1.

INTRODUCTION:
1.1 Introduction
Generators are useful appliances that supply electrical power during a power outage
and prevent discontinuity of daily activities or disruption of business operations.
Generators are available in different electrical and physical configurations for use in
different applications. In the following sections, we will look at how a generator
functions, the main components of a generator, and how a generator operates as a
secondary source of electrical power in residential and industrial applications.
An electric generator is a device that converts mechanical energy obtained from an
external source into electrical energy as the output.

The modern-day generator works on the principle of electromagnetic induction

discovered by Michael Faraday in 1831-32. Faraday discovered that the above flow of
electric charges could be induced by moving an electrical conductor, such as a wire
that contains electric charges, in a magnetic field. This movement creates a voltage
difference between the two ends of the wire or electrical conductor, which in turn
causes the electric charges to flow, thus generating electric current.

The main components of an electric generator can be broadly classified as

follows (refer to illustration above):
1. Engine
2. Alternator
3. Fuel system
4. Voltage Regulator
5. Cooling and Exhaust system
6. Lubrication System
7. Battery Charger
8. Control Panel
9. Main Assembly/ Frame

1.2 Problem definition:

Many industries, companies, or places like irrigation plants, mobile towers and
hospitals need continuous power supply. If in case the supply from M.S.E.B. fails,
then they use a back up generator for providing supply. So it becomes very necessary
that the generator should be in working condition when required. When generator is
not used, and if some fault or problem occurs, then at the time of need, the generator
may not prove useful causing many problems. So to solve this, generator should be
checked randomly when not in use, so that we can find the problem if any and can
solve it as early as possible. So it is necessary to run the generator for around 10 min
after regular intervals and all its necessary parameters should be checked.

1.3 Outline:
This system utilizes 12 bit analog to digital converter for measurement of phase
voltage of R phase, Y phase and B phase. It also monitors fuel level, engine
temperature and oil pressure via relevant switch. This system enables random check if
system is not energized for 12 hours i.e. if electricity board supply does not fail for
continuous 12 hours. Engine is switched ON to check its function. System enables 3
cranking attempts. If engine does not start with 3 attempts then alarm will be given
which will declare the failure of generator. If engine starts before this, 3 voltage levels
will be measured and engine will be kept ON for at least 10 min to ensure proper
lubrication of oil in cylinders as well as turbo charger if used with engine.
Temperature, diesel level and oil pressure can be monitored using temperature
switch; float switch and pressure switch respectively. Also R,Y B phase voltages are
measured. We require a signal conditioning block for each parameter. Output of this is
given to multiplexer, analog to digital converter and then microcontroller. We are
using ADuC 812 which is 8-channel 12 bit ADC flash microcontroller. We are also
using an alarm system and a LCD display. If in case any fault occurs then alarm will
start ringing. Also LCD will display the R, Y, B voltages and other parameters.

2. LITERATURE SURVEY:

Till now no automatic system had been used to check the working status and
parameters of generator. They use to start the generator when required and if in case it
did not work, they had to face problems. So it became very necessary to check the
working of generator from time to time. And doing the same procedure automatically
may prove much convenient. This setup proves useful in many industries. In mobile
towers automatic switching is used, i.e. when MSEB fails at that time generator is
switched on automatically. But no random check is available their. Thus if by chance
generator fails, due to any of its parameters not meeting the requirement, the mobile
towers stop working and for some time other mobile tower has to manage the
responsibility of handling the traffic of the failed mobile station. These may cause
hectic, which may be avoided only if the parameters are checked regularly.
Usually in military this concept of checking any mechanical or automobile
equipment is used. They make all their vehicles, planes, tanks etc go for a test ride
daily, just to check whether all the parts are in proper working condition.
In todays world some of the industries, hospitals, and mobile towers work for
24 hours continuously. And electricity plays a very major role in this. So it becomes
necessary to provide a continuous power supply to the industries, though MSEB may
or may not be available. A generator is used as optional supply. So whenever MSEB
goes off, the generator should automatically start. This will save time and manpower
as well. Also the generator is checked one in a day by running it for a specific period.
This helps to check whether the generator is in working condition. Thus due to both
time and manpower is saved and industry can work without any interrupt

3. BLOCK DIAGRAM:

Display

Temperature
Pressure
Level

Communication
Interface

Mseb vtg
Gen vtg

Micro
RMS to
DC
convert
er

MUX

A to D
controller
convert
er

Relay driver

Bluetooth
module

3.1 Block diagram description

3.1.1 Input section

This section is used for acquisition of input. The section consist of sensors, RMS to
DC converter, Multiplexer and Analog to digital converter

3.2.1 Controller section:

This section consist of the microcontroller

3.1.3 Output section:

This section is useful for indicating the result on various applications. This involves
LCD, Relays, LED and Bluetooth module

3.1.1 Input section

There are total 5 inputs to be given to the system. They are as follows
1. Temperature
2. Pressure
3. Level
4. Voltage from MSEB (reference)
5. Voltage from generator
3.1.1.1 Sensors:
We need different sensors to measure parameters. The sensors are required for oil
pressure switch, temperature switch, float switch, and phase voltages. The output of
the sensors of pressure, temperature and level are given directly to the micro
controller unit. This is possible because we have used sensor switch. But the other two
inputs i.e. voltages from MSEB and generator cannot be directly given to the
controller. We use the input section for these two voltages
Sensors used are
1. Temperature sensor switch:
If temperature exceeds a certain value at input then the switch is opened
2. Pressure senor:
If pressure exceeds a certain value at input then the switch is opened
3. Float switch:
If fuel level exceeds a certain value at input then the switch is opened

3.1.1.2 RMS to DC converter:

1. The input supply is analog voltage, which cannot be given directly to the
controller. So we have to first convert it in digital form.

