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

©2001 Xantrex Technology Inc. 5
1.0 INTRODUCTION
Figure 4
Internal Components
F1 protects
relay R 7 F2 protects
relay R 8
F3 protects
relay R 11
GROUNDING
screw
Terminal
Block
Communication
jack J1
Internal Components (continued)

©2001 Xantrex Technology Inc.
The SM should be mounted close to the generator in a location where it
is easily accessible. Knockouts, 3/4 and 1 inch, are provided for cable routing
and conduit connections. Mount the SM to a flat, vertical surface, such as
awall.
Tools Required
screwdrivers (Phillips and flat blade)
wood screws (#10)
anchors (if required)
drill and assorted bits
wire strippers
WARNING: before making any onne tions to the generator or
inverter, ensure that all inverter power is dis onne ted and the
generator starter isdisabled.
Pre-Installation
Before installing the SM, read all instructions and cautionary markings
located in this manual. The unit should be mounted in a clean, dry, protected
environment.
Determine the wire route (or conduit runs) to the SM, generator, inverter
and error indicator (if used).
NOTE Check for existing electrical, plumbing, or other potential
areas of accidental damage prior to making cuts in structural
surfaces.
Mounting Procedure
 Remove the two Phillips screws from the units front panel and remove the
cover.
 Open the inverters access panel and locate the EN connector if
necessary. Refer to the inverter operators manual for the location of the
connector.
 Hold the SM against the surface to be mounted and use the unit as a
template to mark the four hole locations.
NOTE Six holes are provided in the back panel of the GSM.
Use the two top and two bottom screw holes.
 Drill holes for mounting and insert appropriate anchors if necessary.
 Use four #10 wood screws to mount the unit to the wall or other vertical
surface.
 Install conduit runs if necessary for the generator control wires, error
indicator (if used), and communication cable (between the inverter and
SM).
2.0 INSTALLATION

©2001 Xantrex Technology Inc. 7
2.0 INSTALLATION
6-9/64 4-27/32
19/32
3-11/16
4-7/8
19/32
J1
SW1
SW2
975-0008-002
1-13/64
Figure 5
Dimensional Drawing
Mounting Procedure (continued)

8©2001 Xantrex Technology Inc.
2.0 INSTALLATION
Figure 6
Mounting Holes
Mounting Holes Mounting Holes
Mounting Procedure (continued)

©2001 Xantrex Technology Inc. 9
2.0 INSTALLATION
Figure 7
Terminal Blo k Conne tions
Generator Wiring
Connect the generator auto-start wires to RY7 for the RUN/ LOWSTOP
functions and RY8 (if used) for the START circuit.
To onne t the generator wires to the terminal blo k
 Lift the appropriate lever for the relay contact.
 Insert the wire (stripped back 1/4 inch) into the terminal block.
 Snap the lever down to secure the wire.
Please refer to the generator section of the inverters operation manual
for additional information.
NOTE Due to the various wiring schemes used by different
manufacturers, detailed wiring instructions can not be given in this
manual. Please refer to the generator manufacturers documentation
for wiring details.
CAUTION: DO NOT WIRE THE RELAYS DIRECTLY TO A HIGH-
AMPERAGE DEVICE, SUCH AS A STARTER MOTOR. THESE
RELAYS ARE DESIGNED TO INTERFACE WITH THE
GENERATORS AUTO-START CIRCUIT (LOW-CURRENT SIG-
NALS) ONLY. CONNECTION TO A HIGH-CURRENT DEVICE WILL
OPEN THE FUSE IN THE COMMON LINE AND Possibly DAMAGE
THE RELAY.
NOTE All wiring described in this manual must be performed by a
qualified, licensed electrician and meet local and national codes,
such as NEC.
RELAY 7
Connections
RELAY 8
Connections
RELAY 11
Connections

10 ©2001 Xantrex Technology Inc.
Generator Wiring (continued)
Two-Wire Start Cir uits
Two-wire starting generators are the easiest to control and are highly
recommended for this type of application. A contact closure starts the
generator, while an open contact stops the generator.
 Connect the two wires from the generators remote, auto-start, control
circuit to the RY7, N.O. and COM terminals.
 Select RUN from the SWRCs SET RY7 FUNCTION menu item (found
under the GEN STARTING DETAILS (13) menu heading).
COM N.O.
N.C.
GEN START MODULE
RY7
REMOTE START/
STOP
TERMINALS
INTERNAL
FUSE
2-WIRE START TYPE
GENERATOR
To Inverter’s
GEN Connector
Figure 8
2-Wire Start Conne tions
2.0 INSTALLATION

