A generator controller, rich in features, poor in cost (hopefully)

[Crossy]

Spurred on by comments in a couple of other threads I'm going to build a "universal" generator controller along the lines of this https://www.gencontrol.co.uk/auto-start-for-hyundai-genset.html. This unit can directly connect to the key switch of pretty well any generator with key start and stop and an automatic choke if it's petrol.

 

I hope to get well below 50% of the 102 Squid the Gencontrols unit costs and include additional features found only on the more costly units.

 

Being based on a simple and cheap microcontroller (yes, another Arduino project) it should be readily expandable to do even more, for example it could go the whole hog and control the transfer contactors too, saving even more $$$ for those with a bent for DIY and a logical mind to expand the program.

 

In addition to the basic functions provided by the linked unit let's add:-

1. LCD display of status.
2. Display of voltage and current when the genset is running.
3. Output enable relay to connect the load once the genset is running and up to speed, no starting on-load.
4. Cumulative engine hours, time that oil change to perfection.
5. Emergency Stop input, kill the genset before it kills you.

 

Anything else I (or other forum members) think of.

 

Task A) any input from members for "features"?

 

 

 

[RichCor]

Option to set Preset Delay for STOP when normal MAINS resumes after power fail?

Option for Monthly Maintenance timed RUN mode/switch back to MAINS when complete? 

Remaining run time on fuel available?  (Yes, I know - But thought I'd suggest)

 

Recipes for GenSet exhaust cooker accessory by Crossy 

[Crossy]

Some interesting ideas there @RichCor definitely worth looking into.

 

OK, an initial shopping list:-

 

Arduino Uno clone $3.70

https://www.aliexpress.com/item/Free-shipping-UNO-R3-MEGA328P-with-usb-cable-for-Arduino-Compatible-Dropshipping/32241225914.html

Handy dandy prototype board with a push button and 2 LEDs $1.40

https://www.aliexpress.com/item/ProtoShield-prototype-expansion-board-with-mini-bread-plate-based/726121913.html

16 character  x 2 line LCD $2.10

https://www.aliexpress.com/item/HX-6M20-V4-0-In-stock-Best-price-and-good-service/595894389.html

30A / 10mA (1:3000) current transformer $2.00 - I'm going to use the same one as I used in the Mains monitor (still have 4 spares)

https://www.aliexpress.com/item/Make-30A-input-10mA-cable-output-type-current-transformer/32468074352.html

4 channel relay module $1.90 This unit has 10A relays so won't need additional relays for small gensets.

https://www.aliexpress.com/item/With-optocoupler-4-channel-4-channel-relay-modules-relay-control-panel-PLC-relay-5V-four-way/1952619257.html

4 channel opto isolated module $0.96 really intended to be used as an output device this chap will do the job of isolating the inputs just fine.

https://www.aliexpress.com/item/TLP281-4-Channel-Opto-isolator-IC-Module-For-Arduino-Expansion-Board-High-And-Low-Level-Optocoupler/32833060865.html

12V 1A switching power supply $2.71 same one as I've used on the other projects. This one can be adjusted down to 9V which would reduce the stress on the 5V regulator.

https://www.aliexpress.com/item/AC-100-260V-To-DC-12V-1A-12W-Switch-Power-Supply-Driver-Adapter-LED-Strip-Light/32820289977.html

"Dupont" cables $2.50 I have a box of various lengths anyway.

https://www.aliexpress.com/item/120pcs-20cm-male-male-male-female-and-female-jumper-wire-Dupont-cable-for-Arduino/1682122216.html

The smallest 12V power transformer you can find, NPE have loads for around 150 Baht. You need 12V AC so a bare transformer is the easiest option.

 

You'll also need assorted resistors, capacitors and a 5V regulator, we'll come to those when we need them.

 

This far we have spent about $18. Apart from a box and a handful of electrical bits (which would be needed anyway) I think that's all the major bits.

 

 

 

 

 

[Air Smiles]

 

Might need some mulling to implement, but the poll could be exploited for many things, eg kwh/ltr, would be handy for seeing real time efficiency, set min efficiency alarm, keep records etc.

http://www.instructables.com/id/Measure-Fuel-Level-With-Arduino/

https://maker.pro/projects/arduino/ultrasonic-arduino-water-level-indicator

[Crossy]

1 hour ago, Air Smiles said:

Might need some mulling to implement, but the poll could be exploited for many things, eg kwh/ltr, would be handy for seeing real time efficiency, set min efficiency alarm, keep records etc.

The sky is actually the limit on the additional functions. All worth bearing in mind.

 

I fear this becoming a monster, enter Baron Frankenstein.

 

[Crossy]

19 hours ago, RichCor said:

Remaining run time on fuel available?  (Yes, I know - But thought I'd suggest)

I'm failing to find a low-rate fuel flow sensor 

 

[Crossy]

Whilst waiting for assorted bits to arrive from AliExpress I did the schematic.

 

 

The observant will note I ended up using the same opto-isolator arrangement as I did for the pond controller, so the little boards I ordered will be spare.

 

I've included two 220V interfaces, one for the genset and the other for a possible plan to monitor the incoming supply and control the under/over and ATS contactors all from the one unit. The 220V-12V 100mA transformers were 44 Baht each from NPE.

 

Software is coming along, but not ready for public display, all good fun.

 

 

 

[monkeybottom]

Crossy,

 

this is highly dependent on engine, but bear in mind that most diesel engines have a fuel supply and also a return to the service tank.(at least they do on the vessel i work on).

You would need two flow sensors and calculate the difference.

If its a common rail engine it's possible to get the fuel rate direct from the engine data bus ( if it has a CAN bus or similar).

 

[Crossy]

Time for a brief update.

 

The completed interface board:

 

And the back, not a work of art I'm afraid:

 

 

The prototype under test.

 

 

 

 

[Crossy]

The current software.

 

Genset_V1.6.ino

 

At present we have:-

• Three switchable modes, Auto, Manual and Off.
• Three start re-tries.
• Once running display of generator voltage and current.

 

Also adjustable timers for:

 

• Cranking time
• Delay between start attempts
• Mains fail to generator start (if the mains returns during this period the generator will not start)
• Warm up (generator running, output not connected)
• Mains good to generator output off
• Cool down (generator running output not connected)

 

Next task, stop the engine if the generator output fails.

 

 

[Crossy]

On 3/12/2018 at 6:25 PM, Crossy said:

Next task, stop the engine if the generator output fails.

Done.

 

Genset_V1.7.ino

 

This version works fine for those who just want to control their genset and have a means of sensing the mains to a relay contact.

 

Now for a slight (ish) change of direction.

 

It has been decided that to minimise the number of boxes and flashing lights in the lounge that we are going to combine the mains monitor and logger with the generator controller.

 

This should be fun as we are going to be pushing the envelope of the available memory.

 

Gotta lurve a challenge