DESIGN AND CONSTRUCTION OF

AUTOMATIC HOUSEHOLD GENERATOR CONTROLLER

BY

AGBEJE, ESHIADIME CLEMENT EEG/2006/026

A DISSERTATION SUBMITTED TO THE DEPARTMENT OF ELECTRONIC AND ELECTRICAL ENGINEERING, OBAFEMI AWOLOWO UNIVERSITY, ILE-IFE, OSUN STATE, IN PARTIAL FULFILMENT OF THE AWARD OF BACHELOR OF SCIENCE (B.Sc.) DEGREE IN ELECTRONIC AND ELECTRICAL ENGINEERING

DECEMBER, 2012

Department of Electronic & Electrical Engineering, Obafemi Awolowo University, Ile-Ife, Osun State. 26th Jan., 2012.

The Project Co-ordinator, Department of Electronic & Electrical Engineering, Obafemi Awolowo University, Ile -Ife, Osun State. Dear Sir, LETTER OF TRANSMITTAL In partial fulfilment of the requirement for the award of Bachelor of Science in Electronic & Electrical Engineering, I hereby submit this dissertation titled Design and Construction of Automatic Household Generator Controller as my final year project report for due considerations and approval. Thanks for your cooperation. Yours faithfully,

Agbeje E.C EEG/2006/026.

ii

CERTIFICATION
I hereby certify that the contents of this report are commensurate with and representative of the work done by AGBEJE, ESHIADIME CLEMENT (Reg. EEG/2006/026), of the department of Electronic and Electrical Engineering, Obafemi Awolowo University, Ile-Ife during the course of his final project.

____________________________ Date

___________________________________ Mr. Olawale Akinwale Supervisor

iii

DEDICATION
TO Almighty God my Life force and source of Inspiration. To my parents also, Mr and Mrs Agbeje who have been there for me through thick and thin.

iv

ACKNOWLEDGEMENT
First and foremost, my greatest gratitude goes to God, the giver of life and the air that I breathe oxygen, without whom life would be void, meaningless and purposeless. To my supervisor, Mr Olawale Akinwale, for the sacrifices he made and support he gave to ensure the successful completion of this programme. A Very outstanding, thoughtful, and intelligent lecturer; Im glad to have had the privilege of meeting and learning from you and you have opened the door to learning for me. God bless you sir.. I am indebted to, Mr Fiyinfolu Dele-Ijagbulu, who came up with this project idea and has been really supportive. Mr Ogunba, Dr Thomas Yusufu, Mr Ilori, Mr Isaac Inyang and other lecturers of the department of Electronic and Electrical Engineering who have shaped me into what I have become. I appreciate the contribution of the entire staff of the department both academic and non-academic. My sincere gratitude goes also to like my Project partner Owamokele, Oluwaseun Samuel for his ruggedness during the course of this project implementation without him this project would not have gotten to this phase. Profound gratitude goes to my parents, who have stood by my side over the years, come Rain come Sunshine. I can never repay the unconditional Love, sacrifices and prayers to ensure I get the best out of life, could never ask for better parents. To Clementina my twin Sister, I cant recount my success without mentioning you, I treasure and appreciate all your efforts to make my dreams come true. Also

to Augusta and Celestina, my sisters, who stood by me every step of the way and other wonderful members of my family for their unconditional love God bless and replenish everyone. Finally to my special friends Ismail, Kazeem, Odenema, Sunkanmi, Abiola Ibrahim, Folajaiye, Ibidokun Wale, Taiwo, Tomi, Williams , and to others not on the list who I have had the opportunity of meeting during the course of my degree, you all have kept me going over the years, and made my stay interesting. I love and appreciate you all in ways words can never sufficiently express. God bless you all.

vi

TABLE OF CONTENTS
CERTIFICATION............................................................................................................................... iii DEDICATION ...................................................................................................................................... iv ACKNOWLEDGEMENT.................................................................................................................... v TABLE OF CONTENTS .................................................................................................................. vii LIST OF FIGURES............................................................................................................................... x LIST OF PLATES................................................................................................................................ xi ABSTRACT ........................................................................................................................................ xii CHAPTER ONE ................................................................................................................................... 1 INTRODUCTION ................................................................................................................................ 1 1.1 1.2 1.3 Brief Introduction ........................................................................................................... 1 Aim and Objective ........................................................................................................... 1 Justification ........................................................................................................................ 1

CHAPTER TWO .................................................................................................................................. 3 LITERATURE REVIEW .................................................................................................................... 3 2.1 2.2 Introduction ...................................................................................................................... 3 Existing Automatic Generator Controllers ............................................................ 3 The Dale 5050 controller ..................................................................................... 3 ECONOSTART 8000 series controller ......................................................... 7 The GSCM-mini Controller ............................................................................... 12 The Xantrexs Automatic Generator Start (AGS) Control System ..... 22

2.2.1 2.2.2 2.2.3 2.2.4

CHAPTER THREE ........................................................................................................................... 26 METHODOLOGY (PROJECT IMPLEMENTATION) ............................................................. 26 3.1 3.2 Project Description ...................................................................................................... 26 System Requirement ................................................................................................... 28 Ignition relay switch ........................................................................................... 28 Choke pneumatic switch ................................................................................... 30 Parameter Monitoring ....................................................................................... 32 The Processing Unit ............................................................................................ 36 Human interface devices .................................................................................. 38 Software development tools............................................................................ 42 Hardware development tools ......................................................................... 44

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.3.1 3.3.2

Development Tools ...................................................................................................... 42

CHAPTER FOUR .............................................................................................................................. 45 TEST AND RESULTS ...................................................................................................................... 45 4.1 Software Testing ........................................................................................................... 45 vii

4.2

Hardware Testing......................................................................................................... 45 Cranking .................................................................................................................. 47 Manual Starting .................................................................................................... 47 Automatic Starting .............................................................................................. 49 Timed Running of Generator........................................................................... 49

4.2.1 4.2.2 4.2.3 4.2.4

CHAPTER FIVE ................................................................................................................................ 51 CONCLUSION AND RECOMMENDATION.............................................................................. 51 5.1 5.2 5.3 5.4 Introduction ................................................................................................................... 51 Comparison with other Implementations .......................................................... 51 Future Research ............................................................................................................ 51 Recommendations ....................................................................................................... 54

APPENDIX A ..................................................................................................................................... 55 COMPREHENSIVE CIRCUIT DIAGRAMS ................................................................................ 55 APPENDIX B ..................................................................................................................................... 59 SOURCE CODE FOR THE PROJECT .......................................................................................... 59 APPENDIX C ..................................................................................................................................... 61 BILL OF MATERIALS FOR THE AHGC .................................................................................... 61 APPENDIX D ..................................................................................................................................... 63 USERS GUIDE FOR AHGC ........................................................................................................... 63 SAFETY SUMMARY ................................................................................................................... 63 Fuse Replacement ............................................................................................................ 63 Power Source....................................................................................................................... 63 Servicing ................................................................................................................................. 63 OPERATION .................................................................................................................................. 64 POWER Light ............................................................................................................................... 64 GEN STATUS Light .................................................................................................................... 64 FAULT Light ................................................................................................................................. 64 MODE Switch ............................................................................................................................... 64 PWR button.................................................................................................................................. 65 RESET button .............................................................................................................................. 65 MENU/SELECT button............................................................................................................. 65 UP button ...................................................................................................................................... 65 DOWN button .............................................................................................................................. 65 START/STOP button ................................................................................................................ 65 AUTO Mode .................................................................................................................................. 65 MANUAL Mode ........................................................................................................................... 66 viii

