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

[nabeelryk]

yes u r right positive is doing the job now what should i do?

do according to moizirfan schematic (circuit diagram).

[afnan1112]

have a look at this i have changed it a bit.

@moizirfan
i have made ats from the picture u posted before of agoodfriend's circuit this one now u r showing is different tell me which connection I should cancel in previous circuit and I will not be adding 25 amp cut off relay becoz I haven't got it.
Thanks!

[MoizIrfan]

@MoizIrfan
i have made ats from the picture u posted before of agoodfriend's circuit this one now u r showing is different tell me which connection I should cancel in previous circuit and I will not be adding 25 amp cut off relay becoz I haven't got it.
Thanks!

i have just removed one extra time delay.

T1 delay:

this time delay circuit is powered by battery positive coming from s2 switch and negative coming from 14 point relay. ok............
now further extend battery positive and connect to its common point on relay..........
then extend a wire from Normally close of the relay which will act as battery positive for T2 delay...........ok
set its time to 30 seconds....
its function is to disconnect battery positive after 30 seconds.........u got this part right????

T2 Time delay.

it positive is powered by above wire extended from T1 time delay normally close point..........ok
negative is coming from 14 point relay...........
now test T1 & T2 together. both should work simultaneously but after 30 seconds power to T2 gets disconnected........ok

now extend T2 positive and connect it to common point on its relay...........
normally close point connects to petrol solenoid............
normally open connects to flasher circuit..............
the negatives of petrol solenoid and flasher are both connected from 14 point relay......
set T2 time of 2 seconds...................

function: when T2 gets power petrol solenoid is ON for about a second only. as soon as it switches off flasher circuit switches ON.......

now test the whole T1 & T2 in combination. As soon as u give 12 volts. petrol solenoid activates for 2 seconds then goes off. immediately flasher circuit then activates...... after 30 seconds flasher circuit also goes off.........

Hope u got it...........my diagram is correct

[MoizIrfan]

@afnan1112

don't test the circuit using a fan as it will drop voltage and sometime relay won't work as well..........
test it using a petrol solenoid or multimeter..................
i use a 1.5 ampere transformer for testing. not anything below that..............

[MoizIrfan]

dude the normally open point of T2 goes to petrol and normally close goes to flasher circuit, please correct that, because thats the reason people getting confused.

Bro just swap the wires from FAN to Flasher, means the one which is connected to flasher will go to FAN(petrol solenoid) & FAN wire to teh flasher.

Bro the normally close goes to petrol solenoid as petrol solenoid gets disconnected after 1 second.
normally open goes to flasher. as soon as petrol solenoid disconnects. flasher activates.

[MoizIrfan]

@afnan1112

just follow this diagram and forget the previous ones. i have just removed one extra time delay from my previous diagram. and gas solenoid as well. waiting for ur response

[mtn.ubl.ali]

i have strange issue with my 2.5kva gen that it is not producing any current it is starting and all but no current even the volt meter is dead what to do ?

[MoizIrfan]

i have strange issue with my 2.5kva gen that it is not producing any current it is starting and all but no current even the volt meter is dead what to do ?

your avr is dead i suppose

[afnan1112]

i have just removed one extra time delay.

T1 delay:

this time delay circuit is powered by battery positive coming from s2 switch and negative coming from 14 point relay. ok............
now further extend battery positive and connect to its common point on relay..........
then extend a wire from Normally close of the relay which will act as battery positive for T2 delay...........ok
set its time to 30 seconds....
its function is to disconnect battery positive after 30 seconds.........u got this part right????

T2 Time delay.

it positive is powered by above wire extended from T1 time delay normally close point..........ok
negative is coming from 14 point relay...........
now test T1 & T2 together. both should work simultaneously but after 30 seconds power to T2 gets disconnected........ok

now extend T2 positive and connect it to common point on its relay...........
normally close point connects to petrol solenoid............
normally open connects to flasher circuit..............
the negatives of petrol solenoid and flasher are both connected from 14 point relay......
set T2 time of 2 seconds...................

function: when T2 gets power petrol solenoid is ON for about a second only. as soon as it switches off flasher circuit switches ON.......

now test the whole T1 & T2 in combination. As soon as u give 12 volts. petrol solenoid activates for 2 seconds then goes off. immediately flasher circuit then activates...... after 30 seconds flasher circuit also goes off.........

