Xantrex Technology Automatic Generator User Manual
Automatic Generator Start
Owner’s Guide
Automatic Generator Start
Owner’s Guide
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells,
microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and variable speed drives
that convert, supply, control, clean, and distribute electrical power.
Trademarks
Automatic Generator Start is a trademark of Xantrex International. Xantrex and Xanbus are registered
trademarks of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners
and are used herein for identification purposes only.
Notice of Copyright
Automatic Generator Start Owner’s Guide © November 2004 Xantrex International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.
(“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUIT ABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.
Date and Revision
November 2004 Revision C
Part Number
975-0082-01-01
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct)
Fax: 1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email: customerservice@xantrex.com
Web: www.xantrex.com
About This Guide
Purpose
The purpose of this Owner’s Guide is to provide explanations and
procedures for installing, operating, maintaining, and troubleshooting the
Automatic Generator Start.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, procedures for installing the Automatic Generator Start, as
well as information about configuring, operating and troubleshooting the
unit. This guide does not provide information about choosing a generator
or operating a generator.
Firmware Revision
The information in this manual applies to firmware revision 1.03.00.
Some Auto Gen Start features and functions described in this manual may
be incompatible with earlier firmware revisions. To view the firmware
revision number of your product, see page 4–8.
Audience
The Guide is intended for anyone who needs to install and/or operate the
Automatic Generator Start. Installers should be certified technicians or
electricians.
iii
About This Guide
Organization
This Guide is organized into five chapters and three appendixes.
Chapter 1, “Introduction”, introduces and describes features of the
Automatic Generator Start.
Chapter 2, “Installation”, contains planning information and procedures
to install the Automatic Generator Start.
Chapter 3, “Configuration”, provides information and procedures for
configuring the Automatic Generator Start.
Chapter 4, “Operation”, describes common tasks you may need to
perform with the Automatic Generator Start.
Chapter 5, “Troubleshooting”, contains information and procedu res to
troubleshoot the Automatic Generator Start.
Appendix A, “Specifications”, contains the electrical, mechanical, and
environmental specifications for the Automatic Generator Start.
Appendix B, “Generator Auto Start Requirements and Types”, provides
general information about generators that will work with the Automatic
Generator Start.
Appendix C, “Relay Timing”,
contains information about relay
configuration and timing for each basic type of Auto Gen Start
starting mode.
“Warranty and Return Information” contains the warranty for your
Automatic Generator Start as well as instructions for returning the
product for servicing.
iv 975-0082-01-01
Conventions Used
The following conventions are used in this guide.
WARNING
Warnings identify conditions or practices that could result in personal injury or
loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or
other equipment.
About This Guide
Important:
but is not as critical as a caution or warning.
These notes contain information that is important for you to know,
Abbreviations and Acronyms
Auto Gen Start, AGS
DC V
SOC
Abbreviations for the Automatic Generator Start
used in this manual and on the Control Panel.
DC voltage—usually refers to battery voltage
State of charge—refers to a percentage of a
battery’s remaining capacity.
Related Information
For more information about related products, refer to:
Xanbus System Installation Guide (975-0136-01-01)
Inverter/Charger Installation Guide (975-0126-01-01)
Inverter/Charger Operation Guide (975-0125-01-01)
System Control Panel Owner’s Guide (975-0083-01-01)
These guides are available at www.xantrex.com, where you can find
more information about Xantrex Technology Inc. and its products and
services.
975-0082-01-01 v
vi
Important Safety Instructions
WARNING: Save these instructions
This Owner’s Guide contains important safety and operating instructions.
Before using your Automatic Generator Start, be sure to read, understand, and
save these safety instructions.
WARNING: Restrictions on use
The Automatic Generator Start shall not be used in connection with life support
systems or other medical equipment or devices.
WARNING: Safety hazard
Disable the Automatic Generator Start if the generator or vehicle equipped with
the generator is in an enclosed building or area where the generator exhaust is not
vented to the outside.
General Precautions
1. Before installing and using the Auto Gen Start, read all appropriate
sections of this guide.
2. If the Auto Gen Start is inoperative, see “Warranty and Product
Information” on page WA–1.