TIMER ............................................................................................................................................ 66 SETTING THE TIMER ...................................................................................................... 66 AHGC DISPLAY MESSAGES .................................................................................................... 67 TIME DELAYS .............................................................................................................................. 68 STARTING A GENERATOR WITH AHGC ........................................................................... 69 AUTO START ........................................................................................................................ 69 MANUAL START ................................................................................................................. 69 STOPPING THE GENERATOR WITH AHGC ...................................................................... 69 AUTO STOP............................................................................................................................ 69 MANUAL STOP .................................................................................................................... 70 SPECIFICATIONS ...................................................................................................................... 70

ix

LIST OF FIGURES
Figure 2.1: The Dale 5050 front panel ......................................................................................... 5 Figure 2.2: Econostart Front panel and Electrical Connections .................................... 9 Figure 2.3: The GSCM-mini front panel ....................................................................................... 13 Figure 2.4: GSCM-mini wiring diagram and controller configuration............................. 18 Figure 2.5: The Xantrex AutoGenStart front panel ................................................................. 24 Figure 3.1: Block Diagram ................................................................................................................ 27 Figure 3.2: Ignition and Engine relay switches ........................................................................ 29 Figure 3.3: Polarity reversal circuit for choke pneumatic switch operation ................ 31 Figure 3.4: Battery monitoring circuit ......................................................................................... 33 Figure 3.5: Circuit for monitoring mains availability and generator output feedback................................................................................................................................................... 35 Figure 3.6: Pin-out diagram of the PIC18F4520 that was used in this project ............ 37 Figure 3.7: LCD circuit connection with the PIC data connections labeled as shown ....................................................................................................................................................... 39 Figure 3.8: The LED indicator connection .................................................................................. 39 Figure 3.9: Button connection circuit .......................................................................................... 41 Figure 3.10: An in- circuit buzzer in simulation ...................................................................... 41 Figure 3.11: The Proteus simulator interface/environment .............................................. 43 Figure 4.1: The Structure and the Table of reference of the key-starter switch of Tiger TG6500 generator.................................................................................................................... 46 Figure 5.1: Bridge for capacitive level sensor ........................................................................... 53 Figure A1: Monitoring Circuits ....................................................................................................... 55 Figure A2: Main Circuit for project ............................................................................................... 56 Figure A3: Ignition and engine switch actuating circuits ..................................................... 57 Figure A4: Polarity reversal circuit for actuating the choke pneumatic switch .......... 58

LIST OF PLATES
Plate 4.1: Front panel of AHGC showing the face ...............................................................48 Plate 4.2: Another view of the showing the fuse protection for mains sensor .......50

xi

ABSTRACT
This project is all about the design and implementation of controller for the purpose of automation of a household generator. This is how the name Automatic household generator controller (AHGC) is coined. Also this automation is desired for the purpose of self-start whenever there is mains failure, timing of its hours of operation, fuel level indicator, oil level, and battery sensor. Automation is desired to be carried out on the start command (ON), run duration (desired time one wishes to have it work), and stop command (turning off the generator). These operations will be possible based on some certain input parameters. During the course of research, controllers for diesel powered generators and petrol powered generators along with differences in design consideration and limitations were observed. AHGC was born out of these implemented ideals. This project circuitry is desired to be simple so as to come out with portable equipment. With this in mind, the use of a microcontroller (PIC18F4520) is necessary as it cuts out other circuit components like 555-timer that would have been needed, and consequently cost. This PIC combines other functions like the timer to allow the microcontroller to perform timing functions; the ADC module to allow the microcontroller to accept analogue input data for processing. Human interface devices such as LEDs and LCDs are used to relay information to the user. Buttons are made available for the user to define control to the device.

xii

CHAPTER ONE INTRODUCTION

1.1 Brief Introduction
The Automatic Household generator Controller, AHGC, is basically equipment that integrates or brings together some basic controls present in a household generator for the purpose of remote access and control. It adds flexible timing capabilities like run time (in hours) quite time. The user can, in fact specify these times depending on his specifications and community noise/generator policies. It also combines the ability to determine some parameters that are necessary before a generator is actually set into operation. Parameters like fuel level, oil level, battery charge status, etc. These parameters are determined with the aid of appropriate sensors and circuits.

1.2 Aim and Objective

This project is aimed at providing convenience and safety in the operation of a household electric generator. No significant modification is done on the generator but to add some easiness to the utilization of an electric generator for household power generation. In this design, cost is also kept in mind so that the whole essential of the end product is not subdued.

1.3 Justification
Due to the erratic nature of the power supplied to some residential areas from the national grid network, there are times when it is very inconvenient going out

2 turning the generator because of the power from the mains might be restored before the owner/user gets back inside the house. So the AHGC compensates for this by carrying out this automation of start without human intervention if desired. It is also intended for better user-friendliness with the use of human interface devices such as LCD displays, LED indicators for the said parameters, buttons for User-defined control, and so on. This makes it possible for information to be relayed from the user to the generator and vice versa.

CHAPTER TWO LITERATURE REVIEW

2.1 Introduction
The Automatic Household Generator Controller (AHGC) as discussed earlier simply deals with the monitoring and operation of standby generators or household generators remotely. This kind of automation is not something entirely new since so many controllers have been designed for this purpose. However, after careful literature research, the need for the design of a simple but an all-encompassing controller with cost in mind is necessitated. Discussions will be made on existing models or designs.

2.2 Existing Automatic Generator Controllers

The following are some of the available auto-generator controllers.

Ottormotores Dale 5050 controller; Modex Automations ECONOSTART 8000 series controller; Atkinson Electronics Inc.s GSCM-mini; Xantres Automatic Generator Start (AGS) controller

2.2.1 The Dale 5050 controller

The DALE 5050 is an automatic engine control module, designed to provide advanced load share functionality for large diesel and gas generating sets that include non-electronic and electronic engines (Ottomotores, 2004).

4 The modules load share functions include, automatic synchronizing with built in synchroscope1and closing onto dead bus. Direct and flexible outputs from the module are provided to allow connection to the most commonly used speed governors and automatic voltage regulators (AVRs). The module has been designed to combine a maximum of 16 generators and 16mains (utility) supplies up to a maximum of 20 in one system, e.g. 16 generators and 4mains (utility) supplies. The module has the ability to monitor under/over generator volts, over current, under/over generator frequency, under speed, over speed, charge fail, emergency stop, low oil pressure, high engine temperature, fail to start, low/high DC battery volts, fail to stop, generator short circuit protection, reverse power, generator phase rotation error, earth fault protection, loss of speed signal, fail to open, fail to close, out of sync, MPU open circuit failure, negative phase sequence and loss of excitation.

