2400W Generator Fails to Start Shop Floor Tools

Are you trying to run shop tools with a higher inrush (or starting current) than the 2400W generator can provide?

The easiest way may be to just get the generator running first and then pulse the tool start button.

Depending on the tool, you could (perhaps) try a motor soft starter, but I don't think this is that helpful in this application, especially if the loaded tool current exceeds the generator current.

What are the tools exactly and their power and start current ratings?

It sounds like the starting current is too high for the generator, by switching it on and off you get the motor spinning so the starting current isn't as high.

2400W / 120V = 20A

2400W / 240V = 10A

If your start-up, combined, or under load current exceeds 20A @ 120V or 10A @ 240V you will need a larger genny.

Could also be the gen is starting from a "no load" condition and the gen is not "ready" to supply load.

Try putting a 100W light bulb powered by the gen (so there is some current flow) and then from another outlet try your "shop tools".

If there is any (cheap) electronics in the power control circuit the extremely low current in the "no load" condition means that is cannot respond to a sudden demand for power.

Your proposal to cycle the switch, or any other component in the circuit REALLY worries me from a safety point of view. While there is probably appropriate personal protection in the circuit, such actions invite failure and similarly, the distraction while the operator is perfoming those actions could lead to other problems.

Sorry, I'm not into numbers! It is obvious that I am starting the appliance "slowly" by toggling the on/off. The toggle is part of the generator which allows for my "slow" start procedure. The question is straight and simple, - "Is there an automatic switch that will do the "toggling" for me? I will not switch to a bigger generator because it does the job just fine, after my special start-up procedure. No more numbers, please and thanks.

I don't think you will harm anything, if you can keep the power surges under control by cycling the switch rapidly.

I'm sure there are switches that can do this, but, back on the farm, I'd just do what you are doing, recognizing the minimal risk.

Be safe.

A while ago, I used to use a trick for starting an induction motor from an inverter that the starting current was too high for the inverter.

I made a little circuit with a diode (that could handle the current) and a switch, where the diode was in series with the motor, and the switch shorted across the diode.

Without going into details, by putting in a diode you are basically cutting the sign wave in half, so it should make an induction motor run slower. Once the motor was spinning I would just flip the switch to take the diode out of the circuit.

Depending on your shop equipment this could damage it, so I don't know if I would do it, but it worked for me.

I used to use the same trick with a soldering iron without temperature control. I put a diode and switch inside the plug. I have done it on UK 3 pin and continental plugs.

With the diode in circuit, the soldering iron in question could not quite melt normal solder (lead based).

Flip the switch and 20 seconds later you can solder.....

Nowadays I have a temperature controlled iron, they have so dropped in price over the last 10 years or so.....

I like your idea. Can you go into more detail? I am frankinbccan@yahoo.ca

You may be talking about a simple diode/switch to cut half the cycle off, reducing RMS voltage, therefore some motors run slower, heating is cut in half.

Its important that the diode can take far more current than the maximum for an inductive load which may take 8x the normal running current (Motor, transformers etc..) For a resistive only load, you can reduce it to 2 x.....

It does not matter which way round the diode is placed....

Simple schematic:-

Do remember that this is a mains voltage circuit, get someone to help you who understands why this can be dangerous if you yourself don't know!!!!!

umhum..........there is a gizmo..........in your case it would not be practical considering the cost.....seem your using a borderline generator with a slow rise time in current output and it wont charge the start capacitor and supply the needed extra current needed to rotate the windings to keep a nominal current drain.......toggleing the switch eliminates temporarily the bucking current and since the cap is already charged there is enough balance to rpm the motor to centrifigal balance 0 current and voila el starto.......continued use of this pratice may get someone injured ot cause a fire etc. chipmunks work cheap hard to keep their rotation turning start windings the correct way.....cheap is for the birds(baby chicks i mean..) luck to ya...tmog(the mean old grandpa)