Installing and Connections

Installing and Connections

(Last revised 8-5-2014)



This section contains steps used to install the controller onto the generator.  For this you will need some additional parts.  See the BOM / Parts list for details and sourcing ideas.

• DS18S20 based temperature senders
• K-type EGT probe
• Cruise Control actuator from junk yard + hardware to connect it to the throttle
• External relay for starter (v0.1.3 PCB)
• External fuse holder with fuse sized for the total system load.  (15-20 A typically)
• At least two push buttons for local control (Start and Stop)
• And at least one on/off switch for local power on/off

Of course, if you do not wish to use all the features there is no need to purchase the probes.   Even the throttle Cruise Control module can be eliminated if desired.  The following are the steps I used when installing this project onto our existing Kubota Dc Generator / Watemaker.  (See more on that installation here:  http://mvvikingstar.blogspot.com/search/label/Kubota%20DC%20Generator)

Kubota Throttle Control

To controll the throttle, an automobile cruise control throttle unit is used.  The controller provides three wires to the throttle unit:

• Clutch
• Throttle UP
• Throttle Down

When selecting a Cruise Control module make sure it has built in limit switches that will disable the throttle motor when Full On or Full Off position has been reached.  The controller assumes it  can get Full Throttle by simply enabling the clutch and powering the Throttle-up wire indefinitely, and that the throttle unit will automatically cut power when it has reached full throttle position.

Temperature Sensing

 Up to 5x DS18S20  (or 18S20)  based 'waterproof' temperate senders are used to sense various temperatures throughout the system, both for optimization as well as fault determination.  I made small tabs for 4 of the senders, and used a brass fitting for the 5th one where it bolts into the Kubtoa.  (See details here:  http://smartdcgenerator.blogspot.com/2013/01/preparing-ds18b20-temperature-senders.html)

These are used to monitor the following system temperatures:

• Battery temp
• Alternator temp
• Kubota temp
• Sea Water Pump temp
• Exhaust / Sea Water mixer temp

You will need to learn the addresses of each probe and edit that into the SERC_config.h file.  This can be done using the controller board, or an external Arduino UNO if you wish.  to use the controller board, connect the service cable, make sure all the libraries are copied from the 'Ardino Libraries' tab above to your local system.

• Opening the Arduino IDE you can select: File/Examples/Dallastemperature/Tester
• Change "#define ONE_WIRE_BUS 2" from 2 to 10 (Controller used port 10 for the one-wire)
• Upload the sketch

Connect one prob at a time to the controller (any position will work for this), upload the tester sketch and open a communications window.  Any probe found will have its address displayed.  Copy this down, or cut-n-paste it into the config.h file for where THAT sender will be used.

EGT - K-type probe.

The EGT us a standard K-type probe.  Select one designed for EGT usage, as it will have the correct case material and the ability to provide a gas tight seal into the exhaust pipe.

Alternator and Battery Electrical Connections

Connections are made to the System and House batteries to get operating power as well as sense the house battery voltage state.  Wiring to the Alternator are used to provide Field voltage, as well as sense the Stator pulses.  This is used to determine system RPMs as well as lock-step the battery voltage measurements with the Stator.

in V2 of the controller, there are two additional connections   FLD-DRIVE and FLD-FLY.  These are used to isolate the Field power from the controllers power lines.

FLD-DRIVE:  Provides the DRIVE level for the field circutes.  If you have a HIGH Drive (P-Type) alternator, this should be connected to +BAT.  If you are driving your alternators LOW (N-Type), then connect this wire to Gnd.

FLD-FLY:  This is used to protect the FETs from fly-back voltage.  Connect this wire to the opposite if FLD-DRIVE.  e.g., in a P-Type deployment, this would go to GND, while in a N-type deployment, this would go to +BAT

In V1 of the PCB, these are connected internally to BAT+ and BAT-

COMMON AMP SHUNT NEED

The controller used starter current draw to determine if the engine has started.  Because of this, the engine AND the alternator need to share a common Amp Shunt.  In a single battery installation this is rather simple, but when split batteries (and voltages) are used for the System and House batter, the Shunt will need to be installed in a common GROUND line.  In addition  caution must be taken around any other charging sources, ala, a 2nd alternator connected to the System battery, as this will interfere with the regulators function.

It is possible to repurpose the EGT connection to support a 2nd Shunt to measure only starter current.  The hardware would not require any changes, but there would need to be some modification to the controller firmware.

Kubota Electrical Connections

Take note that V1 of the controller drive the STARTER wire LOW to engage the starter, while V2 drives it high.

The Oil Pressure switch should ground the wire when oil pressure is low.  likewise, the Waterflow switch should ground its wire when water flow is low.

The GlowPlug and Fuel Pump wires are active HIGH and can be used to power these devices directly.

Local Control Switches

3 switches may be connected locally to control the system:
  Start Generator
  Start Watermaker
  Stop-All

Grounding the Start-Generator wire will instruct the controller to start the Generator mode.  if the engine is not running, it will start the engine and then ramp up the alternator.  If the engine is already running (either in a ramp-down phase, or running the Watermaker), the controller will turn off the watermaker clutch and ramp the alternator up to full power.

Grounding Start-Watermaker will also start the engine if it is not running.  If it is already running, (ala, is currently generating), it will reduce the alternator output and start enable the watermaker clutch.