2. The AD536A RMS to DC converter is used for this purpose. It is a complete

monolithic integrated circuit which performs true rms-to-dc conversion.
3. The AD536A directly computes the true rms value of any complex input waveform
containing ac and dc components and gives an equivalent dc output level.

Features of AD536A:
1. True rms to dc conversion
2. Laser trimmed high accuracy
3. Low power 1.2 mA quiescent current

3.1.1.3 Multiplexer:
1. The supply which is converted to dc is to be given to multiplexer.
2. We have used the ADG508A multiplexer so that pins of controller are saved, also
we can give more analog inputs in future if needed.
3. This mux has 8 inputs and selects its respective with the help of three control lines.
The control lines are given to the microcontroller. With the help software, we program
the controller in such a way that it continuously monitors the two inputs one after
other.
4. It has 5 V cmos and ttl logic compatible digital inputs
Features of ADG508A:
1.

44 V supply maximum rating

2.

Vss to Vdd analog signal range

3.

low power dissipation (28 mW max)

4.

low leakage (20 pA type)

3.1.1.4 Analog to Digital converter:

1. The output of multiplexer is given to A to D converter. This is done to make sure
that the supply voltage going as input to the controller stays in the range of 5 V.
2. The Microchip Technology Inc. MCP3201 is a successive approximation 12-bit
Analog-to-Digital (A/D) Converter with on-board sample and hold circuitry.
3. Communication with the device is done using a simple serial interface compatible
with the SPI protocol.
4. The device is capable of sample rates of up to 100ksps at a clock rate of 1.6MHz.

Features of MCP 3201:

1.12-bit resolution
2.1 LSB max DNL
3. 1 LSB max INL
4. On-chip sample and hold
5. SPI serial interface (modes 0,0 and 1,1)
6. Single supply operation: 2.7V - 5.5V
7. 100ksps max. Sampling rate at VDD = 5V
3.1.2 Controller section:

1. The controller is heart of the whole circuit. . We are using AT89S52

microcontroller in our car. The AT89S52 provides various features due to which it can
be used in many applications.
2. The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with
8K bytes of in-system programmable Flash memory. The device is manufactured
using Atmels high-density nonvolatile memory technology and is compatible with the
industry standard 80C51 instruction set and pin out.
3. The on-chip Flash allows the program memory to be reprogrammed in-system or
by a conventional nonvolatile memory programmer.
4. By combining a versatile 8-bit CPU with in-system programmable Flash on a
monolithic chip, the Atmel AT89S52 is a powerful microcontroller which provides a
highly-flexible and cost effective solution to many embedded control applications.
5. In addition, the AT89S52 is designed with static logic for operation down to zero
frequency and supports two software selectable power saving modes. The Idle Mode
stops the CPU while allowing the RAM, timer/counters, serial port, and interrupt
system to continue functioning. The Power-down mode saves the RAM con-tents but
freezes the oscillator, disabling all other chip functions until the next interrupt or
hardware reset.
6. The controller section takes the input from input section, processes it and then
gives the result to the output section. Three inputs have been given to the controller
directly, i.e. temperature, pressure and level. The controller monitors them
continuously whenever generator is in use, and if any of the parameter goes below a
certain value, then it indicates an error at the output section. Also it stops the generator
immediately.
7. The other two inputs, i.e. voltages from MSEB and generator are given with help of
input section. The controller also monitors them continuously. If the MSEB voltage
which is used as reference goes low, the controller reacts immediately and starts the
generator. When the generator is working, at that time it monitors the generator pin

continuously, and if that voltage goes beyond a certain value, it immediately stops the
generator. Also if when MSEB returns back, it understands as the respective pin goes high
and immediately it stops the generator.
8. Also this controller is used for random checking purpose. After a random interval, the
controller will automatically perform random check

Features of 89C5RD2:
The basic architecture of AT89S52 consists of the following features:

1. 8K Bytes of In-System Programmable (ISP) Flash Memory

2. 4.0V to 5.5V Operating Range
3. Fully Static Operation: 0 Hz to 33 MHz
4. 256 x 8-bit Internal RAM
5. 32 Programmable I/O Lines
6. Three 16-bit Timer/Counters
7. Eight Interrupt Sources
8. Full Duplex UART Serial Channel
9. Low-power Idle and Power-down Modes
10. Interrupt Recovery from Power-down Mode

3.1.3 Output section

3.1.3.1 Relay Driver and Relays:

Relay driver
1. The eight NPN Darlington connected transistors in this family of arrays are ideally
suited for interfacing between low logic level digital circuitry (such as TTL, CMOS
or PMOS/NMOS) and the higher current/voltage requirements of lamps, relays,
printer hammers or other similar loads for a broad range applications.
2. All devices feature opencollector outputs and free wheeling clamp diodes for
transient
suppression.
3. The ULN2803 is designed to be compatible with standard TTL families
Features of ULN 2803:
1. Output Voltage 50 V
2. Input Voltage 30 V
3. Collector Current Continuous IC 500 mA
4. Base Current Continuous IB 25 mA
5. Operating Ambient Temperature Range TA 0 to +70 C
6. Storage Temperature Range Tstg 55 to +150 C
7. Junction Temperature TJ 125 C

Relays
A relay is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism. Relays find applications where it is necessary to control a circuit by a
low-power signal, or where several circuits must be controlled by one signal.

