Cycling Champion generator control module useing BS2 detect 12v start\stop gen. batt. chargers

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  • kwinnkwinn Posts: 7,436
    The method I have used to detect voltage just fails. The 219's may work for low amp applications. They don't work for high amp 12 volts.

    Volts are volts regardless of the amperage. To measure battery voltage in a high current situation you need to measure it as close to the battery as possible. Even heavy gauge wires have some resistance, and each connection some, which will cause a drop in voltage as you measure further away from the battery. A connection right on the battery posts would be ideal.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • kwinnkwinn Posts: 7,436
    .......
    I think the combined amperage of eight 12 volt batteries is just too many amps for the Adafruit INA219 current sensors.

    That is why we are only measuring the voltage using the 219, since that is all that that is needed for this application.

    The current could be measured, but it would need a much higher power sensing resistor in the load circuit.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • kwinnkwinn Posts: 7,436
    The other option would be to change the code to "11700 millivolts".
    because 11.7 volts is below the 12 volt wall adapter powering the BS2.

    ???????? As long as the voltage from the wall adapter is high enough for the regulator to provide a stable 5V for the BS2 (approx. 7V or more) the voltage has nothing to do with the code running on the BS2 or measuring the voltage on the INA219 Vin+.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • DPST relays how do i direct wire it to the BS2??
  • kwinn wrote: »
    I think its time to explore other options. Maybe a direct wire to the BS2?
    I agree, already suggested that in my last post. Now that I have access to the generator manual I can figure out how to do that.
    The BS2 cannot directly switch high amp relays.
    Three p.c. board micro 1 amp 12 volt relays to connect the coils to ground on three high amp relays.
    I think that would work.
    That's one option, and probably the simplest. The other is to use a relay driver that can drive the coils.
    Problem is how do I shut down the runaway magneto ignition system?

    I can shut that "battery switch" off and it will stay running
    I'm sure we can find a solution to that problem.

    Kwinn if u can figure out a way to wire DPST relays to a relay driver on the BS2 I'm ready to start over
  • I tried to wire it directly to the VLZ voltage detection relays . 12.3 started it an the generator ran for 13min an shut down at what it thought was 13.3volts If I set the EAZY relay at 14.2 for the stop value it just runs forever
  • Inverter manufacturer says I should be useing 4 aut gauge cables I am waiting for package with new cables Then I will start more tests
  • I melted a plastic base on a 500 amp fuse holder located between inverter positive an the battery
  • Waiting for several packages
  • Two inch 00 gauge cable got hot Needed to have 0000 gauge cable 12 inch long at inverter
  • Too many electrons speeding up an slowing down in different size cables
  • kwinnkwinn Posts: 7,436
    Two inch 00 gauge cable got hot Needed to have 0000 gauge cable 12 inch long at inverter

    Keep in mind that while 3500 Watts at 120V is only 29.17 Amps, the same 3500 Watts at 12V is 291.7 Amps. That's a lot of current and requires a hefty cable.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • Do not purchase products from EAZY relay company !! They manufacture poor quality products
  • Often ebay or Amazon shipped from China or hongkong Electronic hobbyist beware VLZ dual relay with voltage detection is not quality I just had two of these fail. One just got hot. Both activated the relays immediately opon power on regardless of the programming The most recent purchase of 3 from a separate online vender The EAZY 2.3 will not change logic gates opon user button entry The 2.3 has intermittent operation while jammed in voltage detection mode manualzilla has detailed schematics\ instructions Received refund wasted time
  • FRM01 better quality
  • The BS2 has left the mouser project box Too many inconsistent starts with the 219's. If the curse doesn't follow I will try new quality red boards. I think the curse maybe the high amps from 8 batteries. Nonetheless i will try VMM01's to activate FRM01's. Hopefully the red boards will live. If anyone has a hardware solution for the BS2 i would go get the Elvis back to do the show. Thanks
  • kwinn wrote: »
    Two inch 00 gauge cable got hot Needed to have 0000 gauge cable 12 inch long at inverter

    Keep in mind that while 3500 Watts at 120V is only 29.17 Amps, the same 3500 Watts at 12V is 291.7 Amps. That's a lot of current and requires a hefty cable.

    Right ,that's why theBS2 works for you Kwinn.It works for your 12volts because you dont have 7 more 12volt batteries to give your BS2 the same amps . There just has to be a piece of hardware missing
  • If anyone can find that hardware I will go buy it an retest {the Kwinn coded, duel relay activates 2 FRM01's BS2& 219's} in my rv.
  • I think the positive from the batteries needs to go through a shunt resistor before the 219. What value I do not know.
  • kwinnkwinn Posts: 7,436
    The BS2 has left the mouser project box Too many inconsistent starts with the 219's. If the curse doesn't follow I will try new quality red boards. I think the curse maybe the high amps from 8 batteries. Nonetheless i will try VMM01's to activate FRM01's. Hopefully the red boards will live. If anyone has a hardware solution for the BS2 i would go get the Elvis back to do the show. Thanks

    I suspect the problem of many inconsistent starts may be due to electrical noise from the generator or loads connected to the batteries. The INA's do not measure the current, but the high currents from loads connected to the batteries will cause the voltage to fluctuate as they switch on and off. It would be a big help if we could log the voltages over an entire battery charge/discharge cycle. The data is sent from the BS2 to the PC so that can be done using a terminal emulator on your PC.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • kwinnkwinn Posts: 7,436
    kwinn wrote: »
    Two inch 00 gauge cable got hot Needed to have 0000 gauge cable 12 inch long at inverter

    Keep in mind that while 3500 Watts at 120V is only 29.17 Amps, the same 3500 Watts at 12V is 291.7 Amps. That's a lot of current and requires a hefty cable.

    Right ,that's why theBS2 works for you Kwinn.It works for your 12volts because you dont have 7 more 12volt batteries to give your BS2 the same amps . There just has to be a piece of hardware missing

    Adding/replacing hardware at random (shotgunning) will not help. If anything we need to simplify the hardware. The BS2 controlling relays connected in parallel to the generator switches and fob is all that is needed. I know that this works because I have done it for an old generator using a propeller board a few years back. It may require some noise filtering for the BS2 and INA's to make it work well.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
  • kwinnkwinn Posts: 7,436
    I think the positive from the batteries needs to go through a shunt resistor before the 219. What value I do not know.

    The shunt resistor is only needed if we want to measure the current to/from the batteries. While that would be nice to do it is not necessary for this application. The shunt resistor value is simple to calculate.
    R = 0.32/Imax, so if the maximum current is 320 Amps the shunt resistor would have to be 0.32 / 320 = 0.001 ohms at 102.4 Watts.

    IOW a shunt resistor is impractical. A hall effect sensor is a better choice.
    In science there is no authority. There is only experiment.
    Life is unpredictable. Eat dessert first.
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