1An instrument used to indicate the difference in frequency between two alternating current supplies.

Microsoft Encarta 2009. 1993-2008 Microsoft Corporation.

Figure 2.1: The Dale 5050 front panel

6 2.2.1.1 Advantages of the Dale 5050 Sends SMS messages to engineers to notify specific engine problems (GSM Modem and SIM card required) On-site and remote (modem required) module configuration In-built engine diagnostics removes the requirement for service equipment Full engine protection & instrumentation without the need for additional senders Remote monitoring of the module using comprehensive PC software License free PC software

2.2.1.2 Operation The module is operated using the front STOP/RESET, MANUAL, AUTO and START push buttons. Three of these push buttons include an LED indicator. Additional push buttons provide LCD display scroll, lamp test, mute functionality and breaker control.

2.2.1.3 Timers and Input Functions The module has been designed to include the several timers and input functions as follows: Start delay timer Stop delay timer Crank timer Crank rest timer

7 Engage attempt & manual crank limit timers Safety on delay timer Warm up timer Cooling timer Fail to stop timer Over speed over shoot timer Breaker pulse control timers DC battery alarm delay timers

The module has the ability to be configured and monitored from a remote PC, using the 810 interface. The module includes a comprehensive event log that shows the 25 most recent alarm conditions and the date and time that they occurred. This function assists the user when fault finding and maintaining the generating set.

2.2.2 ECONOSTART 8000 series controller

The Econostart generator controller has been designed as a low cost Automatic Mains Failure, AMF) enhancement to the Modex Keystart range (Modex Automation, 2005).

2.2.2.1 Features Single phase detection of mains failure/healthy conditions 3 attempt engine start with automatic crank release.

8 Automatic, timed control of engine starting and stopping, and of mains and generator contactors. The combination of key start and Econostart enables a generator to be started either manually (using the key starts switch) or automatically (in response to a mains failure).

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

No connection Mains healthy output ( ve) Mains fail output ( ve) Start fail output ( ve) - ve DC power supply + ve DC power supply Mains AC Line Mains AC Neutral Generator AC Line Generator AC Neutral

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Gen. contactor output N/O Gen. contactor output C/O Gen. contactor output N/C Gen. status output N/O Gen. status output C/O Start output (+ ve) + ve DC (feed for 16 and 18) Run output (+ ve) Mains contactor output N/C Mains contactor output C/O

Figure2.2: Econostart Front panel and Electrical Connections

10 2.2.2.2 Principles of Operation Econostart is powered by either a 12 VDC or 24 VDC supply. The DC supply terminals are protected against transient voltages and reverse polarity connection. The positive DC supply terminal of Econostart is typically connected to the 'Aux. Out' terminal of a key start controller, such that the Econostart is only activated when the key start is switched to 'AUX'. 2.2.2.2.1 Engine Control Econostart controls the starting and stopping of the generator engine through two switched positive relay outputs: Run output: used to control the engine's fuel circuit, normally via the 'Aux. In' terminal of a Modex Keystart. The output activates (goes positive) at the end of the start delay (after a mains fail). It de-activates at the end of the stop delay (after a mains return and restoration' delay). Start output: used to control the engine starter motor circuit. It gives up to 3 engine start attempts, each consisting of a 10 second pulse and 10 second dwell. Econostart automatically releases the starter when it detects that the generator frequency has risen to above 30% of nominal. The Start output remains latched out until Econostart returns the engine to 'standby' mode or the power supply is removed and re- applied. 2.2.2.2.2 Mains and Generator Sensing and Contactor Control The condition of the mains and generator AC supplies is sensed through two single phase inputs. The mains and generator load contactors are then controlled by two separate relay outputs:

11 Mains Contactor relay (SPNC contacts): this relay remains de-energized (contacts closed) while the mains is healthy or when Econostart is powered down. If the mains voltage falls below 60% of nominal, the mains is considered as failed and the Mains Contactor relay energizes (contacts open). Generator Contactor relay (SPCO contacts): this relay only energizes: a) when the generator is required to be on load, and b) provided that the generator's output frequency is above 85% of nominal. The normally open contacts of this relay are normally therefore used in the generator contactor coil circuit. The relay de-energizes, and Econostart allows the engine to run on, off load, if at any time the generator frequency falls below 75%. 2.2.2.2.3 Status outputs An additional set of SPNO contacts provide for the remote signalling of 'generator on load'. Three ve DC outputs (open collector transistor types) are also provided for the signalling of 'mains healthy', 'mains failed' and 'engine failed to start'. (The latter activates if Econostart detects that the generator has failed to start after 3 attempts). 2.2.2.2.4 Timers Econostart has three delay timers for the controlled operation of the generator's starting, stopping and load transfer. Each timer is adjusted using a potentiometer in the front facia: Start: sets a delay between the detection of a mains failure and an attempt to start the engine, preventing an unnecessary engine start during very short fluctuations of the mains AC supply voltage. Restoration: ensures that the mains has returned and has stayed consistently healthy (for this time period) before Econostart transfers the

12 load from the generator back to the mains. If the mains fails again during this time period, the timer resets and Econostart keeps the generator running on load. Stop: allows the generator to run on, off load, after the load has been transferred back to the mains, cooling the engine before it returns to 'standby' mode. If the mains fails during this time period, both 'stop' and 'restoration timers reset and Econostart transfers the load back to the generator.

2.2.3 The GSCM-mini Controller

The GSCM-mini is a microprocessor based generator start-stop module, designed to auto start-stop high speed gas generators needing a 3-wire connection from a 2-wire manual start command (ATKINSON ELECTRONICS, INC., 2005). It

automatically disconnects the starter when a minimum generator AC frequency output is measured. It can monitor the generators output, shutting it down if either an over- or under-frequency condition is detected. LEDs are flashed to indicate the cause of the shutdown. Manually resetting the GSCM-mini by removing the power removes the lockout and allows the generator to restart if called to do so. The GSCM-mini is powered by 12VDC from the generator battery, and can monitor the battery voltage and start the generator to charge its own battery.

13

Figure 2.3: The GSCM-mini front panel

14 2.2.3.1 Features and applications 2-wire to 3-wire start controller for electric start high speed gas generators. Optimized for use with Outback Inverters. Supports three types of 3 wire generator control (momentary, maintained, ignition). Fixed Crank time, over and Under Frequency shutdown thresholds. Optional Battery charging with fixed set points. Remote Run and Fault indication included. Totally sealed for harsh environment operation

2.2.3.2 Operational thresholds The GSCM-mini has fixed operational thresholds. These are: Crank delay, Maximum Crank time, Crank Frequency Disconnect, Under Speed Shutdown, Over Speed Shutdown, and auto detects the Battery voltage to determine the auto start and auto stop threshold values for 12V, 24V, and 48V battery systems.

