Generac/Guardian Residential Standby Generators

Procedure to Enable 2-Wire Remote Start

Document Number: BGS-GRC-RS-1

Date: 15 Mar 2010
Revision: F

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 Revision History
Revision Date Description
Original 22-Dec-09
A 18-Jan-10 Corrected part numbers for insertable pins for J2
1. Added detailed instructions and photos for programming the Control Module
B 12-Feb-10
2. Added instructions for interface to Xantrex, Outback and Magnum Inverters
1. Corrected reference for control module connector from J7 to J2
2. Corrected interface to current Magnum AGS: removed run signal relay
C 24-Feb-10 3. Added interface to new Magnum AGS module
4. Added current limit for Outback Inverter AUX terminals
5. Added programming note for Xantrex SW series inverters
1. Changed additional references for J7 to J2
D 1-Mar-10 2. Changed generator run signal source for Magnum AGS modules
3. Deleted reference to hour meter for Magnum AGS interface
1. Deleted incorrect reference to J7
E 9-Mar-10
2. Added scroll instructions for access to Remote Start function
1. Corrected password to access Remote Start menu
F 15-Mar-10
2. Deleted reference to J7 in TOC

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 Table of Contents

Section Title Page

1 Re-program Control Module and Install Start Control Wires 4
2 Test the Modification 10
3 Connecting the Generator to External Switch or Relay Contacts 13
4 Connection to Specific Inverters 14
5 Reassemble the Control Module Compartment 19
6 What Happens if the Battery Dies or is Disconnected? 19

List of Figures

Figure Title Page

1 Generator Control Panel with Digital Display 4
2 Removing the Access Panel 7
3 Removing the Control Module 7
4 Connector J2 Location 8
5 Inserting New Wires into J2 9
6 J2 Reconnected 9
7 Location of Wires N1 and N2 10
8 Connecting Wires to N1 and N2 13
9 Using an External Switch 13
10 Using an External Relay 13
11 Interface to Xantrex SW Series Inverter 14
12 XW-AGS and Generator Interface Connector 15
13 Generator Interface Connector 15
14 Connecting Generator to Xantrex XW-AGS Connector 15
15 Connections to Outback Inverter 16
16 Connections to Magnum ME-AGS-S Module 17
17 Connections to Magnum ME-AGS-N Module 18

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 Procedure to Enable 2-Wire Start in Generac/Guardian 10kW-20kW Generators

Generac/Guardian residential standby generators in the 10kW to 20kW range may be configured for
remote, 2-wire start. Once configured, only a simple contact closure is required to start the generator.
The generator will continue to run until the contact is opened.

When operating in the Remote Start mode, the following operational changes occur.

a. The generator will not seek or respond to utility power input.

b. The generator will not send signals to or operate a transfer switch.

This operational mode is useful in off-grid applications, where the alternate energy system (solar, hydro,
wind), supplies a dry contact closure that can be used to start the generator. Once started, the generator's
internal electronics controls all generator functions, eliminating the need for additional external
hardware to control the generator.

The procedure listed below can be used to configure the generator for 2-wire start, however, one must be
aware of certain caveats.

a. Generac does not offer warranty support for standby generator products, if they are used in
an off-grid application, where no utility power is available.

b. Once the generator starts, it will continue to run until commanded to stop. The start and stop
commands can be manual (a simple external switch) or automatic from, for example, a DC to AC
inverter, used in many off-grid alternate energy installations.

NOTE: Currently, this procedure applies only to those Generac products using full digital control. The
control panel must have the digital display, as shown in Figure 1.

1.0 Re-Program Control Module and install Start Control Wires

a. Set AUTO-OFF-MANUAL switch to OFF. The display should indicate SWITCHED TO OFF and
show the current date and time, as shown below.

Figure 1: Generator Control Panel with Digital Display

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b. Enter the "password" to access the Remote Start function. The password is entered by pressing
buttons on the control panel in a specific order, as described below. Shown above each button is
the screen display that will result when the button is pressed.

Note: When you open the menu screen, the active function will flash. For example, if you select
History, the word will flash; it is not underlined.

The password has now been entered and you can access the Remote Start function, as
described below. Press the buttons in the order shown below until the word Edit begins to
flash.

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c. Press and a menu will appear, however, it may not be the Remote Start menu.

Press the or keys until the Remote Start Menu appears, as shown below.

Press to select the menu. If the screen shows YES, the

control module is already programmed for remote start.

If the screen shows NO, press and change the screen to

read YES then press Remote start is mow enabled.

d. Press the keys shown below to exit the menu screens.

e. Adding Wires to The Control Module Connector - J2

NOTE: The generator requires a "dry" contact closure, that is to say, neither contact may have a
voltage or ground on it.

