Xantrex Technology Portable Generator AGS User Manual

AGS  
Owner's Manual  
Xantrex  
Automatic Generator  
Start Control System  
 
INTRODUCTION  
Thank you for purchasing a Xantrex Automatic Generator  
Start Control System. Xantrex Technology Inc. takes pride in  
manufacturing quality products specifically designed to meet  
your needs.  
Main Features  
The Automatic Generator Start Control System (AGS) auto-  
matically controls and monitors an auxiliary generator. It will  
automatically start a generator as required to charge a  
battery bank or as heating or cooling systems require. You  
can also set allowable generator run times, so that the  
AGS does not turn on the generator at inconvenient times.  
SAFETY SUMMARY  
General safety information for installation and operation  
is contained throughout this manual where it applies  
and is not completely included in this summary.  
Definitions  
Warning statements identify conditions or practices which  
could result in personal injury, loss of life, damage to equip-  
ment or other property.  
Fuse Replacement  
For continued protection against the possibility of fire, replace  
the fuse only with a fuse of the specified voltage, current and  
type ratings.  
Power Source  
To avoid damage, operate the equipment only within the  
specified AC (line) and DC (battery) voltages.  
Servicing  
There are no user serviceable parts inside. Refer all service  
to qualified personnel.  
3
 
THINGS YOU SHOULD KNOW  
The Automatic Generator Start Control System (AGS) has the  
following features:  
Starts the generator automatically in response to a low  
battery. The AGS continuously monitors the house battery and  
will start the generator automatically if the battery is low.  
Starts the generator automatically in response to air condi-  
tioning/heating requests. The AGS continually monitors the air  
conditioning system and starts the generator, as required by the  
air conditioning system.  
Setting of QUIET TIME. QUIET TIME periods of one hour or  
more can be entered to prevent automatic operation of the gen-  
erator during inappropriate times.  
Easy changing of time setting. A TIME ZONE indicator is pro-  
vided for easy changing of local time when travelling.  
Displays generator status. The Remote Panel indicates if the  
generator is on (GEN ON) and if the generator has a problem  
(GEN FAULT).  
This system...  
• allows the user to have confidence that the battery will  
not be completely discharged and the DC systems will be  
operational. The AGS is not dependent on shorepower and  
will maintain the system even if small appliances and gen-  
eral lighting are on.  
• provides generator power to operate the heating or  
cooling systems. This will allow you (and your pets) to be  
comfortable.  
The system is not intended...  
• to be left unattended.  
• to keep batteries fully charged. The charge period is  
normally two to four hours.  
• to maintain area temperature at a specific temperature.  
• for use with all air conditioners, heaters, heat pumps and  
generators.  
4
 
THEORY OF OPERATION  
System  
The AGS system, when in AUTO or AUTO QUIET TIME  
mode, continuously monitors the house battery and two air  
conditioning/heater thermostats.  
If the LOCAL TIME of day is not within the AUTO QUIET  
TIME window, it will start the generator to charge the battery  
or to cool or heat as required.  
The AGS system is invisible to the normal operation of the  
auxiliary generator manual start and stop controls with the  
following exceptions:  
1. If the generator is started by the AGS, which is in  
AUTO or AUTO QUIET TIME mode, the selection of OFF at  
the AGS Remote Panel will stop the auxiliary generator.  
2. If the AGS system commands the generator to start  
and it does, the AGS system will stop the generator at the  
appropriate time. If the generator stops for some other  
reason, even if it is turned Off by a manual switch other than  
the AGS, the AGS system will assume that there is a FAULT.  
It will turn itself OFF and turn on the GEN FAULT light. At  
this point, the AGS system must be turned on to the AUTO  
mode or AUTO QUIET TIME mode for it to resume control of  
the generator.  
Once started by the AGS system, the generator will run for a  
minimum of two hours. This will ensure that there is a good  
charge in the battery, although it may not be fully charged at  
the end of the cycle. If the battery voltage does not reach  
13.5 volts during the two-hour period, the generator will  
continue to run for an additional two hours. If at the end of  
the second two-hour period the battery voltage is still not up  
to 13.5 volts, then the AGS systems assumes that there is a  
problem and turns the generator OFF. It must be restarted  
manually.  
5
 
