All right, Hahah how is the battle of good and bad about the Honda 2000 coming along
Well, I was busy all day long trying to sort out all the useful BUILT IN and separating it from the Honda 2000..
Of course that takes a little more time to read but I also hope You understand how much time it takes to wrap up 24 pages of caos to one half way clear and compact DOC FOR INTERESTED PERSONS about the topic.....
HONDA 2000 BUILT IN
So here is my promised STAGE Nº 3 with
ELECTRIC START INSIDE
DESIGN CHARACTERISTICS, GUIDELINES and OBJECTIVES
Gasoline evaporates when exposed to the atmosphere but the vapors are not lighter than air. Because gasoline vapors are heavier than air they sink through the normal atmosphere. Volatile, Flammable, EXPLOSIVE amounts of from now on referred to in TERMS of FUEL VAPOR TRAILS can therefore collect in the
bilge and any space below
deck while undetected and nearby remain unaware.
To avoid any such direct risks that the Honda 2000 and STORING GASOLINE represent it is thereby not encouraged to use any space like lockers above deck or below with direct access of ANY kind. Leaking fuel vapor trails can flash back, ignite and cause explosion.
For gasoline
storage tanks/containers with approved labels and with their own individual shut off valve are required.
As with any fuel type Diesel,
Propane used on pleasure crafts effects of inhaled Gasoline Vapors represent a further risk to
health due to there chemical composition as being carcinogenic, cytotoxic, meaning cause of posible damage to cells.
Under those considerations the terms "BUILT IN / INSIDE" as proposed are limited further to the definition of PORTABLE GENERATORS to:.....
!!! NOT electrically hardwired, fuel plumbed, hard mounted and that You can not take at any given time of the boat !!!
and should thereby be taken under consideration when building such a
DIY enclosure as from now on used in TERMS OF
DOCKING STATION for the Honda 2000 generator to guarantee immediate elimination of risks in case of
emergency by removing the entire
Docking Station or the Honda 2000 as required.
For further orientation on design features,handling and evacuation of GASOLINE FUEL VAPORS and TRAILS here You can find additional info on......
Page 9 Quote 128 & 134
Page 17 Quote 251 & 252 and here .......
>
https://www.uscgboating.org/regulati...ENTILATION.pdf
>
https://law.resource.org/pub/us/cfr/....H-02.1989.pdf
Natural venting principals MUST be applied in design to use lowest point of such Docking Station to guarantee natural evacuation of fuel vapor trails when Generator is not in use.
Assisted venting in form of explosion proof rated blowers with sufficient CFM capacity according to Volume of space MUST be used with unrestricted airflow to the outside atmosphere to guarantee evacuation of all fuel vapors when generator in use.
With
Electric Start a TIMER MUST be used to eliminate any posible risks of remaining fuel vapor trails BEFORE START UP of generator.
An explosion proof
electric motor MUST be installed when using with ELECTRIC STARTER
An spark proof flame arrester MUST be mounted on the carburetor and spark protection on
muffler MUST be installed if no further exhaust gas routing is intended.
A Test for leak free function of carburetor,
seals and all fuel lines between tank internal/external and generator MUST be performed.
Rated marine wire with protected terminals MUST be used for all connections used INSIDE/OUTSIDE the Docking Station.
A multiple
water proof main female connector MUST be installed on the OUTSIDE of the Docking Station to allow complete and fast disconnect in case of
emergency.
A wire harness should be used between with quick connectors to connect the docking station with the
electrical distribution box installed on the boat
Connection of all wires to the
electrical distribution box from the boat MUST have respective fuse protection
Individual connection of multiple plugs MUST be installed INSIDE the docking station in a way to allow maximum portability of the generator unit
as also ALLOW the total disconnection of all electrical support lines leading to/from the generator to the distribution box of the boat for
safety measures in case of emergency.
To further limit risks a fire distinguisher MUST be mounted close by with easy unrestricted access.
COOLING of the Honda 2000
PASIVE
COOLING is used for construction by All
Aluminum base plate (former referred to as Flat Surface), round
aluminum perfil TYPE used in modern design and available in general
hardware stores, and aluminum sheet and
parts attached/assembled by aluminum braising as shown for optimum heat transfer.
Further it should be protected by light colour
paint to avoid the transfer of UV sunlight to the docking station.
