U.S. patent application number 11/624882 was filed with the patent office on 2007-09-20 for generator controller.
This patent application is currently assigned to Acutra, Inc.. Invention is credited to Donald P. Aupperle, Richard L. Proctor, Scott R. Schaper.
Application Number | 20070219669 11/624882 |
Document ID | / |
Family ID | 33101185 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070219669 |
Kind Code |
A1 |
Schaper; Scott R. ; et
al. |
September 20, 2007 |
GENERATOR CONTROLLER
Abstract
A generator controller, in its various embodiments, displays
genset fault messages, a genset elapsed time hour meter, service
countdown reminder, monitors battery voltage changes over multiple
periods of time to establish and display the "battery level," uses
the "battery level" to automatically start and stop the genset, and
accepts multiple run requests from AC loads such as HVAC systems,
and incorporates safety or other start inhibit features.
Inventors: |
Schaper; Scott R.; (Seattle,
WA) ; Proctor; Richard L.; (Seattle, WA) ;
Aupperle; Donald P.; (Seattle, WA) |
Correspondence
Address: |
BLACK LOWE & GRAHAM, PLLC
701 FIFTH AVENUE
SUITE 4800
SEATTLE
WA
98104
US
|
Assignee: |
Acutra, Inc.
Seattle
WA
|
Family ID: |
33101185 |
Appl. No.: |
11/624882 |
Filed: |
January 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10788814 |
Feb 27, 2004 |
|
|
|
11624882 |
Jan 19, 2007 |
|
|
|
60449927 |
Feb 27, 2003 |
|
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|
Current U.S.
Class: |
700/287 |
Current CPC
Class: |
H02J 3/00 20130101; H02J
2310/42 20200101; H02M 2001/009 20130101; H02J 2310/40 20200101;
H02M 2001/007 20130101; H02J 7/1415 20130101; H02J 7/1461
20130101 |
Class at
Publication: |
700/287 |
International
Class: |
G05B 23/00 20060101
G05B023/00 |
Claims
1. A generator controller, comprising: a processor; an input
capable of receiving signals from the generator; an output capable
of sending signals to the generator; a display; and a memory
accessible by the processor, the memory containing (1) information
corresponding to, the signals received from the generator, and (2)
stored programming instructions operable by the processor to
control the operation of a generator and to present on the display
the information corresponding to the signals received from the
generator.
2. The generator controller of claim 1, wherein the received
signals comprise fault messages.
3. The generator controller of claim 1, wherein the received
signals comprise binary encoded messages.
4. The generator controller of claim 1, wherein the information
comprises a text message.
5. The generator controller of claim 4, wherein the text message
comprises one or more words representative of the signals received
from the generator.
6. The generator controller of claim 1, wherein the controller is
mountable in a boat or recreational vehicle at a location remote
from the generator.
7. The generator controller of claim 1, wherein the information
comprises an icon.
8. The generator controller of claim 1, wherein the information
comprises an audible alarm and wherein the controller further
comprises a speaker configured to play the audible alarm.
9. The generator controller of claim 1, wherein the memory further
contains stored programming instructions operable by the processor
to send to the generator, as a function of the signal received from
the generator, a request for an additional signal.
10. The generator controller of claim 9, wherein the additional
signal comprises a detailed fault message.
11. A generator controller, comprising: a processor; a display; an
output capable of sending instructions to a generator; and a memory
accessible by the processor, the memory containing stored
programming instructions operable by the processor to control the
operation of a generator, monitor a parameter related to the
duration of operation of the generator, and to present an indicator
related to the parameter on the display.
12. The generator controller of claim 11, wherein the parameter
comprises lifetime operation duration of the generator.
13. The generator controller of claim 11, wherein the parameter
comprises duration since the last time the generator was
serviced.
14. The generator controller of claim 11, wherein the indicator
comprises a time period remaining until the generator is
recommended to be serviced.
15. The generator controller of claim 14, wherein the time period
remaining until the generator is recommended to be serviced is
determined by subtracting a recommended operation duration from a
current operation duration.
16. The generator controller of claim 15, wherein the recommended
operation duration is adjustable by a user.
17. The generator controller of claim 16, wherein the memory
contains stored programming instructions to cause the processor to
present on the display a plurality of alternative generator types,
and wherein the adjustment by the user is performed by selecting
one generator type from the plurality of generator types.
18-70. (canceled)
Description
PRIORITY CLAIM
[0001] This application is a continuation of U.S. application Ser.
No. 10/788,814, filed Feb. 27, 2004, which claims the benefit of
provisional application Ser. No. 60/449,927, filed Feb. 27,
2003.
FIELD OF THE INVENTION
[0002] This invention relates to methods and apparatus for
monitoring and adaptively controlling the starting and stopping of
an engine driven power generator.
BACKGROUND OF THE INVENTION
[0003] This invention is primarily intended for use with power
generators such as those used with Recreational Vehicles (RVs),
including motor homes, coaches, campers, trailers, fifth-wheel
trailers, and boats. It is not intended to be limited to those
applications, and should be understood to be applicable to other
arrangements in which power generators are used.
[0004] To understand the unique and valuable aspects of this
invention it is useful to understand the typical power system found
on Recreational Vehicles (RVs), boats, emergency vehicles, and
stationary energy systems that incorporate engine driven diesel,
gas, liquefied petroleum, or other generators. These systems
frequently have intermittent AC power needs and multiple sources of
power available. Often the critical systems are supplied by a DC
battery system and the non-critical loads are supplied by the AC
system.
[0005] RVs for example have both a 12V DC house or domestic system
and a 120V AC system. The DC system commonly provides power for
area lighting, stereo, water pumping, and other loads requiring
relatively small amounts of power. The 120V AC system powers larger
loads such as the microwave ovens, hot water heaters, heating and
air conditioning (HVAC), and convenience outlets that supply power
to loads such as entertainment systems. The domestic refrigerator
is commonly supplied by both the 12V DC system and the 120V AC
system, and sometimes alternatively by propane. Some systems also
include a 12V DC to 120V AC inverter. Often the RV (or boat or
other power user) is able to operate with only the DC system but
the AC system provides additional comfort and features.
[0006] RVs and boats have similar systems and both typically have a
power inlet for park power or shore power, as these industries
refer to the AC utility power grid. These power inlets are commonly
either 30A 120V single phase AC or 50A 120/240V single phase AC.
Thus there are frequently two or three AC power sources available.
Power transfer relays are commonly configured so that the priority
of the power sources is:
[0007] Utility or Shore Power
[0008] Genset (generator)
[0009] Inverter
[0010] Typically the inverter only supplies AC devices that are the
highest priority, such as the microwave, entertainment, and
convenience outlets. It is not practical to run loads like hot
water heaters and HVAC systems from inverters that are ultimately
powered from batteries. Frequently the total AC power requirement
of all of the system loads exceeds the park/shore power inlet, and
consequently requires running the genset to power the entire
system.
