building a relay box

 Hello again,

    Did a bunch of googles but came up empty. I remember people talking
about building a relay box for generator control via SW inverters. I
have a generator which does not offer a remote kit as an option.
    What I was hoping to do was create a double duty relay/remote setup. I
often take the generator/welder (lincoln ranger 250) out in the field
for welding/contruction work and it would be really handy to have a long
lead (perhaps 50') wich would allow me to start/stop the generator when
needed. Often times you may need the generator for 30-45 minutes
straight then it may just sit an idle for a long while. Running back to
the generator to start/stop it all the time is a real time waster and
leaving it running is a real fuel/life of the generator waster.
    I think the relay for the SW is pretty straight forward using two spst
relays with one powering the ignition, and one doing the cranking. I had
planned on using a couple of the cheap relays at radio shack for this.
    The remote lead could simply be an extension of the ignition switch and
starter button as I think 50' would not be a problem there. I am hoping
to implement both of these in a way that doesnt modify the
generator/controls at all as the unit has a 3 year warranty of which I
am only 1.5 years into.
    I would appreciate anyones help/input on these just to make sure I have
all my ducks in a row.

Thanks to all,
Mark
    

  hey Mark....

why not make it remote control?
I've had some luck with Linx modules available through Digikey.

If I remember right they make a keychain transmitter and a realy reciever
module. Not sure what the current carrying capacity of their relays is or
what you require, but it should be pretty simple to hook it up....
This way you could have multiple remotes and other guys could activate the
genny if they needed it...

If you want more help setting something up email me directly...

henryATdoalelectronicsDOTcom

good luck

 I built a remote start/stop" unit for my B&S 9hp, propane fired generator.

Basically, I bought a similar ingntion switch, a couple leds for indicators,
and used a couple junk relays and 100ft of outdoor wire. I have some
occosional problems with vibration in the relays, because they are mounted
on the generator.

The schematic is here. Save a copy of it if you find it useful, because it
will be moving to a different site in a few days. The generaor had a vacum
proving switch, which I used to connect a LED to indicate that the generator
is running. When the red led is lit, I avoid cranking the starter, because
it means the generaor is already running. If the Green LED is in, it means
that the inition switch on the generator is in the run position, so the
remote starter can start the generator, otherwise not. That way, if you turn
off the ignition at the egnerator, nobody can start it remotely. This is a
safety feature.

Note, a propane powered generator requires no choke. If you have a gasoline
generator, you may need to make provisions to remotely operate a choke.

I'd like to build a remote start/stop for my new Honda Eu3500.

http://www.usol.com/~rickryen/Lake%20House/Power/Generator%20Remote%20Start.htm

Bughunter

 Hey Bug!!,
    Didnt realize til I read the whole mail. Thanks for the schematic. My
generator doesnt have a proving switch but I may want to cobble
something together in that manner. I think you may recall I asked a LONG
time ago about setting up an automatic choke for this generator as it
doesnt have one and Onan seems to think it would require an entire new
carb. The good thing is the generator needs choke to start even when
warm so I think I can put together a choke actuated either by elect. or
by other means pretty easily.
    My only concern with using the SW to start it is the SW uses a timed
cranking period and I am guessing it stops cranking when it sees power
coming in from the generator. Otherwise I will have to set the SW to
crank for the longest time (as if the gen. was dead cold and hadnt been
started for weeks). If the SW doesnt stop cranking the gen. when it sees
power it will be cranking while the generator is running in some cases.
I need to re-read the manual on this one.
    Well, thanks again for the schematic, hope all is well with you and you
are making headway on your project.

Ciao,
Mark & Shauna

r.ryen@verizon.net wrote:

 My project is going somewhat slow. I did install a 200amp main electric box,
and wired 4 rooms for AC. I have been using a small cheap 350watt inverter
for nights, and run the generator (manually connected) during the day for
the occasional large load. I am amazed at how useful even a small 350 watt
inverter can be. I run lights in 3 rooms, as well as a 13' TV, DVD player
and wireless speakers. Luxury!

I did pick up a Honda EU3500 as an emergency and backup generator. I love
how quiet it runs.  It is a bit small, but I find it's nice to use for
medium sized loads and almost as quiet as the inverter.  I do want to take a
closer look at it to see if I can figure out how to make a remote/start stop
switch for it, which is not a Honda option for this model. It too has a
manual choke, and it seems to be required for reliable starting. Perhaps a
simple solenoid can be used to engage and disengage the choke. I may get
around to fooling with it this winter sometime. Nice little generator. I
take it home in the winter as an emergency backup. and it's portable enough
to carry into the field.

The B&S Vanguard still runs fine after 9 years, but it is a bit noisy for my
tastes.
Since it is older, I'm more inclined to hack-it to make it do my bidding.
The remote starter has saved me lots of running back and forth to the
generator. I now see it as a requirement. I hate running out in the rain to
start/stop the generator. I was doing lots of work from scaffolding, and
that makes it especially hard to get to the generator.

My ultimate goal is full generator control with a Trace SW4048. I just
ordered a
PP-Sw4048/S yesterday, but got email a few minutes ago that I had "missed
the sale" and they raised the price by ~75%. Aaarrrrrggghhh!

It's been a while since I've read the Trace manual section on generator
starting. I do recall warnings that their relay control circuits have pretty
light ratings, and that you have to be careful not to over-tax them. I don't
recall if or how the might avoid trying to crank a running generator. Like
you, I suspect that the might simply detect AC production, or maybe even a
simpler and less reliable timing mechanism.

My Vanguard generator has a slight delay or maybe a second or two from when
the engine comes up to speed and the production of AC, but that's not too
long to over-crank it. How long a crank it takes to start it is pretty
unpredictable. Some type of positive feedback mechanism would certainly be
preferable to a "fixed time" deal.

Onans usually have a pretty good remote start capability. I'm surprised that
yours doesn't have capability as a factory option.

The point of my post was not really in the specifics, but that somebody like
me with just a slight-clue can reverse engineer the starting circuitry of a
generator and cobble together a functional remote start/stop. It did take
some trial and error experimentation to make it work.

I ended up using a lot of extra wires to provide some additional led
indicators. These were not a necessity, but "nice to have".

Best wishes, and let us know what you end up creating.




generator.

indicators,

mounted

generator

because

gasoline

http://www.usol.com/~rickryen/Lake%20House/Power/Generator%20Remote%20Start .
htm