3. Do not dismantle the Auto Gen Start; it contains no user serviceable
parts. See “Information About Your System” on page WA–5 for
instructions on obtaining service.
4. Protect the Auto Gen Start from rain, snow, spray, and water.
5. Disable the generator’s starting circuit by disconnecting the starter
battery, spark plug, et cetera, before wiring this device.
6. T o reduce the risk of electrical shock, put the Xantrex Xanbus system
into Safe mode before working on any circuits connected to it. See
“Safe mode” on page 4–7.
7. Disable the automatic starting circuit and/or disconnect the generator
from its starting battery to prevent accidental starting while
performing maintenance.
vii
Safety
Explosive Gas Precautions
WARNING: Explosion hazard
This equipment is not ignition protected. To prevent fire or explosion, do not
install the Auto Gen Start in compartments containing flammable materials or in
locations that require ignition-protected equipment. This includes any space
containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or
other connections between components of the fuel system.
Be sure you follow all relevant instructions exactly before installing or using
your Auto Gen Start.
FCC Information to the User
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a residential environment.
This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction guide,
may cause harmful interference to radio communications. However , there
is no guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interferenc e by one or mo re of
the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment into an outlet on a circuit different from that
to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
viii 975-0082-01-01
Contents
Important Safety Instructions
1
Introduction
About the Automatic Generator Start- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
System Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4
Front and Bottom Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
Front panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Bottom panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Xanbus System Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
2
Installation
Preparing an Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2
Tools and materials required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Choosing a location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Routing the connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3
Installing the Auto Gen Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4
Mounting the unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5
Wiring to the 20-contact connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Connecting the generator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Type 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Type 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Type 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Type 4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Type 5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Type 6 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15
Type 7 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15
Type 8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17
Type 9 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18
Type 10 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19
Type 11 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20
Type 12 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21
Type 13 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
975-0082-01-01 ix
Contents
Connecting the thermostats (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Connecting an external shutdown (optional) - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Connecting an external manual on/off switch (optional) - - - - - - - - - - - - - - - - 2–23
Connecting an external on/off LED - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
Connecting the wiring harness to the Auto Gen Start - - - - - - - - - - - - - - - - - - 2–25
Connecting the control panel and other network-enabled devices - - - - - - - - - - 2–26
Verifying power is available - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
3
Configuration
Configuring the Auto Gen Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Using the System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Changing Auto Gen Start settings using the System Control Panel - - - - - - - - - - 3–3
Viewing the Select Device menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Viewing the Auto Gen Start menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Selecting and adjusting the changeable setting - - - - - - - - - - - - - - - - - - - - 3–4
The Auto Gen Start Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
The Auto Gen Start basic menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Gen Status - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Gen Trigger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
AGS Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
QT Enable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
QT Begin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
QT End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Start SOC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Start DCV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Enable Temp1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
Enable Temp2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16
Gen Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16
Clear Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17
Auto Gen Start advanced menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
Configure Triggers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
Configure Gen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
View Device Info - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
Basic Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
AGS Triggers menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19
Start SOC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19
Stop SOC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19
StartV:30sec - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–20
StartV:15min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–20
x 975-0082-01-01
Contents
StartV:2hr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–21
StartV:24hr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–22
StopBattV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–22
Enable Temp1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–23
Enable Temp2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–23
Enable Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–23
Start Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–24
Stop Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25
Stop Absorb - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25
Stop Float - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–26
Generator Configuration menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–28
Starter Cool Down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–28
Max Run Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–29
Exercise Per - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–29
Exercise Dur - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–30
Exercise Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–31
Relay3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–31
Run Hold Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–32
Crank Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–32
Crank Retry Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–33
Preheat Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–33
Start Tries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–34
AGS: Device Info menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
View Fault Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
View Warning Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
View Event Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
Restore Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
User Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–36
4
Operation
Starting and Stopping the Generator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2
Setting Quiet Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Enabling Quiet Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3
Setting the beginning of Quiet Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Setting the end of Quiet Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Viewing the Advanced Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Changing System Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6
Operating mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Power Save mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–7
975-0082-01-01 xi
Contents
Safe mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Hibernate mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8
Viewing the Firmware Revision Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8
5
Troubleshooting
Faults and Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Warning Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Fault Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
A
Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Regulatory Compliance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
B
Generator Auto Start Requirements and Types
Recommended Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Generator Starting Types- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Two wire - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Three-Wire Onan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
Three-Wire Automotive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4
Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
C
Relay Timing
RunMode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
MomentaryRun Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3
GlowStop Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–4
StartStop Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–4
PulseStop Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–5
Warranty and Return Information
Index
xii 975-0082-01-01
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1
- - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1
1
Introduction
Chapter 1 describes the main features of the Automatic
Generator Start. It also describes the Xanbus System
of which the Auto Gen Start is a component.