(1) Disconnect the black wire from the NEGATIVE battery terminal.

(2) Remove the cover from the control panel area, as shown in Figure 2.

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 Remove 2 screws
(Torx T25)

Remove bolt
(10mm)

Figure 2: Removing the Access Panel

(3) Remove the four screws securing the control module and carefully lift out the module,
as shown in Figure 3.

Remove 4 screws
and lock washers

Figure 3: Removing the Control Module

(4) Carefully turn over the module to access the connectors on the rear panel and locate
connector J2 (the large rectangular connector with 18 pins - 9 in each row), as shown in
Figure 4.

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 Pin 18 Pin 17

Connector J2

Figure 4: Connector J2 Location

(5) The space for pins 17 and 18 should be blank; no wires and no pins. Pin 17 will have
5VDC on it and pin 18 is ground.

(6) You must install a wire with a crimped socket terminal into the spaces for pins 17 and 18.
There are two options.

(a) Call or email Generac and they will send you two 12" wires with the proper pins
already attached. Contact information is listed below.

POC: Bob Cramer

Tel: 888-436-3722, ext. 8045
email: [email protected]

(b) Crimp a socket terminal to each of two wires that will be used to connect to the
remote start switch or relay. The wires should be about 12" long. The wire size
should be at least AWG22. The part numbers for the pins and crimping tool are
shown below.

Pins: Waldom/Molex: 39-00-0039, Digi-Key WM2501

(www.digikey.com)
Crimping tool: Waldom/Molex: 63811-1000, Digi-key WM9999

(7) Carefully disconnect the plug from connector J2.

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(8) Insert the pins into the J2 connector, as shown in Figure 5. Note, they will only go in one
way. DO NOT force them into the housing; you can't get them out without a removal tool.

Pin 17

Pin 18

Figure 5: Inserting New Wires Into J2

(9) Carefully reconnect the plug to J2, taking care that the two new wires are not damaged.
Use ty-wraps to secure the new wires to the wiring harness. Refer to Figure 6.

Figure 6: J2 Reconnected

(10) The modification is complete; proceed to test.

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2. Test the Modification

Under normal operational conditions, 240VAC power from the utility is applied to wires N1
and N2, as shown in Figure 7.

Yellow wires are usually

connected to utility power

Figure 7: Location of Wires N1 and N2

When utility power is present, the Control Module senses it and applies a HI (5VDC) signal on
pin 17 of J2. The microcontroller interprets this as the presence of external utility power. When
utility power is lost, pin 17 of J2 goes LO (0VDC), which the micro-controller interprets as loss
of utility power and the generator start cycle begins. After a delay of 10 seconds, the generator
will start. After another short delay - to allow the generator to warm up and stabilize - a ground
signal will be sent to the transfer switch causing it to switch from utility power to generator power.
The dwelling is now operating on generator power.

When utility power is restored, pin 17 of J2 again goes HI (5VDC), which the micro-controller
interprets as the presence of utility power and the stop cycle begins. The ground signal to the
transfer switch is removed and it switches back to utility power. Simultaneously, the generator
begins a 2-minute cool down period, after which it stops. The dwelling is now operating again on
utility power.

In off-grid applications, there is no utility power, so we have re-programmed the Control Module
to respond to an external contact closure instead of the presence/absence of utility power. When in
the Remote Start mode, a HI (5VDC) is applied to pin 17 of J2, which the micro-controller
interprets as presence of utility power, even though no utility power is applied.

When a short (contact closure) is applied across the 2 wires just installed, pin 17 of J2 is brought
to 0VDC, which the micro-controller interprets as loss of utility power and begins the start cycle.
When the short is removed, the generator enters the stop cycle. In this mode, however, no control
signals are sent to the transfer switch.

When you set up the Control Module, you will see messages that allude to utility power. Ignore
these messages and proceed with the set up procedure.

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Use the following procedure to test the modification.

WARNING: 12VDC from the generator battery will be present in the

compartment. Use caution with tools!

a. Turn over the control module and reinstall it in its place with the four screws and
lock washers.

b. Reconnect the negative cable to the generator battery.

c. The display may indicate a few different messages, as shown below.

d. Press and the display will be: After a few seconds,

the display will show:

e. Press and the display will be:

f. Press and the time/date procedure will begin as follows.

Use the or buttons to set the hour.

g. Press and set minutes.

Use the or buttons to set minutes.

h. Press and set the month.

Use the or buttons to set the month.

i. Press and set the date.