2.2.3.3 Three modes of relay operation The GSCM-minis two relay contacts can be configured for three types of three wire start/stop hook-up configurations; momentary, maintained and Ignition for some brands of generators. This is accomplished with an optional jumper on terminal 6. 2.2.3.3.1 GSCM-mini momentary starting sequence A start signal is created by closing a switch connected between the manual start terminal 5 to B+ terminal 3 or connecting the Aux + and Aux - terminals form an

15 Outback Inverter to terminal 5 (start) and terminal 7( ground). The module may also start in automatic mode based on a battery voltage (see Section-6 for Automatic start for battery charging). If the GSCM-mini detects an AC signal from the generator before a start command is given (ie: the generator is already running) it will not execute a start sequence until the AC Frequency signal has been rectified, and will turn ON the Generator frequency LED. The generator starting sequence is as follows. 1. The start LED blinks once every 5 seconds to indicate that the GSCM-mini is in a Ready mode. When a manual signal is received, the start LED lights continuously. After a 2 second delay, K1 relay closes to crank the starter, and remains closed until either the generator starts or the maximum cranking time period (20 seconds) is reached. 2. If the generator fails to start after the 20 seconds cranking period, K1 relay opens for a resting period of 40 seconds. The K1 relay then closes again cranking the starter until the maximum cranking time is reached or the generator starts. 3. If the generator fails to start after 3 cranking attempts with the associated resting periods, then K2 relay closes for 5 seconds, then the

generatorfrequency LED does a double blink, the Fault LED turns ON and the GSCM-mini enters the Max. Crank lockout condition. This lockout condition remains until the GSCM-mini is reset by removing power from terminal 2 (see GSCM-mini wiring diagram) and reconnecting power. The GSCM-mini will then clear the lockout condition, and enter Ready mode with the Start LED blinking Every 5 seconds.

16 4. When the generator starts, K1 relay immediately opens, stopping the cranking. A valid run condition is determined by the generator AC output frequency exceeding the crank disconnect setting of 45Hz and is indicated with the Run LED turned On.. 5. If the generator starts but shuts down after a few seconds due to a fuel problem, etc. the start sequence will revert to the Ready mode after a 60 second delay. During this delay the start LED will blink rapidly. The GSCMmini will then try to start the generator again in manual mode or after a 5 minute delay period in auto-start mode. 6. When a run condition is detected, the GSCM-mini turns ON the Run LED and transistor output (remote run lamp) and after a 60 second generator stabilization period begins monitoring the AC frequency signal for over/under frequency condition. 7. If the generator starts but shuts down after the 60 seconds stabilization period, due to a fuel problem, etc. the GSCM-mini blinks the Generator frequency LED for an Under frequency condition , after 60 seconds the Run LED turns Off, Fault LED turns On, and K2 relay energizes for 5 seconds. The GSCM-mini enters a Fault shutdown lockout condition. A power down reset is required to clear the lockout condition. 8. The generator continues running until one of the following occurs: the manual start signal is no longer received, the auto battery charge voltage has been reached while running in Auto Charge Mode, an Over or Under frequency condition occurs (If Generator Frequency Shutdown is enabled) or the generator runs out of gas. (No run time limit)

17 9. During shutdown, K2 relay closes to ensure shutdown of the generator by grounding out the ignition, etc. It remains closed until the AC frequency signal from the generator has gone to zero for 5 seconds ensuring that the generator has shutdown. 10. The generator remains off until another start signal is received.

2.2.3.4 GSCM-mini ignition/crank starting sequence The CONFIGURATION terminal 6 has been connected to B+ (terminal 3), configuring the GSCM-mini for ignition/crank start sequence. The GSCM-mini is then powered by connecting B+ (+12 VDC) to terminal 2. After 5 seconds the GSCM-mini indicates that it is ready to receive a start signal by blinking the start LED once every 5 seconds. The starting sequence is as follows. 1. The start LED blinks once every 5 seconds to indicate that the GSCM-mini is in a Ready mode. When a manual signal is received, the start LED lights continuously. After a 2 second delay, K2 relay energizes and remains energized until the start signal is either removed or the generator fails to start after 3 attempts. K1 relay closes to crank the starter. The K1 relay remains closed until either the generator starts or the maximum cranking time period (20 seconds) is reached. 2. If the generator fails to start after the 20 seconds cranking period, K1 relay opens for a resting period of 40 seconds. The K1 relay then closes again cranking the starter until the maximum cranking time is reached or the generator starts.

18

Figure 2.4: GSCM-mini wiring diagram and controller configuration

19 3. If the generator fails to start after 3 cranking attempts with the associated resting periods then K2 relay de-energizes and the GSCM-mini enters its Shutdown Routine, then the Gen frequency LED does a double blink, the Fault LED turns ON and the GSCM-mini enters the Max. Crank lockout condition. This lockout condition remains until the GSCM-mini is reset by removing power from terminal 2 (see GSCM-mini wiring diagram) and reconnecting power. The GSCM-mini will then clear the lockout condition, and enter Ready mode with the Start LED blinking Every 5 seconds. 4. When the generator starts, K1 relay immediately opens, stopping the cranking. A valid run condition is determined by the generator AC output frequency exceeding the crank disconnect setting of 45Hz. 5. If the generator starts but shuts down after a few seconds due to a fuel problem, etc. the start sequence will revert to the Ready mode after a 60 second delay. During this delay the start LED will blink rapidly. The GSCMmini will then try to start the generator again in manual mode or after a 10 minute delay period in auto-start mode. 6. When a run condition is detected, the GSCM-mini turns ON the Run LED and open collector transistor output (remote run lamp) and after a 60 second generator stabilization period begins monitoring the AC frequency signal for over/under frequency condition. 7. If the generator starts but shuts down after the 60 seconds stabilization period, due to a fuel problem, etc. the GSCM-mini blinks the Gen frequency LED for an Under frequency condition , after 60 seconds the Run LED turns Off, Fault LED turns On, and K2 relay energizes for 5 seconds. The GSCM

20 enters a Fault shutdown lockout condition. A power down reset is required to clear the 8. Lock out condition. 9. The generator continues running until one of the following occurs: the manual start signal is no longer received, the auto battery charge voltage has been reached while running in Auto Charge Mode, an Over or Under frequency condition occurs (If Generator Frequency Shutdown is enabled) or the generator runs out of gas. (No run time limit) 10. When the manual start signal is removed, K2 relay de-energizes opening the ignition circuit shutting down the generator. The GSCM-mini then monitors the Generator AC frequency input to watch for a zero frequency condition before returning to Ready mode. If the AC signal remains the GSCM-minis Generator HZ LED turns on indicating AC Frequency Signal still present and will not return to Ready mode until the AC signal goes to zero. Once it goes to zero the GSCM-mini returns to Ready mode. 11. The generator remains off until another start signal is received.

