Xantrex Automatic Generator - Manual

About This Guide 975-0082-01-01 v Conventions Used The following conventions are used in this guide. Abbreviations and Acronyms Related Information For more information about related products, refer to: Xanbus System Installation Guide (975-0136-01-01) Inverter/Charger Installation Guide (975-0126-0...

vii Important Safety Instructions 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 u...

Safety viii 975-0082-01-01 Explosive Gas Precautions 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 interfere...

975-0082-01-01 ix Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii 1 Introduction About the Automatic Generator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Features - - - - - - - - - - - - - - - - - - - - - - - - - ...

Contents x 975-0082-01-01 Connecting the thermostats (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23Connecting an external shutdown (optional) - - - - - - - - - - - - - - - - - - - - - - - - 2–23Connecting an external manual on/off switch (optional) - - - - - - - - - - - - - ...

Contents 975-0082-01-01 xi StartV:2hr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–21StartV:24hr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–22StopBattV - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ...

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 1–2 975-0082-01-01 About the Automatic Generator Start Function and benefits 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 ...

Features 975-0082-01-01 1–3 Features Generator starting 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 ...

Introduction 1–4 975-0082-01-01 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...

Front and Bottom Panel 975-0082-01-01 1–5 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 Two network ports on the bottom panel connect the Auto Gen Start to the Xanbus system. A 20-contact plug...

Introduction 1–6 975-0082-01-01 Bottom panel Network connectors 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 . 20-c...

Xanbus System Components 975-0082-01-01 1–7 Xanbus System Components System description 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 y...

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...

Installation 2–2 975-0082-01-01 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 ...

Preparing an Installation 975-0082-01-01 2–3 Choosing a location The Auto Gen Start should be installed in a location that meets the following requirements: Routing the connections Dry The unit is intended for use in a dry location. The Auto Gen Start complies with UL458 Marine Supplement drip-test ...

Installation 2–4 975-0082-01-01 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 ...

Installing the Auto Gen Start 975-0082-01-01 2–5 Installation overview Installing the Auto Gen Start involves the following steps: 1. Mounting the unit. 2. Connecting the wiring harness to: • the generator (page 2–9) • thermostats (optional) (page 2–23) • external shutdown switch (optional) (page 2–...

Installation 2–6 975-0082-01-01 Wiring to the 20-contact connector ELV circuits ELV (Extra-Low Voltage) circuits have an open-circuit voltage of not more than 30 V rms or 42.2 VDC or peak, and are therefore not a shock hazard. Class 2 circuits As per the US National Electrical Code (NEC) and the Can...

Installing the Auto Gen Start 975-0082-01-01 2–7 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 requ...

Installing the Auto Gen Start 975-0082-01-01 2–9 Connecting the generator To connect the Auto Gen Start to a generator, you must identify the start wiring configuration of the generator you want to use. Generators must be auto-start capable, and generators equipped with remote operation connections ...

Installing the Auto Gen Start 975-0082-01-01 2–23 Connecting the thermostats (optional) Wires 1, 2, 3, and 4 on the wiring harness can be connected to two thermostats. Wires 1 (yellow) and 2 (gray) are intended for thermostat 1 and wires 3 (orange) and 4 (gray) are intended for thermostat 2. These w...

Installation 2–24 975-0082-01-01 If your generator battery does not have the required voltage, any 12V or 24V power source will suit this purpose. If an alternate power source is used, the negative of the power source must be connect to the other contact of the switch. Multiple control panels or sim...

Installing the Auto Gen Start 975-0082-01-01 2–25 Connecting the wiring harness to the Auto Gen Start After all the external connections have been wired to the wiring harness, the connector on the wiring harness must be plugged into the 20-contact connector on the Auto Gen Start. To connect the wiri...

Installation 2–26 975-0082-01-01 Connecting the control panel and other network-enabled devices To connect the Auto Gen Start to a System Control Panel or another network-enabled device, plug a Xantrex network cable or equivalent from another device into one of the network connectors on the bottom p...