©2001 Xantrex Technology Inc. 11
Generator Wiring (continued)
Wiring Honda-Type Generators
In this starting configuration, relay RY7 duplicates the RUN position and
RY8 duplicates the START position, cranking the starter motor.
 Connect the COM contact of RY7 to one of the RUN/STOP switch contacts
of the generator.
 Connect the N.O. contact of RY7 to the other RUN/STOP switch contact of
the generator.
 Connect the COM contact of RY8 to one of the START switch contacts of
the generator.
 Connect the N.O. contact of RY8 to the other START switch contact of the
generator.
 Select RUN from the SWRCs SET RY7 FUNCTION menu item (found
under the GEN STARTING DETAILS (13) menu heading).
GEN START MODULE
RY7 RUN/STOP
SWITCH
CONTACTS
HONDA 3-WIRE TYPE GENERATOR
3597-B00-D29
To Inverter’s
GEN Connector
COM N.O.
N.C.
RY8
COM N.O.
N.C.
START
SWITCH
CONTACTS
INTERNAL
FUSE
INTERNAL
FUSE
2.0 INSTALLATION
Figure 9
Honda-Type Conne tions

12 ©2001 Xantrex Technology Inc.
Generator Wiring (continued)
Wiring Onan-Type Generators
In this system, RY8 duplicates the START position and relay RY7
duplicates the STOP position. Some generators use a similar system with
two push-button switches, one to start and one to stop the generator.
 Connect the COM contact of RY7 to one of the STOP switch contacts of
the generator.
 Connect the COM contact of RY7 to the COM contact of RY8.
 Connect the N.O. contact of RY7 to the other STOP switch contact of
thegenerator.
 Connect the N.O. terminal of RY8 to the START switch contact.
 Select GLOWSTOP from the SWRCs SET RY7 FUNCTION menu item
(found under the GEN STARTING DETAILS (13) menu heading).
GEN START MODULE
RY7
STOP SWITCH
CONTACTS
ONAN 3-WIRE TYPE GENERATOR
To Inverter’s
GEN Connector
COM N.O.
N.C.
RY8
COM N.O.
N.C.
START
SWITCH
CONTACTS
INTERNAL
FUSE
INTERNAL
FUSE
2.0 INSTALLATION
Figure 10
Onan-Type Start Conne tions

©2001 Xantrex Technology Inc. 13
Error Indicator Wiring
If an error indicator is used (light, buzzer, bell, etc.), connect the wires to
the RY11 relay contacts. Depending on the error indicator used, either the
N.O. or N.C. contacts can be used. Typically, the N.C. and COM contacts are
used to complete a circuit, turning on a light, buzzer, etc. The N.C. contacts
are held open until an error condition is detected (or the AC output is OFF);
at which time the N.C. contact will close completing the circuit and activating
the external device.
N.O.
N.C.
COM
EXTERNAL
INDICATOR
POWER SOURCE
975-0008-001
NO SIGNAL FROM
INVERTER
(relay disengaged) External Error
Indicator
External Alarm
OFF Switch
Fuse
CONTROL SIGNAL
FROM INVERTER
(relay engaged)
N.O.
N.C.
COM
975-0008-001A
External Error
Indicator
External Alarm
OFF Switch
Fuse
EXTERNAL
INDICATOR
POWER SOURCE
2.0 INSTALLATION
Figure 11
External Error Indi ator Conne tions
N.O.
N.C.
COM
975-0008-001B
CONTROL SIGNAL
FROM INVERTER
(relay engaged) External Error
Indicator
External Alarm
OFF Switch
Fuse
EXTERNAL
INDICATOR
POWER SOURCE
For convenience, add an external OFF switch in line with the alarm
device. This allows turning off the alarm until the inverters output is restored.
NOTE The diagrams shown here are intended as an example of
how the relays operate an external alarm device. Actual alarm types
may operate differently from these diagrams. Refer to the owners
manual for specific alarm wiring. Do not exceed the voltage or
amperage ratings of the relay and fuse.
Figure 12
External Alarm OFF Swit h

14 ©2001 Xantrex Technology Inc.
Communication Cable
The SM is supplied with a 25-foot, telephone-type, cable with RJ11
connectors on each end.
NOTE Longer cable lengths are available from Xantrex part
Numbers TC/50 for 50 feet (15.24 m) and TC/100 for 100 feet (30.48
m).
 Route the telephone-type cable through one of the knockouts fitted with a
strain relief (or conduit).
 Connect one end of the cable to the jack labeled J1 on the SM
circuitboard.
 Connect the other end of the cable to the jack labeled EN inside the
inverter (refer to the inverter/chargers operators manual for location).
 Reinstall the cover on the SM using the two Phillips screws.
 Reinstall the inverters cover.
NOTE Recheck all wiring before proceeding to the OPERATION
section.
2.0 INSTALLATION
Figure 13
J1 Control Signal Conne tion
J1 Connector
Communication
cable to inverter