AutoGen Ultra User Manual

Coverage

Models Covered

AutoGen Ultra is built on the Unified controller hardware with the Ultra firmware profile. The installed communication variant determines how the controller reaches the AutoGen cloud.

AutoGen Ultra WiFi

Uses BLE for provisioning, WiFi station mode for cloud access, and local AP mode when WiFi credentials are missing, cloud access times out, or local access is requested.

AutoGen Ultra GSM/GPS

Uses a cellular modem for cloud access. GPS telemetry is available where the fitted hardware and signal conditions support it. APN setup is done through the BLE terminal.

Getting Started

Quick Start

1. Power Ultra

Apply controller power and wait for startup. The LED starts solid red during boot.

2. Configure connection

Provision WiFi credentials on Ultra WiFi, or set the APN on Ultra GSM/GPS.

3. Claim the device

Use the AutoGen Pro app to scan the QR code and add the device to the correct account.

4. Verify operation

Confirm online state, firmware version, voltage, run signal, temperature, runtime, and diagnostics.

Registration

Claiming AutoGen Ultra

Claiming links the Ultra controller to your AutoGen account. In the AutoGen Pro app, open the claim or QR scan workflow, scan the device QR code, give the unit a clear name, and confirm the claim.

Use clear names such as Ultra Workshop, Ultra GSM Yard, or Ultra WiFi Plant Room so the right controller is easy to identify later.

Connection

Connectivity

Ultra WiFi

Ultra WiFi stores WiFi credentials in the controller and connects as a WiFi station. After WiFi association succeeds, it opens the AutoGen cloud connection on port 3000, sends its device ID, synchronizes settings, publishes telemetry, and enters normal connected operation.

Provision from the app

Use the WiFi provisioning flow, or send a BLE JSON command with {"cmd":"wifi_config","ssid":"network","password":"password"}.

Provision from terminal

Use wifi ssid <ssid> and wifi pass <password>. Use wifi_status to check stored credentials, station state, cloud state, and AP state.

Ultra GSM/GPS

Ultra GSM/GPS uses the fitted cellular modem. Insert an active data SIM, connect over BLE, open the terminal, and set the APN before expecting cloud connectivity.

APN setup

Open the AutoGen Pro app and connect to the controller over BLE.
Open the BLE terminal.
Send apn set <your_apn>. Example: apn set cytamobile.
Send apn show to confirm the stored APN.
Use modemdiag for modem diagnostics on GSM builds.

Ultra GSM/GPS may take longer to return online after reboot or OTA because the modem must boot, register to the network, attach data, open the socket, and reconnect to the AutoGen cloud.

BLE

BLE Terminal

AutoGen Ultra advertises over BLE using an Ultra-specific device name. The BLE terminal is used for connection setup, local access, diagnostic checks, calibration, and service commands.

Connection and identity commands

wifi_status

Shows Ultra WiFi SSID status, password status, station connection, cloud connection, and local AP state. On GSM builds, reports that WiFi cloud status is only available in the WiFi build.

{"cmd":"wifi_config",...}

App JSON command for Ultra WiFi. Saves WiFi credentials using ssid and password.

{"cmd":"wifi_status"}

App JSON command that returns WiFi/cloud/AP status.

wifi ssid <ssid>

Ultra WiFi only. Saves the cloud WiFi SSID.

wifi pass <pass>

Ultra WiFi only. Saves the cloud WiFi password.

wifi

Starts local WiFi AP mode. Connect to AutoGen_Local with password 12345678, then open 192.168.4.1.

apn show

Ultra GSM/GPS only. Shows the stored cellular APN.

apn set <value>

Ultra GSM/GPS only. Saves a new cellular APN in flash. Example: apn set cytamobile.

modemdiag

Ultra GSM/GPS only. Temporarily runs modem diagnostics from BLE.

setid <id>

Sets and stores a device ID, then reloads it for verification.

id

Shows the current firmware version and loaded device ID.