Hope u got it...........my diagram is correct

thanks got it

[afnan1112]

@afnan1112

don't test the circuit using a fan as it will drop voltage and sometime relay won't work as well..........
test it using a petrol solenoid or multimeter..................
i use a 1.5 ampere transformer for testing. not anything below that..............

but I have small transformer costed RS 100 don't know it's ampere

[afnan1112]

@afnan1112

don't test the circuit using a fan as it will drop voltage and sometime relay won't work as well..........
test it using a petrol solenoid or multimeter..................
i use a 1.5 ampere transformer for testing. not anything below that..............

thats what I thought sometimes relay works and sometime it doesn't multimeter was showing 8volts

[babarhailian]

@all,

My generator just started a problem that it's 12V is gone. It is not even coming out from it's dynamo. The ATS that I have made needs Gen 12V to detect if gen is on and stops cranking, otherwise it keeps on cranking even if gen is running, So I have to either make its 12V out working or I have to add a 220V relay and bridge Gen 220V wires to my ATS box.

Can anyone help me out about why is gen not producing 12V anymore. Engine is also throwing some oil in dynamo case and is dripping from black dynamo cover near exhaust can it be the reason?

[babarhailian]

@ALL,

My generator just started a problem that it's 12V is gone. It is not even coming out from it's dynamo. The ATS that I have made needs Gen 12V to detect if gen is on and stops cranking, otherwise it keeps on cranking even if gen is running, So I have to either make its 12V out working or I have to add a 220V relay and bridge Gen 220V wires to my ATS box.

Can anyone help me out about why is gen not producing 12V anymore. Engine is also throwing some oil in dynamo case and is dripping from black dynamo cover near exhaust can it be the reason?

@moizirfan

Moiz! Can you help me on this?

[OmRON]

@babarhailian
Well
I believe its because the small round shaped circuit breaker. It need to be pushed again. These are hardly noticeable if they are blown. They have written around its round ring 12V DC Breaker.

As my knowledge 12 DC volts are not coming from dynamo, They are coming from small wire wound transformer. And these are rectified at the point where DC breaker is attached. Its frequent blow is an indicator of battery is short at some point during charging.

It will take hardly 1 minute to sort out if breaker need to reset.
L@@K at the 12 Volt DC reset Breaker.

[omar4494]

Need help from all the expert members, i have gen set of Honda 3.5KVa coil start. It was running fine on gas from last two years, but now its gas kit has developed a strange problem, supply from gas kit to generator does not remain constant, at times it shuts down due to over supply of gas, when gas flame adjusted to two inches (as described in the starting pages of this thread) , it runs fine but after three or four days its flame again increased.
Please advise should i install a new gas kit or existing one can be corrected .

Thanks to All

[mtn.ubl.ali]

your avr is dead i suppose

well after giving up called the mech he openned the denmo and gsve it to electrician what he said wad carbon needs to be changed plus he needs to charge the denmo just like we charge normal battery any expert and detail view on this would really help me n others facing such problem.

[nabeelryk]

well after giving up called the mech he openned the denmo and gsve it to electrician what he said wad carbon needs to be changed plus he needs to charge the denmo just like we charge normal battery any expert and detail view on this would really help me n others facing such problem.

he is bluffing dynamo dont requires charging just replace carbons using mahran or cultus carbons will cost you only 30 rupees.

[nabeelryk]

Bro the normally close goes to petrol solenoid as petrol solenoid gets disconnected after 1 second.
normally open goes to flasher. as soon as petrol solenoid disconnects. flasher activates.

difference between normally close and noramally open point of relays or switches coil based.

The state conditions Normally open (NO) and Normally closed refer how the contacts sit when the switch is off, relay coil voltage is 0, etc.

-If when a relay coil has 0 volts, two contacts make a complete circuit , then that contact set has a normally closed configuration.
-If when a relay coil has 0 volts, two contacts (in the same set) do not make a complete circuit, then that contact set has a normally open configuration.

complete details available at Explain Normally Open Vs. Normally Closed? - Yahoo! Answers

[nabeelryk]

@all,

My generator just started a problem that it's 12V is gone. It is not even coming out from it's dynamo. The ATS that I have made needs Gen 12V to detect if gen is on and stops cranking, otherwise it keeps on cranking even if gen is running, So I have to either make its 12V out working or I have to add a 220V relay and bridge Gen 220V wires to my ATS box.

Can anyone help me out about why is gen not producing 12V anymore. Engine is also throwing some oil in dynamo case and is dripping from black dynamo cover near exhaust can it be the reason?

first of all check the breaker as Mr. OmRon described.
after that check bridge rectifiers, now days china gene dont have transformers , the AC 12 volts are also coming from dynamo (note thats AC not DC so to convert that AC into DC bridge rectifier is used) bridge rectifier is inside the panel box of gene. (square shaped).

[nabeelryk]

Need help from all the expert members, i have gen set of Honda 3.5KVa coil start. It was running fine on gas from last two years, but now its gas kit has developed a strange problem, supply from gas kit to generator does not remain constant, at times it shuts down due to over supply of gas, when gas flame adjusted to two inches (as described in the starting pages of this thread) , it runs fine but after three or four days its flame again increased.
Please advise should i install a new gas kit or existing one can be corrected .

Thanks to All

make sure you place a lock nut and that is not loose.