[0011] The operators of RVs must constantly monitor these various
systems and make decisions about which power source to use and
when. This results in less than optimal operating efficiency and
great inconvenience. For example consider the RV camping situation
in which there is no AC power. The DC system is used for lighting,
refrigeration, and other applications. Perhaps there is also an
inverter. Eventually the battery will become discharged under such
constant use. The operator must monitor the battery and decide when
to start the generator to recharge the battery and then continue to
monitor it until it is charged and then stop the generator. Loads
like HVAC systems which have intermittent on/off duty cycles
require the operator to choose either to let the generator to run
continuously or to repeatedly manually stop and start the
genset.
[0012] Current systems for monitoring and controlling generators
are generally lacking. In U.S. Pat. No. 1,507,300 Replogle teaches
starting and stopping an internal combustion engine-driven
generator based on battery voltage. Today there are a number of
commercially available systems that will initiate starting and
stopping the generator based on fixed voltage points. But the use
of a single voltage point for starting and stopping requires
considerable compromise because the state-of-charge of the battery
is difficult to assess from the instantaneous voltage. Additionally
many of the commercially available systems impose fixed minimum run
times which can lead to excessive genset running.
[0013] The general notion of starting and stopping the genset based
on demand from HVAC systems is taught by Picklesimer in U.S. Pat.
No. 4,788,487. The Picklesimer system controls both starting and
stopping of the genset and includes transfer relays for
sequentially loading the genset after a fixed time delay from
starting the genset. A fixed time is also imposed after the HVAC
demand has been satisfied for genset cool down. As Picklesimer
explains, " . . . the invention will permit continued repetition of
the start up and shut down procedures as described to permit the
interior of the motor home to be held to a narrow thermostat
temperature range setting . . . " Though seemingly better then
previous systems, the resultant "short-cycling" of repeated
starting and stopping the genset causes excessive wear on the
engine starting system. If the on demand time is relatively high it
is actually better for the genset to run continuously.
[0014] Commercially available automatic starting systems suffer
from the shortcomings described above as well as a lack of
sufficient inputs and outputs to allow comprehensive control of the
RV power system. The manufacturers of inverters have incorporated
automatically starting and stopping the genset as part of the
inverter system. It typically requires the purchase of a specific
expensive model of inverter as well the optional monitoring panel
(for example, a Trace RV series with RC-7G). Even so it does not
include servicing run requests from HVAC systems. Some stand alone
generator starting systems (for example, Heart AGS) have attempted
to integrate automatic genset starting using both HVAC run requests
and battery voltage. By imposing a minimum run time of 2 hours the
unit effectively causes continuous genset running. Additionally
none of the existing units interface well to the genset. No genset
fault or error messages are displayed, the genset battery is not
monitored, and typically the genset cannot even be conveniently
started and stopped manually from the user interface.
[0015] The user interface supplied by most genset manufactures is
very simple. Onan a Cummins Inc, subsidiary, has a remote that
consists of an ON-OFF-ON rocker switch with a back-light and an
hour meter or an analog volt meter. The back-light in the rocker
switch is use to annunciate genset faults. Two levels of faults
exist. For the first level the light is flashed about once per
second if the engine temperature is high, it will flash about twice
per second if the oil pressure is low, and if the light flashes
about three times per second the user may hold the stop switch down
for one to five seconds to access a second level of diagnostics.
The light flash sequence now contains two digits corresponding to
an error message. For example if the fault code were 38 there would
be a sequence of three flashes followed by eight more that would
lead the user to a table of error codes for the message: Over
current low power factor loads, reduce load. Users are likely to be
confused and unsuccessful when decoding this type of information.
Additionally genset faults are only annunciated for five minutes,
which means the user could have a fault but not know it. When the
system is automated this is an issue as more elements are involved
in the start/stop process.
[0016] Safety should be prime concern when automating the starting
and stopping of the genset in a RV. Many RV owners have garages,
buildings, or sheds where they park their RV. If there is a
possibility of carbon-monoxide poisoning or suffocation from
exhaust gasses automatic genset starting should be prohibited.
Systems that are currently available have not adequately addressed
the safety problems. The Heart AGS for example, recommends turning
it off when the coach is in motion. This means it cannot be used in
the automatic mode while traveling, even though this would be
desirable for most motor homes.
[0017] The integration of genset user interface, system monitoring,
and automatic control has substantially lagged monitoring and
control systems of inverters. Inverter manufactures have also
generally failed to integrate genset monitoring and control.
Presently the typical RV may have a monitoring and control panel
for the inverter, for the genset starting system, and for manual
control and limited fault annunciation, perhaps with a mechanical
hour meter or an analog voltmeter. The components of the system
inappropriately overlap, have missing control features, tend to be
costly, and nonintuitive. For the typical RV user the systems need
to be simple to use with functionality appropriately divided.
[0018] Current systems reveal a lack of integration of key system
elements, a lack of a user interface that is intuitive and
informative, and a lack of safety features to protect users. They
also rely on single point fixed times and voltage for control,
potentially resulting in excessive running or excessive starts and
stops. Thus there is a need for an improved system that addresses
one or more of these shortcomings and advances the art with several
significant new innovations.
SUMMARY OF THE INVENTION
[0019] The present invention, in its various preferred embodiments,
provides methods and systems for a genset user interface and system
monitor that displays genset fault messages, a genset elapsed time
hour meter, service countdown reminder, monitors battery voltage
changes over multiple periods of time to establish and display the
"battery level," uses the "battery level" to automatically start
and stop the genset, and accepts multiple run requests from AC
loads such as HVAC systems, and incorporates safety or other start
inhibit features.
[0020] A preferred embodiment includes a system to monitor genset
flashing fault or status light output and display its equivalent
message in English (or other language) in a user display.
[0021] In accordance with another preferred embodiment, the system
adaptively adjusts the stop/start duty cycle to optimize genset
running without excessive run time or starts and stops.
[0022] An additional alternate preferred embodiment monitors the
battery state-of-charge and uses the resulting "battery level" to
start and stop the genset, rather than relying on fixed voltages,
which improves system performance.
[0023] In accordance with additional preferred embodiments, the
invention inhibits the genset from starting if it is not in a safe
environment.
[0024] Yet another alternate embodiment starts the genset if the
inverter is overloaded, which enables the use of a smaller less
costly inverter.
[0025] These and other alternate preferred features are described
in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The preferred and alternative embodiments of the present
invention are described in detail below with reference to the
following drawings.