Configuration 3–2 975-0082-01-01 Configuring the Auto Gen Start The Auto Gen Start has a number of settings that you must configure to ensure that the generator automatically starts and stops under the right conditions and at the right time. If your Auto Gen Start was pre-installed in your Xanbus sy...

Configuring the Auto Gen Start 975-0082-01-01 3–3 Changing Auto Gen Start settings using the System Control Panel If you need to change an Auto Gen Start setting, use the buttons on the System Control Panel to perform three basic steps: 1. View the Select Device menu. 2. Select the Auto Gen Start fr...

Configuration 3–4 975-0082-01-01 Viewing the Auto Gen Start menu On the Select Device menu, select the Auto Gen Start to view and change its settings. To select the Auto Gen Start from the Select Device menu: 1. On the Select Device menu, use the down arrow button to highlight Auto Gen Start. 2. Pre...

The Auto Gen Start Menu 975-0082-01-01 3–5 To select and adjust a changeable setting: 1. On the Auto Gen Start menu, use the up arrow or down arrow button to highlight the setting you want to change. 2. Press Enter to highlight the current value of that changeable setting. Some values appear with an...

The Auto Gen Start Menu 975-0082-01-01 3–7 The Auto Gen Start basic menu The Auto Gen Start basic menu lists settings you may have to adjust routinely. The System Control Panel displays the Auto Gen Start basic menu by default. If you would like additional control over automatic generator starting, ...

Configuration 3–8 975-0082-01-01 Gen Status Full name Generator Operating Status Purpose “Gen Status” reports the current operating state of the generator. You cannot adjust any “Gen Status” values. Gen Trigger Purpose “Gen Trigger” reports the source of the active generator start trigger. Start tri...

The Auto Gen Start Menu 975-0082-01-01 3–9 AGS Mode Purpose “AGS Mode” is a changeable setting that controls the current operating mode of the Auto Gen Start. When to use You should change “AGS Mode” when you want to switch between automatic generator control and manual generator control. When the X...

Configuration 3–10 975-0082-01-01 • External Shutdown—When the Auto Gen Start is connected to a sensor or meter (a moisture detector, for example) wired to contacts 5 and 6 of the 20-contact connector, it stops the generator when the device is activated. See “Connecting an external shutdown (optiona...

The Auto Gen Start Menu 975-0082-01-01 3–11 QT Enable Full name Quiet Time Enable Purpose “QT Enable” enables or disables the Quiet Time functionality of the Auto Gen Start. “QT Enable” applies only when the Auto Gen Start is in Automatic mode. When to use When you need to use the Auto Gen Start Qui...

The Auto Gen Start Menu 975-0082-01-01 3–13 QT End Full name Quiet Time End Purpose “QT End” is a changeable setting that defines the end of quiet time. This setting also requires you to set “QT Begin”. When to use “QT End” functions only if the Auto Gen Start is in Automatic mode. For more informat...

Configuration 3–14 975-0082-01-01 State of charge information When a DC Monitor is installed, you can monitor the batteries’ state of charge on the System screen or inverter/charger menu. Outcomes If you set “Start SOC” too high, the generator will start more frequently than is convenient. If you se...

The Auto Gen Start Menu 975-0082-01-01 3–15 Whenever the generator starts automatically in response to “Start DCV”, it will stop when the battery voltage reaches the Stop Battery Voltage (“StopBattV”) setting. If you have enabled “Stop Float” or “Stop Absorb”, the generator will stop when the Absorp...

Configuration 3–16 975-0082-01-01 Enable Temp2 Full name Enable Thermostat 2. Purpose “Enable Temp2” is intended to be used when the Auto Gen Start is connected to a second thermostat. All information and procedures for “Enable Temp1” also apply for “Enable Temp2”. Gen Type Full name Generator type ...