OPERATION  
GEN ON Light  
The GEN ON light is on whenever the generator is running. This  
includes when the auxiliary generator is run manually.  
DEFAULT: Light OFF  
GEN FAULT Light  
The generator has failed to start or has stopped during AGS  
control. This will happen if the generator is manually stopped by a  
generator start/stop switch that is independent of the AGS. Cy-  
cling the ON/OFF switch will clear the fault. Check generator for  
normal operation.  
DEFAULT: OFF  
ON/OFF MODE Switch  
Pressing the ON/OFF switch changes the status of  
On/Off  
the AGS from OFF to AUTO to AUTO QUIET mode.  
When it is off, the OFF light is illuminated.  
DEFAULT: OFF mode.  
AUTO Mode  
In AUTO mode, the Control Module will respond to requests for  
generator start from a low battery condition or from an air condi-  
tioning demand.  
AUTO QUIET Mode  
In AUTO QUIET mode (both lights on at the same time) the Control  
Module will respond to requests from low battery or air condition-  
ing because the time is outside of the user-set Quiet Time. In  
AUTO QUIET mode (AUTO light on and QUIET light blinking) the  
AGS will not respond to requests for low battery or thermostats  
starting because the Local Time is within the Quiet Time window.  
6
 
PM  
Set Time  
Sets the LOCAL TIME, QUIET TIME “BEGIN” or QUIET TIME  
“END” according to the selection made by the SELECT switch. To  
set a time parameter, select the hour by repeatedly pressing the  
SET TIME button until the correct hour light is on.  
DEFAULT: LOCAL TIME  
Time  
Zone  
Pressing the TIME ZONE button changes the LOCAL TIME by  
cycling through the available time zones. EST (Eastern Standard  
Time), CST (Central Standard Time), MST (Mountain Standard  
Time), or PST (Pacific Standard Time) are possible. Only one can  
be on at a time. Light is on.  
DEFAULT: PST  
SELECT changes the time displayed by the  
Local  
Time  
Begin  
End  
AGS Remote and is used to set the TIME/  
HOUR. In LOCAL TIME mode the user can set  
the “Time/Hour” display to the local hour. (Min-  
utes are preset at the factory and do not require  
user adjustment).  
Select  
DEFAULT: LOCAL TIME  
To Program Local Time (USUALLY NOT REQUIRED):  
Use the SELECT switch to select LOCAL TIME. Press the TIME  
ZONE switch to select the time zone. Press the SET TIME switch  
to set the local time hour.  
Quiet Time BEGIN (REQUIRED SETTING):  
Use the SELECT switch and press it until the BEGIN light is on.  
Use the SET TIME switch to select the time in hours Quiet Time is  
to begin.  
Quiet Time END (REQUIRED SETTING):  
Use the SELECT switch and press it until the END light is on.  
Use the SET TIME switch to select the time in hours Quiet Time is  
to end.  
7
 
INSTALLATION  
The Automatic Generator Start Control System (AGS) consists of  
two modules, the Remote Panel and the Controller.  
Service Precaution Labels  
Install service precaution labels on or near the generator and near  
the AGS Remote.  
AGS Remote Panel  
This AGS Remote Panel provides information and control of the  
Control Module. Power for this Remote Panel comes from the  
Control Module. The Remote Panel comes on automatically when  
power is applied to the AGS Control Module.  
The AGS Remote Panel measures 5.75'' (W) X 3.75'' (H) X 0.65''  
(D). Use the supplied template to cut the proper size hole. Mount  
the Remote Panel unit using the screws supplied.  
Route the control cable from the AGS Remote Panel to the Con-  
trol Module. Connect the control cable to the AGS Remote Panel  
and Control Module using the data connectors on the supplied  
cable.  
Power Up Indications  
When power is first applied to the AGS Remote, the AGS Remote  
establishes communications with the Controller. It can take up to  
four seconds to establish communications.  
AGS Controller  
The AGS Controller may be mounted in any convenient location.  
Mount the AGS Controller using the screws supplied. The AGS  
Controller may be mounted up to 250 feet from the AGS Remote.  
8
 
#18 AWG wire should be used. The in-line connector for the  
Controller has the following DC connections.  
NO. DESCRIPTION  
1
2
3
4
5
START: Generator start signal contact.  
STOP: Generator stop signal contact.  
GENERATOR DC HOUR METER.  
RESERVED (Future ignition lock-out).  
POWER POSITIVE: Connect to house battery positive.  
2-amp fuse required. See INSTALLATION NOTE page 10.  
THERMOSTAT 1: Connected to positive signal from  
thermostat/heating-cooling system, 12 VDC = ON.  
THERMOSTAT 2: Connect to positive signal from thermo-  
stat/heat-cooling system, 12 VDC = ON.  
6
7
8
9
PREHEAT: Contact for generator preheat signal.  
START COMMON: Generator Start signal contact. Typi-  
cally connect to generator ground.  
10  
11  
STOP COMMON: Generator Stop signal contact. Typically  
connect to generator ground.  
THERMOSTAT 3: Connected to positive signal from  
thermostat/heating-cooling system, 12 VDC = ON. This is  
only available on units over S/N 150.  
12  
13  
14  
15  
16  
BATT SENSE POSITIVE: Connect to house battery posi-  
tive. 2-amp fuse required.  
POWER/SENSE NEGATIVE: Connect directly to house  
battery negative.  
THERMOSTAT 1,3 COMMON: Contact for thermostat 1  
and 3. Connected to ground.  
THERMOSTAT 2 COMMON: Contact for thermostat 2.  
Connected to ground.  
PREHEAT COMMON: Contact for Preheat signal. Typically  
connected to generator ground.  
9
 