Since relays are switches, the terminology applied to switches is also applied to relays. A relay
will switch one or more poles, each of whose contacts can be thrown by energizing the coil in
one of three ways:

Normally-open (NO) contacts connect the circuit when the relay is activated; the circuit

is disconnected when the relay is inactive. It is also called a Form A contact or "make" contact.

Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the
circuit is connected when the relay is inactive. It is also called a Form B contact or "break"
contact.

Change-over (CO), or double-throw (DT), contacts control two circuits: one normallyopen contact and one normally-closed contact with a common terminal. It is also called a Form
C contact or "transfer" contact ("break before make"). If this type of contact utilizes make
before break" functionality, then it is called a Form D contact.
The following designations are commonly encountered:

SPST Single Pole Single Throw. These have two terminals which can be connected or

disconnected. Including two for the coil, such a relay has four terminals in total. It is
ambiguous whether the pole is normally open or normally closed. The terminology "SPNO"
and "SPNC" is sometimes used to resolve the ambiguity.

SPDT Single Pole Double Throw. A common terminal connects to either of two others.
Including two for the coil, such a relay has five terminals in total.

DPST Double Pole Single Throw. These have two pairs of terminals. Equivalent to two
SPST switches or relays actuated by a single coil. Including two for the coil, such a relay has
six terminals in total. The poles may be Form A or Form B (or one of each).

DPDT Double Pole Double Throw. These have two rows of change-over terminals.
Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has eight
terminals, including the coil.

The relays are driven by controller through driver IC. We have used SPST and SPDT
relays. The relays are used to indicate following

1] Cranking relay:
This relay indicates the process of starting the generator. When the mains will go
low, the controller will drive this relay to indicate the process of starting of the
generator.

2] Alarm relay:

This is used to inform the supervisor that some fault has occurred. The fault
maybe low oil pressure, sudden rise in temperature (above the threshold or predefined level), low fuel level, or wrong phase voltages. The alarm is used as a audible
indicator and only rings as programmed by the microcontroller. This alarm is driven
with help of ULN 2803. Basically a relay is used for driving the alarm. This relay is
operated through driver.

3] Generator and MSEB relay:

It is a two way relay which indicates that either generator is on and currently
supplying to the load or MSEB is ON and supplying the load

3.1.3.2 LCD:

1. Liquid crystal display (LCD) is a thin, flat electronic visual display that uses the
light modulating properties of liquid crystals (LCs). LCs does not emit light directly.
2. LCDs therefore need a light source and are classified as "passive" displays. Some
types can use ambient light such as sunlight or room lighting. There are many types of
LCDs that are designed for both special and general uses. They can be optimized for
static text, detailed still images, or dynamic, fast-changing, video content.

3. LCDs are more energy efficient, and offer safer disposal, than CRTs. Its low
electrical power consumption enables it to be used in battery-powered electronic
equipment. It is an electronically-modulated optical device made up of any number of
pixels filled with liquid crystals and arrayed in front of a light source (backlight) or
reflector to produce images in color or monochrome.
4. Here is used to display the current measuring parameter. All the status, either
working or non working is displayed on this LCD. This helps in keeping the track of
quantity of each required parameter and if any quantity is previously seen exceeding
its limit then essential steps can be taken.
5. The R/W pin is grounded permanently. Also the other control signals which are
essential for LCD are RS i.e. register select, which is used to specify whether the
given information to the LCD is data or command. And enable pin which is used for
writing the data in LCD. The remaining four data bits of LCD are grounded. Also the
other remaining pins of LCD are used to adjust contrast, brightness etc.

3.1.3.3 Bluetooth Module

1. SC10B is Bluetooth V.2.0-certified and is backward compatible with v1.1/1.2 devices. You
can connect between your computers (Master) and RS232 devices (Slave) 100 meters away
without cables in your working environments.
2. Security of Bluetooth wireless communication is very strong because it uses the frequency
hopping and 128-bit encryption in 2.4 GHz frequency range. One pair of SC10B will try to
connect automatically whenever powered ON after finishing the devices parameters
configuration.

3. It does not require extra software for operation. No installation of driver and application
software.
4. It supports Win 98 / ME / 2000 / XP / XPx64
5. here we have used the Bluetooth module so that the status of the parameter and genset can
be transmitted on the computer.

Bluetooth Port
Bluetooth: 1 Port
Compliance: With Bluetooth v2.0+ EDR
Support Bluetooth Serial port profile (SPP)
Operate in 2.4 GHz 2.483 GHz ISM Band
Support Bluetooth Radio with Class 1 & 2 RF
Operating Distance: Up to 100 Meters
Power: 5V DC / 200mA, 80mA
Led Indications: SYS (Red), Pairing (Green)

Environment
Operating Temperature: 0to 60
Storage Temperature: -25 to 70
Dimensions: 65 * 30 * 12 mm (not including antenna)
Weight: 35 gm

Product description
DC-In Power Outlet
The SC10B Bluetooth to RS232 is powered by a single 5V DC 200 mA Power supply. Power
SC10B is given through the adapter. If the Power is properly supplied, the red color LED will
glow.