The Auto Gen Start Menu 975-0082-01-01 3–17 When to use Use this setting after installing the Auto Gen Start. Selecting a suitable “Gen Type” automatically configures the Auto Gen Start to work with the ignition system and starting requirements of your generator. If you are not sure of your generato...

Configuration 3–18 975-0082-01-01 Auto Gen Start advanced menu The Auto Gen Start advanced menu contains settings that can give you even more control over automatic generator starts and stops. To view the Auto Gen Start advanced menu on the System Control Panel, see page 4–5. In addition to several ...

The Auto Gen Start Menu 975-0082-01-01 3–19 AGS Triggers menu The AGS Triggers menu contains additional settings for automatically starting and stopping the generator. This menu allows you to adjust the default settings for state of charge (when a DC Monitor is installed), battery voltage, thermosta...

Configuration 3–22 975-0082-01-01 If the Auto Gen Start is set to Automatic mode, then the Auto Gen Start will start the generator when the system battery voltage (as measured by the inverter/charger) falls below the “StartV:2hr” setting for 2 hours. See “StartV:15min” for more information. StartV:2...

Configuration 3–24 975-0082-01-01 Outcomes Selecting On enables the Start on Inverter Load Current (“Start Load”) and Stop on Inverter Load Current (“Stop Load”) functionality. If the Auto Gen Start is in Automatic mode and “Enable Load” is set to On, the Auto Gen Start stops and starts the generato...

The Auto Gen Start Menu 975-0082-01-01 3–25 Stop Load Full name Stop on Inverter Load Current Purpose “Stop Load” sets the Auto Gen Start to stop the generator at a specified AC load on the inverter. The “Stop Load” setting applies to situations when the Auto Gen Start has started the generator to a...

Configuration 3–26 975-0082-01-01 In power systems with long cables between the batteries and the inverter/charger (over 10 feet [3 m]), the measured battery voltage can be a poor indicator of battery condition. In such cases, the batteries are more assured of a full charge if the generator runs unt...

Configuration 3–28 975-0082-01-01 Generator Configuration menu The Generator Configuration (AGS Gen Config) menu contains additional options for configuring the Auto Gen Start for your make and model of generator. The items on this menu include the settings you automatically select when you select a...

The Auto Gen Start Menu 975-0082-01-01 3–29 Max Run Time Full name Maximum Generator Run Time Purpose The Max Run Time setting allows you to set a limit on how long the generator will run. This setting overrides any automatic start triggers. For example, if the generator starts in response to low ba...

Configuration 3–30 975-0082-01-01 This setting also requires you to set an Exercise Duration (see “Exercise Dur” on page 3–30) and an Exercise Time (see “Exercise Time” on page 3–31). When to use Generators need to run regularly in order to maintain mechanical health and performance. If you have no ...

The Auto Gen Start Menu 975-0082-01-01 3–31 Exercise Time Purpose “Exercise Time” allows you to set the time of day that the Auto Gen Start exercises the generator. This setting also requires you to set an Exercise Period and an Exercise Duration. When to use You must set the Exercise Time when you ...

Configuration 3–32 975-0082-01-01 Some diesel generators require preheating of their glow plugs before start cranking. Setting “Relay3” to Preheat enables Relay 3 to perform this function in addition to Relay 1. Some generators require Relay 3 to switch 12 volts to the glow plugs, while some generat...

The Auto Gen Start Menu 975-0082-01-01 3–33 Crank Retry Time Purpose “Crank Retry Time” specifies the length of time the Start relay is engaged (and cranking the starter motor) for the second and subsequent attempts to start the generator, in cases when the generator fails to start on the first atte...

Configuration 3–34 975-0082-01-01 Start Tries “Start Tries” specifies how many times the Auto Gen Start will attempt to start the generator. On the first start try, the Auto Gen Start cranks the starter motor for the Crank Time. If the generator does not start, on subsequent start tries, the Auto Ge...

