Owner’s Guide XW Automatic Generator Start
XW 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 1 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.
About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the XW Automatic Generator Start. Scope The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the XW Automatic Generator Start, as well as information about configuring, operating and troubleshooting the unit.
About This Guide Appendix B, “Generator Auto Start Requirements and Types”, provides general information about generators that will work with the XW Automatic Generator Start. Appendix C, “Relay Timing” contains information about relay configuration and timing for each basic type of starting mode for the XW Automatic Generator Start. “Warranty and Return Information” contains the warranty for your XW Automatic Generator Start as well as instructions for returning the product for servicing.
Important Safety Instructions WARNING: Save these instructions This Owner’s Guide contains important safety and operating instructions. Before using your XW Automatic Generator Start, be sure to read, understand, and save these safety instructions. WARNING: Restrictions on use The XW Automatic Generator Start shall not be used in connection with life support systems or other medical equipment or devices.
Safety 7. Disable the automatic starting circuit and/or disconnect the generator from its starting battery to prevent accidental starting while performing maintenance. Explosive Gas Precautions WARNING: Explosion hazard This equipment is not ignition protected. To prevent fire or explosion, do not install the XW Automatic Generator Start in locations that require ignitionprotected equipment.
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Introduction Purpose - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 System Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 Features - - - - - - - - - - - - - - - - -
Contents Connecting the Thermostats (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - Connecting an External Shutdown (optional) - - - - - - - - - - - - - - - - - - - - - - Connecting an External Manual ON/OFF Switch (optional) - - - - - - - - - - - - Connecting an External ON/OFF LED - - - - - - - - - - - - - - - - - - - - - - - - Connecting the Wiring Harness to the XW Auto Generator Start - - - - - - - - - Connecting the XW Auto Generator Start to the Xanbus Network - - - - - - - - Verifyin
Contents Gen Run Hold Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Crank Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Crank Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Crank Retry Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–26 Preheat Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–26
Contents 5 Troubleshooting Faults and Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Warning Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Fault Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6 A Specifications Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Mechanical Specifi
Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 4-1 XW Automatic Generator Start Basic Function - - - - - - - - - - - - - - - - - - 1–2 XW Auto Generator Start Front Panel - - - - - - - - - - - - - - -
Figures Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure A-1 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure C-5 Figure C-6 xii Starting and Stopping the Generator- - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3 Using the Quiet Time Feature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Changing the Mode to Standby - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6 Returning the Mode to Operating- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7 XW
Tables Table 1-1 Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 2-6 Table 2-7 Table 2-8 Table 2-9 Table 2-10 Table 2-11 Table 2-12 Table 2-13 Table 2-14 Table 2-15 Table 2-16 Table 2-17 Table 2-18 Table 2-19 Table 3-1 Table 3-2 Table 3-3 Table 5-1 Table 5-2 Front panel features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Circuit Limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Required Wiring Size Based on Length of Cable -
Tables xiv 975-0307-01-01
1 Introduction Chapter 1, “Introduction” describes the features and functions of the XW Automatic Generator Start Module. For this Topic.... See....
Introduction Purpose Important: The XW Automatic Generator Start (XW Auto Generator Start) is designed for use in an XW Power System only. ADDITIONAL EQUIPMENT REQUIRED. The XW Auto Generator Start requires the use of a XW System Control Panel for configuration and monitoring. For details see “System Requirements”. Use the XW Power System Installation Guide to integrate this component into the overall system.
System Requirements System Requirements Minimum basic system components include the following. ❐ An XW Inverter/Charger ❐ An AC Generator or DC Generator ❐ An XW System Control Panel ❐ An XW Automatic Generator Start Network Communication Protocol The XW Auto Generator Start uses Xanbus™, a network communications protocol developed by Xantrex, to communicate its settings and activity to other Xanbus-enabled devices. All network components used in the system must be Xanbus-enabled.
Introduction Functions Generator Starting Triggers Generator Stopping Triggers The XW Auto Generator Start can automatically start a generator in response to: • low battery voltage • high battery drain from the AC loads • a thermostat signal • a pre-programmed exercise period at a specified time of day.
Features Features Indicator Lights Four lights on the front panel indicate the operating status and network status of the XW Auto Generator Start. Connectors Two network ports on the bottom panel connect the XW Auto Generator Start to the Xanbus system. A 20-contact pluggable connector (also on the bottom panel) allows the XW Auto Generator Start to connect to the generator’s starting circuitry, thermostats and external switches. See “Bottom Panel” on page 1–6.
