Replacement 15 Kva alternator

solarman216 · 06-12-2023, 05:01

As said, old unit suffered a control box fire which required a complete replacement alternator, sounds easy enough until you understand that the old one was automatic and could be started from any place in the yard with a two wire switch, I needed to keep this arrangement for ease of use by none understanding people, so how do you with a two wire switch from any location start up a diesel gen set?

Bearing in mind that you first need to enable the fuel, then operate the starter and stop it once the engine has fired, but it does not stop there, you now need to only connect the alternator once the engine has got up to speed, then on shut down you need to disconnect the alternator from the load first, all of which will fry the automatic voltage controller if not done correctly, not a big deal on a modern cheap genny as they are cheap and available, but my 1970 kit not so easy.

I have sorted it but your thoughts on a post card please, Rick

panelbeater · 08-12-2023, 13:20

bit of a headache there rick,sorry its beyond me but a good electrician should be helpful.

jims-terrano · 08-12-2023, 21:26

So am I right in thinking you are wanting to remote start a generator from pretty much anywhere on your property?

How about this little gadget, a GSM Relay that you control by text message.
https://www.gsm-uk.net/shop
This website is the company that I have used a few times before. Ive used the 4 channel version. You can get the relays to turn on or pulse like a momentary push switch.
The owner of the business is really helpful.
I got a sim card from a company called 1penny mobile, £30 a year works for me and because the sim has credit you can set the relay to text you back to confirm it has received your instructions.

solarman216 · 08-12-2023, 23:17

Yes Jim that is correct, we had that before with the original gen set and it was all controlled by the system on the alternator ( google Lister start O matic) for a full description, but now of course I have just an engine driving an alternator and needed to use the existing hard wired switches from most of the buildings in the yard that have a generator supply (7) all are simply two wires.

I have purchased an auto generator start control but it did not quite cut the mustard, so pulled it to bits and did some mods, now it works well, but does not address the connection/disconnection of the loads at start-up and shutdown, but with a couple more bits and bobs have sorted this, well on paper anyway, as I get into it properly next week if you are interested I will post some pics and details, Rick

jims-terrano · 09-12-2023, 21:51

Always interesting to hear about your off grid setup Rick

solarman216 · 10-12-2023, 01:05

Thanks Jim, only times I ran the genny from April to September was for the vehicle hoist and welder, solar provided for everything else including the washing machines and also the chainsaw for cutting logs as have now got a battery powered jobbie, charged by solar, pics next week, Rick

solarman216 · 11-12-2023, 22:24

Busy on other jobs today but just done a schematic of the wiring, here it is.

solarman216 · 11-12-2023, 22:26

And this is the auto start box layout, I will not be using much of it as not applicable to my old Lister, Rick

solarman216 · 14-12-2023, 00:12

Added 8 more solar panels today, pic tomorrow as got dark just as we finished, Rick

solarman216 · 14-12-2023, 01:49

Just had a count up from earlier pics, makes 38 so far, more to come, this is what stores my power Li that is, being reconfigured due to needed more space for 14 more cells due in the new year, the old lead acid are getting tired now so will be weighing them in before long, around a tonne of lead, Rick

jims-terrano · 14-12-2023, 11:06

Thats an impressive setup Rick, definitely better than my little Solar setup.

solarman216 · 21-12-2023, 22:03

Here are a couple of the many cables needed to connect the banks together via heavy duty switches, I now crimp the terminals with the workshop bench vice after making a Die to suite, much quicker than solder

solarman216 · 21-12-2023, 22:04

Close up of the crimp

solarman216 · 21-12-2023, 22:06

Latest solar addition

solarman216 · 21-12-2023, 22:09

Revamp of the solar terminations and controllers, this is just for the Li cells the Lead Acid are still as was, will be getting on with more tomorrow, Rick

06-12-2023, 05:01	#1
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,430	Replacement 15 Kva alternator As said, old unit suffered a control box fire which required a complete replacement alternator, sounds easy enough until you understand that the old one was automatic and could be started from any place in the yard with a two wire switch, I needed to keep this arrangement for ease of use by none understanding people, so how do you with a two wire switch from any location start up a diesel gen set? Bearing in mind that you first need to enable the fuel, then operate the starter and stop it once the engine has fired, but it does not stop there, you now need to only connect the alternator once the engine has got up to speed, then on shut down you need to disconnect the alternator from the load first, all of which will fry the automatic voltage controller if not done correctly, not a big deal on a modern cheap genny as they are cheap and available, but my 1970 kit not so easy. I have sorted it but your thoughts on a post card please, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

08-12-2023, 23:17	#4
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,430	Yes Jim that is correct, we had that before with the original gen set and it was all controlled by the system on the alternator ( google Lister start O matic) for a full description, but now of course I have just an engine driving an alternator and needed to use the existing hard wired switches from most of the buildings in the yard that have a generator supply (7) all are simply two wires. I have purchased an auto generator start control but it did not quite cut the mustard, so pulled it to bits and did some mods, now it works well, but does not address the connection/disconnection of the loads at start-up and shutdown, but with a couple more bits and bobs have sorted this, well on paper anyway, as I get into it properly next week if you are interested I will post some pics and details, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

10-12-2023, 01:05	#6
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,430	Thanks Jim, only times I ran the genny from April to September was for the vehicle hoist and welder, solar provided for everything else including the washing machines and also the chainsaw for cutting logs as have now got a battery powered jobbie, charged by solar, pics next week, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

14-12-2023, 00:12	#9
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,430	Added 8 more solar panels today, pic tomorrow as got dark just as we finished, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

08-12-2023, 13:20	#2
panelbeater Senior Member Join Date: Dec 2012 Location: clacton on sea essex Vehicle: nissan terrano 2 2.7 tdi Posts: 1,637	bit of a headache there rick,sorry its beyond me but a good electrician should be helpful.

08-12-2023, 21:26	#3
jims-terrano Senior Member Join Date: Sep 2004 Location: UK Posts: 12,965	So am I right in thinking you are wanting to remote start a generator from pretty much anywhere on your property? How about this little gadget, a GSM Relay that you control by text message. https://www.gsm-uk.net/shop This website is the company that I have used a few times before. Ive used the 4 channel version. You can get the relays to turn on or pulse like a momentary push switch. The owner of the business is really helpful. I got a sim card from a company called 1penny mobile, £30 a year works for me and because the sim has credit you can set the relay to text you back to confirm it has received your instructions.

09-12-2023, 21:51	#5
jims-terrano Senior Member Join Date: Sep 2004 Location: UK Posts: 12,965	Always interesting to hear about your off grid setup Rick

14-12-2023, 11:06	#11
jims-terrano Senior Member Join Date: Sep 2004 Location: UK Posts: 12,965	Thats an impressive setup Rick, definitely better than my little Solar setup.