[0027] FIG. 1a is a front plan view of a preferred generator
controller;
[0028] FIG. 1b is a front plan view of an alternate preferred
generator controller;
[0029] FIG. 2 is a block diagram of a preferred generator
controller integrated with a generator and other components;
[0030] FIG. 3 is a block diagram of a preferred generator
controller;
[0031] FIG. 4a is an exploded view of a preferred construction for
a generator controller;
[0032] FIG. 4b is a bottom perspective view of a preferred
generator controller;
[0033] FIG. 5 is a flow diagram for a preferred management of a
generator during a quiet time;
[0034] FIG. 6 is a flow diagram for a preferred management of a
battery charging cycle;
[0035] FIG. 7 is a flow diagram for a preferred management of a
battery charging cycle;
[0036] FIG. 8 is a flow diagram for a preferred management of a
battery charging cycle;
[0037] FIG. 9 is a flow diagram for a preferred management of a
battery charging cycle incorporating battery state of charge
information; and
[0038] FIG. 10 is a block diagram for a plurality of start inhibit
sources.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] The generator controller has a host of innovative features
that are variously incorporated into the different preferred
embodiments of the invention. As such, a characterization that a
feature is incorporated by the invention should only be taken to
mean that one or more preferred embodiments adopts that
feature.
[0040] In one form, the generator controller constantly monitors
the 12V DC system and if the battery charge is low it automatically
starts the generator and runs it until the battery is recharged. If
a load such as an Air Conditioner requests power the generator
automatically starts and services the Air Conditioner. It imposes a
typical minimum run time of 30 minutes (or other adjustable
duration) to avoid short cycling the generator. It is able to
accept multiple start requests; for example, three are provided in
one embodiment. It also has an AC power present signal that can be
used to start and stop the generator, as appropriate, if utility or
shore power is present.
[0041] The preferred embodiment also incorporates knowing when to
stop or not run the generator. For example National and State
parks, as well as many private parks, have quiet hours during which
the running of a generator is prohibited. Respecting a quiet time
is best accomplished if the control system knows the local time.
The preferred embodiment has a real time clock with a battery
backup so that the unit it will keep accurate local time even if
the main 12V power supply is disconnected. The local time is
displayed and is easily set. The start and end of the quiet hours
is also easily set using the operator interface. These and other
preferred features are discussed in greater detail below.
[0042] Generator Controller User Interface
[0043] FIGS. 1a and 1b provide a front view of a preferred
generator controller 10, including the user interface. The
controller 10 includes an up/down rocker key 12, including an up
key portion 12a and a down key portion 12b. An enter key 14 and a
set key 16 are provided, in addition to a start/stop rocker switch
20 having a start ("1") key portion 20a and a stop ("0") key
portion 20b. Each of the keys can be implemented in a variety of
ways, for example, the preferred keys are rubber keys with
conductive pucks. Alternatively, dome switches, discreet switches,
or other embodiments are also possible. Likewise, the positioning
of the keys on the face of the controller is only one of many
possible arrangements within the scope of this invention. The
embodiment depicted in FIG. 1b includes an additional key, which is
a generator mode key 18.
[0044] The controller 10 includes a display 40 that is capable of
presenting messages, time, battery state of charge, warnings,
modes, and other information to the user. In the preferred form,
the display is an LCD display, although it could take the form of
an LED or other display.
[0045] The controller 10 comprises an external housing 30 that is
preferably formed from plastic. The housing retains internal
components such as a printed circuit board (not visible in FIG. 1).
A metal subpanel 32 is mounted adjacent the rim of the housing 30.
A magnetic overlay 34 is magnetically attached to the subpanel 32,
and includes printed information such as labels for the keys, a
device model number, and an OEM label.
[0046] Generator Controller System Interface
[0047] The generator controller 10 interacts with a generator
(genset), battery, AC power supplies, and other components that are
typically installed in a boat, RV, or other structure that uses a
generator, as depicted in FIG. 2. Any number of devices such as
Heating Ventilation and Air Conditioning (HVAC) 50a-c may generate
run requests and are coupled to the generator controller 10 via
cables 84.
[0048] A safety start inhibit device 52 is also connected to the
controller 10 via a cable 84. The safety start inhibit 52 is
described in greater detail below, and is used to prevent operation
of the generator in certain unsafe conditions.
[0049] Other devices 72 may also be present on a system
communication bus 90 and in signal communication with the
controller 10. The other devices 72 may take nearly any form, and
could be, for example, a load manager, vehicle information system,
or other devices in which integration into the system provides a
benefit to the system and user.
[0050] A genset 59 is coupled to the controller 10 via a
multiconductor signal cable. The bidirectional signal communication
allows the controller to, for example, start and stop the genset
59, to receive messages from the genset, and to send responses or
other control messages to the genset 59.
[0051] The genset 59 is also coupled to a main AC distribution
system 62 via a gen/shore transfer switch 58. The gen/shore
transfer switch selectively allows power to be provided either from
the genset 59 or utility (shore) incoming AC power 58, which is
also coupled to the gen/shore transfer switch. The utility incoming
AC power 58 is the power provided at the shore or at, for example,
an RV park from a land power line. The utility AC incoming power is
also coupled to a utility AC sensor 54, which may take the form of
a doorbell transformer or a transformer/rectifier to provide a DC
signal to the controller 10 via a signal cable 84 to indicate that
AC power is present from a utility AC power source 58. The
controller is then able to direct the gen/shore transfer switch 58
to connect the utility AC incoming power 58 to the main AC
distribution system 62, and to disconnect the genset 59 from the
main AC distribution system 62. The controller 10 will also, if
appropriate in view of short cycle or other operating
considerations, direct the genset 59 to shut off.
[0052] The main AC distribution system 62 is connected to a battery
charger 64, which is connected to a battery 60 in order to charge
the battery by drawing power from the genset 59 or utility AC
incoming power 56, as described above. The battery 60 is also
coupled to the controller 10 via a signal cable 84 so that the
controller can determine the current battery voltage and other
battery parameters such as rate of charge or discharge.
[0053] The battery 60 is also connected to an inverter 66 in order
to provide AC power when desired. The inverter is coupled to an
inverter transfer switch 70, which is also connected to the main AC
distribution system 62. The inverter transfer switch 70 selectively
allows power to be supplied from the inverter 66 or the main AC
distribution system 62 to an AC distribution inverter sub-panel 68.
The inverter transfer switch 70 is connected to the controller 10
via a cable 82 so that the controller can direct the transfer
switch to supply power from the desired source, as explained in
greater detail below. The AC distribution inverter sub panel 68
comprises one or more power outlets or other connections to which
electrical devices may be connected.
[0054] Generator Controller Hardware & Construction
[0055] The internal components of the controller 10 are shown in
the block diagram of FIG. 3. The controller includes a processor
102 and a memory 104. The memory may take any of a variety of
forms, such as RAM, ROM, EPROM, EEPROM, optical devices, or any
other structure capable of storing data and programming
instructions. The memory 104 may also comprise a combination of
different devices. The memory contains stored programming
instructions that are operable by the processor 102 in order to
perform the algorithms and processes described in this
specification. It also stores data received from external sources
or produced by the processor.