Introduction Bottom Panel 20-contact Generator Connector Port Network Port (accepts eight-pin RJ45 plug) Generator Network CAUTION: Connect only to Class 2 ELV circuits. ! Refer to manual. Figure 1-3 XW Auto Generator Start Bottom Panel Network Port Each network port can accept an eight-pin RJ45 plug attached to a Category 5 (CAT 5) network cable. Depending on the installation, both ports may be required.
2 Installation Chapter 2, “Installation” contains information and procedures to install the XW Automatic Generator Start. For this Topic.... See....
Installation Preparing an Installation Before installing the XW Auto Generator Start, consider how and where the unit will be mounted. Pre-plan the connection routes between the XW Auto Generator Start, the generator, thermostats, and the XW System Control Panel. Refer to the XW Power System Installation Guide for additional information.
Preparing an Installation Routing the Connections WARNING: Explosion Hazard This equipment is not ignition protected. To prevent fire or explosion, do not install the XW Auto Generator Start 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 a fuel system. Follow all relevant instructions exactly before installing or using your XW Auto Generator Start.
Installation Installing the XW Automatic Generator Start Installation Overview Installing the XW Auto Generator Start involves the following steps: 1. Mounting the unit. 2. Connecting the wiring harness to: • • • • the generator (page 2–8) thermostats (optional) (page 2–22) external shutdown switch (optional) (page 2–22) external ON/OFF switch and LED (optional) (page 2–23) 3. Connecting the wiring harness to the 20-contact connector on the XW Auto Generator Start. 4.
Installing the XW Automatic Generator Start Wiring to the 20-contact Connector CAUTION: 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.
Installation 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 XW Auto Generator 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. Tape, or otherwise secure, the unused wires to ensure they do not make unintended connections. 2.
Installing the XW Automatic Generator Start Table 2-3 Contact Numbers and Functions Wire Number Function 975-0307-01-01 Wiring Harness Wire Color 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+ (bat
Installation Connecting the Generator To connect the XW Auto Generator Start to a generator, identify the start wiring configuration of the generator to be used. Generators must be autostart capable, and generators equipped with remote operation connections are ideal.
Installing the XW Automatic Generator Start Type 1 Type 1 is a three-wire GlowStop configuration recommended for “threewire” generators with glow plugs that need to be operated before a start is attempted. XW AGS Harness Wires Relay 1 Relay 2 Generator Wires 12 GENERATOR RUN SIGNAL 13 GENERATOR BATTERY NEGATIVE (–) 14 5A fuse PREHEAT 5A fuse START 16 17 18 For additional information, see “Circuit Limitations” on page 2–5.
Installation Type 2 Type 2 is a three-wire GlowStop configuration recommended for “threewire” generators that don’t require a dedicated preheat signal, such as Onan generators. In this configuration, the start signal is applied for longer because the generator does its own preheat and cranking while the start signal is applied.
Installing the XW Automatic Generator Start Type 3 Type 3 is a three-wire GlowStop with shutdown bypass configuration. The configuration shown in Figure 2-5 uses a shutdown bypass output to temporarily disable the generator’s low oil pressure shutdown functionality during cranking. Generators with this functionality often have a manual means of disabling it during cranking.
Installation Type 4 Type 4 is a three-wire StartStop configuration that uses relay 3 to provide the preheat signal for Generac’s Guardian Gas generators. XW AGS Harness Wires Generator Wires GENERATOR RUN SIGNAL 12 GENERATOR BATTERY NEGATIVE (–) 13 Relay 1 Relay 2 Relay 3 14 5A fuse STOP/PREHEAT 5A fuse START 5A fuse FUEL PRIME (PREHEAT) 16 17 18 19 12V GENERATOR BATTERY + 20 For additional information, see “Circuit Limitations” on page 2–5.
Installing the XW Automatic Generator Start Type 5 Type 5 is a three-wire StartStop configuration that uses relay 3 to provide the preheat signal for Generac’s Guardian Diesel generators. XW AGS Harness Wires Generator Wires GENERATOR RUN SIGNAL 12 13 Relay 1 Relay 2 Relay 3 GENERATOR BATTERY NEGATIVE (–) 14 5A fuse STOP/PREHEAT 5A fuse START 5A fuse FUEL PRIME (PREHEAT) 12V GENERATOR BATTERY + 16 17 18 19 20 For additional information, see “Circuit Limitations” on page 2–5.