Further more the Honda GXR
engine has a powerful fan for cooling installed on the crank shaft. Removing of the
muffler and using an external muffler for exhaust routing will result in taking away another heat source from the Honda 2000 factory housing with the added benefit of better air flow inside the housing for cooling.
BUT also further complicates PORTABILITY of the GEN and MAXIMUM CAUTION must be taken with the resulting implications of the HAZARDOUS EXHAUST GASES IN GENERAL.
CAUTION Exhaust fumes contain certain poisonous chemicals, including carbon monoxide, sulfur dioxide, nitrogen oxides, formaldehyde, benzene and soot, all of which can be detrimental to the human body if consistently inhaled in large quantities.
ACTIVE COOLING is used consisting of 2 independent explosion proof blowers also used the for fuel vapor evacuation,
EACH with sufficient CFM capacity according to space allowing sufficient air flow for cooling of
inverter and
engine in combination of size of Docking Station with.....
a) wired in parallel to share the DC
power of the Honda 2000 ( 12 V max 8,3 Amp) to drive both blowers at half capacity in normal condition.
b) to drive 1 blower at full capacity with
alarm indicator ON in case of failure of the second blower.
c)
Alarm indicator and Automatic SHUT DOWN of the Honda 2000 in case of failure of both blowers.
d) SHUT DOWN actuated by interruption
power supply to spark
plug and fuel supply
e) Same principals apply to independent AC power supply INSIDE of Docking Station in case DC supply is insufficient.
f) Active cooling is actuated by timer BEFORE start of generator
........ to eliminate risks of ignition fuel vapors and risks damage to the honda 2000.
EXHAUST GASES
Without further comments on the
danger when handling exhaust gases containing poisonous chemicals, including carbon monoxide, sulfur dioxide, nitrogen oxides, formaldehyde, benzene and soot and the implications to the human body if consistently inhaled in large quantities.......
LOCATION OF THE DOCKING STATION ON BOARD must be considered.
As this depends on the lay out of the boat there is no best location, only the ones that more favorable and the ones that are not that good.
In GENERAL the same principals as with the exhaust system of the main engine are valid.
In general the best advantages are at the after location of the boat and away from hatches, windows vents, doors , fresh air supply access to AirCon that allow easy and direct access to the
interior of the boat when at anchor. Usually the bow will direct in the
wind, but MAXIMUM CAUTION must be taken when there is no
wind or the boat is tied by
rope to shore.
Optimizing the evacuation of exhaust gases by routing with external muffler and extensions further complicates PORTABILITY of the GEN and MAXIMUM CAUTION must be taken with the resulting implications of the HAZARDOUS EXHAUST GASES.
A flexible exhaust pipe connection MUST be used to allow compensation for the vibrations of the Honda 2000. To further enhance
SAFETY and maintain the max portability of the GEN an adjustable quick release snap on connection with flange on both sides that allow an exchangeable seal between both flanges MUST be installed on the outside of the Docking Station to connect to the exhaust routing system that is installed/bolted to the boat.
All exhaust components should be
Stainless Steel, rated for the temperature and welded to be leak free or couplings that will comply with the same requirements. .....
https://www.amazon.com/Eberspacher-W...a-802597554185
https://www.mcmaster.com/55125k105-55125K38
A test for
leaks MUST be performed as also regular routine follow ups to verify SAFE performance.
Further orientation Page 15 Quote 223
ELECTRIC STARTER with
REMOTE CONTROL DETAILS FOR DOCKING STATION
In Stage 3 the factory tank of the honda 2000 is removed to allow space for the starter
motor.
As an off the shelf component the kits from FROG PRODUCTS Inc. are used for starter
motor and
remote control.
3 Components are required for the electric start in Stage 3
Dock Station.
Nº1 THE GEARED RING mounted to the Fly
Wheel
Nº2 The
GEAR mounted to the shaft of the
electric motor
Nº3 The EXPLOSION PROOF MOTOR for safety in regards IGNITION GASOLINE FUEL VAPORS / TRAILS
In addition to my detailed commentary Page 19 Quote 276 & 278 I encourage anyone to further explore
Nº1 is most likely not manufactured by Frog Products Inc. and there are other sources. Most likely the GEARED RING of the Honda GXR 160 will fit the GXR 120 engine model.... to be confirmed !
Nº2 The
GEAR on the shaft of the motor in this case is the same story as in Nº 1 as there would also be the starter motor that officially is available as option from Honda for the Mod GXR 160
Nº3 Frog Products informs by mail he does not supply an explosion proof Starter MOTOR.