Stop-All:  Grounding this will  stop EVERYTHING.  It overrides the remote panel, and leaving this switch grounded will provide a safety interlock when servicing the engine.  Normally the engine does a cool-down phase, but if you close this switch to enter cool-down, and then open the switch and close it again (in effect, pressing STOP twice), the engine will immediately turn off.  This can be used as a safety feature if something has gone wrong.

EXAMPLE WIRING SUMMARY DIAGRAM

The only difference between the version of the controller boards is how the Field drive is connected.  See table below for details.  Make sure to read PCB errata for silk-screen errors on the connectors.

WIRING SUMMARY TABLE

Name	Grouping	Purpose	Connect to	Expected Voltage	Min Wire Size	Fuse	Note
BAT +	System Battery	Provides power to controller.  Also powers FIELD in V1 of controller PCB.	System Battery +	Up to 24v	14g	15A
VBat +	House Battery	Measures voltage in house battery	House Battery +	With appropriate configuration up to 48v.	18g, twisted pair	2A	Connect these wires AT the house battery as close to the battery terminals as allowed.
VBat -			House Battery –
BAT -			House Battery –		14g		Connecting BAT – to the House Battery Ground gives better stability in VBat measurements.
BATTERY Temp		Measure House Battery temperature	Battery Temperature probe		Cable		Typical place probe on – terminal of battery in middle of battery bank.
CSh +	Common Battery	Measured alternator current, as well as starter current to determine if engine has started.	+ terminal on Current Shunt (Terminal on BATTERIES side of shunt)		18g, twisted pair		System can be modified to support separate shunt for Alternator and Starter, by re-purposing EGT port.  Will require modification of controller code.
CSh  -			- terminal on current shunt
FLD  (v0.1.x &    v0.2.x)	Alternator	Provides field voltage to control alternators.	F terminal on Alternator	PWM controlled – between 0v and FLD-DRIVE  voltage (Configurable to 48v)	14g		Use larger wire if Field currents in excess of 10A expected.
FLD DRIVE (v0.2.x only)		Allows selection of P-type or N-type alternators (along with board stuffing options – see Configuration)	System Battery + for HIGH DRIVE alternators, System Battery  - for LOW DRIVE alternators		14g	15A (If connected to Battery +)
F-FLY (v0.2.x only)			System Battery - for HIGH DRIVE alternators, System Battery  + for LOW DRIVE alternators		14g
Alt + (v0.3.x & up)		Drive power for Field	+ terminal of field voltage source.  Typically VBat, but can be independent	Vbat or other field source.	14g	15A
A		Selected High Drive or Low Drive mode for Field.	High Drive: ·   Jumper A/B ·   Field  = C/D Low Drive: ·   Field  =  A/B ·   Jumper C/D	PWM Controlled
B
C
D
Alt -		Field return.	Ground	0v
STATOR		Determine RPMs of alternator (and hence engine).  Also used to lock-step voltage and current measurements with Stator.	Stator terminal on Alternator		16g	2A
ALT Temp		Measure Alternator temperature	Alternator Temperature probe		Cable		Typically place probe on + terminal of alternator.
EGT - EGT +	Engine	Determine EGT of engine.  Used to prevent overloading engine	EGT probe		EGT probe wires		Do not extend these wires, purchase probe w/ needed length.
START		Engage starter.  This will raise to System + voltage when starter is be engaged.	Starter solenoid	BAT + when active  (See note re: V1 boards)	14g		Note that in V1 of controller, this is an ACTIVE LOW signal
FUEL P		Engage Fuel Pump	Fuel pump	BAT + when active	14g
GLOW		Engage Glow Plug	Glow Plug	BAT + when active	14g
Oil Low		Indicated to controller oil pressure is low.	Low Oil Sender	Sender should GROUND this line when oil pressure is low.	16g
RAW-W		Indicated to controller cooling water flow is low.	Water Flow Sender	Sender should GROUND this line when water flow is low.	16g
Th-CL		Engages Throttle Controller clutch		BAT + when active	14g
Th-UP		Increases Engine Speed		BAT + when active	14g
Th-DN		Decreases Engine Speed		BAT + when active	14g
ENGINE Temp		Measure engine coolant temperature	Engine coolant Temperature probe		Cable
SEA WATER temp		Measures temperate of sea water pump, used to detect run-dry conditions	Sea Water Temperature probe		Cable
Exh-MIX		Measured temperature of exhaust mixer.  Use to detect failure in coolant water flow.	Exhaust mixer Temperature probe.		Cable		Typically this probe is attached to the sea water injection point on the exhaust system.
W-Mkr	Water maker	Engages Watermaker high pressure pump	Clutch on Water maker.	BAT + when active	14g		This can be reconfigured via #define statements in the source code to drive coolant co-gen pump instead.
R-GN	Local Control Switches	Request  starting of Generator mode	SPST-MOM switch to Ground to request generator		16g
R-WM		Request start of Watermaker mode	SPST-MOM switch to Ground to request Watermaker		16g
S-ALL		STOP ALL!   Also provides safety interlock / override for remote control panel	SPST switch to ground to stop all, leave connected to Ground for safety interlock.		16g		If left on ground, ‘LOCKED OUT’ will appear on remote LCD display.
Remote	Remote	Wiring and Power to remote control panel	Remote Panel		CAT-5 cable

Capture Run Data

After you have things installed and running, consider capture debug data for your own use as well as sending it to me to help improve the core code.  See: http://smartdcgenerator.blogspot.com/.../capturing-log-data..
for details on how to do this.