Installation Type 6 Type 6 is a three-wire GlowStop configuration that has a normally closed Run/Stop contact. This generator type is intended for Yamaha generators. XW AGS Harness Wires Relay 1 Generator Wires 12 13 14 15 5A fuse GENERATOR RUN SIGNAL GENERATOR BATTERY NEGATIVE (–) PREHEAT STOP 5A fuse START 5A fuse 16 Relay 2 17 18 For additional information, see “Circuit Limitations” on page 2–5.
Installing the XW Automatic Generator Start Type 7 Type 7 will work with both two-wire and three-wire run mode configurations that require a preheat signal before cranking, such as Generac Backup/Renewable generators. This Gen Type setting is suitable for generators with an automatic engine cranking control system (twowire) and generators that require that the XW Auto Generator Start control their starter separately (three-wire).
Installation Type 8 Type 8 will work with both two-wire and three-wire run mode configurations and is intended for Northern Lights and Fisher Panda generators. Type 8 is identical to Type 7 except that it provides no preheat signal before cranking. XW AGS Harness Wires Relay 1 12 13 14 16 Generator Wires GENERATOR RUN SIGNAL GENERATOR BATTERY NEGATIVE (–) 5A fuse RUN For additional information, see “Circuit Limitations” on page 2–5.
Installing the XW Automatic Generator Start Type 9 Type 9 is a StartStop mode configuration with shutdown bypass functionality on relay 3. This configuration is intended for Westerbeke generators. XW AGS Harness Wires Relay 1 Relay 2 Relay 3 Generator Wires GENERATOR RUN SIGNAL 12 13 14 16 GENERATOR BATTERY NEGATIVE (–) 5A fuse STOP 17 18 5A fuse START 19 5A fuse FUEL PRIME (PREHEAT) 12V GENERATOR BATTERY + 20 For additional information, see “Circuit Limitations” on page 2–5.
Installation Type 10 Type 10 is a StartStop mode configuration with no preheat signal or shutdown bypass functionality. XW AGS Harness Wires Generator Wires GENERATOR RUN SIGNAL 12 GENERATOR BATTERY NEGATIVE (–) 13 Relay 1 Relay 2 14 5A fuse STOP 5A fuse START 16 17 18 For additional information, see “Circuit Limitations” on page 2–5.
Installing the XW Automatic Generator Start Type 11 Type 11 is a two-wire run mode configuration intended for Kohler generators. It requires only two wires and one relay to control the generator. Relay 1 closes momentarily once to start the generator, and closes momentarily again to stop the generator. XW AGS Harness Wires Relay 1 Generator Wires GENERATOR RUN SIGNAL GENERATOR BATTERY NEGATIVE (–) 12 13 14 16 5A fuse RUN For additional information, see “Circuit Limitations” on page 2–5.
Installation Type 12 Type 12 is a three-wire GlowStop configuration recommended for “threewire” generators that don’t require a dedicated preheat signal, such as Onan propane generators. In this configuration, the start signal is applied for longer because the generator does its own preheat and cranking while the start signal is applied.
Installing the XW Automatic Generator Start Type 13 Type 13 is a three-wire PulseStop configuration that uses relay 3 to provide the preheat signal for PowerTech’s Diesel generators. With this generator type, there will be a delay between the generator turning off and the XW Auto Generator Start recognizing that the generator is off.
Installation 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.
Installing the XW Automatic Generator Start Connecting an External Manual ON/OFF Switch (optional) The external manual ON/OFF inputs (wires 7 and 8 on the wiring harness) are intended for wiring to one or more remote ON/OFF switches for starting and stopping the generator manually. Wire 7 (Start) and wire 8 (Stop) should each run to their own momentary-contact switch or push-button. The other contact on both switches (common) should be connected to wire 11 on the harness.
Installation Table 2-19 Wiring for Connecting an External Manual ON/OFF Switch Wire Number Function Wiring Harness Wire Color 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+ for External On/ Off/LED Indicator Red 11 External On/Off/LED Indicator return Black Multiple generator control panels or simple contact closures can be wired to the external manual ON/OFF inputs.
Installing the XW Automatic Generator Start 2K 7 START PUSHButton BU TTON Start Push 8 S top PPUSH ush BBUTTO utton N STOP 2K 5K11 9 10 E xternal LELED D EXTERNAL Fused 12V O R12V 24V or 24V External LED EXTERNAL LED 11 XW A utom atic G enerator Start 13 -12V or -24V G enerator GRO UN D B attery N egative (–) Figure 2-18 External ON/OFF Switch and LED Wiring Diagram 975-0307-01-01 2–25
Installation Connecting the Wiring Harness to the XW Auto Generator 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 XW Auto Generator Start.