[0056] A display 106 is provided and is in signal communication
with the processor and configured to display information obtained
from the memory or other sources. As explained above with regard to
FIG. 1, the display is preferably an LCD device.
[0057] A speaker 108 is also provided and in signal communication
with the processor and adapted to produce audible sounds,
preferably including sounds stored in the memory and retrieved
under control of the processor. For example, the memory may contain
stored alarm sounds corresponding to genset conditions or battery
state of charge conditions so that the alarm can play those sounds
when directed by the processor to do so.
[0058] An input/output jack 110 is provided and shown to be in
signal communication with the processor 102. It should be
understood, of course, that all of the various signal connections
depicted in FIG. 3 may be via a communication bus. The input/output
jack comprises electrical, optical, electromagnetic, or other
connectors sufficient to enable signal communication between the
controller 10 and external devices such as those illustrated in
FIG. 2. In that regard, it should be understood that any cables
described with reference to FIG. 2 may be replaced by other methods
of signal communication, such as a serial data bus or an IR or RF
wireless signal. One of the input sources that is preferably
connected via the input/output jack 110 is the battery 60 (see FIG.
2), which provides 12V power to the controller 10.
[0059] A clock 112 is provided and coupled to the processor 102.
The clock is preferably a real-time clock that is also powered by a
backup battery (not shown) so that real time is maintained even
when the external battery 60 is disconnected.
[0060] The housing and construction of the generator controller is
illustrated in FIGS. 4a and 4b. A housing 130 is formed from
plastic or other materials suitable for packaging electronic
devices. The housing preferably forms a shallow rectangular box,
having a floor and four upright walls open at the top. One or more
printed circuit boards 132 nests within the box adjacent the floor.
It should be appreciated that the electronic components need not be
configured on a printed circuit board, but rather may be
constructed in alternate means. The printed circuit board 132 also
supports the rocker switches and keys discussed above with regard
to the user interface.
[0061] A metal plate 134 is secured over the open top of the
housing, preferably using screws or other removable fasteners
(although it may alternatively be snap-fit or otherwise attached).
The plate 134 includes openings in appropriate positions so that
the rocker switches and keys extend through the openings and seat
snugly within the openings. The internal printed circuit boards are
retained by snap fittings, but the plate 134 may alternatively the
printed circuit board within the housing 130. In the preferred
form, the plate is formed from a ferromagnetic material so that a
magnetic sheet 136 having an attached label overlay 138 is
removably attachable to the plate. Both the magnetic sheet 136 and
the overlay 138 include cutouts and openings that match those of
the plate 134 so that the rocker switches, keys, and display extend
or are visible through the openings. The magnetic sheet and overlay
allow for the manufacture of a common housing, circuit board, cover
plate, and magnetic sheet along with a plurality of overlays that
are tailored to specific customers or OEMs.
[0062] FIG. 4b provides a bottom perspective view of the housing
130, including the location and configuration of a preferred jack
140 with its various pin connections for inputs and outputs. The
preferred input/output jack 140 is a standard Molex/Amp/Tyco plug
which is simply plugged into a harness that is pre-wired in the
vehicle.
[0063] Adaptive Cycle Management
[0064] The controller 10 uses an Adaptive Cycle Management system
that anticipates the system power requirements. For example as the
start of Quiet Time approaches the controller 10 checks the state
of charge of the batteries and if needed will automatically start
the generator to ensure the batteries enter Quiet Time fully
charged. It is able to adapt the time at which it starts the
generator based on the state of the battery.
[0065] One presently preferred form for the adaptive cycle
management process is depicted in FIG. 5. The controller memory
includes stored programming instructions operable by the processor
to implement the process. At a first block 200, the processor
queries whether quiet time is approaching. The quiet time is
user-definable and can vary as the user travels from one location
to another. In order to determine whether quiet time is
approaching, the processor compares the stored quiet time with the
present real time as provided by the real time clock. Whether quite
time is "approaching" is also user-settable and may, for example,
be defined as a period of time within one hour of the defined
beginning of quiet time.
[0066] If quiet time is approaching, the method proceeds to block
202, where it determines whether the current battery state of
charge is sufficient to manage expected loads throughout the quiet
time interval. In one form, the sufficiency evaluation compares
state of charge data stored in the controller memory. The state of
charge data can comprise present battery voltage, current rate of
discharge or charge, and other aspects of battery usage. The
expected load data may comprise a preset value for one or more of
the above parameters, user-defined values, or stored history values
for recent battery usage during the quite time period. By comparing
the present state of charge with the expected load, the processor
determines whether the state of charge is sufficient to handle the
expected load. If the battery charge is not sufficient, the
controller 10 starts the genset (or if it is already operating,
ensures that it continues to operate).
[0067] Adaptive cycle management also actively balances excessive
run time and short cycling. It compares the duty cycle of generator
run time required to meet the start and run requests with the
generator off time, and automatically adapts the run time to avoid
short cycling or excessive running. Consider a typical day in the
life of an RV that is camped in a summer time vacation spot with no
AC grid power available. If the batteries are sized properly the
domestic demand overnight will not have discharged them before
morning. If they are low, as soon as quiet time ends the controller
will automatically start the generator and run it for minimum of 30
minutes (or other adjustable duration). It will then assess the
state-of-charge of the batteries and determine if additional
running is required. If they are sufficiently charged to meet the
morning demand the generator will be stopped rather than continue
charging until the batteries are full. The controller anticipates
more run time as the day progresses, during which there will be
additional charge time for the batteries.
[0068] A preferred process for implementing the short cycle
management aspect of the controller is illustrated in FIG. 6.
Again, the controller memory contains stored programming
instructions operable by the processor to carry out the preferred
processes. At a first block 220, the controller evaluates whether
the present state of charge is too low. This initial inquiry may be
in the form of a comparison of the state of charge with a preset
value such that the controller will presumptively start the
generator, block 221, if the state of charge is too low. In order
to avoid short cycling, the generator will run for a minimum time,
preferably 30 minutes or other adjustable duration.
[0069] At the end of the minimum run time, the process advances to
block 222 to determine whether the near term expected demand will
be met in view of the present state of charge. The near term demand
may be a user-defined load level for a particular time of day, or
may be based on stored historic usage levels for near-term portions
of a day such as morning, afternoon, and evening. If the battery is
sufficiently charged after the initial minimum run time, the
controller causes the generator to stop; if a greater charge is
required, the controller causes the generator to continue to
operate, block 224. The continued operation time may be either a
fixed additional time period or a variable one. In a variable mode,
the generator continues to operate while the process continually
compares state of charge with expected demand levels. Once the
state of charge exceeds expected demand, the controller causes the
generator to stop, block 226.
