Generator Engine Overhauling & ATS Dedicated Thread ( Advice , DIY, Repair ,Install)

[dr3vil]

dude you dont get the point, and you are miss calculating

The power P in watts (W) is equal to the current I in amps ( A), times the voltage V in volts (V):
P(W) = I( A) x V(V)
So watts are equal to amps times volts:
watt = amp x volt
or
W = A x V
for example if your AC is running on 240 volts MAIN supply with 7 amp load then watts=A x V; w= 240 x 7 = 1680
and as generators are rated according to petrol power your gene is 11(amp)* 195(volts) =2145 watts capable, now the point is as your gene is on gas so will lose some power due to difference of octane levels.
normally dropout
HONDA ep2500 (2.5 max power 2.2 Kv Max load) dropout rate 1.5AMP
JD 3500 (2.5 max power 2.2 Kv Max load) dropout 2.5 Amp
lincon 3500 (2.5 max power 2.2 max load) dropout 2.5 Amp

so when gene is running on its peak load dropouts voltage also in my case voltage drops to 195 if i run Mitsubishi split AC.
normally dropout to 205 volts.

so i guess your gene will dropout to (11-2.5 amp) x (195) = 1658
and 1658 is < your required load 1680.

best way to calculate is put and amp meter and volt meter and start ac and note down volts and amps of both starting and running condition.
then use Amp and volt meter to calculate dropout of gene.

BTW never witnessed and heard about 11 Amp breaker
10 15 20 Amp breakers normally available in market.

well not plaing to add a .5 ton ac on it as there is some locha in wiring the wires comming from dynamo to the main gen pannel a wire is loose or somthing as it sometimes gives 0 electricity so will be changing those wires if i can find but when i turn breaker off then problem arrises else it works
ac breakes remains on just load arram se dalata hun
my normal laod is 3 room fans
1 room cooler
2 padistal fans
1 zainusi friedge

[afnan1112]

@moizirfan
What about wires of carbeurator chok puller gas solenoid in s3?
I am not using those points?

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[babarhailian]

@Babar you are rite i did rechecked the flame after reading your reply just to make sure its not more than 2/3 inches i also shut the gas handel upon shutting the gen down just till i dont have ATS.well waiting for the detials i m cant wait to start the project.

Materials Needed:

1: 12 Volt Relay

2: 220V, 14 point Relay

3-Timer Circuit (with 2 variable resistors) :

4-Connectors 1 set of 8 pin:

5-Soldering Iron, wire and paste (Will cost about 300):

5-Auto Changeover switch

[babarhailian]

This is the simplest diagram to automatically start and switch off your generator.

In material list you'll also need some 6 meters of wire used for car wiring from auto store. Buy the wire with seven copper wires in it (they call it saat-taari). And some LAN cable from computer shop. This will be used to connect your generator with the ATS box; you have to keep your box at a place safe from rain. LAN cable has 8 insulated wires in it and there would be 8 wires going from your generator to ATS box; so it is the best option.

[babarhailian]

@Babar you are rite i did rechecked the flame after reading your reply just to make sure its not more than 2/3 inches i also shut the gas handel upon shutting the gen down just till i dont have ATS.well waiting for the detials i m cant wait to start the project.

This is how whole system works. It's not that complex; things get very simple once you start doing. Best of luck. I'll be right here for support.

[MoizIrfan]

@MoizIrfan
What about wires of carbeurator chok puller gas solenoid in s3?
I am not using those points?

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you don't require choke puller if u will use your generator on gas.
s3 switch will work as on/off switch for gas solenoid. u can directly power the gas solenoid via two wires (no:10 and no:11 terminal) coming from 14 point relay to S3 and remove S3 if u want.

[shoaib40]

Adjust its tappets.

i adjust it tappets and i started on petrol after a while i converted it on gas after 5 minutes its stoped and generator was heated too much after i was starting its results was same as before its about to come on start and fire burst sound coming again i asked to mechanic he said me its valve are weak now you have to change it
is it problem ?
if not tell me a right solution of it please i set tappet on 0.4 m
thanks

[dr3vil]

i adjust it tappets and i started on petrol after a while i converted it on gas after 5 minutes its stoped and generator was heated too much after i was starting its results was same as before its about to come on start and fire burst sound coming again i asked to mechanic he said me its valve are weak now you have to change it
is it problem ?
if not tell me a right solution of it please i set tappet on 0.4 m
thanks

If u mean patkaha then change plug to ngk

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[ToxicDevil]

i adjust it tappets and i started on petrol after a while i converted it on gas after 5 minutes its stoped and generator was heated too much after i was starting its results was same as before its about to come on start and fire burst sound coming again i asked to mechanic he said me its valve are weak now you have to change it
is it problem ?
if not tell me a right solution of it please i set tappet on 0.4 m
thanks

The value depends on the engine. My 2.5 kVa specs are as under.

Intake valve: 0.04mm-0.06mm
Exhaust valve: 0.06mm-0.08mm

Please note that these values are in mm and it is 0.04 not 0.4 and that you have to set the tappets when the engine is cold.

[afnan1112]

you don't require choke puller if u will use your generator on gas.
s3 switch will work as on/off switch for gas solenoid. u can directly power the gas solenoid via two wires (no:10 and no:11 terminal) coming from 14 point relay to S3 and remove S3 if u want.

