KUSSMAUL 091-269-12-2000 Installation Manual Download Page 40

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Installing the Inverter/Charger

This guide for use by qualified personnel only.

Wall Mount DC Up

Not acceptable.
This orientation does not meet regulatory
requirements.

Wall Mount DC Down

Not acceptable.
This orientation does not meet regulatory
requirements.

Orientation

Approved Mounting
Orientation?

Comment

Summary of Contents for 091-269-12-2000

Page 1: ...gers Installation Guide Auto Power 2000W shown Model Numbers 091 269 12 2000 091 269 12 3000 K 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul...

Page 2: ......

Page 3: ...ALLED _______________________________________________________ INSTALLED BY _________________________________________________________ VEHICLE IDENTIFICATION ____________________________________________...

Page 4: ...rovide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience The information in this Guide is intended for qualified personnel...

Page 5: ...r Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed This is the safety alert symbol It is used to alert you to p...

Page 6: ...power sources are connected and present the unit is always energized Do not operate the inverter charger with damaged or substandard wiring Make sure that all wiring is in good condition and is not u...

Page 7: ...With Batteries NOTES Mount and place the Inverter Charger unit away from batteries in a well ventilated compartment Always have someone within range of your voice or close enough to come to your aid w...

Page 8: ...flooded non sealed batteries add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer This helps to purge excessive gas from cells Do not overfill F...

Page 9: ...allation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications H...

Page 10: ...al environmental regulations Many of the electrical components used in the XWR 3RZHU are made of recyclable material like steel copper aluminum and other alloys These materials can be auctioned off to...

Page 11: ...us System 4 anbus System 4 Planning the Installation 5 Two Key Performance Factors 5 Size and Length of DC Cables 5 Planning Preparations 6 AC DC and Network Components 6 AC Components 10 AC Input for...

Page 12: ...nverter Charger 21 Step 2 Mounting the Inverter Charger 23 Considerations 23 Step 3 Connecting the AC Input and AC Output Wires 27 General AC Wiring Considerations 27 Connecting AC Input Wires 28 Conn...

Page 13: ...nvert Mode Testing in Charge Mode and AC Bypass Mode Installation Complete Stacking Features Parallel Stacking Series Stacking 46 Stacking Cable 47 Series Stacking Operation DC Connections for Stacked...

Page 14: ...stimating Battery Requirements Calculating Battery Size Battery Banks Battery Bank Sizing Worksheet Restrictions on Motor Size Battery Cabling and Hook up Configurations 6 Battery Parallel Connection...

Page 15: ...d DC circuits and connecting the inverter charger to the anbus system The XWR 3RZHU DQG DUH a anbus enabled device that typically powers the anbus system This Installation Guide provides Safety instru...

Page 16: ...shers for the DC terminals NOTE If any of the items are missing contact customer service or any authorized XVVPDXO dealer for replacement See Contact Information on page i IMPORTANT Keep the carton an...

Page 17: ...ocation and application of the installation Some examples are U S National Electrical Code NEC Canadian Electrical Code CEC Canadian Standards Association CSA and RV Industry Association RVIA for inst...

Page 18: ...tallation Guide About the anbus System Figure 2 Typical Kanbus System Diagram VTTNBVM Auto Power 2000 PS 3000 AC Panel BATTERY Inverter Load Panel network terminator Super Auto Eject Deluxe Cover w Di...

Page 19: ...page 1 The DC cables should be as short as possible and large enough to handle the required current in accordance with the electrical codes or regulations applicable to your installation If there are...

Page 20: ...nect and Over Current Protection Device Distribution Panels AC Wiring AC Output Neutral Bonding DC components include Batteries DC Cabling DC Disconnects and Over Current Devices DC Grounding Network...

Page 21: ...e Battery BTS Generator Transfer Switch AC In AC Main Inverter Panel Isolator Engine Battery AC Panel Alternator Utility Power RESET TEST AC DC Low Voltage DC IMPORTANT Figure 3 does not show all requ...

Page 22: ...DC fuses are required 7 inches from the positive terminal of the battery and another from the positive terminal of the charger A DC Switch is recommended on the battery side as well For Marine applica...

Page 23: ...inches from the positive terminal of the battery and another from the positive terminal of the charger A DC Switch is recommended on the battery side as well For Marine applications see NOTE below NOT...