Installing the XW Automatic Generator Start Connecting the XW Auto Generator Start to the Xanbus Network CAUTION: Equipment Damage Connect only to other Xanbus-enabled devices. Although the cabling and connectors used in this network system are the same as those used for Ethernet, this network is not an Ethernet system. Equipment damage may result from attempting to connect a Xanbus-enabled device to an Ethernet system.
Installation Verifying Power Is Available When the XW Auto Generator Start has been installed properly, the Power and Network indicator lights illuminate. If one or both lights are out, check the network connections. Check the XW Inverter/Charger to ensure it has battery power. Check to make sure the other devices in the network are responding, such as the XW System Control Panel, to confirm the network is still active. Verify Power and Network indicator lights are illuminated.
3 Configuration Chapter 3, “Configuration” contains information and procedures for configuring the XW Automatic Generator Start. For this Topic.... See....
Configuration Overview The XW Auto Generator Start has a number of settings that must be configured to ensure that the generator starts and stops under the appropriate conditions and at the appropriate time. The XW Auto Generator Start is configured using the XW System Control Panel. The XW System Home Screen on the XW System Control Panel displays basic system operational status. On the lower left corner of the XW System Home Screen, there is an arrow that points to the Enter Button below the display.
Accessing the XW Auto Generator Start Menu Accessing the XW Auto Generator Start Menu Use the XW AGS Menu to change configuration settings, set operating mode, clear fault warnings, and view device information. To access the XW Auto Gen Start Menu, start from the XW System Home Screen.... To view the Select Device Menu, press the Enter Button. Enter XW System Home Screen To select the XW AGS Menu, use the navigation buttons to highlight XW AGS. Press the Enter Button to select the XW AGS Menu.
Configuration To change operational settings on the XW AGS Menu: 1. Use the Navigation Buttons to select the desired operation. 2. Press Enter to highlight the current value for that setting. Asterisks (*) indicate the last value set. 3. Use the Navigation Buttons to change the value. Holding the Navigation Button down without releasing it will scroll through the values quickly. 4. Press ENTER to select the value. 5. Press Exit twice to return to the XW System Home Screen.
The XW Auto Gen Start Menu To access the Advanced Settings Menu, see Figure 3-5 on page 3–6 For details, see page 3–28. For details, see page 3–28.
Configuration When the XW Auto Generator Start Home Screen is first displayed, the menu defaults to the GenMode Menu. If configuration changes need to be made, the Configuration Menu can be accessed by pressing the ENTER button, the Up Arrow button, and Down Arrow button all at same time to access the Advanced Settings. For details on the Configuration menu options, see page 3–7.
The XW Auto Gen Start Menu The Configuration Menu The Configuration Menu is where specific start-stop parameters are set. This menu contains the following settings: • • • • • • • • QT EN QT Begin QT END Gen Type Cfg Trigger Cfg Gen Multi-unit Config Restore Defaults QT En Full name Quiet Time Enable Purpose “QT En” enables or disables the Quiet Time functionality of the XW Auto Generator Start. Quiet time refers to a period of time when the generator should not run.
Configuration Important: If quiet time is set for overnight, be aware that overnight battery drain can be significant as it may be necessary to use the inverter and batteries to supply AC Power without the help of a generator. Therefore, it is important to conserve battery power during this time. Minimize the use of interior lights and set thermostat temperature lower to prevent the furnace from coming on at night during cool weather.
The XW Auto Gen Start Menu 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 a setting for “QT Begin”. Dependencies “QT End” functions only if the XW Auto Generator Start is in Automatic mode. This setting requires “QT En” be set to [Enabled] and also requires a setting for the “QT Begin” trigger.
Configuration Table 3-1 Generator Type Descriptions and Examples(Continued) Description For Technical Details, see...
The XW Auto Gen Start Menu Cfg Trigger Menu The Cfg Trigger menu contains the settings for automatically starting and stopping the generator. This menu allows the adjustment of the default settings for battery voltage, thermostat ON/OFF signals, inverter load, and battery charging stage. There are three classes of triggers: charger-based, thermostat-based, and inverter load-based. If the generator is started by a trigger in one class, a stop condition must also be set in order for the generator to stop.