The Auto Gen Start Menu 975-0082-01-01 3–35 AGS: Device Info menu The Device Info menu allows you to view the Fault, Warning and Event logs. On the Device Info menu you can also restore the default settings for the Auto Gen Start. View Fault Log Purpose The Fault Log displays the last 20 Auto Gen St...

Configuration 3–36 975-0082-01-01 User Settings Use this table to record any customized Auto Gen Start settings for future reference. Setting Values Default User Setting “QT Begin” 12:00AM–11:59PM (12-hour clock)00:00–23:59 (24-hour clock) 9:00PM (12-hour clock)21:00 (24-hour clock) “QT End” 12:00AM...

4 Operation Chapter 4 describes the operation of the Auto Gen Start and how to get the most from its features. This includes information about:• using the Auto Gen Start for both manual and automatic generator control. • setting Quiet Time. • displaying the advanced Auto Gen Start menu. • changing s...

Operation 4–2 975-0082-01-01 Starting and Stopping the Generator You can use the Auto Gen Start to start the generator manually (on demand, using the System Control Panel) and automatically (in response to an electrical system condition). In general, to avoid Auto Gen Start faults, try not to combin...

Setting Quiet Time 975-0082-01-01 4–3 Setting Quiet Time Use the Quiet Time feature to ensure that the Auto Gen Start will not start the generator during the night, or during times that might clash with “Quiet Time” guidelines at RV parks and campgrounds. Setting Quiet Time for the first time involv...

Operation 4–4 975-0082-01-01 3. Use the up or down arrow button to select the minute, then press Enter. If you are using the 24-hour clock, go to step 5. 4. Use the up or down arrow button to select AM or PM, then press Enter. 5. Press Exit twice to return to the System screen. Setting the end of Qu...

Viewing the Advanced Menu 975-0082-01-01 4–5 Viewing the Advanced Menu The System Control Panel can display the Auto Gen Start menu in two formats: basic and advanced. The Auto Gen Start basic menu is displayed by default. It lists status information and settings you may have to adjust routinely. Se...

Operation 4–6 975-0082-01-01 Changing System Modes The system modes described in this section affect the behavior of the Auto Gen Start and every Xanbus-enabled device in the system. You will have to change the system mode when setting a Generator Type, travelling, putting your vehicle in storage, o...

Changing System Modes 975-0082-01-01 4–7 Operating mode Characteristics Operating mode is the default mode of the Auto Gen Start. In Operating mode, the Auto Gen Start communicates on the network, responds to signal input, and can start and stop the generator automatically. Operating mode includes a...

Operation 4–8 975-0082-01-01 Hibernate mode Characteristics Hibernate mode removes power from the Auto Gen Start and all Xanbus-enabled devices on the Xanbus system. The Auto Gen Start suspends all operations (including starting and stopping the generator) until power is restored to the network. If ...

5 Troubleshooting Chapter 5 contains information and procedures to troubleshoot the Auto Gen Start, including tables of warnings and faults for your reference.

Troubleshooting 5–2 975-0082-01-01 Faults and Warnings Under certain conditions, the Auto Gen Start generates a fault or warning message. These messages appear on the System Control Panel. This section describes how to respond to fault and warning messages when they appear. Acknowledging messages Wh...

Warning Messages 975-0082-01-01 5–3 To view a fault list or warning list: 1. On the Select Device menu, highlight System and press Enter. 2. On the System Settings menu, highlight View Fault List or View Warning List. 3. Press Enter. Warning Messages Table 5-1 provides details and suggests action fo...

Fault Messages 975-0082-01-01 5–5 Fault Messages When the Auto Gen Start detects a fault condition, it stops the generator. The red Fault light also comes on, and the System Control Panel displays a fault message. The Auto Gen Start remembers the AGS Mode that it was in at the time it detected the f...

A Specifications Appendix A contains the electrical, mechanical, and environmental specifications for the Auto Gen Start . All specifications are subject to change without notice.