INSTALLATION DIAGRAM  
INSTALLATION NOTE:  
It is advised to interlock the AGS system so that the  
AGS unit is turned off when the coach is in motion.  
This may be done by removing power from the AGS  
Controller. To accomplish this the AGS Controller  
should be interlocked with the ignition switch to  
control the POSITIVE POWER (#5) or with the parking  
brake to disconnect POWER/SENSE NEGATIVE (#13).  
DC CONNECTIONS  
16 pin Connector  
RESERVED(FOR IGN. LOCK-OUT)  
GEN HOUR METER  
STOP  
POSITIVE POWER (+)  
THERMOSTAT 1  
THERMOSTAT 2  
PREHEAT  
START  
8
7
6
5
4
3
2
1
9
16 15 14 13 12 11 10  
PREHEAT  
START COMMON  
THERMOSTAT 2 COMMON  
THERMOSTAT 1, 3 COMMON  
NEGATIVE POWER/SENSE(-)  
STOP COMMON  
THERMOSTAT 3  
BATT SENSE POSITIVE(+)  
Connector view is looking into the AGS CONTROLLER.  
All wires should be #18 AWG  
MATING CONNECTORS:  
Xantrex P/N 76-0090-01 (mating connector and harness) is  
recommended for easy installation.  
Note: Connector below matches both AMP and MOLEX  
connectors, but pin numbers only match AMP connector.  
AMP: 770583-1, PINS 770988-1  
10  
 
AGS REMOTE PANEL  
AGS CONTROLLER  
DATA CABLE  
4 CONDUCTOR  
SUPPLIED  
11  
 
COMMON QUESTIONS  
Why is the display blank except for the mode lights?  
If buttons are not pressed within five seconds, the Remote Panel  
goes into a sleep mode to conserve energy.  
Why is action not immediate?  
The Remote Panel waits 15 seconds to determine if any more  
changes are to be made. At the end of this period, the display  
goes to sleep and actions previously entered take effect.  
When the On/OFF is moved to OFF position, the generator  
does not stop immediately.  
The action from the buttons on the Remote Panel is delayed to  
ensure that action is required.  
How long is the delay from request for thermostat request to  
generator start?  
The time delay is 60 seconds.  
What is the low battery set point and how long does the  
battery voltage have to stay there to initiate a generator start?  
The Low Battery set point is around 11.5 VDC. The battery voltage  
must stay at or below 11.5 volts for approximately 15 seconds  
before the AGS will start the generator.  
PARAMETER VALUES  
Low battery voltage set point  
Run time for generator  
11.5 VDC  
2 hours  
4 hours  
3 times  
Maximum generator run time  
Number of generator start tries  
12  
 
TROUBLESHOOTING GUIDE  
The following is a list of troubleshooting items. Please see  
page #8 for the installation diagram. A qualified service technician  
should be contacted to service your system. Refer to the installation  
diagram for more information.  
PROBLEM  
SOLUTION  
No lights on the AGS  
Remote are on  
Check data cable connected to  
AGS Remote Panel and AGS  
Control Module. Check for 12 VDC  
at AGS Controller (wires #5 and  
#13).  
Generator automatically  
comes on but does not stay  
on.  
Verify that the Generator Hour  
Meter Signal (wire #3) is connected  
to the AGS Control Module.  
Generator turns on when  
batteries are charged and  
air conditioner/heaters are  
off.  
Verify Battery Sense Positive (wire  
#12) connection.  
Generator does not  
automatically turn on when  
AGS control attempts to  
turn on.  
Check the preheat, if required  
(wires #8 and #16) and start signal  
connections (wires #1 and #9).  
Generator does not  
automatically turn OFF  
after the AGS system runs  
the generator for two  
hours.  
If the battery voltage did not rise  
above 13.5 VDC, this is normal  
operations. Otherwise check the  
stop signal connections (wire #2  
and #10).  
AGS System starts  
generator at too high of a  
DC voltage.  
Verify quality of Power/Sense  
negative connection (wire #13).  
13  
 