Introduction
About the Automatic Generator Start
Function and
benefits
Applications The Auto Gen Start is ideal for users who desire the convenience of
System
component
The Xantrex Automatic Generator Start (Auto Gen Start) automatically
starts and stops your generator using dry contact relays to operate the
auto-start function of your generator. (Dry contacts operate only as
switches. The Auto Gen Start does not provide any voltage or current to
the connections.)
The Auto Gen Start continuously monitors your power system and starts
the generator if the battery voltage or state of charge reaches preset limits,
or the air conditioner or heater needs to be run. The Auto Gen Start also
starts the generator to assist the inverter/charger when power demands are
high. When properly configured, the Auto Gen Start ensures that your
power requirements are met and that your batteries stay charged.
automatic generator starting when dry camping or when shore power is
otherwise unavailable.
The Auto Gen Start uses Xanbus™, a network communications protocol
developed by Xantrex, to communicate its settings and activity to other
Xanbus-enabled devices. You can configure and monitor the Auto Gen
Start and every Xanbus-enabled device in the system using a single
System Control Panel.
Xanbus-enabled products are:
• Easy to use. The Xanbus system simplifies operation and automates
routine tasks.
• Reliable. Software control eliminates errors due to analog signalling.
• Accurate. Digital information is less susceptible to interference and
line loss.
• Upgradable. Firmware upgrades mean your purchase will remain up
to date.
For detailed instructions and a complete list of Xanbus-enabled devices,
visit our website at www.xantrex.com.
1–2 975-0082-01-01
Features
Features
Generator
starting
Generator
compatibility
Programmable
features
Status reporting The Auto Gen Start reports its operating mode, its settings, generator
Installation
options
The Auto Gen Start can automatically start a generator in response to:
• low battery voltage
• low battery capacity (“state of charge”)
• high inverter load
• a thermostat signal
• a pre-programmed exercise period
You can also use the Auto Gen Start to manually start and stop the
generator at any time.
The Auto Gen Start supports two and three-wire generator starters. It
starts generators made by Onan (Quiet Diesel, gasoline, and LP), Power
Tech, Generac, Martin, Kohler, Honda, Yamaha, and others.
Quiet Time The Auto Gen Start also features a quiet time setting,
which prevents the generator starting at night or during other
inconvenient periods.
Exercise Period During times of prolonged generator inactivity, the
Auto Gen Start can be programmed to run (or “exercise”) the generator
for a pre-defined period. This ensures the generator remains operational
and that the starting battery stays charged.
activity , and the reason for generator starts to the Xanbus system. You can
view this information on the System Control Panel.
The Auto Gen Start can be installed with an external shutdown input, a
manual generator on/off switch, and an external on/off indicator light.
975-0082-01-01 1–3
Introduction
System Requirements
The Auto Gen Start is not designed for stand-alone operation. It does not
function in a simple system containing only an Auto Gen Start and a
generator. The Auto Gen Start requires several other components for
configuration and operation.
Generator The generator should have automatic starting capability.
Some manufacturers of generators without this capability may sell an
optional automatic engine control module that will simplify operation
with the Auto Gen Start.
The generator should also supply a Generator Run signal, which the Auto
Gen Start uses to detect whether the generator is running. Some generator
manufacturers refer to this signal as the hour meter signal or
Switched B+.
Control panel A separate control panel is required to configure the
Auto Gen Start and monitor generator starting and stopping activity. The
control panel also provides real-time clock information for the Auto Gen
Start Quiet Time and Exercise Time features.