Thanks

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[babarhailian]

i adjust it tappets and i started on petrol after a while i converted it on gas after 5 minutes its stoped and generator was heated too much after i was starting its results was same as before its about to come on start and fire burst sound coming again i asked to mechanic he said me its valve are weak now you have to change it
is it problem ?
if not tell me a right solution of it please i set tappet on 0.4 m
thanks

Set your tappets as:

Intake: 0.1mm
Exhaust: 0.15 mm

Make sure your engine is cold (about 4 hours without starting)when you adjust tappets.

Always use original Denso Plug; it will be hard to find but it is best for these generators.

[awais.asghar3]

This is how whole system works. It's not that complex; things get very simple once you start doing. Best of luck. I'll be right here for support.

bhai where i can get this timer circuit? i asked for it but he gave me single resistance circuit...

what is its specific name...

[babarhailian]

bhai where i can get this timer circuit? i asked for it but he gave me single resistance circuit...

what is its specific name...

If you are in Lahore, you may easily get it from Hall Road, you may get the picture with you. If you can't approach Hall Road easily, then search from any electronics parts (like resistors, IC's Transistors) shop; you may also want to search the shop or market where they sell voltmeters, main switches e.t.c;

I live in Sargodha and I managed to find it here; it means it is available in all cities of Pakistan; I had to search for it for about 5 hours. All you need to do is take its pic in cell phone and search.

[babarhailian]

bhai where i can get this timer circuit? i asked for it but he gave me single resistance circuit...

what is its specific name...

They usually call it "on-off timer". The one which comes with single resistance is called "on timer" that one won't work here.

[nabeelryk]

They usually call it "on-off timer". The one which comes with single resistance is called "on timer" that one won't work here.

if you know how to use soldering iron than you can make one flasher circuit by yourself , requires 2 capacitor , 2 variable ressitance, 2 diodes, 12v relay , 555 ic, viro board, or PCB.
if you want it more simple and professional use one fixed R and single variable resistance and NPN transistor to conduct relay.

[OmRON]

@nabeelryk

I personally think you need two flashers ( basically timer circuits ), One for Starting and One for turning generator OFF.
Otherwise it will kill generator as soon as AC present again. Which is need a time delay otherwise its strange, AC= Present , Generator Thak!!! off.

[nabeelryk]

@nabeelryk

I personally think you need two flashers ( basically timer circuits ), One for Starting and One for turning generator OFF.
Otherwise it will kill generator as soon as AC present again. Which is need a time delay otherwise its strange, AC= Present , Generator Thak!!! off.

no you dont need two flasher, you need 0ff-delay timer, that can be a 555 reverse triggered,or couple of NPN transistors. Flasher will not do the job, because flasher is astable mode. so in case if MAINs is OFF the flasher circuit will not allow gene to start. if you switch from relay n/o to n/c then your flasher will trigger the kill switch as soon as power is applied.(which is same as "AC= Present , Generator Thak!!! off."
if your dont want to make your own then just pay a visit to the stabilizer repairing shop and ask for stabilizer timer.

[babarhailian]

if you know how to use soldering iron than you can make one flasher circuit by yourself , requires 2 capacitor , 2 variable ressitance, 2 diodes, 12v relay , 555 ic, viro board, or PCB.
if you want it more simple and professional use one fixed R and single variable resistance and NPN transistor to conduct relay.

It would be of great use for the readers in small cities if you could elaborate this second option with a schematic; please also mention if this little circuit would be able to power the relay on-and-off with intervals, or what exactly would it do?
What I understand is that as per this plan, we won't need a relay and the transistor would conduct and interrupt the current stream repeatedly. Is it the case?

[nabeelryk]

It would be of great use for the readers in small cities if you could elaborate this second option with a schematic; please also mention if this little circuit would be able to power the relay on-and-off with intervals, or what exactly would it do?
What I understand is that as per this plan, we won't need a relay and the transistor would conduct and interrupt the current stream repeatedly. Is it the case?

no dear, the 555 timer when configured in astable mode that is FLASHER for newbie, the R1 is used for on-time whereas R2 is used for off-time, and if you change the value of R2 that will also result in change of on-time value,
means to say
R1= change of on-time
R2= change of on-time + off-time
and 555 timer is capable of 200mAmp on its output so if you change relay from that SPDT to bigger one (although which is not required because that SPDT relay is capable of handling 5-8 Amp on 12volts whereas your starter solenoid load iss 2 amps that means SPDT is more then enough for self solenoid) the bigger relay coil put forwards more load on 555 IC and 555 IC will leak or go bad.
so transistor will be used on 555 output to drive the relay, transistors can handle heavy load.

and to avoid complications and for cost-cutting purpose we will fix the value of R2, and will use variable resistance and R1 for on-timer only.in the end your output is capable of heavy load, your off-time is fixed and on-time is adjustable.

[nabeelryk]

This is the simplest diagram to automatically start and switch off your generator.

In material list you'll also need some 6 meters of wire used for car wiring from auto store. Buy the wire with seven copper wires in it (they call it saat-taari). And some LAN cable from computer shop. This will be used to connect your generator with the ATS box; you have to keep your box at a place safe from rain. LAN cable has 8 insulated wires in it and there would be 8 wires going from your generator to ATS box; so it is the best option.

sorry to say but
i dont know why you all are using 8 or 16 wires u just need.
4 wires if you are using simple on and OFF without petrol solenoid, or gas solenoid .
6 wires if you are using petrol and gas solenoids.

as you can see in my tweaks i just used 6 wires for almost 18 to 20 functions. (including petrol and gas solenoid and oil alert also)