2.2.3.5 GSCM-mini fault shutdown conditions The GSCM-mini detects three (3) fault shutdown conditions (over/under frequency detection not enabled until the generator has been running for 60 seconds) and will shut down the generator after 10 continuous seconds of Frequency fault condition, locking it out until a power down reset and power back up. The Fault open collector transistor output (terminal 12) will energize a user supplied remote lamp or DC relay (not exceeding 300 milliamp coil current)

21 whenever a fault shutdown occurs and will de-energize the relay when the fault is reset. The shutdown conditions are as follows: 1. Failure to start with 3 cranking attempts. The Generator frequency Shutdown LED does a double blink and Fault LED On continuously. 2. High frequency condition. The generator AC frequency is monitored on terminals 9 and 10. If the Generator Frequency enable terminal #8 is grounded and the generator output frequency exceeds the 65 Hz fixed threshold for 10 seconds, the generator shuts down and the Generator frequency shutdown LED blinks rapidly. The Generator Hz LED blinks during this 10 second period. 3. Low frequency condition. If the Generator Frequency enable terminal #8 is grounded and the generator output frequency remains below the 55 Hz fixed threshold for 10 seconds, the generator shuts down and the Generator frequency shutdown fault LED blinks slowly. The Generator Hz LED blinks during this 10 second period.

2.2.3.6 Automatic starting for battery charging The GSCM-mini can monitor either the generator battery voltage or a battery bank voltage and automatically start/stop the generator based on battery voltage. This is accomplished by connecting the battery voltage to the battery sense input (terminal 4). The GSCM-mini monitors a battery voltage range of 0 to 60V DC and automatically determines the start and stop set point based on battery voltage (12, 24, or 48VDC).

22 1. The GSCM-mini monitors the battery sense input and when the battery voltage drops below the start threshold the Start LED begins blinking (three fast blinks with 2 second off time). When the battery sense voltage has remained below the start threshold for 5 continuous minutes the Auto start sequence begins. If the battery voltage rises above the start threshold during the 5 minute period the 5 minute timing cycle starts over. (Temporary battery voltage fluctuations such as instantaneous inverter loads will not start the GSCM.) The start LED blinks every 3 seconds while the GSCM-mini is running the generator in auto-start battery charging mode. 2. The GSCM-mini starts the generator in; momentary start, maintained start, or ignition start modes. 3. The GSCM-mini shuts down the generator whenever the battery voltage exceeds the stop threshold for 10 minutes. The Start LED blinks (three fast blinks with 2 second off time) during this 10 minute period. The GSCM-mini will exit the 10 minute period and shutdown the generator if the battery voltage exceeds the stop point by +1.0V (for a 12V system, 2V for 24V system, voltages are proportional). The generator remains off until the battery voltage drops below the start threshold voltage. 4. There is no maximum runtime shutdown in either manual or auto start.

2.2.4 The Xantrexs Automatic Generator Start (AGS) Control System

The Automatic Generator Start Control System (AGS) automatically controls and monitors an auxiliary generator (Xantrex Technology Inc., 2002). It will automatically start a generator as required to charge a battery bank or as heating

23 or cooling systems require. You can also set allowable generator run times, so that the AGS does not turn on the generator at inconvenient times.

2.2.4.1 Mode of operation The AGS system, when in AUTO or AUTO QUIET TIME mode, continuously monitors the house battery and two air-conditioning/heater thermostats. If the LOCAL TIME of day is not within the AUTO QUIETTIME window, it will start the generator to charge the battery or to cool or heat as required. The AGS system is invisible to the normal operation of the auxiliary generator manual start and stop controls with the following exceptions: 1. If the generator is started by the AGS, which is in AUTO or AUTO QUIET TIME mode, the selection of OFF at the AGS Remote Panel will stop the auxiliary generator. 2. If the AGS system commands the generator to start and it does, the AGS system will stop the generator at the appropriate time. If the generator stops for some other reason, even if it is turned OFF by a manual switch other than the AGS, the AGS system will assume that there is a FAULT.

24

Figure 2.5: The Xantrex AutoGenStart front panel

25 It will turn itself OFF and turn on the GEN FAULT light. At this point, the AGS system must be turned on to the AUTO mode or AUTO QUIET TIME mode for it to resume control of the generator. Once started by the AGS system, the generator will run for a minimum of two hours. This will ensure that there is a good charge in the battery, although it may not be fully charged at the end of the cycle. If the battery voltage does not reach13.5 volts during the two-hour period, the generator will continue to run for an additional two hours. If at the end of the second two-hour period the battery voltage is still not up to 13.5 volts, then the AGS systems assumes that there is a problem and turns the generator OFF. It must be restarted manually.

CHAPTER THREE METHODOLOGY (PROJECT IMPLEMENTATION)

3.1 Project Description
The automatic household generator was to expected to self-start whenever there is power failure supplied to the house from the mains after a certain time delay as it also does a pre-check for the level of fuel and oil, and the health of the battery before starting. Also, this project is intended to bring a sort of control over the hours of operation i.e. the run time in such a way that a user can instruct the generator to operate for a specified period of time as far as the volume of fuel in the generator tank can accommodate it. The generator is also expected to stop operation after a certain time delay i.e. restoration time whenever the mains supply returns.

26

27

Fuel Level

LED & LCD displays + buttons

Oil Level

AHGC
Battery monitor GEN FEEDBACK SENSORS

GEN

Mains monitor SENSORS FROM GEN SENSORS

Figure 3.1: Block diagram of the whole system

28

3.2 System Requirement

The following are the requirements of the project design implementation: Form-A Relay switches Pneumatic switch for choke control Monitoring circuits (battery level, mains output, generator output) PIC 18F4520 microcontroller 16 2 LCD display LEDs and buzzer Plastic casing Proteus & Multisim for circuit design and analysis mikroBasic for PIC programming

3.2.1 Ignition relay switch

Here, since remote start operation is needed, the household generator ignition switch is connected with 3 wires one for the engine ON position, another for the ignition (crank), and the third for ground connection. Also two Form-A (SPCO2) relays are used for the purpose of the automation interfacing with the PIC microcontroller. Below is a circuit diagram (Fig. 3.2) of the configuration of the starter control. The PIC microcontroller sends a HIGH to the relays in a sequence already determined in software during coding.

2Single-pole

change-over or SPDT (single-pole, double-throw) type of relay contacts

29

Figure 3.2: Ignition and Engine relay switches

30 Hence, while the other parameters are determined and OK according to pre-set thresholds, after the choke has been actuated to choke the air inflow, RL2 is actuated to switch on the engine. Thereafter, RL3 is then actuated for 10 seconds to crank the generator engine. After the given 10 seconds, while RL2 is still active, and the engine is still not started, RL3 is re-energized for another 10 seconds to crank-up the engine again. If the engine is still not started after the fourth try, the AHGC gives an alert of a fault. 20 seconds later, the above cranking sequence is repeated.

3.2.2 Choke pneumatic switch

The choke is another important part of the generator, considering its role in airfuel mixture while cold-starting a generator; nevertheless, it might not be needed when generator is already hot. To carry out control of the choke, an electric pneumatic switch is attached by means of plastic rod to the existing lever of the choke. Since the pneumatic switch which is made up of a DC motor, it therefore can be made to rotate in two directions making the switch to actuate in two directions. So, to harness the two directions in closing and opening the choke, we made use of two Form-A relays in the following circuit configuration. To open the choke when the generator has already started, the PIC is made to send a HIGH signal to the first relay (CHOKE_F), while the other receives a LOW, giving the polarity as shown (Fig. 3.3). To choke the air intake of the generator (or to close the choke), the PIC is made to send a HIGH to the second relay (CHOKE_R) and a LOW to the former giving a reversed polarity.