[0070] As the day warms the air conditioner (AC) begins to request
power, the generator will automatically start. Initially it may
only take a few minutes to cool the interior; the controller will
stop if the previous minimum run time had occurred recently enough
that the generator was still warm. If not it would run for the
adjustable minimum run time of 30 minutes or other period as set by
the user. This avoids excessive running by allowing the generator
to be run for less than its minimum run time if it is already warm.
Perhaps the generator will only have to run for a few minutes to
bring satisfy the AC demand early in the day.
[0071] A preferred process for implementing this cycle management
feature is depicted in FIG. 7. At a first block 240, the controller
determines whether the AC power is on. This determination may be,
for example, in the form of a run request signal from the HVAC to
the controller (see FIG. 1). If the AC power is switched off, the
controller causes the generator to run if not already running,
block 242. The generator continues to run while the AC is on.
[0072] Once the AC is switched off, the process determines whether
the generator had recently been operating for a minimum run time
(e.g., 30 minutes or other specified time), block 246. Thus, for
example, if the generator had completed a minimum 30 minute run
time within the previous five minutes, there would be no need to
continue to operate the generator to avoid short cycle concerns and
the controller causes the generator to stop, block 250. This
process allows the generator to be safely operated for less than
the minimum run time under such conditions.
[0073] If a minimum run time had not been completed within a recent
defined period, the controller may optionally cause the generator
to continue to run until the end of the minimum run time, block
248, to avoid short cycling of the generator.
[0074] The controller also manages the operation of the generator
with regard to the duty cycle of the generator. The on/off duty
cycle of the generator will continue to increase as the day
continues to warm and the demand for AC increases. The controller
monitors the change in the duty cycle and if the on time verses the
off time passes a programmable limit the generator will continue to
run in anticipation of the next start/run request from the air
conditioner. The preferred default on/off duty cycle is
approximately 70%. If the ratio of the start/run request time to
the off time is greater than 0.7 the controller will cause the
generator to continue to run. This avoids excessive starting and
stopping of the generator. Additionally if the actual number of
start and stop requests exceeds a programmable threshold the
controller will run the generator continuously, again avoiding
excessive cycling.
[0075] When evening comes and the temperatures begin to fall the
controller Adaptive Cycle Management system will reverse its
management style. When the duty cycle falls below the programmed
value (70% default value) it will once again turn off the generator
when it is not required and will allow an increase in the number of
starts and stops allowed. This minimizes generator running
hours.
[0076] In anticipation of quiet time the controller will run the
generator to top off the batteries before quiet time starts. It
uses preprogrammed algorithms and historical performance of the
system to determine the optimum start and run times. By looking at
such values as rate of change of voltage during discharging and
charging, historical battery voltage averages, the current value of
voltage, the estimated state-of-charge, and other variable and
inputs that the system monitor, it adapts the run time to optimize
generator run time. When quiet time starts the generator will be
inhibited from starting until Quiet Time ends the following
morning.
[0077] One preferred implementation of the duty cycle management
process is depicted in FIG. 8. At a first block 260, the generator
is in a running condition. At block 262, the controller receives a
stop request, for example in the form of the air conditioning
cycling off. Upon receipt of the stop request, the process proceeds
to block 264 where it determines whether the duty cycle of the
generator in the applicable period (for example, in the morning,
afternoon, or other defined period) exceeds the stored value (for
example, 70% or other adjustable level). If so, the generation
continues to operate for an additional minimum duration.
[0078] If the duty cycle operation has not been exceeded, the
process continues to block 266, where the number of start and stop
requests in the applicable period (for example, morning, afternoon,
or evening) exceed an adjustable value. If so, the controller
causes the generator to continue to operate for an additional
minimum duration.
[0079] If the number of start and stop requests are not excessive,
the process proceeds to block 268 where it determines whether an
anticipatory quiet time charge is required (as explained above with
regard to battery state of charge and expected load levels). If no
quiet time charge is required, the controller proceeds to block
270, where it determines whether the generator has been run for a
minimum time recently. Because the controller continually monitors
and stores the times during which the generator is being run, it is
able to readily determine whether a minimum run time has been
completed. If it has not been completed within an adjustable stored
time, the process proceeds to block 272 where the processor causes
the genset to continue to run for a minimum run time.
[0080] If a minimum run time has completed recently, the process
continues to block 274, where the controller causes the generator
to stop.
[0081] The above adaptive cycle management is superior to existing
systems. The typical system has a fixed minimum run time that is
normally greater than 30 minutes, and is commonly two hours. This
is to ensure the batteries are full and certainly avoids excessive
starting. But under many common conditions the generator would
start in the morning due to a low battery or an AC request and then
run for two hours regardless of the AC demand. This same typical
system would continue to run the generator for another two hours if
the voltage has not reached a threshold (13.5V for this typical
system), without regard to expected demands. At the end of this run
time the generator may only be providing a few amps of battery
charging. At the end of one of these two hour cycles the generator
would be shut off. But the next AC request will trigger the two
hour cycle all over again. It is typical to have very little off
time with this type of a system.
[0082] Determining Battery State
[0083] Aside from specific demands from HVAC systems, the
controller causes the generator to operate in order to maintain
battery charge levels. The controller uses the actual battery
voltage as well as the rate of change of voltage (dV/dt) to assess
the need to start or continue to run the generator. These values
are obtained by reading and storing in memory the battery voltage
at regular intervals, then evaluating the voltage levels over time.
This ensures that the generator is not run for extended periods of
time to maintain a battery that is not accepting charge. The
adaptive cycle management system is able to compare historical
charge data and infer how it is being charged. Keeping historical
data such as: lowest battery voltage, average discharge voltage,
time at key voltage thresholds, time since last charge, average and
maximum charge time, and other data that can be derived from its
inputs the controller adapts its estimate of the battery state of
charge. This same data is used to determine the battery
state-of-charge bar graph display.
[0084] A preferred flow diagram for implementing adaptive cycle
management using battery state of charge information is shown in
FIG. 9. Initially, the battery voltage is sampled at block 280.
Short term average battery voltages are calculated at block 281 and
compared with stored settings for desired minimum voltage at block
282. If the short term voltage is less than a preset stored level,
the battery is deemed to have too low a charge and the process
proceeds to block 290, where the generator is started.
[0085] If the battery short term average is not below an adjustable
value, the process proceeds to block 283, where the controller
processor calculates long term changes in battery voltages over
time, and averages of those values. At block 284, the long term
average voltage is compared with adjustable stored settings for
long term battery voltages. If the battery long term average
battery voltage is below the stored value, the process proceeds to
block 290, where the generator is started. If not, the process
proceeds to block 285, where it estimates the present battery state
of charge.