Page 24: ...s are 180 degrees out of phase with each other so that the two voltages total to 240 volts AC line to line The voltage between each line and neutral is still 120 volts AC and the voltage between the n...

Page 25: ...ection Device To meet CSA UL and electrical code requirements and to protect system wiring the AC inputs and outputs of the inverter charger must be provided with overcurrent protection on both the AC...

Page 26: ...ker GFCIs are intended to protect people from electric shocks and are usually required in wet or damp locations Installation in recreational vehicles requires GFCI protection of certain branch circuit...

Page 27: ...tallation For VRPH applications this may be solid wire in multi conductor cables but stranded wire is required if single conductors are used All wiring must be rated 90 C or higher Size of AC Input Wi...

Page 28: ...If the input breaker on the specific line is greater than 25 amps the wire size for that line and its neutral must be coordinated for that amperage If the input breaker on the specific line is less t...

Page 29: ...ning battery banks Restrictions on the size of appliances For information on cabling and hooking up batteries see Battery Cabling and Hook up Configurations on page For detailed information about spec...

Page 30: ...ated to match the cables ampacity at 75 C 275 Auto Power 2000 350 Auto Power 3000 DC Disconnects and Over Current Devices The DC circuit from the battery to the inverter charger must be equipped with...

Page 31: ...1 Blank Page for future use...

Page 32: ...need warranty service Save the original shipping carton and packing materials If the inverter charger needs to be returned for service it should be shipped in the original carton Packing the XWR 3RZHU...

Page 33: ...GH 1 Screw length depends on wall material and thickness Materials You will need the following materials to complete your installation Strain relief clamp s for AC cables not provided 3 4 and or 1 DC...

Page 34: ...Choosing a Location for the Inverter Charger on page 2 Step 2 Mounting the Inverter Charger on page 2 Step 3 Connecting the AC Input and AC Output Wires on page 2 Step 4 Connecting the DC Cables on p...

Page 35: ...ment with limited airflow Overheating may result Failure to follow these instructions can result in minor or moderate injury Ventilated Dry Cool Clearance Do not operate the inverter charger in a clos...

Page 36: ...ter charger directly above the batteries gases from battery will corrode and damage the inverter charger If the inverter charger is installed in a compartment above the batteries make sure there is a...

Page 37: ...atory requirements the Auto Power must be mounted in one of the orientations shown in Figure 6 on page 2 Mark the position of the mounting holes Pilot drill the six mounting holes Fasten the inverter...

Page 38: ...Aut FREEDOM o Po SW wer 3000 Reset In Enabl vert e er Inver On ter C A har C ge Fault Kanbus Interface Reset Inv Enable erte r I nve On rter Cha AC r ge Fault Kanbus Interface 2000 Auto P 2000 ower Au...

Page 39: ...nverter Charger 25 25 Installing the Inverter Charger Wall Mount DC on Right Orientation Approved Mounting Comment Orientation Auto Power Auto Power 3 300 2000 On a vertical surface with DC terminals...

Page 40: ...ualified personnel only Wall Mount DC Up No Not acceptable This orientation does not meet regulatory requirements Wall Mount DC Down No Not acceptable This orientation does not meet regulatory require...

Page 41: ...utput inverter to back to the main panel could result in ground bonding to occur in multiple locations in contravention of applicable wiring codes and may result in nuisance tripping of Ground fault p...

Page 42: ...g Compartment BATTERY POLARITY WILL CAUSE DAMAGE TO UNIT WIRING BOX COVER MUST BE IN PLACE DURING OPERATION TO REDUCE RISK OF INJURY TO PERSONS 30A CHARGER AC INPUT 20A INVERTER AC OUTPUT AC IN AC OUT...

Page 43: ...t remove the screws Connect the line and neutral wires to the input terminals labeled AC Input on the terminal block Figure 7 on page 28 XWR 3RZHU Connect Line 1 to L1 Neutral to N Line 2 to L2 XWR 3R...

Page 44: ...tput on the terminal block Figure 7 on page 28 as follows 6 Tighten the terminal screws Leave some slack wire inside the wiring box 7 Connect the ground wires to a free position on the ground bus Figu...

