Xantrex GSM - REV A User manual

Installation and Operation Guide
GSM
Generator Start Module
ã2001 Xantrex Technology Inc. P/N 975-0008-01-02 Rev. A 01/01


©2001 Xantrex Technology Inc. i
GSMGenerator Start Module
Table of Contents
1.0 INTRODUCTION ................................................................. 1
Unpacking and Inspection ............................................................................. 1
Controls and Indicators ................................................................................. 2
Indicator LEDs ....................................................................................... 2
ENERATOR RUN/ LOWSTOP RELAY 7 LED ......................... 2
ENERATOR START RELAY 8 LED ........................................... 2
INVERTER OPERATIONAL LED ................................................. 2
Switches ................................................................................................ 3
ENERATOR START Switch ....................................................... 3
INVERTER ERROR Switch .......................................................... 3
Internal Components ..................................................................................... 4
Relays .................................................................................................... 4
Relay Terminal Block ............................................................................. 4
round Stud .......................................................................................... 4
Fuses ..................................................................................................... 4
2.0 INSTALLATION ...................................................................
Tools Required ............................................................................................... 6
Pre-Installation .............................................................................................. 6
Mounting Procedure ...................................................................................... 6
enerator Wiring ........................................................................................... 9
To connect the generator wires to the terminal block ........................... 9
Two-Wire Start Circuits ....................................................................... 10
Wiring Honda-Type enerators .......................................................... 11
Wiring Onan-Type enerators ............................................................ 12
Error Indicator Wiring .................................................................................. 13
Communication Cable ................................................................................. 14
3.0 OPERATION ...................................................................... 15
Operation and Test ...................................................................................... 15
Internal Sticker .................................................................................... 16
Danger Label ....................................................................................... 16
4.0 TROUBLESHOOTING ...................................................... 17
5.0 SERVICE INFORMATION .................................................. 18
.0 WARRANTY ...................................................................... 19
7.0 SPECIFICATIONS.............................................................. 20

ii ©2001 Xantrex Technology Inc.
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety instructions that should be followed
during the installation and maintenance of this product.
To reduce the risk of electrical shock, and to ensure the safe installation
and operation of this product, the following safety symbols have been placed
throughout this manual to indicate dangerous conditions and important safety
instructions.
WARNING - A dangerous voltage or condition exists in this area.
Use extreme caution when performing these tasks.
AVERTISSEMENT - Une tension ou condition dangereuse existe
dans cette zone. Faire preuve dextrême prudence lors de la
réalisation de ces tâches.
CAUTION - This procedure is critical to the safe installation or
operation of the unit. Follow these instructions closely.
ATTENTION - Cette procédure est essentielle à linstallation ou
lutilisation de lunité en toute sécurité. Suivre ces instructions
deprès.
NOTE - This statement is important. Follow instructions closely.
NOTE - Cette déclaration est importante. Suivre les instructions
deprès.
 All electrical work must be done in accordance with local, national,
and/or international electrical codes.
 Before installing or using this device, read all instructions and cautionary
markings located in the manual and on the generator.
 Do not expose this unit to rain, snow or liquids of any type. This product is
designed only for indoor mounting.
 To reduce the chance of short-circuits, use insulated tools when installing
or working with this product, the inverter, the batteries or generator.
 Remove all jewelry such as rings, bracelets, necklaces, etc., while installing
the SM. This will greatly reduce the chance of accidental exposure to live
circuits.
 The inverter contains more than one live circuit (batteries, PV array, AC
line, etc.). Power may be present at more than one source.
 To reduce risk of electric shock, disconnect all wiring before attempting any
maintenance or cleaning. Turning off the device may not reduce this risk.
 Disable the generators starting circuit by disconnecting the starter battery,
spark plug, etc., before wiring this device.
SAVE THESE INSTRUCTIONS

©2001 Xantrex Technology Inc. iii
Disclaimer of Liability
Since the use of this manual and the conditions or methods of installation,
operation, use and maintenance of the unit are beyond the control of Xantrex
Technology Inc., the company does not assume responsibility and expressly
disclaims liability for loss, damage, or expense arising out of or any way
connected with such installation, operation, use, or maintenance.

iv ©2001 Xantrex Technology Inc.
NOTE Due to continual improvement through product updates,
photographs and/or illustrations used in this manual may not exactly
match your unit. Xantrex Technology Inc., reserves the right to
update this product without notice or releasing an updated manual
when fit, form or function are not affected.

©2001 Xantrex Technology Inc. 1
The SM ( enerator Start Module) is an accessory for selected Trace
inverter/charger models allowing automatic generator control and inverter error
indication when using the optional SWRC remote control. The unit contains
three relays providing normally open (N.O.), normally closed (N.C.) and
common (COM) contacts. Relays RY7 and RY8 are used for generator
control. Relay RY11 is used to indicate an error condition (via an external
indicator) whenever the inverters output is shutdown. This could be a bell,
buzzer, light, etc.
The unit interfaces the inverter (via a phone type cable) to an auto-start/
stop generator. Commands from the inverter control the generator when
defined parameters (programmed via the SWRC or SWCA for PS Series
models) are met. Refer to the inverter operators manual for setting the
various parameters for generator operation.
Front panel LEDs provide a visual display of relay activity whenever a
relay contact receives an engage command from the inverter. A highly visible
blue LED indicates the inverter is operational.
Unpacking and Inspection
Carefully inspect the contents of the shipping carton for damages. Report
any damages to the carrier immediately.
The following items are packed with the SM:
 enerator Start Module unit ( SM)
 25-foot cable
 Operators manual
 enerator Danger Label
Report any missing items to Xantrex Technology Inc., immediately.
Figure 1
Generator Start Module (GSM)
1.0 INTRODUCTION