[0086] The battery state of charge preferably includes an
evaluation of one or more parameters indicative of the state of
charge of the battery. By continually monitoring and storing
battery voltages over time, the processor is able to determine a
variety of battery state of charge parameters. In one embodiment,
the processor evaluates the lowest battery voltage, average
discharge voltage, time at key voltage thresholds (which may be
preset and adjustable), time since last charge, average and maximum
charge time, and other data that can be derived from its inputs the
controller adapts its estimate of the battery state of charge. The
state of charge may be deemed to be too low if, for example, the
time since last discharge is greater than a stored duration. If the
evaluation of the state of charge indicates that the state of
charge is too low, the process continues to block 290, where the
generator is started. If not, the process continues back to block
280 to sample battery voltage.
[0087] Once the generator has started at block 290, the process
performs similar battery state of charge monitoring to determine
when to stop the generator. Initially, the process continues to
block 291 where short term average voltages over time are compared
with stored settings. Once the averages exceed the stored settings,
the battery is deemed to be charged and the process proceeds to
block 294 where the generator is stopped.
[0088] If the short term average voltages do not exceed the stored
values, the process continues to block 292, where long term average
voltages are compared with stored values. This step enables the
processor to stop the generator if it is only providing a trickle
charge over a long duration. If the long term average exceeds
stored values, the process proceeds to block 294, where the
generator is stopped. If not, the process continues to block 293 to
evaluate one or more parameters related to battery state of charge.
The parameters may include, for example, the parameters described
above with regard to state of charge. If the evaluation of one or
more such parameters indicates that the battery is fully charged,
the process continues to block 294 where the generator is stopped.
If not, the process continues to block 291 to monitor the battery
charge.
Safety Start Inhibit
[0089] Safety is always a concern when integrating automation into
a system. The preferred controller has a number of safety features
that are unique and innovative. One safety concern is to not
automatically start the engine when it is in a garage. The typical
system today requires that power to it be disconnected when the
vehicle's ignition switch is on or when the parking brake is
released. Previously existing systems are disabled by turning them
off. Unfortunately this means that the automatic mode cannot be
used while underway, while driving down the road. The present
preferred controller in contrast has a Safety Start Inhibit input
that can receive its signal from a variety of sources. It can
accept a signal from a parking brake switch or an ignition relay.
When the controller sees a change the input signals it will change
the mode to manual. If the operator wants to return it to the AUTO
mode they may do so and enjoy the benefits.
[0090] One embodiment of the safety start inhibit feature is
depicted in FIG. 2. In such an embodiment, one or more
safety-related sources 52 is coupled to the controller 10 via an
opto-coupled input. In an embodiment in which a plurality of safety
start inhibit parameter is desired, a construction such as that of
FIG. 10 may be used. Thus, output signals from a parking brake
switch 300, ignition relay 302, gas sensor 304, building sensor
306, AC power present detector 308, or other device 310 are each in
signal communication with a safety start inhibit adaptor 52. An
active signal from any of the input sources causes a corresponding
signal to be conveyed to the controller 10. The processor, in turn,
causes the generator to stop operating or prevents the operation of
the generator under conditions in which it would otherwise have
operated until the safety start inhibit signal is no longer
present.
[0091] As depicted in FIG. 2, the safety start inhibit 52 is
depicted as a block external to the controller. Depending on the
embodiment, however, the safety start inhibit may be nothing more
than an input pin on the controller to enable it to be connected to
the particular safety input source. Alternatively, it may include
circuitry to receive and decode safety parameters to determine
whether an input is unsafe. It may also comprise wireless receivers
such as proximity detectors to determine the presence of a building
or other object. In yet another embodiment, it may include a
speaker capable of sounding an alarm under certain safety
conditions, and circuitry sufficient to provide a signal to the
controller to indicate the nature of the safety condition where
multiple safety inputs are connected.
[0092] The safety start inhibit may accept an input from external
sensors, such as sensors for Carbon Monoxide and Carbon Dioxide.
These sensors are required in many installations but typically only
sound an alarm. As explained above, in one embodiment, the
controller can sound an alarm and inhibit the generator from
starting. Likewise, each of the plurality of sensors may be
incorporated into the generator controller itself, rather than
being external devices in signal communication with the
controller.
[0093] Additionally the Safety Start Inhibit can accept an input
signal from a sensor system designed to signal or detect the
presence of a building or garage in which the vehicle is parked.
The configuration of such building detectors may consist of two
categories, one in which the presence detector is located in the
garage where the vehicle is normally parked. Sensors might include
infrared, radar, ultrasound, RF or other wireless presence
detectors readily available from the alarm and intrusion detection
industry. The other category is where the detector is installed on
the vehicle and designed to detect the presence of any building in
which the vehicle is parked.
[0094] Optionally the stop input (reference number 20a in FIG. 1a)
may be pulsed and the controller will switch to the manual mode.
This allows any remote start switch for the generator to override
the automatic starting function. This is a critical safety issue
for the generator service technician. Pressing the local stop
switch on at the generator ensures that the generator is under
manual control. The controller is preferably supplied with a tag
that is placed on the generator shroud or adjacent to the generator
that informs the service technician that there is an automatic
control system for the generator.
[0095] Though the foregoing discussion is primarily related to
inhibiting the operation of the generator under specified safety
conditions, it may also be adapted for more general environmental
operating conditions in which it is preferred that the generator
not operate. Such environmental conditions may include, for
example, the presence of shore power.
[0096] Start Inhibit due to AC Present
[0097] The controller also solves another shortcoming of current
generator starting systems that allow the generator to run when
shore power is present. As depicted in FIG. 2, there is an input
from a utility AC sensor 54 that tells the controller that AC from
the shore or park is present. Programming stored in the memory and
operated by the processor continually monitors for the presence of
AC shore power as indicated by the AC sensor input 54. As long as
the utility power is present, the controller provides a signal to
the generator that causes the generator not to operate. This avoids
the wasteful condition in which the generator is running while the
loads are being supplied from shore power.
[0098] Decoding Generator Messages & Remote Control
[0099] The preferred controller also serves as a remote control for
the generator, storing and displaying key generator data useful for
technicians. Because the generator is started and stopped under
control of the controller, the controller is able to track the
number of hours the generator has run over its lifetime or over
particular periods, storing this information in the memory.
Likewise, the operation information may be displayed on the user
interface display upon the request of a user. The memory also
stores programmable service reminders that are automatically
displayed, for example, when it is time to change the oil or
perform other service functions.
[0100] Some generators, such as those produced by Onan, provide
indicators in the form of a light that flashes if there is problem
with low oil pressure, high temperature, or if service is required.
The operator must count the rate of the flashes and then look at a
table to determine the meaning of the error message. This is
inconvenient and requires the operator to interpret the rate of
flashing. In some cases, there are multiple levels that require the
user to depress a button after seeing an initial flashing message
in order to receive a more detailed message. The preferred
controller decodes these signals and displays a text message to
indicate the precise error message. If warranted, it can sound an
audible alarm.