Control and status commands

start

Requests a managed start over BLE. Start is blocked if the controller is service-locked or not ready.

stop

Requests a controlled stop over BLE and disables throttle control for that stop action.

reset

Power-cycles the controller with ESP.restart().

schedule or schedule status

Shows weekly schedule status, UTC offset, selected days, duration, and time-source state.

relay status

Shows start relay GPIO26, stop relay GPIO25, and aux relay GPIO27 output states.

relay test [ms]

Bench test only. Pulses start, stop, and aux relay one at a time. Duration is constrained from 100 to 5000 ms. Blocked while the controller is running, starting, or stopping.

canstat

Shows CAN valid-frame status, freshness, frame count, CAN battery voltage, and last-update age where CAN data is present.

Run-signal commands

runsig or runsig status

Shows selected run-signal mode, scale, threshold, raw value, display value, display floor, and detect yes/no state.

runsig ac

Selects AC run-signal mode and publishes the setting to the dashboard.

runsig dc

Selects DC run-signal mode and publishes the setting to the dashboard.

runsig scale <factor>

Saves the selected-mode run-signal scale manually.

runsig cal <actual-voltage>

Calibrates the selected run-signal mode from a known applied signal. Requires a valid pin voltage above the firmware threshold.

ac sense

Shows AC/run-signal ADC status and a snapshot of raw standby generator-signal readings.

ac sense on

Enables live standby generator-signal debug output.

ac sense off

Disables live standby generator-signal debug output.

adc scan

Prints a snapshot of ESP32 ADC pins 34, 35, 36, and 39.

io35 raw

Compares Arduino and ESP-IDF ADC reads on IO35.

Pressure, throttle, choke, and oil commands

pressure

Shows pressure-control status, ADC voltage, sensor voltage, pressure in bar, low/high band, and direction state.

pressure on

Enables pressure-based throttle control and saves the setting.

pressure off

Disables pressure-based throttle control, stops actuator movement, holds the throttle actuator, and saves the setting.

pressure set <low> <high>

Sets the pressure band in bar. Values must be finite, within 0 to 10 bar, and low must be lower than high. Example: pressure set 2.0 3.0.

pressure dir normal

Sets normal throttle direction for pressure control and saves the setting.

pressure dir reverse

Reverses throttle direction for pressure control and saves the setting.

throttle dir

Shows throttle actuator direction: normal or reverse.

throttle dir normal

Sets throttle actuator direction to normal and saves the setting.

throttle dir reverse

Sets throttle actuator direction to reverse and saves the setting.

choke dir

Shows choke actuator direction: normal or reverse.

choke dir normal

Sets choke actuator direction to normal and saves the setting.

choke dir reverse

Sets choke actuator direction to reverse and saves the setting.

oil sense

Shows whether oil sense is enabled, normal/reverse logic, and reported pressure value.

oil sense on

Enables oil-sense input for run detection and protection, then saves the setting.

oil sense off

Disables oil-sense input, then saves the setting.

oil sense dir normal

Sets oil logic so open/high means pressure OK.

oil sense dir reverse

Sets oil logic so closed/low means pressure OK.

Up/down arrows

Manual throttle movement from terminal escape keys: up arrow increases throttle, down arrow decreases throttle.

sf

Actuator test: sends an increase-throttle pulse.

sb

Actuator test: sends a decrease-throttle pulse.

ss

Actuator test: holds/stops actuator movement.

Calibration and service commands

calhelp

Prints the AutoGen battery calibration guide for the active ADC build.

vcal <volts>

Voltage-divider calibration on non-16-bit VBAT builds. Under load, firmware includes voltage-drop compensation automatically.

vpin 35 <V>

Standby battery-voltage calibration. Allowed only in standby on non-16-bit VBAT builds.

vpin 36 <V>

Running battery-voltage calibration. Allowed only while running on non-16-bit VBAT builds.

dropcal <A> <V>

Stores voltage-drop calibration at the nearest supported current point using DMM battery voltage.

dropcal show

Shows stored drop-calibration points.

dropcal erase

Clears drop calibration and keeps 0 A drop at 0.000 V.

dropcal defaults

Loads the conservative default drop-calibration table.

linedrop <A> <V>

Stores one-point linear voltage-drop calibration while running at steady load.