2©2001 Xantrex Technology Inc.
1.0 INTRODUCTION
Controls and Indicators
Indi ator LEDs
Three LEDs located on the front panel of the SM indicate the relay
control signal status from the inverter.
NOTE The LEDs are unaffected by the GSMs switch positions or
fuse condition.
GENERATOR RUN/GLOWSTOP RELAY 7 LED
The yellow LED indicates relay RY7 is receiving a control signal to
engage the relay and RUN the generator or provide a LOWSTOP signal
(for diesel generators). The LED turns ON when the relays COM and N.O.
contacts engage. The function of this relay is dependent on the selection
made (using the SWRC) as to whether it is used to RUN the generator or
provide LOWSTOP control.
GENERATOR START RELAY 8 LED
The green LED indicates relay RY8 is receiving a START signal from the
inverter. The LED turns ON when the relays COM and N.O. contacts
engage.
INVERTER OPERATIONAL LED
The blue LED indicates the inverters operational status. If the inverter is
powered and ready for operation, the blue SYSTEM OPERATIONAL LED
turns ON as soon as the phone-type cable is plugged into the inverter. If
the blue LED does not turn ON, the inverter is either not powered, is set to
the CH only mode without any utility pass-through, or has no AC output
which may be caused by an error condition.
Figure 2
Indi ator LEDs
ellow LED
RUN/GLOWSTOP
RELA 7
Green LED
GENERATOR START
RELA 8
Blue LED
INVERTER OPERATIONAL
OFF = INVERTER ERROR

©2001 Xantrex Technology Inc. 3
Controls and Indicators (continued)
Swit hes
Two switches are provided on the right side of the SM to effectively
disconnect the relay coils from the inverters supply voltage (11 VDC), thus
preventing the relays from engaging if a control signal is sent out from the
inverter. This is a safety feature which allows the generator to be serviced
without it unexpectedly starting due to an inverter EN-START command.
GENERATOR START Swit h
The ENERATOR START switch enables the relays by providing the
operating voltage to the relay coils RY7 and RY8. When the relays are
enabled, they will respond to the control signals provided by the inverter.
When the switch is in the RELAYS DISABLED position, the inverter control
signals have no effect on relay operation (i.e., the COM and N.C. contacts
engage). This switch does not affect the operation of the LEDs which
continue to light whenever the inverter sends a CLOSE CONTACT
command to therelays.
INVERTER ERROR Swit h
The INVERTER ERROR switch provides a simple way to test an
externally connected alarm. Once the alarm is tested, this switch should be
switched to the RELAY READY position.
Figure 3
Swit hes
1.0 INTRODUCTION
GENERATOR
Switch
(R 7 and R 8)
INVERTER ERROR
Switch (R 11)

4©2001 Xantrex Technology Inc.
Internal Components
The enerator Start Module ( SM) is designed to control generators
equipped with two- or three-wire, electronic, automatic start operation (not all
generators are supported) and provides the following features.
Relays
There are three 12 VDC relays, rated at 10 amps/250 VAC; 8 amps/
30VDC (forresistive loads), with gold contacts increasing the low-end
signalrange.
 Relay RY7 is used for generator RUN/ LOWSTOP functions.
 Relay RY8 is used for the generator START function.
 Relay RY11 can be connected to an external indicator device to display
or sound an alarm whenever the inverter AC output is lost.
 The normally open (N.O.) and normally closed (N.C.) contacts are
available to accommodate the various generator auto-start circuits.
Relay Terminal Blo k
Connections to the SM are accomplished by the nine position, spring
clamp, terminal block with quick connect levers. All relay contacts (N.O.,
COM and N.C.) are available at this connector, which accepts wire sizes
from #28 AW to #14 AW . No tools are required to secure the wires as
the spring clamp holds the wires securely in place.
Ground Stud
A ground screw is provided in the SM to provide a safety ground path
when hazardous voltages are connected to the relays. Connect this screw
to a grounded conductor whenever high voltages (i.e., above 90 volts) are
connected to the relays.
NOTE No hazardous voltages are supplied from the inverter to
power or control the relays; however, some generator control circuits
may use a high voltage in their starting/control circuits or 120 V
could be used for an external error indicator.
Fuses
Each relays common (COM) contact is protected with a 6.3 amp (5 mm
x 20 mm) 250 VAC fuse which will open if excess current is drawn through
the relay contacts. Always replace this fuse with the same type and rating.
Type DC (Bussman) or 218 (Littlefuse) is recommended.
NOTE These fuses can be replaced with lower amperage fuses to
also protect the connected circuitry, if desired. Refer to the
generators specifications for the correct size fuse. In no case,
should this fuse be replaced with one of a higher amperage.
1.0 INTRODUCTION