Page 45: ...harger 8 Secure the strain relief clamp on the AC output cable jacket 9 Attach the wiring compartment cover panel and tighten the four screws 10 Connect the outgoing AC wires to an AC load panel equip...

Page 46: ...rimp connector is used it should be crimped using the tool indicated by the connector manufacturer 2 Cut the DC ground cable to the required length Strip off enough insulation so you can install the t...

Page 47: ...gative cables close together ideally held together by straps loom or insulated clamps at regular intervals To ensure maximum performance from the inverter charger do not route your DC cables through a...

Page 48: ...e flat washer steel lock washer steel and 3 8 bolt brass 5 Connect the other connector to the POSITIVE terminal on the fuse or breaker Observe polarity carefully while completing the installation FIRE...

Page 49: ...ITIVE on the inverter charger is connected to the POSITIVE on the battery and NEGATIVE cable is connected to the NEGATIVE terminal on the inverter charger 8 Connect the other end of the cable to the N...

Page 50: ...r a dedicated chassis ground bus 3 Tighten the nut to a torque of 1 0 1 25 ft lbs 1 47 1 7 Nm Figure 9 DC Terminal Covers DC Grounding The Chassis Ground point on the inverter charger is used to conne...

Page 51: ...37 Installing the Inverter Charger Figure 10 DC Wiring and DC Grounding rter AC n Ch arge Fa ult 012 Chassis ground point...

Page 52: ...ive backing and attaches to the side of the battery A 25 foot 7 6 m cable is supplied with the BTS Mounting Options You can mount the BTS in one of two ways Mounting the sensor to the negative battery...

Page 53: ...wiring ring terminals on the battery negative terminal stud so there is a flat surface on which to seat the BTS mounting plate You may need to bend the ring terminal crimp and or wires slightly downw...

Page 54: ...ly and cannot be moved 8 Turn the battery switch on again if you opened it in Step 2 9 Route the sensor cable to the inverter charger and plug it into the blue BTS port as shown in Figure 13 Secure th...

Page 55: ...t with the battery electrolyte Do not install the sensor near the top of the battery or on the battery s top surface 3 Clean the selected area thoroughly to remove any oil or grease that could prevent...

Page 56: ...ype of network layout to install as well as guidelines for installing the network EQUIPMENT DAMAGE Connect the VUP 1PXFS only to other anbus compatible devices Although the cabling and connectors used...

Page 57: ...rrectly on the terminal block and not reversed Positive battery cable is connected to the positive battery terminal through the DC fuse and disconnect switch or DC circuit breaker Negative battery cab...

Page 58: ...WR 3RZHU Wait for all the lights on the front panel to flash on and off indicating that the unit has successfully initialized 10 to 30 seconds If the bulb does not come on make sure the voltage at the...

Page 59: ...XWR 3RZHU starts charging 2 After a few seconds verify that the AC IN CHARGING LED on the front panel is turned on indicating that the batteries are being charged To verify that XWR 3RZHU correctly sw...

Page 60: ...ng of up to 2000 watts See Parallel Stacking on page 4 In series stacking mode you may stack two different XWR 3RZHU inverter chargers of different power ratings XWR 3RZHU DQG ZLWK same voltage rating...

Page 61: ...played NOTE Do NOT connect a stacking cable to the STACKING port on the front panel of Auto Power to configure two units for parallel stacking Figure 17 Parallel Stacking Using Two Auto Power 3000s L1...

Page 62: ...l If L2 is connected to any incoming or outgoing AC line the inverter charger may suffer internal damage not covered by warranty GENERAL PRECAUTIONS Install stacked inverter chargers in close proximit...

Page 63: ...place during use to reduce risk of injury to persons REM BTS DC Ground or Grounding Electrode Terminal See manual for more information WARNING INCORRECT BATTERY POLARITY WILL CAUSE DAMAGE TO UNIT BAT...

Page 64: ...n for charging the batteries Each unit in the stack can provide a full pass through current of 30 amps for 120 volt systems When AC input power is lost both units in the stack switch from charger to i...

Page 65: ...tery temperature sensors BTS if needed Figure 20 Connecting Battery Cables and DC Ground Wires Vented Battery Enclosure 12Vdc or 24Vdc Vehicle Chassis Ground AC IN WARNING INCORRECT BATTERY POLARITY W...