linedrop enable

Enables linear drop mode.

linedrop disable

Disables linear drop mode and uses the piecewise table.

linedrop show

Shows linear drop mode, slope, and max current.

linedrop reset

Disables linear mode and clears the slope.

r

Reads current-sensor voltage and estimated current.

c <val>

Adds a current calibration point using the live sensor voltage and supplied actual current.

showcal

Shows current calibration table.

erase

Clears current calibration table.

defaultcal

Loads the default Ultra current table.

set <value>

Accepted by the parser, but manual current/voltage setpoint control is not used in AutoGen Ultra.

16-bit ADC build commands

vbat16 cal1 <V>

Stores 16-bit VBAT calibration point 1 from a live ADS1115 sample.

vbat16 cal2 <V>

Stores 16-bit VBAT calibration point 2 from a live ADS1115 sample.

vbat16 status

Prints 16-bit VBAT calibration status.

vbat16 clear

Clears 16-bit VBAT calibration.

actcs

Reads ADS1115 actuator current-sense channels CS1 and CS2.

thrcs up <ms>

Diagnostic throttle-up drive with CS1 current sampling. Duration is constrained from 50 to 1500 ms.

thrcs down <ms>

Diagnostic throttle-down drive with CS1 current sampling. Duration is constrained from 50 to 1500 ms.

Service commands can affect relay outputs, calibration, start behavior, and protection behavior. Use them only when you understand the connected hardware state.

Local Access

Local WiFi Access

Local AP mode starts a WiFi access point named AutoGen_Local. Connect with password 12345678, then open 192.168.4.1 from the app WiFi connection mode or a browser.

How to enter AP mode

Send wifi in the BLE terminal, use the medium front-button hold, or let Ultra WiFi enter local fallback when WiFi/cloud connection is unavailable.

What AP mode provides

Local status, live values, controls, and supported local setup pages. Ultra cloud tasks pause or retry while local AP mode is active.

Monitoring

Dashboard Readings

Ultra publishes live telemetry approximately every 3 seconds while connected. The exact readings shown depend on fitted sensors, account scope, and firmware state.

Battery voltage

Main battery-bank voltage used for monitoring and automatic thresholds.

Run signal

AC or DC run-confirmation signal, selected by run-signal mode and calibration scale.

Current

Charge or pressure-sensor related current input depending on installed configuration.

Temperatures

Engine temperature, alternator temperature, and environment temperature where sensors are reporting valid data.

Oil pressure

Oil sense and oil pressure status where fitted and enabled.

Runtime and energy

Total runtime, last runtime, total kWh, and last-session kWh.

GPS data

Latitude, longitude, altitude, speed, heading, satellite count, and fix mode on GSM/GPS builds where a fix is available.

Control

Controls

Ultra control actions are managed requests. The controller checks state, readiness, run confirmation, and protection inputs before moving between states.

Start

Starts from standby when the system is ready. Cloud commands, BLE commands, the local AP, schedule, and the front button can request a start.

Stop

Requests a controlled stop from running, starting, or stop-like states. Stop sources include cloud, BLE, local AP, and the front button.

Reset

Clears error states such as STATE_ERROR and 2-wire error states after the condition has been reviewed.

Aux relay

Aux relay manual control is available from the cloud where permitted and is echoed back to the dashboard.

Operating states

Ultra states include standby, starting, running, shutting down, error, check, start pause, post stop, auxiliary start/running/pause, 2-wire auto start/running/pause/error, checking, and service lock.

Button Guide

Front Button Actions

While held

The status LED toggles red on and off every 500 ms.

Short tap

Up to about 1.5 seconds. Starts from standby/check states when the system is ready, or requests stop from running, starting, or stop-like states.

Medium hold

About 3 to 10 seconds. Starts local WiFi AP mode after release.

Long hold

10 seconds or more. Requests a force stop after release.

Continuous long hold

If held for 10 seconds while still pressed, the firmware can request a start from standby when the system is ready.