Antenna Connector
The connector for antenna is a standard Reverse SMA jack. Simply connect it to a 2.0dBi
dipole, 50 Ohms impedance and 2.4GHz frequency antenna. (The Antenna is changeable for
high gain Antenna)
Serial Port: RS-232
Connect the RS-232 port to the Serial device.
Set-up Button
This is to the left side of the SC10B. The purpose is to synchronize between SC10B device
and BT RS232 Config Tool software. After finishing the parameter setup of BT RS232
Config Tool software, when you click the icon of Connect in BT RS232 Config Tool
software, use any point tip to push this button You will see the icon of Connect turn into
Disconnect and this means successful activation of the device. The Read & Write Icons will
turn active & the version nos is displayed.
LED Indicators
Red Color LED: Power indicator
Green Color LED: Before synchronizing green LED will blink.
After synchronizing the Red & Green LED will be blink alternately

SC10B Hardware Installation

Connect SC10B Bluetooth adapter to COM Port of PC and connect Power adapter. You will
see the Red LED is On and the Green LED blinks.
After running the BT RS232 Config Tool and finishing configuration, Click the icon of
Connect in Tool software and press the SET-UP button immediately. The Green & Red LED
will blink alternatively.SC10B is active.
There are two types of RS232 devices in field. One is DTE - Data Terminal Equipment (such
as a PC) and the other one is DCE - Data Communication Equipment (such as a Modem). You
can setup your SC10B accordingly.

SC10B Hardware Installation

Connect SC10B Bluetooth adapter to COM Port of PC and connect Power adapter. You will
see the Red LED is ON and the Green LED blinks.
After running the BT RS232 Config Tool and finishing configuration, Click the icon of
Connect in Tool software and press the SET-UP button immediately. The Green & Red LED
will blink alternatively.SC10B is active.
There are two types of RS232 devices in field. One is DTE - Data Terminal Equipment (such
as a PC) and the other one is DCE - Data Communication Equipment (such as a Modem). You
can setup your SC10B accordingly.

BT RS232 Config Tool Installation & Setup

When setting up SC10B adapter for the first time, you have to install and
runBT1.exe / BT RS232 config tool in your computer. The utility CD is

enclosed in the device box. All the SC10B Bluetooth to RS-232 devices
must be configured first before you use it. The purpose of configuration is
to pair two SC10B devices for an exclusive connection between them, and
pairing is done by utilizing Bluetooth address and PIN code

SC10B Config Tool Parameters Configuration

Double click the icon of BT1 / BT RS232 Config Tool, the configuration
screen will be pop-up.
COM Port
Select COM port number, you have to avoid the port conflict with other
device in computer and use available port number.

Device Name
Select device name for identifying each one device. You can use the same
name or retype the new name.
Local Address
Local address will be automatically changed after finishing the parameter
configuration.
Peer Address
Peer address is for two or more devices to communicate in a same
network address.
PIN Code
PIN code is for the purpose of security consideration. Device uses this PIN
Code to identify during connection and communication.
Role
Role is for identifying a role of the device as a Master or Slave. In Master,
SC10B will play like a DTE mode - Data Terminal Equipment (such as a PC).
In Slave, SC10B will be play like a DCE - Data Communication Equipment
(such as a Modem).
Discoverable
Allowing (or not) SC10B to be detected by other Bluetooth devices.

Baud Rate
From 1200 bps to 115.2 kbps. Default is 9600
Handshake (DSR/DTR, RTS/CTS)
Default is Disable.
Stop Bit
Default is One Bit. Select from 1 or 2

Parity
Default is None. Choose from None, Odd, Even

Apply Connect

After finish the parameters configuration, click the icon of Connect in BT

RS232 Config Tool screen and press the SET-UP button immediately on the
left side of the device. Next screen of parameters configuration will popup. The icon of Connect changes to Disconnect and two icons will be
turned into active mode on the bottom of the BT232 Config Tool screen.

Apply Read
Read, means load all last saved parameters from the BT232 Config
Tool. The local address will be updated as the real device address.

Apply Write

RS-232 Pin Assignment

DSUB-9 PIN details

Pin 1 NC Pin 6 DTR (data output)
Pin 2 TXD (Output) Pin 7 CTS (data input)
Pin 3 RXD (Input) Pin 8 RTS (data output)
Pin 4 DSR (Input) Pin 9 DC 5v power (in)
Pin 5 GND
Remark: PIN CODE: 1234
: Default setup value: 9600, N, 8, 1

3.1.3.4 Communication Interface

1. In our project, Serial communication is being used to send the data between the
Bluetooth and the Car and Remote modules. For which RS 232 has been used along
with the DB9 male and female connectors.
2. RS 232 can be directly interfaced with the Microcontroller with same signal
timings as that of microcontroller. These parts are especially useful in battery-powered
systems, since their low-power shutdown mode reduces power dissipation to less than
5W.

4.