Configuration Start DCV 30 sec Full Name Starting Battery Voltage—30 seconds Purpose The “Start DCV 30 sec” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 30 seconds. The XW Auto Generator Start will stop the generator when the stop trigger is provided (“Stop V”, “Stop Absorb”, or “Stop Float”).
The XW Auto Gen Start Menu Start DCV 15 min Full Name Starting Battery Voltage—15 minutes Purpose The “Start DCV 15 min” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 15 minutes. The XW Auto Generator Start will stop the generator when the battery voltage has risen to the “Stop V”, or when the batteries have been recharged to the Absorption or Float stage.
Configuration Start DCV 2 hr Full name Starting Battery Voltage—2 hours Purpose The “Start DCV 2 hr” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 2 hours. Dependencies The “Start DCV 2 hr” trigger requires the XW Auto Generator Start to be in Automatic mode and needs the “Stop Absorb” or “Stop Float” trigger be enabled or a parameter to be set for the “Stop V” trigger.
The XW Auto Gen Start Menu Start DCV 24 hr Full name Starting Battery Voltage—24 hours Purpose The “Start DCV 24 hr” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 24 hours. Dependencies The “Start DCV 24 hr” trigger requires the XW Auto Generator Start to be in Automatic mode and needs the “Stop Absorb” or “Stop Float” trigger be enabled or a parameter to be set for the “Stop V” trigger.
Configuration Stop Float Full name Stop at Float Charge Stage Purpose The “Stop Float” trigger allows the XW Auto Generator Start to stop the generator when the inverter/charger has recharged the batteries to the Float stage. Considerations Values Default Disabled, Enabled Enabled “Stop Float” or “Stop Absorb” would typically be used if the generator was started due to a low-battery voltage setting.
The XW Auto Gen Start Menu charge. If the generator is the only charging source, Stop Absorption will leave the batteries consistently undercharged and may shorten the battery life. Alternately, Stop Absorption can be useful during utility outages, when it is desired to keep the generator run time to a minimum, but are expecting a full recharge once the power is restored. For more information on battery charging, see XW Inverter/Charger Operator’s Guide.
Configuration Temp1 Full name Thermostat 1 Purpose The “Temp1” trigger enables the generator to start in response to a signal from a thermostat. With “Temp1” set to [Enabled], the XW Auto Generator Start will start the generator to help power the item controlled by that thermostat. Values Default Disabled, Enabled Disabled When to use Enable this setting if a thermostat is available that controls a component that has a high-power requirement such as a furnace or an air conditioning system.
The XW Auto Gen Start Menu Dependencies The “Load” trigger requires the XW Auto Generator Start to be in Automatic mode and needs parameters to be set for both the “Start Load” and “Stop Load” triggers. Value Default Disabled, Enabled Disabled Important: This function is intended to protect the batteries from rapid drain. It is not intended to protect the inverter against overload.
Configuration Stop Load Full name Stop on Inverter Load Current Purpose The “Stop Load” trigger enables the XW Auto Generator Start to stop the generator when the AC load falls below a specific level for 1 minute. The “Stop Load” setting applies to situations when the XW Auto Generator Start has started the generator to assist the inverter with powering the AC load.
The XW Auto Gen Start Menu Starter Cool Down Purpose When to use The Starter Cool Down setting allows an interval to be set between start attempts if the generator fails to start on the first attempt. This time period allows the start motor to cool sufficiently before the XW Auto Generator Start signals it to begin cranking again. Values Default 1s to 250s (increments of 1s) 60s This setting is automatically configured when a “Gen Type” is selected for the generator.
Configuration Max Run Time Full name Maximum Generator Run Time Purpose “Max Run Time” allows a limit to be set on how long the generator will run. This setting overrides any automatic start triggers. For example, if the generator starts in response to low battery voltage, and the batteries are not fully charged before “Max Run Time” is reached, the generator will stop.
The XW Auto Gen Start Menu Dependencies Considerations The “Exercise Per” trigger requires parameters to be set in the “Exercise Dur” and “Exercise Time” menu items. Values Default 0 (Off), 1day to 250days (increments of 1day) 21days Generators need to run regularly in order to maintain mechanical health and performance. If the generator isn’t needed and doesn’t run, it is recommended that an Exercise period be set to keep the generator in good working condition.
Configuration Exercise Time Purpose “Exercise Time” sets the time of day that the XW Auto Generator Start exercises the generator. The “Exercise Time” trigger requires that any parameter other than “0” be set in “Exercise Per” and a value be set in the “Exercise Dur” trigger.