31

Figure 3.3: Polarity reversal circuit for choke pneumatic switch operation

32

3.2.3 Parameter Monitoring

The objective of this stage is to carry out the monitoring of parameters of the generator required for safe starting. This includes the battery level of the generator, mains supply availability, fuel level and oil level. These whole processes of monitoring are to be carried out by a pre-programmed PIC. 3.2.3.1 Battery level monitoring This is one important parameter in starting the generator. From observation, it is apparent that if the battery goes below a certain threshold value the generator may not be able to start. Below is a circuit for this purpose (Fig. 3.4). The circuit consists of a voltage divider R18 and R19 that converts the 12 VDC voltage of the generator to half its value and then clipped by the Zener diode D8. Because the PIC ideally can respond to voltages of 5 0.5 VDC, the voltage of the battery has to be brought to a level which the PIC can read because the voltage reference of the ADC is usually VDD (voltage supply for a CMOS device such as the PIC 5 VDC). A fuse has also been added for extra-protection for the delicate PIC device as well as the whole system.

33

Figure 3.4: Battery monitoring circuit

34 3.2.3.2 Mains monitoring and generator output feedback As part of the design the generator is expected to automatically turn ON whenever there is a mains failure and to also detect that the generator is delivering output to serve as feedback to the system (as shown in Fig. 3.1). However, if auto-start is not desired there is a provision for manual mode of operation. This allows a user to override the device to turn generator on whenever there is power failure from the mains. The circuit is designed as a transformer-less power supply to drive transistor Q1 to switch on a HIGH or a LOW when there is AC input or not as the case may be. So when there is utility power, the system remains in the idle state else, transistor Q1 switches a LOW to the PIC pin for monitoring mains. A 0.5-ampere fuse has also been included for additional safety to isolate the system from possible fault such as surge in utility mains supply.

Figure 3.5: Circuit for monitoring mains availability and generator output feedback

35

36 3.2.3.3 Fuel and oil level monitoring sensor The level of non-conducting, volatile liquids can best be determined by capacitive sensors (Heidary, 2010). The method is generally based on the difference between the dielectric constant of the liquid and that of the gas or air above it. However, due to unavailability of this kind of sensor a variable resistor has been modelled for this level measurement or monitoring.

3.2.4 The Processing Unit

This is a 40-pin PIC microcontroller (PIC18F4520) with 13 10-bit analogue channels (Ibrahim, 2008) (Microchip Technology Inc., 2008). It does the main processing of the system; for the measurement of fuel level, oil level mains and battery SOC. The choice of this device is simply because of the complexity of the project. Some of its advantages are: It is a low power device (Nano-watt technology) It has an extended program memory compared to PIC 16F family It combines so many functions which makes its application a simple and less-complex altogether

37

Figure 3.6: Pin-out diagram of the PIC18F4520 that was used in this project

38 3.2.5 Human interface devices These are devices that make the device more user-friendly in relaying information to the user. The user can also interact with the system though these devices especially through the buttons. Such devices include, as already mentioned, LCD displays, LED indicators, buttons, sound output devices such as buzzers. 3.2.5.1 16 2 LCD Display Liquid Crystal Displays (or LCDs) are still used extensively in commercial and industrial equipment, particularly where display requirements are reasonably simple (Ilett, 1997). This is used to display information that is relevant to the user. Information like fuel level quantity, oil level quantity, battery SOC (state of charge), and others are displayed on the LCD. The LCD is driven by the PIC microcontroller as part of its responsibility. Refer to the main circuit diagram in the Appendix section.

39

Figure 3.7: LCD circuit connection with the PIC data connections labeled as shown.

Figure 3.8: The LED indicator connection

40 3.2.5.2 LED Indicators and buzzers Light emitting diodes (LEDs) are diode with illumination when current is made to pass through them. They come in different colours and current ratings depending on the use. The buzzer in conjunction with is also used to also alert the user of any fault. In this project, three LEDs are used they are: Gen status LED; this indicates that the generator is on run mode Power indicator LED; indicates as soon as the generator is on. Fault indicator LED; glows/blinks whenever there is fault. May be due to failure of the engine to start after the 3 crank attempts; fuel low, oil low, low battery SOC.

41

Figure 3.9: Button connection circuit.

Figure 3.10: An in-circuit buzzer in simulation

42 3.2.5.3 Buttons These are the devices that are made available to the user to communicate with the system. These include the power button, up and down menu scroll buttons, manual start/stop, whole system reset (Fig. 3.9)

3.3 Development Tools

Development tools used for this project can be categorized into software and hardware development tools.

3.3.1 Software development tools

MikroBasic and Proteus are the two software programs exploited for the design and development of the controller. MikroBasic, a software program consists of the following features which are all embedded in it: Text editor, used to writes or edit program codes Assembler generates mid-level assembly codes from the high-level BASIC language. And compiler/linker generates HEX file which is burnt into the PIC.

Proteus is a SPICE simulator for testing the codes and circuitry before actual implementation.

43

Figure 3.11: The Proteus simulator interface/environment

44

3.3.2 Hardware development tools

Device Programmer: After the program is written and translated into executable code, the resulting HEX file is loaded to the target microcontrollers program memory with the help of a device programmer.

45

CHAPTER FOUR TEST AND RESULTS

4.1 Software Testing
Testing was done on the firmware with Proteus ISIS to determine and fine-tune the time delays involved in the whole system. We also checked the response to each input such as buttons and sensors, including the output responses.

4.2 Hardware Testing

Testing was also done on the hardware being incorporated to a generator. The generator utilized for the testing was a Tiger TG6500 2.5-kVA generator with 3wire electric starter. The key-starter switch is a rotary switch with 3 possible positions as shown in Fig 4.1. Because the engine switch is a normally-closed switch, and opening this switch sets the gen in the ON position. This switch was left so as to enable the user to control the generator with its factory-made switch in case of any system failure.

46

SW2 POSITION 1 (OFF) 2 (ON) 3 (Momentary ON)

J1 STATE OFF ON ON

J2 STATE OFF OFF ON

Fig 4.1: The Structure and the Table of reference of the key-starter switch of Tiger TG6500 generator

47

4.2.1 Cranking
Before the AHGC can control the starting of the generator, the key-starter switch was initially set to the position 2. Each crank session was about 10 seconds. Time difference between each crank session was about 3 seconds

4.2.2 Manual Starting

Manually starting the generator with AHGC involved pressing the START/STOP button. Refer to Appendix E: Users Guide for AHGC. Pressing the button invokes a display message Gen starting There was a delay of 10 seconds before the generator starts to crank up. At the first try, the generator did not start after 5 attempts. The AHGC gave an error massage that the generator failed to start. At the second try, the generator started after the second attempt. As specified already, the generator was stopped with the same START/STOP button.

