Auto-gen start testing

One of the tasks that we have had done on Carl's RV while it has been here at National Indoor RV Center (NIRVC) is to have an auto generator start module installed. This will allow us to cause the generator to start automatically in case of several conditions -- if the battery voltage or state of charge (SOC) gets too low, if it has been more than a given number of days since the generator has run, or if the temperature in the RV gets too warm -- so if we leave the rig on a warm day, and we don't have shore power for some reason (boondocking or the shore power fails) - the generator can cut on so the air conditioner will be able to run and we don't come home to a cooked kitty cat.

The gen start module had been installed, but we wanted to test it and make sure it was working the way we wanted it to... we had gone through all the settings a couple of days ago and had it configured the way we wanted it, but we hadn't made sure it was working according to our understanding. So, this morning, we decided that we'd test the temperature control.

We unplugged from shore power. Carl set up a space heater near the temperature probe so we could test it with the temperature we wanted programmed. We got the temperature up beyond the set point, and the generator came on... but it only ran a short time and then cut off. We tried it several times... we had it programmed that the generator should run for 2 hours if it started due to a temperature control, but the longest we were getting it to run was 5 minutes or less... and the temperature had not come down (since we were still heating the probe).

So, we called Magnum Energy to make sure that we were understanding the functionality correctly. The technician went through all of our settings with us, and then said that we needed to go to the gen start module and do some tests directly on it... well... it is installed within a bay that has a lot of stuff stored in it... so we said we'd call back when we were able to get to it.

We pulled the things out of the bay, Carl got in where he could see the module, and we called Magnum Energy back. A different technician got our call this time (there are 4 currently working), and he talked us through testing the gen start module. Carl did a lot of different tests... and ultimately, the technician indicated that the module was correctly installed. But... we were still having the same problem. It appeared that he was in consultation with another technician, and they came to the conclusion that we have a faulty gen start module... but they have never seen this specific type of error occur before. They suggested that we ask NIRVC to install a new module and see if that corrects the problem. From what he said, it appeared that they don't know whether this is a hardware problem or a software problem... if hardware, a new module should fix it, but if it is software, we'll have the same problem on a new module... and then, I got the idea, it will be more challenging.

So, we talked to the service advisor at NIRVC, and he is scheduling the installation of a new module (we aren't sure that they actually have another module here, so the part may have to be ordered).

All in all, we spent about 3-3.5 hours debugging with Magnum Energy and then time talking with the service advisor -- so that took up a good part of our day. More later on what took up the rest of the day!

Some pictures:

Auto Generator Start module installed on the side of the bay near the roof

Inverter Charger - also in the bay - installed near the ceiling of the bay

Documentation picture for future reference...

BMK Shunt - also installed while the RV has been here at NIRVC

During the debugging activity, Carl took the faceplate off the auto gen start module to check the dip-switch settings. It was in such a difficult place to see that he took a picture with his phone to be able to look at the switch settings more easily.

At least he could zoom in then and see that they were all "down" or to the right or OFF (which was evidently how they should have been set in our system).

So, we're glad to have found the issue while we're still here and hoping that it can get corrected. We are going to put pressure on to ensure that this issue does not cause us to have to stay any longer than the wait for the awning is already delaying us...