The XW Auto Gen Start Menu Gen Run Hold Time Full name Generator Run Signal Hold Time Purpose “Gen Run Hold Time” specifies the length of time the generator run signal (or B+ or hour meter signal) must be active before the XW Auto Generator Start considers the generator to be running and cranking can be stopped. Some generators assert their run signal when they are being cranked, but before they have started.
Configuration Crank Retry Time Purpose Considerations “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 attempt. Values Default 0s to 250s (increments of 1s) 40s This setting is automatically configured when a “Gen Type” is selected for the generator.
The XW Auto Gen Start Menu Multi-unit Config “Multi-unit Config” provides the means to identify multiple units within the same configuration. Dev Name The “Dev Name”, or Device Name, menu item gives each Xanbusenabled device a unique identifiable name. This makes each device easier to identify when multiple Xanbus-enabled devices are connected together. See the XW Inverter/Charger Operator’s Guide for additional information.
Configuration Generator This generator name is used by the XW inverter/charger to identify which generator is connected to the AC2 input. It is only necessary to change this setting in installations with more than one XW Auto Generator Start in a system. In this case, the “generator” name on each XW Auto Generator Start will have to be unique. Example: If a generator is connected to AC2 on an XW inverter/charger, the generator name (e.g., Gen1, Gen2 etc.
The XW Auto Gen Start Menu Time feature, which prevents the generator from starting during evening hours or other inconvenient times (see “QT Begin” on page 3–8, “QT End” on page 3–9, and “Using Quiet Time” on page 4–4). Automatic Mode Overrides When the XW Auto Generator Start is in Automatic mode, several settings and conditions override automatic start and stop triggers.
Configuration Manual Off Mode Selecting Manual Off Mode overrides the automatic stop settings and manually stops the generator. Manual Off must be selected to stop the generator when the generator has been started manually. The XW Auto Generator Start will not automatically start the generator again until “Automatic” is selected in the GenMode Menu. Important: The GenMode mode must be set to Manual Off before any start trigger parameters can be changed.
The XW Auto Gen Start Menu View Event Log Purpose The Event Log displays the last 20 XW Auto Generator Start events for reference. Events can include: • • • • • Starting and stopping the generator. Trigger events. See Table 3-2 for a detailed list of trigger events. Changing the system mode. Changing the system clock. Commands to restore the default settings.
Configuration User Settings Use this table to record any customized XW Auto Generator Start settings for future reference.
User Settings Table 3-3 Generator Configuration Settings, Values, Defaults, and User Settings Setting Values Default User Setting Generator Menu Items: “Starter Cool Down” 1s to 250s (increments of 1s) 60s “Gen Cool Down” 0s to 90 s (increments of 1s) 30s “Max Run Time” 0hours–24 hours 8hours “Exercise Per” 0days (Off)–250days 21days “Exercise Dur” 1min–250min 30min “Exercise Time” 12:00AM–11:59PM (12-hour clock) 00:00–23:59 (24-hour clock) 9:00AM (12-hour clock) 9:00 (24-hour clock)
Configuration 3–34 975-0307-01-01
4 Operation Chapter 4, “Operation” describes the operation of the XW Auto Generator Start and how to get the most from its features. For this Topic.... See....
Operation Accessing the XW Auto Generator Start Home Screen Use the XW Auto Generator Start Home Screen to view basic operational status information for the generator. The XW Auto Generator Start Home Screen displays the generator start settings (i.e., ManualOff), the generator state (running or stopped), the stop trigger, and the Generator signal. XW System Home Screen When the XW Auto Generator Start Home screen is displayed, press the Enter button to move into the XW Auto Generator Start Setup Menu.
Starting and Stopping the Generator Starting and Stopping the Generator Use the XW Auto Generator Start to start or stop the generator manually using the XW System Control Panel or automatically in response to an electrical system condition. To set the XW Auto Generator Start to start and stop the generator automatically: 1. On the XW Auto Generator Start menu, highlight GenMode and press Enter. 2. Use the navigation button to select [Automatic]. 3. Press Enter. To start the generator manually: 1.
Operation Using Quiet Time Use the Quiet Time feature to ensure that the XW Auto Generator Start will not start the generator during the night or during times that conflict with local noise restrictions. Using Quiet Time involves three steps. 1. “QT En” must be set to [Enabled]. The default setting is [Enabled]. 2. “QT Begin” must have an appropriate time set for Quiet Time to start on schedule. The default setting for “QT Begin” is [9:00 PM] or 21:00 if using a 24-hour clock. 3.