CIRCUIT DIAGRAM

4.1 Circuit diagram description for controller and output section

4.1.1 Controller section

1.

The circuit diagram is shown. An 89s551rd2 is used as the controller. The

parameters, i.e. temperature, pressure, level are given as input to the controller
directly to the pins P 0.4, 0.5, and 0.6.
2. The other two inputs that is the two voltages are first stepped down with the help
of transformers. Then through the input section they are then given to port P 3.6,
which is actually output from analog to digital converter. The other also CLK and CS
are connected to P 3.5 and P 3.7 respectively.
3. The LCD is also connected to the controller. The data lines of lcd are connected to
pin P 1.0 to P 1.7. Control signals RS RW and E of LCD are given to P 3.2, P 3.3 and
P 3.4. these lines are used to select register, select read or write mode and enable the
signal.

4. The relays at output are driven through ULN 2803. This driver IC is connected to
P 0.0 to P 0.3 of controller
5. Select lines of multiplexer are connected to P 2.0, P 2.1 and P 2.2 which helps the
multiplexer to select the input.
6. P 3.0 and P 3.1 are connected to TX and RX of MAX 232, which is used for serial
communication purpose
7.

Reset and oscillator circuitry is used for the controller. Pin number 9 is used as

reset whereas pin number 18 and 19 are used as oscillator circuit. Pin number 40 is
supplied with power supply of 5V and pin number 20 is grounded

4.1.2 Relay section

1. Pin number 1, 2, 3, 4 of the relay driver ULN 2803 are connected to P 0.0 P 0.3
of microcontroller, which drives the four output relays.
2. The output of the relay driver is obtained from pin number 13, 14, 15, 16, which is
then given to each relay.
3. Power supply of 5V is given at pin number 17 and ground is connected to pin
number 9. Also the unused input pins 5, 6, 7, 8 are grounded

4.1.3 Communication interface

1. In our project, we are using serial communication for which we are using RS 232 for serial
port connection. Pin 14 is T1-Out which sends the signal from the IC to the DB9 connector pin
no. 2. Here, this pin acts as the transmitter pin, which transmits the signal to the other module.
Pin 13 is R1-In which receives the signal from the DB-9 connector pin no. 3. This pin then acts
as the receiver pin, which receives the signal from other module.
2. The Bluetooth module is connected to this DB-9 male connector. The pin no. 5 is connected
to the ground.
3. The pin no. 11 is T1-In which receives the signal from the controller, which is then
forwarded to the DB-9 male connector (Pin 2). The pin no. 12 is R1-Out which gives the signal
to the controller, which comes from the DB-9 male connector (Pin 3).

4.1.4 LCD section

1. Pin numbers 4, 5, 6 of LCD are connected to P 3.2, 3.3, 3.4 of

microcontroller.
2. They are RS, RW, and EN (Register select, read/write, enable) of the
LCD.
3. RS is used to select either command register or data register. RW is
used for reading or writing purpose.
4. Pin numbers 1 to 8, i.e. P 1.0 - P 1.7 are connected to the data lines of
the LCD.

4.1.5 Power supply

1. The controller and other ICs strictly require the power supply of 5V.
2. To get that voltage we have used a small circuit which consist of a regulator IC 7805, which
gives +5V at its output, which is then given to the controller and other IC.

4.2 Circuit diagram description for input section

4.2.1 Input section

1. It is used as input circuitry for the two input voltages. The voltages cannot be used directly
in the circuit.
2. They need to be stepped down and transform so that they can be used for further processing.
This is done with help of input circulatory
3. It consists of an input transformer and rms to dc converter section. Input transformer steps
down the voltage to 6 V so that it can be given to the rms to dc converter.
4. Input to the converter is given at pin number 4 through a pot. And output is taken from pin
number 8. Pin number 1 is connected to preset.
5. Pin number 2 is grounded, pin number 3 is supplied with positive supply and pin number 5
is supplied with negative supply. Supply given is +/-12 volts.

4.2.2 Multiplexer

1. The next step is to give these voltages to an analog multiplexer. Here we have used
DG 508 as analog multiplexer
2. It has 8 input lines and three control lines. The inputs are given to pin numbers 4
and 5 which are the input pins of the multiplexer.
3. Pin number 1, 16 and 15 (A0, A1, A2) are the select lines which are given to P 2.0, 2.1, 2.2
of controller.
4. Using these pins we select the input. The output of the multiplexer is obtained from pin
number 8.
5. Pin number 13 is given to +12 V and pin number 3 is given to -12 V

4.2.3 Analog to dc converter

1. Output of the multiplexer is then given to analog to digital converter.

2. Pin number 5, 6 and 7 i.e. CS, DATA and CLK are given to the P 3.5, P 3.6, P 3.7 of
controller.
3. The input is given to the pin number 2 of converter.
4. Pin number 4 is connected to ground while pin number 8 is connected to + 5 V.
5. Pin number 1 is used to set reference voltage required for conversion

4.2.4 Power supply

1. Power supply of +/- 12 V is used to give supply to RMS to DC converter and analog to
digital converter.
2. 7812 and 7912 are used as voltage regulator so that voltage stays constant at 12 V