Almost all electric motors around the world are manufactured to standard sizes.
With the inside Dia of the hole for the gear that fits the size of the shaft of the starter motor, the flange type for mounting to other devices and the info of rated Volts and Watts of power any decent ONLINE
electronics component supplier should be able to find the right motor. Also there are cheap kits on Amazon and EBAY for exploration. Best chances for Info are the shops that
work with Quads, GoCards, small engine speciality vehicles and 4x
wheel drives. They all use electric start and are familiar with all the engine manufacturers.
An alternative Remote Control can be found here .....
>
https://www.pinellaspowerproducts.com
ELECTRICS and the DOCKING STATION POWER SUPPLY
As the Electric Start will eliminate the possibility of manual start by hand crank sufficient
battery capacity is installed with an isolated independent
charging source of the boats main power supply.
An individual DC/AC connected to the
inverter generator of the Honda 2000 DC outlet is installed in the DOCKING STATION that allows the use of a High Capacity Emergency Jump Starter Power Supply to reliable start the Honda 2000 engine.
To show sufficient capacity for start
reliability at this date the Audew Mod. 2000A Jump Starter as a result of a test is used that also shows many other useful applications.(for further info watch test @ title ....
"Which Car Jump Starter Is Best? Let's find out!" by
PROJECT FARM YTube channel)
This type of power supply has a BMS that is used in response to the unregulated DC power of the Honda 2000.
Proposed electric
wiring sheme and CONNECTIONS FOR
WIRING DISTRIBUTION BOX
included !!!!on Page 7 Quote 104 and used for CONFIGURATION STAGE Nº3
but later changed for reasons on page 11 Quote 151 !!! IF DESIRED !!!
Previsions STAGE 3 ELECTRIC START for Stand Alone Island Power Supply with isolated AC-DC
Charging Circuits from Honda 2000 to the Docking Station to charge the Starter Power Supply/Audew Jump Starter.
OBJECTS, FEATURES, FUNCTIONS of ELECTRIC START
Electric Start in combination with REMOTE CONTROL by hard wire/wireless allows
* SIGNALS from SET POINTS to control the state of charge of the battery when a
Victron Mod. BMV battery
monitor is installed on the Dockking Station
This function is useful when using small undersized battery banks to drive AC and DC High Demand constant loads or AC direct loads up to max 2000W and rated constant 1600 W
and DC loads 12 V up to 70-80 Amps whereby the battery is only used as a buffer to stabilize loads
* Due to individual SET POINTS the
batteries can be protected adapting desired charge profile.
This will enhance longevity of the
batteries
* Raw DC Bulk Charging Capacity of up to70-80 Amps for batteries to supplement
solar and other charging sources
* with High and Low voltage protection in case of cloudy conditions essential for charging
Lithium batteries. and good second stage of protection after the BMS.
* Optimizing the run time of the generator
* Using the more cost effective Honda 2000 for charging batteries instead of the main engine.
* * EMERGENCY BACK UP of MAIN POWER SUPPLY.
In case of a failure of the entire break down of the main power supply on the boat this function will allow
a) Power Supply to vital systems for
Navigation and systems to sustain minimum comfort levels till main power supply can be reestablished.
b) Use of power tools and
instruments for
repair in case of emergency ON THE BOAT and on shore of remote places with extended Back Up for portable Power Tools.
c) Charge the starter battery for the main engine in case of LOW state of charge or TOTAL failure of ALL batteries and ALL main charging sources, (engine
alternator,
solar etc)
d) The Audew Mod. 2000A and 20000mAh has sufficient capacity to be reliable to start the Honda in Emergency mode
e) With sufficient cold cranking amps the Audew Jump Starter will also allow to start a mid size main engine direct in extreme cold climate.
f) Charged independent and totally isolated from the main power on the boat the DOCKING STATION....
either by direct DC power supply (12 V-8,3 amp) of the Honda 2000 DC outlet
or by the inside of the Docking Station installed AC
Charger using the AC outlet from the Honda 2000 will ALWAYS !!! be able to back up any situation of loss of power on board without external help
g) EXCEPT when the Audew Jump Starter power supply has not enough cranking amps to start the Honda 2000.
