Connecting the Controller up

I have been working on documenting how to connect up the controller, see INSTALLATION section above.

http://smartdcgenerator.blogspot.com/2000/01/installing-and-connections.html

 And here is a table I made as well:

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	Alternator	Provides field voltage to control alternators.	F terminal on Alternator	PWM controlled – between 0v and FLD-DRIVE  voltage (Configurable to 48x)	14g		Use larger wire if Field currents in excess of 10A expected. Note:  FLD-DRIVE and FLY-Fly are not used on V1 of controller board.  Instead these are internally connected to BAT + and BAT – (System battery)
FLD DRIVE		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			System Battery - for HIGH DRIVE alternators, System Battery  + for LOW DRIVE alternators		14g
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