5. METHODOLOGY:
The system works in two modes

5.1 Auto mains switching

As seen from the block diagram, the microcontroller has five inputs, four from
generator and one reference input from MSEB. The reference input is continuously

monitored by the controller, to check the status of mains supply. While remaining
other inputs are checked when generator is to be started
So for first objective the MSEB reference is continuously monitored by the
microcontroller. As soon as the mains supply fails, the respective pin of
microcontroller will go low, and microcontroller will understand that the power
supply has failed. A separate powers supply is provided to the microcontroller
circuitry so that if the mains supply fails, microcontroller should be in working
condition. That is why the controller works though the mains supply has failed. Now
the microcontroller has to start the generator. But before that it should check for the
initial parameters, like fuel level, which are very necessary for starting. Once the
initial check is complete, and all the parameters are found ok, then the microcontroller
can start the generator, or else it will display on LCD the parameter which is not
meeting the requirement and also indicate it through alarm.
For starting the generator, cranking procedure is required. Cranking is a mechanical
process which is required to start the generator. So microcontroller will make the
generator crank automatically, i.e. no manual help is required for this process. The
microcontroller will make total of three attempts to start the generator. If within three
cranking attempts generator starts, then it can be concluded that the generator is in
proper working condition. But if in three attempts (this number of attempts can be
changed as per user requirement through program) the generator does not start, again
it will indicate on LCD and through alarm. Now this can be considered as a serious
error because it has occurred even when all the parameter status are fine, indicating an
internal problem.
If within the three cranking attempts the generator starts, then again all the parameters
are checked continuously. This time the initial parameters like fuel level as well as the
parameters which have to be monitored after the generator starts like phase voltages,
engine temperature are monitored. This is done until and unless the generator is
working. Now again during the working condition if any parameter is exceeded above
or below its threshold level, it is indicated with both LCD and alarm. Also when the
generator starts, load is transferred from MSEB to generator. The load is transferred

only and only when the generator is in proper working condition, which ensures
safety of the appliance or load. The status or error is periodically sent to the supervisor
via Bluetooth on his computer

5.2 Random check

The second objective is random check of generator. If in 24 hours or in a single day

the generator is not required, or if MSEB doesnt fail, then just to check the working
status of the generator random check is done.
For this random check the load transfer is not essential. This is because load is already
working on MSEB and does not need backup from generator. And the random check
is just a routine process to check the status of generator, so load transfer is not
essential. During random check the generator monitors and displays all the parameters
and if any problem occurs it can be previously known. The time taken for this check is
entered through program and can be changed. Here we have taken the time of
checking of 10 minutes. Thus the generator run continuously and automatically for 10
minutes and after 10 minutes it shuts down. When the time of random check matches,
at that time the generator is cranked, again in three attempts if does not start then
message is displayed on screen. And if it starts then all parameters are checked, status
is indicated on screen. All this process does not require load transfer. After
predetermined period the a random check is stopped and so is the generator
Now some conditions should be taken into consideration.
1] If in case during the time of random check, the MSEB fails, i.e. supply goes off
when generator is under random check at that time the microcontroller immediately
interrupts the process of random check, but before that it checks whether all
parameters are correct or not. Once this is ensured, the process of random check is
stopped at that instant and load is transferred on the generator itself. So there is no
need of waiting till the checking of generator ends.

2] Suppose generator is providing supply to load, i.e. MSEB has failed and the
generator is on, and the time of random check also matches with the current time. At
that time if the microcontroller follows the regular process of random check, then it
has to first transfer the load, which may interrupt the supply to the appliance. So to
avoid this, if such clash occurs, the microcontroller will not transfer the load, instead
it will cancel the routine of random check for that day or it can be postponed as per
the user requirements.

6. SOFTWARE
6.1 FLOWCHART:
START

LCD
INITIALIZATOIN

5*7 MATRIX 16
CHARACTERS AND 2 LINES
(38H & 0EH)

CLEAR DISPLAY (O1H)

W
CHEK PRESSURE SWITCH
OF GENERATOR

Y
IS

HIGH PRESSURE
ALARM

OPE
N? N
CHECK
TEMPERATURE

IS
OK
?
Y

CHECK FUEL LEVEL

OVER TEMPERATURE
ALARM

IS
OK

LOW FUEL LEVEL

ALARM

?
Y
CHECK MSEB POWER
SUPPLY

MAINS
SUPPY
AVAILA
BLEAVA
ILABLE?
Y

MSEB CONTACTOR ON
SET A VARIABLE Q=1

RANDOM ATTEMPT TIMER

ON
CHECK TIMING

DISPAY VOLTAGES

Y
N
X

IS
OK?

N
IS
MAT
CH
.
?

Y
CHECK R, Y, B
VOLTAGES

CRANKING ATTAMPT 1 TO
START GENERATOR

IS
ON?

CRANKING ATTEMP 2 TO
START GENERATOR

IS
ON?

Y
Y

5 MIN STABILIZATION
DELAY

N
CRANKING ATTEMP 3 TO
START GENERATOR

Y
GENERATOR IS ON AND
MEASURE R, Y, B
VOLTAGES

IS
ON?
N

CRANKING FAILED
ALARM

B
GENERATOR FAIL ALARM
N

IS
OK?