GLOSSARY  
AGS (Automatic Generator Start Control System) A control system to  
automatically start the auxiliary generator in response to a low battery  
and/or cooling/heating demand.  
AGS Controller The part of the AGS Control System that connects to the  
wiring of the coach. It contains a micro-controller and a real-time clock.  
AGS Remote Panel The user interface part of the Automatic Generator  
Start Control System. It connects to the Control Module through the data  
cable.  
AUTO MODE In this mode the AGS will automatically start the generator  
as required by a low battery or a requirement for heating/cooling.  
AUTO QUIET MODE In this mode is the same as AUTO mode, except  
the AGS will not start the generator during quiet hours.  
Battery Sense This is the input to the AGS control module used to  
determine if the battery is low. This battery sense voltage may or may not  
be the same battery supplying the power to the AGS control module.  
Data cable A six-pin telephone-style cable used to carry power and data  
between the Remote and the Control Module.  
Ground The reference potential of a circuit. In automotive use, the result  
of attaching one battery cable to the body or frame which is used as a  
path for completing a circuit in lieu of a direct wire from a component.  
Negative Designating or pertaining to a lower electrical potential.  
Positive Designating or pertaining to electrical potential; opposite of  
negative. The positive battery terminal.  
QUIET TIME The period of time that the AGS is prohibited from starting  
the auxiliary generator regardless of battery condition or demands for  
heating/cooling. The AGS is in this mode when the QUIET TIME light is  
blinking.  
Thermostat The heat/cooling thermostat.  
Volt Short for voltage, the unit of measure for electric potential.  
VDC Direct current voltage.  
14  
 
LIMITED WARRANTY  
What does this warranty cover?  
This Limited Warranty is provided by Xantrex Technology, Inc. (“Xantrex”) and covers  
defects in workmanship and materials in the Automatic Generator Start Control System.  
This warranty lasts for a Warranty Period of 12 months from the date of purchase at point of  
sale to you, the original end user customer.  
This Limited Warranty is transferable to subsequent owners but only for the unexpired  
portion of the Warranty Period.  
What will Xantrex do?  
Xantrex will, at its option, repair or replace the defective product free of charge, provided  
that you notify Xantrex of the product defect within the Warranty Period, and provided that  
Xantrex through inspection establishes the existence of such a defect and that it is covered by  
this Limited Warranty.  
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair  
and building replacement products. Xantrex reserves the right to use parts or products of  
original or improved design in the repair or replacement. If Xantrex repairs or replaces a  
product, its warranty continues for the remaining portion of the original Warranty Period or  
90 days from the date of the return shipment to the customer, whichever is greater. All  
replaced products and all parts removed from repaired products become the property of  
Xantrex.  
Xantrex covers both parts and labor necessary to repair the product, and return shipment  
to the customer via a Xantrex-selected non-expedited surface freight within the contiguous  
United States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer  
Service for details on freight policy for return shipments outside of the contiguous United  
States and Canada.  
How do you get service?  
If your product requires troubleshooting or warranty service, contact your merchant. If you  
are unable to contact your merchant, or the merchant is unable to provide service, contact  
Xantrex directly at:  
Phone: 1-800-670-0707 (toll free in North America), 1-604-422-2777 (direct)  
Fax: 1-604-420-2145  
Direct returns may be performed according to the Xantrex Return Material Authorization  
Policy described in your product manual. For some products, Xantrex maintains a network  
of regional Authorized Service Centers. Call Xantrex or check our Web site to see if your  
product can be repaired at one of these facilities.  
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  
from Xantrex.  
Proof of purchase may be in any one of the following forms:  
The dated purchase receipt from the original purchase of the product at point of sale  
to the end user, or  
The dated dealer invoice or purchase receipt showing original equipment  
manufacturer (OEM) status, or  
The dated invoice or purchase receipt showing the product exchanged under  
warranty  
15  
 
