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Generac generator as a node using genmon and nodelink


johnstonsean

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Posted (edited)

 

Thanks to io_guy adding support for GenMon in nodelink I was able to add my Generac 11kw standby into ISY as a node. Also, thanks to the developer of GenMon jgates. You do need to have some experience using a Raspberry PI but other than that it’s as simple as following the guides of the two pieces of software as the both are documented very well, but I will lay out the basics and some things I did different.

 

Genmon runs on Raspberry PI and uses a serial board and cable into the Generac controller to interface the generator. It's the same port used for the Generac cellular monitoring solution.

I am running genmon and nodelink on different PIs because the GenMon PI needs to be located in the generac cabinet and I use nodelink for multiple devices.

 

The first thing you need to do is get all your hardware together.

 

The github page has a good list of the hardware needed https://github.com/jgyates/genmon/wiki/Hardware , I made a couple changes to this list.

 

The enclosure he lists is a little large for the space available in the 11kw enclosure so I ordered this one instead https://www.amazon.com/gp/product/B005T9HMQW/ref=oh_aui_detailpage_o09_s02?ie=UTF8&psc=1 everything does fit in this. I used 3M mounting tape to mount the PI and the serial board. In order for everything to fit I had to mount the serial board to the inside of the door with the ribbon cable on the hinge side.

 

I also ended up using this serial board, https://www.amazon.com/gp/product/B01JYNHNW6/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1 and this breakout board, https://www.amazon.com/gp/product/B07437GS66/ref=oh_aui_detailpage_o09_s03?ie=UTF8&psc=1. The serial port he lists in his hardware list never worked right for me and the chip got hot, the one I linked worked perfect for me.

 

The connectors he lists on the hardware page worked perfect for the evolution controller. You will need a Molex crimp tool for the connectors, https://www.amazon.com/s/ref=nb_sb_ss_c_1_10?url=search-alias%3Daps&field-keywords=molex+crimping+tool&sprefix=molex+crim%2Caps%2C141&crid=G0JOXESNUV36 . Also he lists a few different cable types for the serial cable, I ended up using two conductor shielded alarm wire.

 

Use his recommendation and power the pi off the generators battery using the usb cord he lists.

 

Now the hardware is in order you need to setup your pi and load mono, plenty of guides on this and you can use io_guy's guide for nodelink PI setup if you need to. Pages 1 and 2 of this doc http://automationshack.com/Files/Raspbian_Setup_V5.pdf

 

Then follow the guide on git for setting up genmon software, https://github.com/jgyates/genmon/wiki/Setting-up-your-Pi-and-genmon .

 

If you want to run the serial test he lists on this page make sure you stop genmon "sudo /home/pi/genmon/startgenmon.sh stop" before running the test or the test will fail because the application locks the serial port.

 

I had WiFi connectivity issues with the PI until I did the following. Run "sudo rpi-update" , edit the script.sh file "sudo nano script.sh" and add "iwconfig wlan power off" the file, save it and reboot.

 

Once you are able to connect the the GenMon web interface and everything looks good you can add the GenMon device in Nodelink and use Nodelink to install the node to the ISY. If you don't have nodelink setup yet use io_guy's guide for this. http://automationshack.com/wp/nodelink/

 

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Sent from my iPhone using Tapatalk

 

Edited by johnstonsean
  • Like 4
Posted
Just now, johnstonsean said:

I’ll fix it thanks!


Sent from my iPhone using Tapatalk

We both got it wrong its io_guy :D

Posted

Sean I'd recommend putting a additional short  post over in Nodelink with Nodelink, Generac and V5 as tags, and simply point a link back here. That way those looking through nodelink will find it. That's a likely place they'd start. The post does belong here, but its very well written and helpful to the Nodelink crowd as well

Thank you for taking the time for a thorough "how to". Nice job!

Paul

  • 1 year later...
Posted

Just finding this, haven't been around for a while.  How have you found this in the cold / heat - I am in seattle so we don't go much below freezing or over 100f very often.

Posted
3 hours ago, Scyto said:

Just finding this, haven't been around for a while.  How have you found this in the cold / heat - I am in seattle so we don't go much below freezing or over 100f very often.

I live in NH and I'm using this same setup.  It worked right through last winter and this summer without a problem.

  • Like 1
  • 2 weeks later...
Posted (edited)

Thanks for the info!  i decided to have a go at this even though i only have a lowly nexus controller.

I have a pi4, genmon installed, and cables loopback tested and all ready to go.  Just waiting on an enclosure, the one recommend in this post seems to now have a defect that means door wont close once opened fully without manually squeezing and wiggling one of the hinge pins each time - same on two units.  I have an alternate coming.