Network power supply The Auto Gen Start requires a Xanbus power
supply to operate. Network power is carried by the network cables, and
can be supplied by a Xanbus-enabled product (such as an inverter/
charger) or an external Xanbus power supply.
As a device that draws network power, the Auto Gen Start consumes a
maximum of 3 watts.
Start and stop triggers The Auto Gen Start requires a source of start
and stop triggers for automatic operation. These triggers can come from:
• thermostat 12/24 V input.
• battery voltage, state of charge, and inverter load status. This
information must be transmitted over the network by another Xanbusenabled device, such as an inverter/charger or DC Monitor.
When network-broadcast battery voltage, state of charge, and inverter
load information are not available, the Auto Gen Start could operate in a
reduced system with a control panel and network power supply. In this
system, the Auto Gen Start would be limited to automatically starting and
stopping the generator from thermostat 12/24 V input. In such a system,
you could also start and stop the generator manually using the control
panel, and Quiet Time, Exercise Time, and maximum run time settings
would function.
1–4 975-0082-01-01
Front and Bottom Panel
Front and Bottom Panel
Indicator lights Four lights on the front panel indicate the operating status and network
status of the Auto Gen Start.
Connectors T wo network ports on the bottom panel connect the Auto Gen Start to the
Xanbus system. A 20-contact pluggable connector (also on the bottom
panel) allows the Auto Gen Start to connect to the generator’s starting
circuitry, thermostats and external switches. See “Bottom panel” on
page 1–6.
Front panel
1
2
3
4
Figure 1-1
Table 1-1
Feature Description
1
2 Generator On light (green) indicates the generator is running.
3
4 Fault light (red) indicates an Auto Gen Start fault has occurred.
975-0082-01-01 1–5
Auto Gen Start front panel
Front panel features
Power light (green) indicates the Auto Gen Start
network power.
This light turns on when the generator run signal is active. See
“Important” on page 2–24.
Network light (green) indicates the Auto Gen Start
communicating with other Xanbus-enabled devices.
See “Troubleshooting” on page 5–1 for information about Auto
Gen Start faults.
is receiving
is
Introduction
Bottom panel
Network
connectors
1
Figure 1-2
Table 1-2
Feature Description
1 Network port (eight-pin RJ45)
2 Network port (eight-pin RJ45)
3 20-contact generator connector
Auto Gen Start bottom panel
Auto Gen Start connection points
23
Each network port can accept an eight-pin RJ45 plug attached to a CAT 5
cable. Depending on your installation, you may need to use one or both
the network connectors. For more information, see the Xanbus System
Installation Guide.
CAUTION: Equipment Damage
Connect the Auto Gen Start only to other Xanbus compatible devices.
Although the cabling and connectors used in this network system are the same as
Ethernet connectors, this network is not an Ethernet system. Equipment
damage may result from attempting to connect these two different systems.
20-contact
connector
1–6 975-0082-01-01
The 20-contact connector allows you to plug in a wiring harness that
connects the Auto Gen Start to a generator and thermostats. The wiring
harness also provides lines for connecting external generator shutdown
sensors or switches and external generator on/off controls.
Xanbus System Components
Xanbus System Components
System
description
Network
diagram
The Xantrex Xanbus system includes the Auto Gen Start and other
Xanbus-enabled devices. Each device interacts and communicates with
the other devices, creating a power system that can be precisely
configured to your needs.
Figure 1-3 shows the Auto Gen Start as part of a Xanbus system.
AC Out
AC In
Figure 1-3
975-0082-01-01 1–7
Xanbus system diagram
1–8
2
Installation
Chapter 2 contains information and procedures to
install the Auto Gen Start.
This chapter will help you prepare to install the Auto
Gen Start by providing:
• a summary of the tasks involved
• a list of materials and tools required
• recommendations for choosing an installation
location
This chapter then provides procedures for mounting
the Auto Gen Start, as well as guidelines for
connecting it to:
• a generator
• thermostats
• the System Control Panel and other Xanbusenabled devices
Installation
Preparing an Installation
Before you install the Auto Gen Start, you must consider how and where
the unit will be mounted, and plan the connection routes between the
Auto Gen Start, the generator, thermostats and the control panel.