LIMITED WARRANTY  
What does this warranty not cover?  
This Limited Warranty does not cover normal wear and tear of the product or costs related  
to the removal, installation, or troubleshooting of the customer’s electrical systems. This  
warranty does not apply to and Xantrex will not be responsible for any defect in or damage  
to:  
a) the product if it has been misused, neglected, improperly installed, physically  
damaged or altered, either internally or externally, or damaged from improper use or  
use in an unsuitable environment;  
b) the product if it has been subjected to fire, water, generalized corrosion, biological  
infestations, or input voltage that creates operating conditions beyond the maximum  
or minimum limits listed in the Xantrex product specifications including high input  
voltage from generators and lightning strikes;  
c) the product if repairs have been done to it other than by Xantrex or its authorized  
service centers (hereafter “ASCs”);  
d) the product if it is used as a component part of a product expressly warranted by  
another manufacturer;  
e) the product if its original identification (trademark, serial number) markings have been  
defaced, altered, or removed.  
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), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR  
CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR  
PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A  
PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO  
APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD  
STIPULATED UNDER THIS LIMITED WARRANTY.  
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT,  
INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES  
HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT  
RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO  
PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR  
AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION,  
INTEGRATION OR OPERATION OF THE PRODUCT.  
Exclusions  
If this product is a consumer product, federal law does not allow an exclusion of implied  
warranties. To the extent you are entitled to implied warranties under federal law, to the  
extent permitted by applicable law they are limited to the duration of this Limited Warranty.  
16  
 
LIMITED WARRANTY  
Some states and provinces do not allow limitations or exclusions on implied warranties or  
on the duration of an implied warranty or on the limitation or exclusion of incidental or  
consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.  
This Limited Warranty gives you specific legal rights. You may have other rights which  
may vary from state to state or province to province.  
Warning: Limitations On Use  
Please refer to your product user manual for limitations on uses of the product.  
Specifically, please note that the Automatic Generator Start Control System (AGS) is not  
intended for use in connection with life support systems, and Xantrex makes no warranty  
or representation in connection with any use of the product for such purposes.  
Return Material Authorization Policy  
Before returning a product directly to Xantrex you must obtain a Return Material  
Authorization (RMA) number and the correct factory “Ship To” address. Products must also  
be shipped prepaid. Product shipments will be refused and returned at your expense if  
they are unauthorized, returned without an RMA number clearly marked on the outside of  
the shipping box, if they are shipped collect, or if they are shipped to the wrong location.  
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  
17  
 
LIMITED WARRANTY  
Return Procedure  
1. Package the unit safely, preferably using the original box and packing materials.  
Please ensure that your product is shipped fully insured in the original packaging or  
equivalent. This warranty will not apply where the product is damaged due to  
improper packaging.  
2. Include the following:  
The RMA number supplied by Xantrex Technology Inc clearly marked on the outside  
of the box.  
A return address where the unit can be shipped. Post office boxes are not  
acceptable.  
A contact telephone number where you can be reached during work hours  
A brief description of the problem  
3. Ship the unit prepaid to the address provided by your Xantrex  
customer service representative.  
If you are returning a product from outside of the USA or Canada  
In addition to the above, you MUST include return freight funds and are fully responsible  
for all documents, duties, tariffs, and deposits.  
If you are returning a product to a Xantrex Authorized Service  
Center (ASC)  
A Xantrex return material authorization (RMA) number is not required. However, you must  
contact the ASC prior to returning the product or presenting the unit to verify any return  
procedures that may apply to that particular facility.  
18  
 
SPECIFICATIONS  
XANTREX PART NUMBERS  
AGS System............................................................ 84-2064-00  
includes Remote Panel, Controller, and 50' data cable (4/6 conduc-  
tor)  
INSTALLATION  
Mating Connector ...................................... AMP 770583-1  
Mating Pins (16) ......................................... AMP 770988-1  
Crimping Tool ............................................. AMP 90759-1  
The Xantrex AGS Harness (P/N 76-0090-01) includes these  
three items.  
MECHANICAL  
Controller Size: 6.57'' (W) X 4.25'' (H) X 1.875'' (D)  
Remote Panel Size: 5.75'' (W) X 3.75'' (H) X 0.93'' (D)  
Remote Panel Cutout size: 4.875'' (W) X 2.875'' (H)  
Weight: Controller.................................................. 1 lb. 12 oz.  
Remote Panel........................................ 3 oz.  
ELECTRICAL  
Inputs:  
Supply voltage.................................................. 9–15.5 VDC  
Supply current .................................................. 125 mA DC  
2 Thermostats DC  
Battery sense.................................................... 9–15.5 VDC  
Control Module Outputs:  
2 wire Preheat/ Start/ Stop Lines  
Remote Port Data cable (proprietary data)  
ENVIRONMENTAL  
Operating temperature range ................... 0–70 °C  
AGS Remote ............................................... Splash proof  
19  
 
Xantrex Technology Inc.  
Toll free 1 800 670 0707  
Direct 1 604 422 2777  
Fax 1 604 420 2145  
www.xantrex.com  
445-0190-01-01 Rev. 1  
Printed in the U.S.A.  
 

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