Actuator Logic

Choke Operation

AutoGen Ultra uses the secondary actuator channel for choke control. In the active firmware profile, the choke actuator is driven during each start attempt, then held or returned depending on the result.

Actuator channel

Secondary actuator on GPIO2/GPIO4.

Start attempt

The controller engages choke and starts cranking. Choke drive is turned off after 3000 ms, while the starter can remain active up to the 5000 ms crank limit.

Run confirmed

When run proof is detected from run signal or oil pressure, the starter stops and the choke actuator is commanded to return.

Return time

The choke return window is up to 8000 ms. After that, both choke actuator outputs are held off.

Failed attempt

If the run is not confirmed before the crank timeout, the controller pauses for 5000 ms and retries. It allows up to three attempts.

Failed startup

After three failed attempts, the controller returns the choke and enters error state.

Cold engine example

On a cold engine, the choke may be needed for the first crank. Ultra engages choke for the first 3000 ms of the attempt. If the engine catches, the controller stops cranking, begins returning the choke, and continues to monitor run proof. If the engine does not catch, the controller releases the starter, waits 5000 ms, and tries again.

Warm engine example

On a warm engine, run proof may arrive quickly. The choke drive still starts with the attempt, but the controller stops cranking as soon as run proof is confirmed and commands choke return. In practice, the warm engine should spend less time cranking and transition to running sooner.

If choke movement is physically reversed, use choke dir reverse. To return to normal direction, use choke dir normal. Check the current setting with choke dir.

Pressure Control

Throttle Actuator And Pressure Sensing

AutoGen Ultra reserves the primary actuator channel for throttle movement. The active firmware keeps normal automatic throttle chasing disabled unless pressure-based throttle control is explicitly enabled and saved.

Actuator channel

Primary actuator on GPIO18/GPIO19.

Default state

Pressure throttle control is off unless pressure on has been used and saved.

Sensor input

Pressure sensing uses the current-sensor ADC path on GPIO36 in the active Ultra profile.

Sensor range

Firmware maps a 0.0 to 4.5 V pressure transducer to 0.0 to 10.0 bar.

Divider ratio

The profile expects the ADC voltage to be converted back to sensor voltage using ratio 1.4545.

Default band

Low target 2.0 bar, high target 3.0 bar.

Pulse size

Each pressure-control throttle correction is an 80 ms actuator pulse.

Settle time

The controller waits 1500 ms between pressure-control corrections.

How pressure control works

Pressure too low

If pressure is below the low target, the controller pulses throttle in the direction that increases pressure.

Pressure too high

If pressure is above the high target, the controller pulses throttle in the direction that reduces pressure.

Pressure in band

If pressure is between the low and high target, the controller holds the throttle actuator.

Not running or invalid sensor

If the controller is not in a running state, pressure control is disabled, or the pressure value is invalid, the throttle actuator is held.

Example: enabling pressure control

1. Check live value

Send pressure. Confirm sensor voltage and pressure reading are valid.

2. Set band

Send pressure set 2.0 3.0 to use a 2.0 to 3.0 bar operating band.

3. Confirm direction

Use pressure dir normal or pressure dir reverse so throttle corrections move in the correct physical direction.

4. Enable

Send pressure on. The setting is saved in flash.

5. Disable

Send pressure off. The throttle actuator is held and the disabled state is saved.

Example behavior

With the band set to 2.0 to 3.0 bar, a reading of 1.7 bar causes an 80 ms throttle-up correction, then the controller waits 1500 ms before checking again. A reading of 3.4 bar causes an 80 ms throttle-down correction. A reading of 2.5 bar holds the actuator.

The pressure feature uses the current-sensor input path in this Ultra profile. If a pressure transducer is not installed or is wired incorrectly, keep pressure control off.

Setup Values

Important Settings

Low battery start

Voltage level used to begin automatic operation where battery-based automation is enabled.

High battery cutoff

Voltage level used to stop operation after recovery.

Tail current

Current threshold used near charge completion where supported.

Low temperature start

Temperature threshold for low-temperature start behavior where enabled.

High temperature shutdown

Temperature threshold for protective shutdown behavior.