Tools and materials required
Before beginning an installation, you will need the following tools and
materials:
❐ Mounting template (supplied)
❐ Wiring harness (Xantrex part number 809-0917, supplied)
❐ Four #6 screws, 1 1/4 inch (supplied)
❐ #16 or #18 AWG wire (see “Wire size and length” on page 2–7)
❐ Xantrex network cables or equivalent
❐ Network terminators (if required)
❐ Phillips screwdriver
❐ Wire cutters
❐ Wire strippers
2–2 975-0082-01-01
Choosing a location
The Auto Gen Start should be installed in a location that meets the
following requirements:
Preparing an Installation
Dry
Cool
Safe
Close to
generator
Routing the connections
WARNING: Explosion hazard
This equipment is not ignition protected. To prevent fire or explosion, do not
install the Auto Gen Start in compartments containing flammable materials or in
locations that require ignition-protected equipment. This includes any space
containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or
other connections between components of the fuel system.
The unit is intended for use in a dry location. The Auto Gen
complies with UL458 Marine Supplement drip-test
Start
requirements, but the location should be as dry as possible.
The Auto Gen Start
50 °C).
The Auto Gen Start
areas requiring ignition-protected equipment, such as
compartments housing gasoline engines.
Avoid excessive wire lengths and use the recommended wire
lengths and sizes (see “Wire size and length” on page 2–7). It is
more important for the Auto Gen Start
generator than close to the inverter, although for safety reasons,
the Auto Gen Start should not be installed in the same
compartment as a gasoline-powered generator.
operates between -4 and 122 °F (-20 and
is not ignition protected. Do not install it in
to be close to the
Follow all relevant instructions exactly before installing or using your Aut o Gen
Start.
WARNING: Shock and energy hazards
Before making any connections to the generator, ensure that the generator’s
starter is disabled and the generator’s start battery is disconnected.
975-0082-01-01 2–3
Installation
Because the Auto Gen Start will be part of a Xanbus system, you must
consider how to route two types of connections:
• connections to the generator, thermostats, and other external devices
and switches, using the 20-contact connector and wiring harness.
• connections to other Xanbus-enabled devices, using network cables.
For information on designing and installing the network, see the Xanbus
System Installation Guide.
Network ports
Network cables to other
Xanbus-enabled devices
Figure 2-1
Auto Gen Start external connections
20-contact
connector
Wiring harness (connection
to generator, thermostats,
and external switches)
Installing the Auto Gen Start
After selecting your tools and choosing the best location and connection
routes for your installation, you are now ready to mount the Auto Gen
Start and connect it to the generator, thermostats and System Control
Panel.
2–4 975-0082-01-01
Installing the Auto Gen Start
Installation
overview
Installing the Auto Gen Start involves the following steps:
1. Mounting the unit.
2. Connecting the wiring harness to:
3. Connecting the wiring harness to the 20-contact connector on the
4. Connecting the Auto Gen Start to the System Control Panel and other
Note: Because each installation varies according to the location, the type of
generator, and the overall complexity of the Xanbus system, these instructions
can offer only general guidelines for the many installation options available.
Mounting the unit
The Auto Gen Start is to be mounted vertically on a wall with the
connectors facing downwards.
• the generator (page 2–9)
• thermostats (optional) (page 2–23)
• external shutdown switch (optional) (page 2–23)
• external on/off switch and LED (optional) (page 2–23)
Auto Gen Start.
network-enabled devices (page 2–26).
WARNING: Shock hazard
Before installing the Auto Gen Start as part of a pre-existing Xanbus system, put
the system in Safe mode in order to disable the electrical operation of networked
devices. See “Changing System Modes” on page 4–6.
To mount the Auto Gen Start:
1. Hold the unit flush and square against the wall, panel or horizontal
surface.
• If your mounting surface requires you to pre-drill holes for the
screws, use the supplied mounting template to mark, then drill,
four holes.
2. With a Phillips screwdriver and the supplied #6 screws, secure each
corner of the Auto Gen Start to the mounting surface.