[0101] The memory of the controller includes stored displayable
messages corresponding to the error signal received from the
generator. Upon receipt of an error message, the processor
retrieves the applicable message and displays it on the display,
sounding an alarm or taking other action if associated programming
instructions require it. In some instances, an additional inquiry
to the generator is also required. For example, the generator may
send an initial message corresponding to a "level 3" warning. The
user may depress a button to then see an additional encoded number
of flashes to decipher the particular level 3 concern. The stored
data in the controller memory decodes the level 3 warning or other
message, then sends a signal to the generator (if applicable) that
corresponds to a user depressing the required button. This causes
the generator to send to the controller the detailed message, which
is processed in order to retrieve the applicable text from memory
for display. In this fashion, the controller is able to remotely
retrieve, decode, and display error messages from the
generator.
[0102] The controller also takes care of the generator by
preheating and priming it for the right amount of time, cranking
only for the time recommended by the manufacturer, and waiting if
it does not start, before trying again, for the amount of time
required by the manufacturer. Each of these operating parameters is
stored in the controller memory so that the controller causes the
generator to operate in accordance with them. The controller also
runs the generator for the minimum time desired; Onan for example,
recommends that the generator be run for a minimum of 30 minutes.
The controller imposes this adjustable minimum run time whenever it
automatically starts the generator, unless over-ridden by other
management variables as discussed above.
[0103] A Tool for Service Departments
[0104] The controller can be a valuable tool for service
departments as well. If a generator such as the Onan Quiet Diesel
remote flashes its indicator light at a rate of 3 that means that
service is required. When the service department wants to find out
more details it initiates a special diagnostic mode. In this mode
the generator controller flashes the light in two multiple count
sequences to indicate a number. For example it would flash the
light twice then three times to indicate the number 23. The service
technician would then look this number in a table and read the
corresponding message for that number.
[0105] The preferred controller automatically decodes this and
other diagnostic messages. The result is faster and more accurate
service. Additionally key historical data about how the power
system and the generator have performed is stored in non-volatile
memory. Examples include: average run time, total run time, error
message history, generator and domestic battery data, and any other
relevant data which the controller processes.
[0106] Storage Mode
[0107] The controller may also be used in a "Storage Mode" which
periodically starts the generator and runs it for a specific amount
of time. Both the frequency and duration of run are adjustable.
This is particularly valuable to the dealer or the owner who must
store his vehicle or boat for extended periods of time. The Storage
Mode ensures that the generator is regularly exercised and that all
the batteries aboard stay charged. The Storage Mode is also
invaluable for the Dealer, as it ensures that all systems will be
in top condition whenever he shows the coach or boat.
[0108] Integration with Inverters
[0109] The controller also integrates DC/AC inverters into the
power system in a unique way. Many RV's, boats, and other mobile
vehicles with generators also have inverters incorporated into
their systems. The inverter changes energy stored in batteries to
alternating current similar to the power grid. These inverters are
often sized to meet the demands of specific loads. In their
simplest form they may plug into a cigarette lighter or have clamps
to attach directly to the battery. In their most sophisticated form
they can supply thousands of watts, incorporate battery charging,
minimal load management, and even integrated generator starting
based on battery state-of-charge.
[0110] The most common systems have inverters of 500 Watt to 2,000
Watts, which are frequently found on midsized RV's and boats. The
typical use of inverters with about 500 Watts of capacity would be
for entertainment and small appliances. The load which most
commonly requires a larger inverter is a microwave. Inverters with
a rating of 1,000 Watts or more are specified for such systems. As
with all electronics the inverter's output rating depends on the
temperature of the power components in the circuit. As inverters
run heavy loads the temperature rises and their ability to maintain
high output is reduced. Many inverters are able to carry
substantial over current for several minutes. However they are
often sized for continuous duty even though the battery system
cannot sustain them for continuous running. Consider the 12V
battery it would take to sustain a 2,500 W inverter consuming
between 200-250A: It would require 3-4 times the current
consumption in battery capacity--that is 600-800 Ahrs--and would
weigh 400-600 pounds, and would only supply 1-2 hours of duty at
such a high discharge rate.
[0111] When the preferred controller is integrated into the system
the inverter and battery system can potentially be substantially
smaller than is common practice today. As depicted in FIG. 2, the
inverter 66 is in communication with the controller 10.
Accordingly, the controller can optionally be programmed to start
the generator with a start request from the inverter. In alternate
forms, the controller may start and run the generator only when the
inverter appears not to be able to handle the load, which may be
based on the inverter's load current, an internally or externally
generated start request signal, an overload signal, or other method
of signaling the controller that the inverter is not able to run
the load. These indicators are either present as depicted in FIG.
2, or may comprise additional system inputs 72.
[0112] This unique feature allows the use of smaller, lighter
inverters and smaller battery systems. By using the controller to
integrate the operation of the generator and the inverter they
complement each other in a way that is unique from the current
state-of-the-art, which depends solely on battery state-of-charge.
Integrating and automating the operation allows more appropriately
sized batteries and inverters. A system like this can easily meet
the relatively low demands of entertainment or other loads, and
sustain modest loads like small microwaves for a few minutes, but
when the loads get too large, runs too long, or if the battery gets
low, the generator automatically starts and takes over.
[0113] An analogous situation is one in which the shore power is
inadequate to supply the AC load demands and may or may not be
managed by a load or energy management system. For example, a RV
that is designed with a 50A input may be supplied by a 30A shore
power circuit. When a load or energy manager turns off loads to
prevent tripping of the shore power breaker the controller can
start the generator to satisfy AC load requirements. These run
requests can include, but are not limited to, HVAC, Load or energy
management systems, inadequate shore power available, and inverter
overload. In such instances, the controller will detect that
certain desired loads have been turned off, and will cause the
generator to run (even though shore power is present) in order to
allow those loads to continue to run.
[0114] The particular operation of preferred controller modes,
programmable parameters, and preset values is further described
below.
[0115] STOP/START Switches
[0116] The controller may be used to manually start and stop the
generator by using the START/STOP rocker switch located on the left
side of the display (see FIG. 1a). This switch functions exactly
like the STOP/START switch located on the genset. There may also be
other START/STOP switches at other locations (the dashboard in a
Coach for example). When any STOP/START switch wired in the system
is operated the generator mode is switched to manual. This is both
a safety and convenience function. As a safety function it prevents
automatic starting, when manually stopped for service. As a
convenience function it prevents the generator from automatically
stopping while using a specific load for which the genset has been
started, for example a washing machine or power tool.
[0117] The START/STOP rocker switch has a red backlight which comes
on when the generator is running. It is turned on by a +12V signal
supplied by the genset. If the genset is equipped with diagnostics
it also flashes to correspond to fault messages sent by the
generator. The controller decodes the flashing fault message and
displays an English fault message.