Specifications A–2 975-0082-01-01 Electrical Specifications *Limited to Class 2 levels (100 VA) as in Chapter 2, page 2–6. Mechanical Specifications Nominal input network voltage 15 VDC Minimum operating network voltage 14.25 VDC Maximum operating network voltage 15.75 VDC Maximum operating current ...

Environmental Specifications 975-0082-01-01 A–3 Environmental Specifications Regulatory Compliance Operating temperature -4 to 122 °F (-20 to 50 °C) Storage temperature -40 to 185 °F (-40 to 85 °C) Maximum case temperature 140 °F (60 °C) Operating humidity 5 to 95% Storage humidity 5 to 95% Ignition...

Generator Auto Start Requirements and Types B–2 975-0082-01-01 Recommended Features In order for the generator to be automatically started by the Auto Gen Start, it must include electric start and an automatic choke. An automatic primer system may also be required on natural gas and propane powered ...

Generator Starting Types 975-0082-01-01 B–3 Two wire The two-wire type is suitable for generators that are fully automatic. This merely requires two wires to be connected together for the generator to start and run. Separating the wires stops the generator. Some generators use a momentary two-wire c...

Generator Auto Start Requirements and Types B–4 975-0082-01-01 Connection The common wire from the generator should connect to the common connections of both Relay 1 and Relay 2 (wires 16 and 18 respectively). The start wire from the generator connects to the normally open contact of Relay 2 and the...

C Relay Timing Appendix C contains information about relay configuration and timing for each major type of Auto Gen Start starting mode. This information applies to each of the generator types described from page 2–10 to page 2–20.

Relay Timing C–2 975-0082-01-01 RunMode For generators with RunMode starting types (Types 7 and 8): • Relay 1 (RunStop relay) can be used for two-wire configured generators. • Relay 1 (RunStop) and Relay 2 (Start) can be used with a common ground for three-wire configured generators. • The Preheat w...

MomentaryRun Mode 975-0082-01-01 C–3 MomentaryRun Mode For generators with MomentaryRun mode starting types (Type 11): • Relay 1 (Run/Stop relay) can be used for two-wire configured generators. • Relay 2 has no unique function in this configuration, but it is easiest to leave it doing the cranking s...

Relay Timing C–4 975-0082-01-01 GlowStop Mode For generators with GlowStop mode starting types (Types 1, 2, 3, 6, 12): • Relay 1 (Stop) and Relay 2 (Start) can be used with a common ground for three-wire configured generators. • The Preheat signal shows up on Relay 1 and also Relay 3 (if enabled) so...

PulseStop Mode 975-0082-01-01 C–5 • The “Delay” refers to the “Preheat to Crank Delay” and may be zero. • Cranking will cease when the generator run signal goes high for the specified hold time or when the crank time has elapsed. • To get the ShutDown Bypass on Relay 3 with no preheat, Relay 3 must ...

975-0082-01-01 WA–1 Warranty and Return Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your Automatic Generator Start. This warranty period lasts for 12 months fr...

Warranty and Return WA–2 975-0082-01-01 What proof of purchase is required? In any warranty claim, dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex. Proof of purchase may be in any one of the...

Warranty and Return 975-0082-01-01 WA–3 Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LI...

Warranty and Return WA–4 975-0082-01-01 When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be prepared to supply:• The serial number of your product • Information about the installation and use of the unit • Information about the failure and/or re...

Warranty and Return 975-0082-01-01 WA–5 Information About Your System As soon as you open your Automatic Generator Start package, record the following information and be sure to keep your proof of purchase. If you need to contact Customer Service, please record the following details before calling. ...

A Advanced menu 3–18 AGS Mode 3–9 AGS Triggers menu 3–19 asterisk beside selected value 3–5 automatic mode 3–9 B B+ wires 2–8 Basic menu 3–7, 3–18 bottom panel features 1–6 C Clear Faults 3–17 clearing faults 5–2 Configure Gen 3–18 Configure Triggers 3–18 Crank Retry Time 3–33 Crank Time 3–32 Custom...

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