975-0082-01-01 2–5
Installation
Wiring to the 20-contact connector
WARNING: Shock hazard
All installation wiring should be performed by a qualified installer or electrician.
WARNING: Fire, shock, and energy hazards
The 20-contact connector is intended for connection to Class 2 ELV (Extra Low
Voltage) circuits only. Do not exceed the circuit limitations specified in the
following section.
ELV circuits ELV (Extra-Low Voltage) circuits have an open-circuit voltage of not
more than 30 V
hazard.
Class 2 circuits As per the US National Electrical Code (NEC) and the Canadian
Electrical Code (CEC), available power in Class 2 circuits is limited to
100 VA, usually by current limiting by means of overcurrent protection or
series resistance. The current is limited to 5 A for circuits with opencircuit voltage of 20 V, and to I=100/V
voltage between 20 V and 30 V.
or 42.2 VDC or peak, and are therefore not a shock
rms
for circuits with open circuit
oc
The advantage of using Class 2 circuits for installing the Auto Gen Start is
that Class 2 circuits don’t have to follow the Class 1 wiring rules
(requiring the use of conduit and wiring boxes, et cetera) that apply
elsewhere in the applicable codes.
Circuit
limitations
The relay contacts in the Auto Gen Start are rated at 5 A maximum and all
circuits on the 20-contact connector are rated at 30 V maximum.
Ensure that all circuits connected to the 20-contact connector obey the
following limits:
Open circuit voltage (Voc)
Overcurrent protection
(fuse size for open circuit voltage up to 20 V)
Overcurrent protection
(fuse size for open circuit voltage from 20 V to
30 V)
2–6 975-0082-01-01
30 V maximum
5 A maximum
5 A to 3.33 A
(100/V
amps maximum)
oc
Installing the Auto Gen Start
Wiring harness Connections to the generator, thermostats, and external on/off switches
are made using a wiring harness that plugs into the 20-contact connector
(see Figure 2-1). The wires on the wiring harness can be extended to meet
installation requirements. When extending the wire harness, ensure that
the extension wires are the same color as the wires on the harness.
To install the Auto Gen Start using the wiring harness:
1. Connect each wire on the harness to its intended wire or contact on
the generator, thermostats, or external switches.
2. Plug the harness into the connector on the bottom panel of the Auto
Gen Start.
Wire
identification
Each wire on the harness is identified by a number and a color. The wire
numbers are shown in Figure 2-2 and their colors and functions are
described in T able 2-1.
Wire size and
Required wire sizes for the external connections to the wiring harness are:
length
0–30 ft. (9 m) Over 30 ft. (9 m)
18 AWG 16 AWG
When planning the routing for external connections, ensure that wire
lengths are sufficient to plug the wiring harness into the Auto Gen Start
once all the external connections are complete.
Figure 2-2
975-0082-01-01 2–7
Auto Gen Start wiring harness
Installation
Table 2-1
Wire
number Function
1 Thermostat 1 input Yellow
2 Thermostat 1 return Gray
3 Thermostat 2 input Orange
4 Thermostat 2 return Gray
5 External shutdown input White/Black
6 External shutdown return Gray
7 External manual on input White/Green
8 External manual off input White/Red
9 External On/Off LED Indicator output White/Blue
10 Constant 12/24 V B+ (battery positive) for
11 External On/Off/LED Indicator return (connected
12 Generator run signal (switched B+) sense input Violet
13 Generator ru n signal (switched B+) sense return
14 Relay 1 (Generator run/stop) Normally open
15 Relay 1 (Generator run/stop) Normally closed
16 Relay 1 (Generator run/stop) Common contact Gray
17 Relay 2 (Generator start) Normally open contact White
18 Relay 2 (Generator start) Common contact Gray
19 Relay 3 (Preheat/cooldown) Normally open
20 Relay 3 (Preheat/cooldown) Common contact Gray
Contact numbers and functions
Wiring harness
wire color
Red
External On/Off/LED Indicator
Black
internally to wire number 13)
Black
(generator battery negative)
Blue
contact
White/Violet
contact
Brown
contact
2–8 975-0082-01-01
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