voltage and available amps on the vehicle's onboard charger. plugged in open EVSE charger, connected generator, set dashboard current to 8 amps for a test, started generator and let her rip!

N.G. Problem, generator voltage dropped to 200 volts and car disconnected EVSE. Gen sped back up, voltage returned to 248, car re-engaged charge, then 1 minute later, same scenario ~ loop! WTF! Looked into non-linear loads and harmonic distortion as the possible problem and solutions for it. Bad power factor? Harmonic Distortion?

http://en.wikipedia.org/wiki/Power_factor and a possible solution https://www.youtube.com/watch?v=worppwXhezI and https://www.youtube.com/watch?v=dPFKcUxbNuQ . In order to solve this problem I needed precise information to make calculations and to arrive at precise values to purchase parts and design a solution. What was needed was a power analyzer like a Fluke 43B meter. At $1600 dollars a little pricey for one project. Decided on a used meter found in Bakersfield CA. for $300, He wanted cash only, face to face, living in San Diego 400 miles + away, that was impractical. Talked him into a postal money order and it arrived last Friday. As a test made a "bread board" for easier measurements See picture

hooked up meter, connected the car to house current then started a charge session with dashboard current set to 8 amps. Load seemed quite linear at 240 volts, 0.99 Power Factor with 12 percent THD. A puzzle, why did the generator overload? Second test, connected car, generator and openESVE charger, set dashboard current to 8 amps for the test, started generator and it loaded down again! meter read 14 amps @ 240v or 3360 watts! No wonder 2800 max watt generator bogged down. the open EVSE charge station allows you to program amps so I reset station from default 16a to 10a @ 240v and the car charged OK (no stalling) on the generator @ L2 2.4 kwatts. PF is 0.98 @ 12percent THD! SUCCESS :mrgreen: Next concern was that if involved in an accident Gen would cruise through the cabin if it was not secured. Chose vinyl coated 1/4 inch aircraft cable and a lock to secure generator to the car with an antitheft side benefit as well. Generator stock cradle had to be modified with some steel and welding.

Total cost in parts was less than $700.00 US

Edited June 11, 2015 by stevon