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G8MNY  > TECHNI   03.10.21 09:00l 107 Lines 5428 Bytes #999 (0) @ WW
BID : 48525_GB7CIP
Subj: HONDA Generator EX500 info
Sent: 211003/0754Z @:GB7CIP.#32.GBR.EURO #:48525 [Caterham Surrey GBR]

By G8MNY                              (Updated Aug 08)
(8 Bit ASCII graphics use code page 437 or 850, Terminal Font)

A few years ago, I was given one of these small old 4 small stroke petrol
generators with no information. It would not start (hence it was given away
less loads of screws!), but I managed to trace the cause to a completely
blocked main carburettor jet, after a major strip down to get at the bits &
several goes at gently cleaning the jet (not to enlarge the hole it) it now
runs OK.

     .컴컴컴컴컴컴.           Breather旼                 .컴컴컴컴컴컴.
    / /~~~~~~~~~~~\ \            Handle  Filler         / /~~~~~~~~~~~\ \
.컴좔좔컴컴컴컴컴컴좔,      Low旼컴컴컨컨콥賽컴풲rips  ,좔좔컴컴컴컴賽嘗좔좔.
    ____                   oil [] 旼컴 o  | 퀁un                         
   넌맙                    Hz 悶 _"_ o                    Speed(O)   
   ____                  Ind 잎 읕컴[_]  쿽ff =                       
    Plug                      ~ ~ ~AC~ DC ~ ~                            
                       첼Pull   悶                渼                 旼컴 
        Exhaust(o)     납Start  납                납              Oil 0  
                       쵬       잎                윱 o Earth         읕컴 
읓컫컴컴컴컴컴컴컴컴컫컫       읓컫컴컴컴컴컫컫     읓컫컴컴컴컴컴컴컴컴컫컫
  ~                   ~           ~    Feet   ~         ~                   ~

But when I laid it up for a while, it can be difficult to start (carburettor
not emptied), I found that putting a few CCs of petrol into the carburettor
intake fixed that (or using a "Cold Start" Ether spay), as dried up petrol is
less volatile.

It could not be simpler, the RUN/OFF leaver operates the engine kill switch &
the double petrol & vent tap. There is a bimetallic operated choke, so nothing
to do other than pull hard on the start cord handle. If the engine has low oil
then the warning light lights.

In the 50Hz low rev quiet & economy mode, it gives 330VA, 400VA MAX, or set to
the noisier higher reving 60Hz it gives 400VA, 500VA MAX, this is also the
"Lamp" mode to reduce 25Hz content of the 4 stroke, that makes lamps flicker,
e.g. 1 power BANG in 4 half wave load cycles.

  BANG /~\255V    _._225V      /~\BANG    _._
      /   \      /   \        /   \      /   \
      High  \  /       \.__./       \  /       \.__./
      Volts  ~~ 240V     210V        ~~
      55Hz   52Hz  49Hz  46Hz
      Fast               Slow

Generators with a much heaver flywheels tend to suffer less from this.

It also has 12V 100W charging output, which is 20V with no load, & 6-8A typical
unregulated charge current, but it is connected to the 220V output!

It is also VERY economical if you don't need high power. e.g. it can run some
small fluorescent lamps, a rotator & float a 12V battery with 100W HF rig OK,
for some 6 hours from 1 fill of its small 2.5L tank. So 1 gallon per day is
feasible when /P for 12 hours/day operating.

I have reverse engineered the diagram & it is very complex for such a small
                       ON Lamp컴컫컴컴컴E      CHARGING
                  ______           13A S/O   +複 DC-        ___o 쿛ush
                 쿟uning쳐컴)컴컴   N     L               __  o 쿚FF
                 쿑orks 쳐컴  gn      rd   Trip              
                 쿓z Ind    /ye   쿫l      10A               
                 읕컴컴켸 gy           Trip    bk            쿫k/rd
              Oil Lamp컫컴컴            3A   퀇h              
Left Alt          ye  쿲y                                  
Module                                읕컴)컴컴)컴컴       
旼컴6 pole Alt                       旼컴)컴컴    퀁d     
   쳐崙컴퓑h                        __      __          
     28)               0.6怨   18 \_/ 1怨1 \_/ 2怨     bk
   쳐崙컴bk             ((((   ((((컨((((((컨(((       
쿌  쳐켰컴컴컴컴컴컴)컴)컴컴컴컴)컴컴컴컴컴컴컴컴컴컴컴        
      gn Feedback             Main 2 pole Alternator        
쿣  쳐켰컴컴컴컴컴컴)컴)컴컴컴컴)컴컴컴컴컴컴컴컴컴컴컴컴  ___  
      bl           \  \      gn쳐컴컴컴(((((컴컴컴컴컴컴캑SCR쳐     /Stark
쿝        r/w   50Hz \  \      __       430      bk/rd   쿔GN   10k Plug
   쳐崙)))))켰컴o    \  \                      ______ bn     쿫k/wh )|  
     ye   읕崙o \__   \  \_旼컴컴커bl         쿟iming쳐崙캑   쳐켰컴)|  
     ye   bk/w 60Hz   \___쿐ngine쳐컴훟      쿓ead  쳐켰캑       1)|  
   쳐崙컴컴컴崙컴컴켸     旼퀾odule쳐컴o/       73   ye 읕쩡      읕쩡
읕컴     op-gn    y/r    __읕컴컴켸bl Oil     읕컴컴켸     __        __
 or  are connectors.

Note, the DC is connected to the 230V! So the 230V will no longer be floating
safely, if it is used with the DC output at the same time!

See my bul on "Regulating 12V genny output" for the circuit that I use with it.

From my long bul "Petrol generators for SSB use", I did the Rev up feed forward
modification, & it did slightly improve voltage regulation under load. I also
did the ignition QRM mods, & fully suppressed this generator.

Y Don't U send an interesting bul?

73 de John G8MNY @ GB7CIP

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