48

Plate 4.1: Front panel of AHGC showing the face

49

4.2.3 Automatic Starting

Automatic response of the AHGC to mains failure happened after 20 seconds of verification. The mains sensor was plugged into a mains supply socket. When the mains socket was switched OFF, the AHGC displayed a message that mains supply was OFF. After about 15 seconds, socket switch was then returned and the AHGC did not start the generator. The mains socket switch was again turned OFF. This time around, the switch was left for more than 20 seconds and the cranking sequence was then initiated. The switch was returned to its ON position and then the generator was stopped after about 10 seconds delay.

4.2.4 Timed Running of Generator

For the purpose of testing, during design, the timing had been scaled Therefore, in reality meant which equals .

. The time was

set accordingly and the generator was seen to run and stop at the required time pre-set. See Appendix E for how the timer is set.

50

Plate 4.2: Another view of the showing the fuse protection for mains sensor

CHAPTER FIVE CONCLUSION AND RECOMMENDATION

5.1 Introduction
The main goal of this report was to present a method of automating a portable generator. Although, this has been implemented for heavy-duty and largercapacity generators, it is rarely a thing for portable generators meant for household use. It also includes functionalities such as fuel and oil measuring including battery monitoring. These are functionalities that most

implementations lack which can help the user to monitor remotely his fuel and oil consumption.

5.2 Comparison with other Implementations

The AHGC is furnished with fuel and oil measuring capability so that the generator is protected and the user kept informed about the status of his generator without having to go to the generator except for major repairs or maintenance. The AHGC also makes use of cheap and locally available components which makes the controller very affordable to lowand middle-class

persons/households.

5.3 Future Research

The only components that were not available locally are the capacitive sensors. We will like to recommend that research should go into making them locally. This can be done using the reactive deflective bridge (Bentley, 2005) as shown in Fig.

51

52 4.2 where the variable capacitor can be made from locally made metals to

form cylindrical shape that can be dipped into the fluid. A wireless remote should also be made such as can communicate with the controller.

53

Fig 5.1: Bridge for capacitive level sensor

54

5.4 Recommendations
The AHGC should be furnished with a RF or Bluetooth remote control such that the AHGC can be controlled from anywhere in the house while the AHGC is fixed at one point. Not only can the AHGC be used for household/portable generators but also with renewable power sources like solar, inverter systems. This is useful in the aspect of maintaining a fully charged battery bank for the inverter system so that power supply is uninterrupted. It can also be used with cooling systems of highly temperature-sensitive facilities in which the AHGC can be configured to receive inputs from a temperature sensor which will measure the temperature of the environment to actuate a generator or inverter system depending on the available power source.

55

APPENDIX A COMPREHENSIVE CIRCUIT DIAGRAMS

Figure A1: Monitoring Circuits

Figure A2: Main Circuit for project 56

Figure A3: Ignition and engine switch actuating circuits

57

Figure A4: Polarity reversal circuit for actuating the choke pneumatic switch

58

59

APPENDIX B SOURCE CODE FOR THE PROJECT

The following is the MikroBasic code for the project. It was edited and compiled with the MikroBasic IDE.
program srccode ' Declarations section ' Lcd module connections sub procedure interrupt if TestBit(INTCON, INT0IF) = 1 then ClearBit(INTCON, INT0IF) end if end sub sub procedure init() Variables declared to initialise PIC end sub sub procedure startTimer() end sub sub procedure stopTimer() end sub sub procedure restoreTimer() end sub sub procedure ledfault() To beep and blink red LED end sub sub procedure timar2() To count down preset timer and to allow user to manually stop timer and gen end sub sub procedure timar() To allow user to set timer end sub sub procedure msrOil() To measure level of oil end sub sub procedure msrFuel() To measure level of fuel end sub sub procedure msrBatt() To measure battery level end sub sub procedure chkload() To check if load is connected 10 secs ' 10 secs

60
end sub sub procedure chkmains() To check if mains is available end sub sub procedure startgen2() To initiate cranking sequence and starting of gen end sub sub procedure startgen() To check parameters before starting gen end sub sub procedure chkbutton() To respond to button inputs and to MODE switch end sub sub procedure act if b_press = 1 then if menu1 = 0 then if menu2 = 1 then msrOil else if menu2 = 2 then msrBatt else if menu2 = 3 then msrFuel else if menu2 = 4 then chkload else if menu2 = 5 then chkmains else if menu2 = 6 then timar end if end if end if end if end if end if end if end if b_press = 0 end sub main: ' Main program init while true chkbutton act wend end.

'

61

APPENDIX C BILL OF MATERIALS FOR THE AHGC

Quantity References 29 Resistors 6 R1, R3-R6, R24 1 R2 4 R7-R9, R25 1 R10 1 R11 2 R12, R21 3 R13, R22, R23 4 R14-R17 2 R18, R19 1 R20 4 R26-R29 7 Capacitors 2 C1, C2 1 C3 2 C4, C6 2 C5, C7 1 Integrated Circuits 1 U1 4 Transistors 4 Q1-Q4 14 Diodes 1 D1 1 D2 1 D3 8 D4, D6, D9-D14 3 D5, D7, D8 Value 10k 470R 330R 4.7K 4.7K 12k 100k 4.7K 4.7K 47K 22k 33pF 100nF 220uF 100nF PIC18F4520 BC547 PWR LED GEN STATUS FAULT LED 1N4001 1N4733A Tantalum capacitor Tantalum capacitor Electrolytic capacitor Tantalum capacitor Microcontroller NPN transistors Green colour Yellow colour Red colour Signal diodes Zener diodes Remarks Cost

62 26 Miscellaneous 2 BAT1, BAT2

12V

Generator battery (not included in design) Push buttons and toggle switch (SW1)

1 7

3 1 6 3 2 1

BUZ1 DWN, MENU/SELECT, PWR, RESET, START/STOP, SW1, UP F1-F3 LCD1 RL1-RL6 RV1-RV3 V1, V2 X2

BUZZER -

0.5A LM016L 6V 5k VSINE CRYSTAL (10.000 MHz)

162 LCD display 100 coil Preset resistors 240 V mains and generator output High speed oscillator

63

APPENDIX D USERS GUIDE FOR AHGC

Main Features

The Automatic Household Generator Controller automatically controls and monitors an auxiliary household generator. It will automatically start a generator when commercial power supply has been switched off. The user can also set the length of time he wants the generator to run so that the generator is stopped after the time elapses.

SAFETY SUMMARY
Fuse Replacement
For continued protection against the possibility of fire, replace the fuse only with a fuse of the specified voltage, current and type ratings.

Power Source
To avoid damage, operate the equipment only within the specified AC (line) and DC (battery) voltages.

Servicing
There are no user serviceable parts inside. Refer all service to qualified personnel.

64

OPERATION

POWER Light
The green POWER light is on when the AHGC is running or active. Pressing the PWR button switches the light off as well as setting the AHGC in standby mode. DEFAULT: Light ON

GEN STATUS Light

The amber GEN STATUS light is on whenever the generator is running. This includes when the standby generator is run manually. DEFAULT: Light OFF

FAULT Light
This red light blinks at about every half second when the AHGC detects a fault. It comes on when oil and/or fuel of generator is low. At the point of starting the generator with the AHGC, either in MANUAL mode or AUTO mode, if any of battery charge, fuel or oil is low, it also blinks. Pressing the MENU/SELECT button will clear the fault. DEFAULT: OFF

MODE Switch
With the MODE switch, you can change the mode in which you want to run your AHGC, either in MANUAL or AUTO mode.