Modes of Operation 3. Use the navigation buttons to select the minutes, then press Enter. If the 24-hour clock is being used, go to step 5. 4. Use the navigation buttons to select AM or PM, then press Enter. 5. Press Exit twice to return to the System Home screen. To set the end of Quiet Time: 1. On the Auto Gen Start menu, use the navigation buttons to highlight “QT End”, then press Enter. 2. Use the navigation buttons to select the hour, then press Enter. 3.
Operation Putting the XW Auto Generator Start in Standby Mode Use the XW System Control Panel to put the XW Auto Generator Start into Standby mode. To put the XW Auto Generator Start in Standby Mode: Enter XW System Control Panel 1 2 XW System Home Screen Select Device Menu Press the Enter button when the XW System Home Screen is displayed. Use the Navigation Buttons to scroll down to the XW AGS Menu Item. Press the Enter Button when XW AGS is highlighted.
Modes of Operation Returning the XW Auto Generator Start to Operating Mode Use the XW System Control Panel to return the XW Auto Generator Start to Operating mode. To Return the XW Auto Generator Start to Operating Mode: Enter XW System Control Panel 1 2 XW System Home Screen Select Device Menu Press the Enter button when the XW System Home Screen is displayed. Use the Navigation Buttons to scroll down to the XW AGS Menu Item. Press the Enter Button when XW AGS is highlighted.
Operation 4–8 975-0307-01-01
5 Troubleshooting Chapter 5, “Troubleshooting” contains information and procedures to troubleshoot the XW Automatic Generator Start. For this Topic.... See....
Troubleshooting Faults and Warnings Under certain conditions, the XW Auto Generator Start generates a fault or warning message. These messages appear on the XW System Control Panel. Acknowledging messages When a fault or warning message appears, it will remain on the screen until it is acknowledged by pressing Enter on the XW System Control Panel. This action removes the message from the screen, but does not clear the condition that caused the fault or warning.
Warning Messages 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 for XW Auto Generator Start warnings. Table 5-1 XW Auto Generator Start Warning Messages Warning Number Message Selfclearing? Cause Action W200 Generator was stopped manually.
Troubleshooting Table 5-1 XW Auto Generator Start Warning Messages(Continued) Warning Number Message Selfclearing? Cause Action W203 Manual Off: Max generator run time reached. Reset GenMode. No The generator has run for its maximum allowable time. The XW Auto Generator Start has stopped the generator and changed the GenMode to [ManualOff]. Acknowledge the warning. Return the XW Auto Generator Start to the desired GenMode [Automatic or ManualOn].
Warning Messages Table 5-1 XW Auto Generator Start Warning Messages(Continued) Warning Number W250 Message The selected value failed to change. Try again. Selfclearing? No Cause Action You have tried to change the Gen Type without putting the system into Standby first. Put the system into Standby, change the Gen Type, then return the system to Operating mode. You have tried to set the “Exercise Dur” for longer than “Max Run Time,” or “Max Run Time” for less than “Exercise Dur.
Troubleshooting Fault Messages When the XW Auto Generator Start detects a fault condition, it stops the generator. The red Fault light also comes on, and the XW System Control Panel displays a fault message. The XW Auto Generator Start remembers the GenMode that it was in at the time it detected the fault. After you have cleared the fault, the XW Auto Generator Start returns to its last known GenMode.
Fault Messages Table 5-2 XW Auto Generator Start Fault Messages Fault Number Message Selfclearing? Action The silicon serial ID number has failed and the XW Auto Generator Start has gone into Standby. Call your dealer or Xantrex. F500 Serial Number Failure, Service Required. F501 Memory Failure. No Service Required. The XW Auto Generator Start Call your dealer or has suffered a non-volatile Xantrex. memory failure. F505 Internal Failure. Service Required.
Troubleshooting 5–8 975-0307-01-01
A Specifications Appendix A contains the electrical, mechanical, and environmental specifications for the XW Auto Generator Start. All specifications are subject to change without notice. For this Topic.... See....
Specifications Electrical Specifications Nominal input network voltage 15 Vdc Maximum operating current 200 mA @ nominal input network voltage Relay contact voltage rating 12 Vdc, 30 Vdc max.* Maximum relay contact current 5 A DC* Nominal 12/24 V thermostat input voltage 12 Vdc/24 Vdc* = On Minimum 12/24 V thermostat input voltage 9.5 Vdc* Maximum 12/24 V thermostat input voltage 30 Vdc* Typical 12/24 V thermostat input current 14.