Run signal mode

AC or DC run-confirmation mode, with calibration scale for the selected mode.

Runtime correction

Total runtime can be corrected from the dashboard when service records require it.

Timed Operation

Weekly Schedule

Ultra supports weekly schedule settings over cloud and BLE status reporting. The schedule can enable selected days, a start hour, start minute, run duration, and UTC offset.

Schedule fields

Enabled, hour, minute, duration from 1 to 1440 minutes, UTC offset from -12 to +14, and weekday selections Monday through Sunday.

Time source

GSM schedule operation uses modem time. WiFi schedule operation uses the cloud/WiFi task timing path and synchronized settings.

Diagnostics

Diagnostics are available from the single-device Manage page for supported Ultra controllers. Use the event stream to review starts, stops, retries, run confirmation, protection shutdowns, service locks, and recovery actions.

Typical events

manual_start, manual_stop, reset, boot_recovery, service_lock, start_attempt, run_confirmed, start_attempt_failed, and protective shutdown events.

Useful details

Events include timestamps, source, reason, run-signal mode, temperature status, pressure status, oil status, state, and related live values where reported.

OTA

Firmware Updates

Ultra firmware uses the dedicated Ultra firmware policy path and is isolated from X Pro and DC Generator releases. Updates can be normal checks or forced checks depending on operator permission.

Ultra WiFi OTA

Downloads through the WiFi cloud connection using the WiFi HTTP client path.

Ultra GSM OTA

Downloads through the cellular data connection using the GSM HTTP client path. Reconnect can take longer after restart.

Keep controller power stable during firmware check, download, flash, restart, modem or WiFi reconnect, and cloud resync.

Visual Guidance

Status LED Guide

Solid red

The controller is booting or starting up.

Slow red blink

The controller is not connected to the AutoGen cloud. The LED toggles red on and off every 1000 ms.

Solid blue

On Ultra GSM/GPS, the modem or GPRS connection is being brought up.

Green blink

The controller is connected to the AutoGen cloud. The LED toggles green on and off every 1000 ms.

Fast magenta blink

Local WiFi AP mode is active. The LED toggles magenta on and off every 100 ms.

Button hold red blink

The front button is being held. The LED toggles red on and off every 500 ms.

Fast red blink

The controller is in an error or protection state. The LED toggles red on and off every 250 ms.

OTA update patterns

New update found

The LED alternates red and green three times. Each color is shown for 180 ms.

No update available

The LED blinks red six times at 180 ms on and 180 ms off.

Downloading update

The LED alternates RGB(0,180,255) and RGB(0,0,255) every 90 ms while firmware data is being transferred.

Update complete

The LED shows RGB(0,0,255), RGB(255,255,255), RGB(0,180,255), then off. Each step lasts 160 ms before restart.

Update failed

The repeating red SOS-style sequence uses short 180 ms pulses, long 540 ms pulses, and a 900 ms pause.

Recovery

Error States And Recovery

Error states are protective. Review the state, diagnostics events, run confirmation, oil pressure, pressure control status, temperature readings, voltage, and service conditions before resetting or restarting.

Common causes

Failed start confirmation, run signal loss, low oil status, high temperature, service lock, cellular or WiFi drop, or invalid operating conditions.

Reset behavior

Reset clears the controller state after review. It does not remove the underlying cause if the same condition remains present.

Technical Reference

Ultra Hardware Reference

RGB LED

GPIO14, WS2811, one LED, brightness limited in firmware.

Front button

GPIO32.

Start relay

GPIO26.

Stop relay

GPIO25.

Aux relay

GPIO27.

Oil trigger input

GPIO33.

Battery voltage

GPIO39.

Current / pressure input

GPIO36, used by the configured Ultra sensor path.

Run signal

GPIO35, AC or DC run-confirmation input depending on selected mode.

Temperature sensor

GPIO13 and PT100-related temperature path.

Actuators

Primary actuator uses GPIO18/GPIO19. Secondary actuator uses GPIO2/GPIO4.

Cellular modem

RX GPIO23, TX GPIO5, PWRKEY GPIO15 on GSM/GPS builds.