[0118] The generator may be started using the START/STOP switch
even if there is no power to the controller. Once the generator is
running the controller display will come on. The power is supplied
from the generator.
[0119] Changing the GENERATOR MODE
[0120] The GENERATOR MODE key, on the left below the display in
FIG. 1b, is used to change the operating mode of the generator.
There are preferably three modes: MANUAL, QUIET ON, and AUTO ON. If
the generator mode is not displayed, pressing the GENERATOR MODE
key immediately exits to the default display (Local Time and
Mode).
[0121] When in the MANUAL mode the genset may be started and
stopped only by using the controller START/STOP, or other
START/STOP switches wired in the system.
[0122] The QUIET ON mode enforces a user adjustable Quiet Time
during which automatic genset starting is not permitted. This
avoids late night automatic starts that may be annoying and break
the quiet time regulations of campgrounds. Two hours prior to Quiet
Time the battery state-of-charge is checked and if it is not full
the genset is started to fill it before Quiet Time begins.
[0123] The AUTO ON mode will start the genset based on run requests
and low battery regardless of the time of day.
[0124] Using the UP/DOWN Key
[0125] The UP/DOWN key, located on the right side of the display,
is used to navigate through the various display and to change
values or parameters that can be set by the user.
[0126] Using the SET Key
[0127] The SET key, located in the center under the display, is
used to initiate change of values that can be changed or selected
by the user: Local Time and the beginning and end of Quiet Time are
examples. When the time is displayed and the SET key is pressed the
time will begin to flash and the digit which may be changed is
underlined. The UP/DOWN key is used to change the value. Change the
Hours digit first, wait for the underline to move to the right,
tens of minutes position, and set it, wait again for the underline
to move to the minutes position, and then set the minutes digit
last. Press ENTER to store the new value. If the UP/DOWN key is
held the display will scroll.
[0128] Using the ENTER Key
[0129] The ENTER key is used to store a value that has been
changed. The ENTER key is also used to ENTER the SETUP & INFO
DISPLAYS. The ENTER key can also be requested by a display to exit,
or to acknowledge a test.
[0130] The controller allows an RV TYPE (COACH or TRAILER) to be
setup. The RV TYPE controls the way the safety feature operates.
For both types the generator mode is forced to MANUAL when a Start
Inhibit Input is first detected. This prevents automatic starting
if the vehicle or trailer has just been parked in a garage. The
COACH type allows automatic modes after the vehicle has been
parked. The table below summarizes operation: TABLE-US-00001 RV
TYPE ACTION MODE COACH Safety ANY (Default) Brake Set Safety ANY
Brake Off Safety Goes to Brake Reset MANUAL TRAILER Brakes ANY Off
Brakes Goes to Applied MANUAL
[0131] Setting the RV TYPE
[0132] From the default display press the UP key for the SETUP
& INFO display and press ENTER. Use the UP/DOWN key to navigate
to the AUTO START display and press ENTER. Navigate to the SAFETY
RV TYPE display and press SET. The display will flash and the type
of RV will be displayed. The default is COACH<. The character
< is used to indicate all default displays. Use UP/DOWN to
select the appropriate RV TYPE. Press ENTER. The new type is stored
in permanent memory. This will not have to be setup again unless
the controller is installed on a different RV TYPE at a later
date.
[0133] Setting the GEN TYPE
[0134] The controller memory stores parameters for many different
generators, and the user may select from among the stored
generators to indicate the one to which the controller is
connected. The controller is set to a default GEN TYPE, and can be
changed to accommodate different generators. The GEN TYPE sets the
Service Interval for service messages and critical automatic
starting parameters. The following table lists a selection of
preferred generator types having parameters that are stored in the
controller memory: TABLE-US-00002 GEN TYPE MODEL Service In QD
7.5/8 Quiet Diesel 100 hours (Default) 7.5-8 kW QD 5.5 Quiet Diesel
50 hours 5.5 kW GAS/LP Emerald, 150 hours Marquis, Microlite, Micro
Quiet, Camp Power QD 10/12 Quiet Diesel 250 hours 10/12 kW
[0135] To change the GEN TYPE navigate to the SETUP & INFO
display and press ENTER. Now navigate to the GENSET display and
press ENTER. The GEN TYPE will be displayed. Press SET, the display
will flash. Use the UP/DOWN key to select the GEN TYPE and press
ENTER when the appropriate type is displayed. The type is stored in
permanent memory and will not have to be changed unless the EGR-1
is installed on a different type genset.
Setting the Hour-Meter
[0136] If the controller is installed on a new genset this step may
be skipped. If the controller is installed on an existing genset,
check the hour-meter on the genset and record the reading. ENTER
the SETUP & INFO menu and navigate to the GENSET display. Press
ENTER and use the DOWN key to select the SET Gen hours display.
Press SET. The next displays says, ENTER to unlock. This prevents
unauthorized changes to the hour-meter. Press ENTER to continue.
The displays will flash and UP/DOWN key can be used to change the
value. Note that the digit to be changed is indicated by an
underline. Waiting about four seconds allows the underline to move
to the right one digit. When the correct genset hours are displayed
press ENTER. The value is stored in permanent memory and will not
have to be changed unless the controller is installed on a
different genset.
[0137] Setting Local Time
[0138] The default display after power up is the Local Time and the
Generator Mode. The Local Time is used to prohibit automatically
starting the genset during Quiet Time. To set the local time simply
press the SET key and use the UP/DOWN key to change the time. Note
that the display flashes and the hour digit is underlined. Set the
hour value, wait about four seconds for the underline to move to
the right, set the tens digit, and then wait again to set the
minutes digit. This method makes changing the time when crossing a
time zone easy and quick. Simply adjust the hour and press
ENTER.
[0139] Setting Quite Time Start and End
[0140] The controller QUIET ON generator mode prohibits the
generator from automatically starting between the start and end of
Quiet Time. To change these times use the UP/DOWN key to navigate
to the QT START or QT END display. The current setting is shown.
Press SET to change the setting. Use the UP/DOWN key to change the
setting and press ENTER to store it in permanent memory.
[0141] Using the Battery Displays
[0142] The battery level indicator and battery voltage should be
wired to the domestic battery. The battery level indicator uses
both short and long term voltage trends to determine the battery
level. It is intended as a guide to the state-of-charge (SOC) of
the battery and its ability to sustain the load. When in the
automatic modes it also serves as the default trigger points for
starting and stopping the genset to charge a low battery. The
genset is started when the bar graph only shows one segment and
stopped when three bars are displayed.
[0143] While the preferred embodiment of the invention has been
illustrated and described, as noted above, many changes can be made
without departing from the spirit and scope of the invention.
Accordingly, the scope of the invention is not limited by the
disclosure of the preferred embodiment. Instead, the invention
should be determined entirely by reference to the claims that
follow.
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