With a Size: 8.73" x 5" x 1.1 inches and a weight of 1,3 Lbs the Audew power supply can easy be disconnected and taken to another boat or the beach when on anchor in the included bag supplied by Audew
to be charged in case of Emergency at ANY !!! DC/AC POWER OUTLET.
https://www.audew.com/Audew-2000A-Pe...-p-100058.html
Power Supply CHARGING TIME aprox 4-5 hour to 100%
That makes the HONDA 2000 STAGE Nº 3 DOCKING STATION WITH ELECTRIC START an absolute unmatched Set Up for BACK UP and with all the versatil combinations and options compared to any other Devices available on the market the BEST CHOICE for LAST RESORT in Case of Emergency.
Further more in this configuration the Honda 2000 with Docking Station, Electric Start and a small light weight Power Supply makes it the ideal choice for smaller vessels with limits of Battery size, Space for sufficient Solar Power,ETC. to handle DC/AC power loads that allow a decent level of comfort on board that with other options can not be achieved in a more cost effective way.
The Honda 2000 is also the smallest and less weight option to run a 12.000 BTU Air Condition with using a Soft Start
modem with PORTABILITY that no Marine generator can offer.
The high capacity battery as an added benefit is a practical power supply for modern communication devices that can be fast charged off the boat and on shore and therefore also used as an independent power source to supplement the lack of limited battery capacity and solar power charging capacity.
This High capacity power supply also comes in handy for extended use and back up when going on shore in remote locations like with video filming for example
Same configuration is also the best choice in vessels where weight factors are of importance.
*Another fact where this configuration Stage Nº 3 configuration is really outstanding is
SERVICE FRIENDLY.
One compact unit with a SEMI PORTABLE Docking Station and FULLY PORTABLE light weight Honda 2000 and Battery are optimum and allowed with in the TECHNICAL LIMITS OF SAFETY result in an easy accessible unit and removing light weight components of the boat for
service or quality
storage while the boat is not in use for the longer off season periods.
All NO proprietary components are used and
parts for service, spares are available of the shelf or OnLine.... ?¿? except the starter issue ?¿?
As this Set Up could be a vital component for the function of the boat the same attention as to the main engines is required to obtain max reliability in return.
Of course in regards to longevity the small Honda 2000 with a dry weight of 47 Lbs can most likely not match a Marine Diesel Gen like the NEXT GEN 3,5 with a dry weight 160 LBS under the same conditions.
But parts and service are a lot cheaper and a similar or better over all cost factor could be the result of a particular care and shorter
maintenance cycles.
However the docking station, wires, the battery and the inverter/generator of the Honda 2000 are more or less
maintenance free for their expected life cycle which leaves only the maintenance of the engine and the fuel supply for reliable and SAFE OPERATION.
That means proper use and maintenance is mandatory.
A few words to YOUR DOCKING STATION
After kicking this thing in all direction I came to the conclusion the best is when all components that belong to the Docking Station are in a fixed and bolted position like for example the blowers.
Ports for external and manual access are also fixed in position. Electrical connection and exhaust are in a fixed position and the Honda Gen is strapped to a fixed position. For this reason I find it the most practical to mount all those components to the base plate and the top of the Docking Station simply comes off and is sliding back in Position.
When designing Your Docking Station first considerations should be Portability and EASY access to the Honda 2000 from all sides for all the requirements of service, maintenance of the engine which most likely will be the only thing of concern. If all is connected to the base plate the top comes of easy and also the Docking Station is easier to install in a more semi portable fashion.
This STAGE 3 CONFIGURATION is designed to function automatic.
That means when taking off the battery the starter motor function is deactivated and passive venting the Docking Station is supposed to remove the fuel vapor trails.
The battery has the same function as the key for a car to prevent unattended running of the Honda 2000 while not on the boat.
Would You leave the door of Your car open with the key in the ignition lock ?
OK, so this will prevent any undesired issues with the
kids and unauthorized touch.
For further safety measures and to prevent theft install a lock that prevents opening of the top and getting to attachments points for the docking Station to the boat.
PS: There might be some details missing but You can find them reading
__________________________________________________ __________________________________________________ ______________________
CAUTION
As any
DIY project might implicate modification of components and the corresponding warranties by manufacturers, it is thereby at OWN RISK, and it should only be done by persons with sufficient skills to control and responsibly manage those risks.
Further orientation can be found here
> The U.S. Electronic Code of Federal
Regulations (e-CFR)
https://www.law.cornell.edu/cfr/text/46
> The Canadian Construction Standards for Small Vessels (TP 1332 E).
https://www.tc.gc.ca/eng/marinesafet...2-menu-521.htm