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2 Hardware
This project has been developed and tested with a Raspberry Pi 3 as the base platform. Since the serial port and network are the only external ports used, the program could be used on other platforms with minor modifications and testing.
In development and testing I used the Raspberry Pi3 with built in WiFi. Depending on your WiFi signal and your generator proximity to the access point your results may vary.
Below is a list of hardware that I used. Since your generator may be different and your network will be different you will need to validate these for your setup.
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Raspberry PI 3 and SD Card
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Power supply for the Raspberry Pi is attached to battery on the generator. Note, this is needed to ensure the raspberry Pi and the generator controller share a common ground. If you use a two prong wall adapter to power your pi you will likely see CRC errors unless you connect ground from the controller through your cable insuring your Pi and Controller share a common ground. I opted for USB power connected to the battery, at the time I started the project I did not know the pinout for power and ground on the controller connector so this option worked best for me. An alternate way to power your Pi is to take 5V and ground from the generator controller connector and power your Pi via the power and ground connections on the GPIO connector. The wiki page on making a cable has additional details on the controller pinout.
NOTE: Some people have reported undervoltage errors on the Pi 3 (not the Pi Zero) when powering through the controller connector. While this has not been reported to prevent the application from running it may not be an ideal way to power the Pi. See this issue for more details.
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This is the enclosure that is used. This may be to large for some smaller air-cooled generators:
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Internal Panel for Enclosure This may be to large for some smaller air-cooled generators.
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Adhesive Magnets from Hobby Lobby (used to attach enclosure to generator). I attached the enclosure to the inside of my generator housing but your generator may be different.
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Tubing for cable (not recommended, possibly use a smaller diameter tube)
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An alternate method for the cable sleeve is to have an inner shield for EMI protection and an outter layer for environmental protection.
The cable I used connects the Molex connector on the Generator Controller to a DB-9 break-out connector. The DB-9 break-out connector is then attached to the RS-232 to TTL converter for the Raspberry Pi. Below are the links for the items used in cabling:
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3.3v TTL to RS232 for RPi or this one. The critical thing here is that the converter must support RS-232 to 3.3V TTL. If it supports RS-232 to 5V TTL only then it will not work with the Pi.
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Break out db-9 (male or female, depending on the above level converter you use)
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I used the following Digi-key part numbers for the molex connectors for the cable. The Evolution /Nexus controller uses a molex type receptacle:
This is the DigiKey part number of the connector that you will use on your cable (plug). This is required.
- Receptacle = WM3703-ND - DigiKey Link
- Female pin = WM3279CT-ND - DigiKey Link
This is the DigiKey part number of the connector on the controller (receptacle). This is for informational purposes and is not required.
- Plug = WM3603-ND
- Male pin = WM2500CT-ND
I used a molex connector on my enclosure and routed the two wires to a break-out box that a DB-9 (see link above) however there are endless ways to make the connection to your enclosure on the Pi.
See the project wiki for info on creating a cable, including alternate methods that do not require using a crimping tool.