GENERATOR STOP
Y
Y
GENERATORS RANDOM
WORKING TEST

IS
Q=1
N

MAINS CONTACTOR
SWITCHED OFF

2 SEC SETTELING DELAY

FOR THE CONTACTOR

GENERATOR CONTACTOR
SWITCHED ON

MEASURE R, Y, B PHASE
VOLTAGES & PRESSUR,
TEMPERATURE & FUEL
LEVEL.
GENERATOR FAIL ALARM

IS
OK?

GENERATOR CONTACTOR
OFF
ENGINE STOP

Y
CHECK STATUS OF MSEB

IS
ARRIVE
D?

Y
10 MIN DELAY FOR
SETTLING

CHECK
R, Y, B
PHASES
OF MSEB
IS OK?
Y
GENERATOR CONTACTOR
SWITCHED OFF

MSEB
2
SEC CONTACTOR
SETTLING DELAY
ON
FOR THE CONTACTOR

CRANKING ATTEMP 1 TO
START GENERATOR

IS
ON?
N
CRANKING ATTEMP 2 TO
START GENERATOR

Y
IS
ON
N
?
VE
D?ATTEMP 3 TO
CRANKING
IS
START GENERATOR
ON?

CRANKING FAILED
ALARM

Y
Y

7. PCB LAYOUT
Much modern electronic system would be virtually impossible to package without
incorporating printed circuit board. A printed circuit board popularly known as PCB, is a piece
of plastic insulating board, on one side of which a complete layout diagram of an electronic
circuit consisting of copper as conductive layer is printed by a special a photo generation
process. On the other side of PCB are mounted electronic components like capacitor, register,
inductor and ICs. The metal conducting part serves as conducting medium for the electronic
components that are assembled on the opposite side of board.

7.1 ADVANTAGES OF PCB:

The advantage of printed circuit over conventional wiring methods is:

1.

Easy adaptability to miniaturization and modular design

2.

Uniformity in production

3.

Low cost

4.

Virtual elimination of wiring error

5.

Minimizing assembly and inspection time

6.

Easier to repair

7.

Greater reliability

8.

Easier testing

7.2DISADVANTAGE OF PCB:

1.

High development cost

2.

Total number of connection is more than required by direct lead soldering

3.

The layout of component have many constant as they must all be on one plane

4.

Certain types of defect have to be repaired by skilled operator

5.

Limited reparability in case of major damage

6.

Limited interchangeability

7.3 TYPES OF PCBs:

PCBs are divided into many classes according to several orbitary-overlapping criteria.

One division is into profession and non-professional or counselor.

Second is related to the number of layers of conductors and to the presence of plated through holes.
a)
b)

1. Single side PCBs

Non PTH
PTH

2.
a)
b)

Double sided PCBs

Non PTH
PTH

3.
a)

Multilayer PCBs
Thin

b)

Thick
Third board classification is based on the insulating material.

According to this one can have rigid flexible, hexi-rigid combination.

Other are depend upon density pattern types.

Signal sided: This type of PCB has conductor on soldering side only. It is often produce simply by
screen printing pattern on the copper clad laminate and etching the excess copper.

Double sided: This PCBs have conductors on both sides of board. If the holes are non-plated there is no
opposite side.

Multilayer PCBs: These PCBs have at least three layer of conductor. Two of them are on outer surface
of the board while remaining are incorporated are insulating board.

7.4 PCB MAKING:

Take proper scale of components and according to such a scale make component layout of
project circuit, on a paper. This layout is simple as well as small in size. The draw mirror image of PCB
layout.

7.5 ARTWORK :-( PAINTING AND DRILLING)

Take copper claded board of required size and transfer mirror image layout on board. Drill
for the connection on proper track. Using the paints i.e. the mirror image drawn by mirror does the
painting. After sometime check whether the painting is in proper alignment with rack and if in case there
is any fault then corrects it. Take solution of FeCl3 in port and deep PCB in solution for some hours.
After some time remove PCB from solution we see that the copper is removed from copper clad board
except that copper, which is painted.

7.6 STEPS FOR PCB DESIGNING:

The following checklist uses the major area of concern in the process of PCB design:
a)
Optimum size and shape of bold should be ensured.
b)
The substrate should be selected properly by taking into consideration its cost,
mechanical properties and electrical properties.
c)
Layout of conductor pattern should be taken care of from cross talk, leakage,
shielding, nos. of jumpers required and their placement.
d)
Selection of conductor width, thickness and spacing should be done after
analyzing their placement.
e)
Proper protective coating should be selected.

f)
g)
h)

Thermal consideration should be analyzed properly.

Proper mounting of heavy and unstable components should be ensured.
Easy maintainability should be built in.

7.6.1 Size and Shape:

The size and shape of PCB is compromise among the many parameters.
The maximum size of board is determined by the available facility, like the wave shouldering station,
cleaning tank, component assembling unit etc. when the board size is big and many components have to
be mounted on it the probability of the failure of the board increases. Troubleshooting for large board
increases. Smaller PCBs uses more connector; more back panel wiring which can be problematic due to
bad contacts.

7.6.2 Substrate material selection:

The mechanical properties that should be considered is water absorption, coefficient of

thermal expansion, thermal reading, tensile strength etc.For most PCBs applications, the dielectric base
material is chosen from one of four items given below:

a.
b.
c.
d.

Phenolic resin impregnated paper.

Acrylic resin impregnated fiberglass cloth.
Epoxy impregnated paper
Epoxy impregnated fiberglass cloth.