65
DEFAULT: MANUAL mode.

PWR button
When pressed, it sets the AHGC to standby mode. In this mode, the AHGC will not respond to any requests to start generator whether automatic or manual. Note: The AHGC will not enter standby mode while trying to start the generator or when the generator is running when the button is pressed.

RESET button
When pressed, it resets the AHGC.

MENU/SELECT button
The MENU/SELECT button is used to show the parameters of the generator such as oil level, fuel level, battery SOC, whether commercial power is available. It also makes the timer option available so that the user can set the timer of the AHGC. Menu Options: OIL LEVEL FUEL LEVEL BATTERY SOC LOAD MAINS TIMER

UP button
This is used to scroll up through the menu options. It also increments the time while trying to set the timer of the AHGC.

DOWN button
This is used to scroll down through the menu options. It is also used to decrement the time value in trying to set the timer of the AHGC.

START/STOP button
This button is used to start the generator manually. It also stops the generator when the generator has been running initially.

AUTO Mode
In AUTO mode, the Control Module will respond to requests for generator start when commercial power supply has been switched off. Note: Gen will not start if fuel or oil level is not enough for starting and also if the generator battery is not charged enough to start it.

66

MANUAL Mode
In MANUAL mode will not respond to request to start generator when commercial power has switched off. Here, the user can press the START/STOP button to start or stop the generator. Note: Gen will not start if fuel or oil level is not enough for starting and also if the generator battery is not charged enough to start it.

TIMER
The user can set the length of time required for the generator to run either in MANUAL or AUTO mode.

SETTING THE TIMER

To set the timer, press the MENU/SELECT button and scroll to the TIMER option in the menu.

Press the MENU/SELECT button to select the option. You screen such as this:

You can set the no of hours with the UP and DOWN buttons Press the MENU/SELECT button again to save the no of hours and to set the no of minutes. Use the UP and DOWN buttons to set the no of minutes.

Press the MENU/SELECT button again to save the no of minutes and to set the no of seconds. Use the UP and DOWN buttons to set the no of seconds.

Press the MENU/SELECT button to set the timer and to exit the timer menu option.

67

AHGC DISPLAY MESSAGES

1. Welcome Message This appears when the AHGC is first powered on and also when the RESET button is pressed.

2. Engine failed to start! This error occurs when the AHGC attempts to start the generator engine, either automatically or manually, and after 5 crank attempts, the generator has yet to start. Press the MENU/SELECT button to clear this fault.

3. Low Battery! Gen cant start! This occurs when the AHGC attempts to start the generator, either automatically or manually, when it detects that the battery SOC is too low for starting. Press the MENU/SELECT button to clear this fault.

4. Fuel level low! Gen cant start! This occurs when the AHGC attempts to start the generator, either automatically or manually, when it detects that the fuel in the generator tank is too low. Press the MENU/SELECT button to clear this fault.

5. Oil level low! Gen cant start! This occurs when the AHGC attempts to start the generator, either automatically or manually, when it detects that the oil level is too low. Press the MENU/SELECT button to clear this fault.

68
6. Gen starting This occurs when the AHGC attempts to start the generator, either automatically or manually.

7. Stopping gen This occurs when the AHGC attempts to stop the generator, either automatically or manually.

8. GEN STOPPED! Fuel level low! This occurs when the AHGC detects low fuel in generator while it is running and stops the generator thereafter, either AUTO or MANUAL mode. Press the MENU/SELECT button to clear this fault.

9. GEN STOPPED! Oil level low! This occurs when the AHGC detects low oil in generator while it is running and stops the generator thereafter, either AUTO or MANUAL mode. Press the MENU/SELECT button to clear this fault.

10. GEN STOPPED! User initiated! This occurs when the START/STOP button is pressed while the generator is running.

TIME DELAYS
1. Start Time Delay: This is the time delay that occurs when the AHGC attempts to start the generator. It is a length of 10 seconds. 2. Stop Time Delay: This time delay occurs when the AHCG is stopping the generator initially running before actually stopping the generator. It lasts for 20 seconds. 3. Restore Time Delay: This lasts for 20 seconds and it occurs when the AHGC detects that commercial power has been restored before stopping the generator.

69

STARTING A GENERATOR WITH AHGC

AHGC can start the generator manually by a press of a button by the user or automatically when commercial power supply is switch off.

AUTO START
When the commercial power supply is switched off, the AHGC senses it and starts the cranking sequence for the generator after a delay of 20 seconds.

Note: If within this 20-second commercial power is restored, the generator will not be started. If mains is not restored through the time delay, after the AHGC has checked for all the parameters (battery, fuel level, oil level) of the generator, and confirmed OK, the AHGC starts the generator. When AHGC senses that the generator is running, it stops the cranking sequence and leaves it running for the time period already set by the user. Note: After 5 crank attempts and the engine failed to start, a message is displayed - Engine failed to start! along with a beeping sound. (See AHGC DISPLAY MESSAGES, p 9)

MANUAL START
To manually start the generator with AHGC, the START/STOP button is pressed when the MODE switch is in MANUAL mode. A message is display Gen starting (See AHGC

DISPLAY MESSAGES, p 9)
After the AHGC has checked for all the parameters (battery, fuel level, oil level) of the generator, and confirmed OK, the generator is started. Note: AHGC will not start the generator when the MODE switch is set to AUTO mode.

STOPPING THE GENERATOR WITH AHGC

The generator can be stopped, in both the AUTO and MANUAL modes, by many factors:

AUTO STOP
Mains Restored: The AHGC will stop the generator if commercial power is restored after the Restore Time delay (p 11). During this period of time, if mains goes off again, the generator continues running until the timer elapses. Time Elapsed: The AHGC will stop the generator when the time set for the timer runs out. Fuel low: When fuel in the tank gets low below a certain threshold, AHGC stops the generator.

70
Oil low: AHGC stops the gen when oil level gets lower than a pre-set level, the generator is automatically stopped. Note: The user can decide to stop the generator even when the timer has not timed out by pressing the START/STOP button.

MANUAL STOP
Manual Stop: The user can decide to stop the generator, when the timer has not yet timed out by pressing the START/STOP button. Time Elapsed: see AUTO STOP Fuel low: see AUTO STOP Oil low: see AUTO STOP

SPECIFICATIONS
Nominal operating voltage Maximum operating current Relay contact voltage rating Maximum relay current Nominal generator battery voltage Nominal Mains Input voltage Nominal Gen Output voltage Fuse rating Low Fuel Detect Low Oil Detect Crank Delay Crank Attempts Gen Start Configuration Compatible Generators Compatible Gen Capacity 5 VDC 200 mA @ nominal 24 VDC 10 A DC 12 VDC 220 - 240 VAC, 50Hz 220 VAC 3A, 250VAC 20% of full tank capacity 30% of full capacity 10 seconds between attempts 5 times, ~10 seconds each 3-wire Almost any 3-wire automotive start configuration generator > 2.5kVA