Use the or buttons to set the date.

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j. Press and set the year.

Use the or buttons to set the year.

k. Press and the display will be:

l. Press and the display will be:

m. Set the AUTO-OFF-MANUAL switch on the Control Module to AUTO.

n. Connect the ends of the two new wires together. The display will be:

The seconds will begin counting down to zero. At zero, the

generator will start. When it starts, the display will be:

OR

o. Allow the generator to run for about 30 seconds, then disconnect the two wires. The display
will be:

p. After approximately 2 minutes, the generator will stop and the display will be:

r. The test is complete. Proceed to external connections.

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3. Connecting the Generator to the External Switch or Relay Contacts

The simplest method to connect an external control is to use the yellow wires connected to N1 and
N2. These wires usually go to a junction box apart from the generator.

Refer to Figure 8 for some suggestions.

Utility Sense Yellow Wires removed

Terminal Board from Terminal Board

QD
Terminals

Figure 8: Connecting to Wires N1 and N2

In this example, the yellow wires have been disconnected from the utility sense terminal board.
A quick disconnect (QD) 0.25" terminal has been installed (crimped) onto each wire. Similarly,
QD terminals have been attached to the two wires coming from pins 17 and 18 of J7. Simply
connect the QD terminals and you have a connection to the Control Module, to which an
external switch or relay can be connected.

Figure 9 shows connection to a simple switch. Figure 10 shows connection to a relay.

Figure 9: Using an External Switch Figure 10: Using an External Relay

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4. Connections to Specific Inverters

a. Xantrex Inverters

(1) SW Series (Older Models)

The SW series uses built-in relays to control a generator. The relay functions can be
programmed in the Control Unit on the front panel of the inverter.

Connect the remote start wires from the generator to the normally open (NO) and
common (C) contacts of relay RY7, as shown in Figure 11. Use 0.25" QD terminals.

Figure 11: Interface to Xantrex SW Series Inverter

Programming Note: Under Menu 13 (Gen Starting Details) set RY7 function to RUN,
not Glowstop.

(2) XW Series with XW-AGS (Automatic Generator Start) Module

All connections to the AGS are made via a connector and wiring harness, as shown
in Figures 12 and 13.

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 Figure 12: XW-AGS and Generator Interface Connector

Figure 13: Generator Interface Connector

Connect the XW-AGS to the generator as shown in Figure 14.

Figure 14: Connecting Generator to Xantrex XW-AGS Connector

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 Program the AGS parameters and use Relay 1 in the Type 14 configuration. Note that
in this configuration, the AGS will only start and stop the generator. All generator
functions are monitored and controlled by the generator's internal electronics.

Note: The XW-AGS must have software version 2.3 or higher to use Type 14
configuration.

b. Outback Power Systems Inverters

All current Outback inverters use the same generator start function. An auxiliary relay
provides +12VDC with respect to ground whenever the generator needs to start. Note that
this is not a "dry closure"; one connection has a DC voltage on it. For this reason, an
additional external relay must be used to provide the dry contact closure required
by the generator.

Generator connections to the auxiliary relay terminals on the inverter are shown in Figure
15.

Figure 15: Connections to Outback Inverter

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c. Magnum Inverters Using AGS (Automatic Generator Start) Module

Magnum offers two AGS modules.

(1) ME-AGS-S

This version is a stand-alone device and will start generator based on battery
voltage or ambient temperature. It does not take instructions from the inverter,
rather, it charges the batteries based on a user-set run time. It does not follow
the Bulk-Absorb-Float cycle, unless the cycle completes during the run time.

Connections for the ME-AGN-S are shown in Figure 16.

Figure 16: Connections to Magnum ME-AG-SS Module

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(2) ME-AGS-N

This version is fully networked, however, it will only work with the ME-ARC
remote control and the curent firmware version. Many generator start options are
available, e.g., voltage start, SOC start, temperature, start, etc., all of which can
be invoked via the ME-ARC remote control.

If you want to start the generator based on state-of-charge (SOC) you will also need
the ME-BMK Battery Monitoring Kit.

Connections for the ME-AGS-N are shown in Figure 17.

Figure 17: Connections to Magnum ME-AGS-N Module

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5. Reassemble the Control Module Compartment

a. Replace the cover over the control panel area.

b. Place the AUTO-OFF-MANUAL switch to AUTO.

c. The generator is now ready to be controlled by a 2-wire remote start.

6. What Happens if the Generator Battery Dies or is Disconnected?

The Control Module will retain the last settings; it should not be necessary to invoke Remote
Start again.

Prepared by:

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