Some of the important technical consideration evolved in selecting coating materials is:
a. Effect of humidity and temperature on the insulation resistance of coating material.
b. Flexibility of the material.
c. Resistance to cracking during thermal shock.
d. Ease of application on the PCB and also the ease with which it can be removed while repairing the
PCB.

7.7 PRECAUTIONS IN PCB DESIGN:

a.
Before mounting any components, examine PCB carefully for any cracks, beaks, or other
defects in conducting paths.
b.
Drill the holes in PCB according to requirements.
c.
Carefully cut the leads of components so that 3 mm of the end extends beyond the wires inside of
PCB.
d.
In case of semiconductor like transistor, diodes the length of the leads extending above the
components side of the PCB should be above 1 cm. This will not only serve as heat sink to each head at
which soldering will also be useful for measuring voltage across their leads.
e. Certain components like transformer and variable capacitor, which are meant for used with the
PCBs, are provided with pin type terminals, which can be simply inserted into the holes and soldered.

8. ASSEMBLY AND SOLDERING

8.1 Assembly
Care has to be taken while soldering the component on the PCB. In a PCB the tracks are quite
closely spaced and probability of damaging them is more with inexperienced persons. This demands
him to have complete concentration. The risk of damaging the track is most while soldering them off.
Use of holder is certainly more advantageous for the soldering the ICs on the PCB. This way we need
not de-solder the ICs to replace in case of failure.
Also while assembling; care should be taken about the polarities whether they are important e.g.
electrolytic capacitors and rectifiers. The IC should be properly placed in the spacing and the pin no.
matching as shown in ckt. Dig.

8.2 Soldering:
For soldering, we have used an alloy which has a composition of 60%Tin and 40%Lead. In
soldering process, first of all we soldered the resistors, capacitors, transistors, LEDs, various links on the
board and then finally the microcontroller.
For soldering on the single side PCB we have used a 25W SOLDERON gun and also different
gun for SMD type soldering. The temperature of the gun is 250 degree Celsius. For the SMD type
soldering pads are used.
Care was taken so as to avoid dry solder and solder bubbles. We used a dissolver for desoldering.

9. PROBLEMS FACED

9.1 AVAILIBIILITY OF COMPONENTS:

9.1.1 RTC with inbuilt battery
SOLUTION: A RTC 48T08 with inbuilt battery was found

9.1.2 True RMS to DC converter LH 0091

SOLUTION: Other converter AD 536 was used

9.1.3 No Availability of AD 536 in DIP package

SOLUTION: circuit d\diagram was changed and ad 536 in metal can package was used

9.1.4 Reset IC for the controller

SOLUTION: AM 408 was the reset IC we needed for our controller which was not available.
So we decided to create a separate reset circuitry for the IC

9.2 CIRCUIT DESIGN:

9.2.1 Interfacing of RTC 48T08 with microcontroller
SOLUTION 1: The RTC had 13 address lines, 8 data lines and 5 control lines which had to be
connected with controller. Hence total 25 pines of controller were required, which left us with
only 7 pins to use. We tried the interfacing using 8255

SOLUTION 2: We tried using latches, but then we faced limitations in accessing the address
and data simultaneously. So we replaced the RTC with one which was i2c based.

9.3 PCB DESIGN:

9.3.1 The designed PCB had incomplete tracks and was not printed through hole
SOLUTION: The tracks which were incomplete were given to their respective terminals with
the help of external connections and the problem of being non PTH was solved by linking
method

9.3.2 Problem in footprint matching

SOLUTION: The footprints of the controller IC didnt match as it was a surface mount device.
We provided the designer with a real IC to match the footprint.

9.4 PROBLEMS FACED IN HARDWARE DESIGN:

9.4.1 The controller was not being detected by the PC
SOLUTION: The controller we used was an ISP. The controller was not detected on the PC.
We checked the voltage levels at the MAX 232 IC as well as at transmit and receive pin of the
controller which were satisfactory, still the IC was not detected. Then we made contact with
the manufacturers of the controller that is Analog Devices, they assured us with their help by
sending us the evaluation board for reference

ADUC812 evaluation board:-

So we decided to change the controller and switched to 89C51

10. ADVANTAGES AND DISADVANTAGES:

10.1 Advantages

a. Daily check keeps all parts of generator in proper working state

b. The switching of load and checking the working status of generator and its parameters is
an automatic process.
c. Fault in the generator can be found out earlier and the problem can be solved at that
instant.

10.2 Disadvantages
Create power disturbance between the time power supply goes off and until the generator is
started

11. REFERENCES:

1. Bright Star Electronics

2. www.alldatasheets.com
3. www.dieselserviceandsupply.com
4. Wikipedia

6. FUTURE SCOPE:

1. Using a GSM module the status can be obtained on mobile.

2. Also using data transfer mode this status can be continuously
monitored on pc though internet.
3. Due to this system a single supervisor can monitor more than one
power supply.
4. With the help of an external battery, power supply can be provided
during switching process, thus providing continuous power.

7. CONCLUSION:

1. Using this system MSEB supply is continuously monitored. As soon as

the MSEB fails generator is switched on automatically.
2. With the help of random check all parameters of generator are checked
regularly and automatically.
3. The project we are working on will help in increasing the performance
and life of generator, thus making it more reliable.