  1. how did folks attach their enclosures - 3m tape or magnets?
  2. did you clip the ends of the motorcycle power supply to the batter or properly uncrew bolts and push on to threaded screw?
Edited by Scyto
  • 2 weeks later...
Posted

I am waiting to hear about the new enclosure - just gearing up to do the same. Have a nexus controller (says siemens on it but looks the same) - keep us posted and if you don't mind, share the enclosure

 

Posted (edited)

Hi Everyone

Sorry for the delay i had some serious issues with networking on the pi 4 and on pi zero.  Turns out raspbian doesn't seem to like the DHCP packets from the Windows 2019 DHCP server i have, so at the end of the lease period it would drop leases on both wifi and LAN - took me 2 weeks to figure that out.

I switched mid project from pi 4 (which was fully installed in the enclosure) to pi zero mainly a) to troubleshoot the network issue and b)its smaller, puts out less heat and i just wanted excuse to get one.  so far it runs about 40% CPU so seems up to the job - i purchased the zero with the GPIO header already installed.

I also installed a real-time clock on the pi, no real reason than i could :-)

Oh an i fitted a grommet to seal the box - not sure if that was a wise idea for something that generates hit, but i live in Seattle and need to keep out damp and mold.  Another reason to stick with the pi zero.  Great news, you can take an SD card straight out of a working pi4 and stick it in a zero and it works!

I also took the suggestion of the project owner and put metal and nylon braid around my serial cables - which is fun, looks neat but may be unnecessary - also i learnt if you do that and use shrink tube only use a little or it affects the radius the cable can turn.  I had to remove about 1 to 2 cm of my heat shrink.

I would advise against putting the braid of TTL serial cable from the gpio pins unless you have interference, it just makes the cable difficult to manage (hence the glue gun glue in the pictures).

 

Thanks to @johnstonsean for the OP and tips and H/W recommendations - they really helped.

This post contains my chosen parts list FWIW, my next post will be random assorted photos.

Pi Zero W header https://www.amazon.com/gp/product/B07B8MMD3V/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1
Pi Zero case - make sticking inside enclosure easy with command strips https://www.amazon.com/gp/product/B075FLGWJL/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1
Enclosure, i like this one better, its door had no issues https://www.amazon.com/gp/product/B07PK8K8S2/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1
Cable Gland https://www.amazon.com/gp/product/B077R1RT2T/ref=ppx_yo_dt_b_asin_title_o07_s01?ie=UTF8&psc=1
Real-time HW Clock https://www.amazon.com/gp/product/B00ZOXWHK4/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1
Cable i modded for connecting to Nexus https://www.amazon.com/gp/product/B07VF887KN/ref=ppx_yo_dt_b_asin_title_o08_s01?ie=UTF8&psc=1  (make sure to cut off the right end - the two ends are different!)
Nylon braid https://www.amazon.com/gp/product/B071WF5K2X/ref=ppx_yo_dt_b_asin_title_o08_s01?ie=UTF8&psc=1
Metal braid https://www.amazon.com/gp/product/B01HE0PDG4/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
Motorcycle USB power https://www.amazon.com/gp/product/B01DYE54LI/ref=ppx_yo_dt_b_asin_title_o08_s01?ie=UTF8&psc=1
RS232 connector https://www.amazon.com/gp/product/B07437GS66/ref=ppx_yo_dt_b_asin_title_o08_s01?ie=UTF8&psc=1
Serial port module https://www.amazon.com/gp/product/B01JYNHNW6/ref=ppx_od_dt_b_asin_title_s01?ie=UTF8&psc=1

@agoltz hope this helps, YMMV, i tended to buy from amazon as seller and i haven't listed shrink tube as i way over bought for other projects

I have some pastic cable clips coming, last part will be to use those on cables outside the case, might use one inside the case too.

Edited by Scyto
  • 1 month later...
Posted

hi @Scyto I wanted to THANK YOU very much for your helpful post. I managed to assemble and get this working on almost the first try (which is amazing). Now my generator is monitored and Im happy.

Really really appreciate your taking the time to post this. I followed your instructions and really have nothing more to add. Worked as advertised.

Thanks


Alex

  • Thanks 1
Posted

@scyto I have a question - the RS232 board is so not It burns fingers to the touch. How are you dealing with that? The raspberry is running about 115F according to genmon

 

Posted (edited)

Using vcgencmd measure_temp my pi zero measures about 23c (73f) with 40f outdoor temp.

just connected via web and its reading 78f now I am using web and shows about 28% CPU usage.

i havent measured heat on ttl board but never noticed it being hot, when it stops raining I can try and get a temp reading?

thoughts:

  • you have a voltage issue supplying too many volts?
  • you have something hitting the CPU heavily and generating heat
  • you generator is running because you live off grid and it’s putting lots of heat into that compartment (joke)

 

Edited by Scyto
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