Mechanical Specifications Mechanical Specifications Dimensions 3¾×5¾x1½ (95.5 × 146 × 37 mm) Weight 0.5 lb. (225 g) Mounting 4x #6 screws Connectors 2x Xanbus: RJ45—8 pins 1x 20-contact pluggable connector (Tyco Mate’n’ Lok 2 connector) Illustration Not to Scale.
Specifications Environmental Specifications 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 protection None Regulatory Compliance A–4 Safety CSA certified to CSA107.1-01 and UL 458 4th Ed.
B Generator Auto Start Requirements and Types Appendix B describes the generator requirements and starting types that can be used with the XW Auto Generator Start. For this Topic.... See....
Generator Auto Start Requirements and Types Recommended Features In order for the generator to be automatically started by the XW Auto Generator Start, it must include electric start and an automatic choke. An automatic primer system may also be required on natural gas and propane powered generators. The generator should also include remote start ability with accessible remote start terminals or a connector.
Generator Starting Types 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 connection for starting and stopping. Identification Generators of this type are usually operated with a simple toggle switch or key that turns to on, then off to shut the generator off.
Generator Auto Start Requirements and Types 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 generator stop wire connects to the normally open contact of Relay 1. Three-Wire Automotive The third generator starting type that is supported by the AGS is similar to an automotive-style ignition.
C Relay Timing Appendix C contains information about relay configuration and timing for each major type of XW Auto Generator Start starting mode. This information applies to each of the generator types described from page 2–9 to page 2–21. For this Topic.... See....
Relay Timing 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 will never overlap the Crank Time. 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.
MomentaryRun Mode 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 so that another configuration is not required for it. Preheat will generally not be used in this configuration. The Preheat will never overlap the Crank Time.
Relay Timing 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 that Relay 1 can be used for both Preheat and Stop. If the ShutDown Bypass is enabled, the Preheat on Relay 1 will remain high for the Crank Time and for the ShutDown Bypass period after cranking.
PulseStop Mode • • • • 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 be configured for Preheat with ShutDown Bypass and have the Preheat time set to zero. StartStop mode is essentially the same as GlowStop mode with no preheat on Relay 1.
Relay Timing • • The XW Auto Generator Start will make three attempts to stop the generator. If the generator has still not stopped at the end of the third attempt, the appropriate Fault will be generated. Each stop attempt will consist of engaging the stop relay for 5 seconds and then waiting 20 seconds before checking the state of the Gen Run Signal to see if the stop attempt was successful.
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 XW Automatic Generator Start. This warranty period lasts for 5 years from the date of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims.
Warranty and Return 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.
Warranty and Return 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 LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE
Warranty and Return 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 reason for the return • A copy of your dated proof of purchase Record these details in “Information About Your System” on page WA–5. Return Procedure 1. 2. 3.
Warranty and Return Information About Your System As soon as you open your XW Automatic Generator Start package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number _________________________________ ❐ Purchased From _________________________________ ❐ Purchase Date _________________________________ If you need to contact Customer Service, please record the following details before calling.
WA–6
Index A AGS Triggers menu 3–11 automatic mode 3–29 clearing 5–2 reference table 5–6 front panel features 1–5 B G B+ wires 2–7 bottom panel features 1–6 C clearing faults 5–2 Crank Retry Time 3–26 Crank Time 3–25 Customer Service preparing to call WA–5 D Device Info menu 3–30 Down arrow button 3–2 Gen Type 3–9 generator auto start requirements B–1 type 3–9 Generator On light 1–5 generator run signal 2–7 generator starting modes glowstop C–4 momentary run C–3 pulsestop C–5 run C–2 startstop C–4 I Inf
Index Enable 3–7 End 3–9 R regulatory listings A–4 Relay3 3–24 Run Hold Time 3–25 run mode C–2 S serial number recording WA–5 settings quiet time 4–4 specifications A–2 Start DC V 3–12 Start Load 3–19 Start Tries 3–26 Starter Cool Down 3–21 startstop mode C–4 StartV 15min 3–13 24Hr 3–15 2Hr 3–14 Stop Absorb 3–16 Stop BattV 3–17 Stop Float 3–16 Stop Load 3–20 switched B+ wires 2–7 V verifying network power 2–28 W Warning Log 3–30 warning messages acknowledging 5–2 reference table 5–3 warranty out of warr
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