Page 66: ...POSITIVE AC GROUNDS BEHIND COVER AC OUT AC IN 30A AC INPUT LINE 1 30A AC INPUT LINE 2 30A INVERTER AC OUTPUT Wiring box cover must be in place during use to reduce risk of injury to persons REM BTS DC...

Page 67: ...its in the system the SCP will display an F71 fault a system configuration fault 2 From the SCP System Status screen press Enter The Select Device screen appears 3 Select the inverter to configure as...

Page 68: ...t In parallel stacking search mode on the Master unit will not function properly When the Master sends out a load search pulse a small current also flows into the output of the Slave unit since the tw...

Page 69: ...erter Charger on page 20 when choosing cables and or wires for AC and DC connections FIRE ELECTRICAL SHOCK AND ENERGY HAZARDS Make sure all wiring being used to make stacking configurations between in...

Page 70: ...rate for the specific battery model being used to construct the bank This total bank maximum charge rate is best determined by a qualified electrical technician Suitable battery types include Flooded...

Page 71: ...rge current as specified by the battery manufacturer Since most battery banks are comprised of the same battery type model and length of interconnecting cables current sharing is roughly equal through...

Page 72: ...the actual System Total BULK output current comes out to about 100A Example 2 System composed of two stacked XWR 3RZHU 30 s Each XWR 3RZHU has a maximum charge capacity of 150A The two stacked XWR 3RZ...

Page 73: ...e value of 1 25 or 125 which means that even when the charger is operating at 100 full power the battery bank can more than adequately accept the current the charger is delivering Set the 0D KJ 5DWH s...

Page 74: ...tput current of 75A by the XWR 3RZHU s maximum charge capacity of 150A So 75 150 gets an approximate value of 0 50 or 50 which can be set exactly to 50 Set the 0D KJ 5DWH setting to which means 50 In...

Page 75: ...sical specifications of the XVVPDXO XWR 3RZHU are described in Table 5 below Table 5 XWR 3RZHU Physical Specifications Length 15 25 inches 387 mm Width 13 5 inches 343 mm Height 7 75 inches 197 mm Wei...

Page 76: ...ted in cranking amps This is not a relevant rating for continuous loads like an inverter Deep cycle batteries use a more suitable rating system such as amp hours Ah Amp hour capacity is the number of...

Page 77: ...p 2 Calculate Battery Size 5 Complete the rest of the worksheet see Table 6 Battery Sizing Example on page 6 for an example Size the batteries at approximately twice the estimated total amp hour usage...

Page 78: ...rating Time per Day Hours Daily watt hours needed for this appliance A B TV VCR 200 W 2 hours 400 Wh Small microwave oven 800 W 15 min 1 4 hour 200 Wh 3 lamps 60 W each 180 W 4 hours 720 Wh Coffee mak...

Page 79: ...lel should be of the same type and amp hour rating and from the same manufacturer It is not recommended to connect batteries of different types amp hour ratings or manufacturers Improper charging and...

Page 80: ...When considering appliances with large motors follow these guidelines Make sure that the motor s LRA rating is no more than 50 amps The XWR 3RZHU may not be able to start a motor with a higher LRA an...

Page 81: ...nce A B W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh Total daily watt hours of AC load Wh Number of days between charges Total watt hours of AC load between...

Page 82: ...battery interconnects should be 4 0 AWG The best configuration is to connect the batteries in series and parallel This requires additional cables but reduces imbalances in the battery bank and can imp...

Page 83: ...eries Parallel Connections As the name series parallel implies both the series and parallel configurations are used in combination The result is an increase in both the voltage and the capacity of the...

Page 84: ...40 C 104 F Invert mode Operating range full power Load maximum ambient 20 to 30 C 4 to 86 F 1700W 60 C 20 to 40 C 4 to 104 F 2600W 60 C Charge mode Operating range full power Current maximum ambient 4...

Page 85: ...00 W 6000 W Output current 17 A 24 A Peak output current 55 A 80 A Output frequency 60 Hz 0 2 Hz 60 Hz 0 2 Hz Output voltage 120 VAC 120 VAC AC output connection s Single Split phase in dual out Dual...

Page 86: ...ture compensation coefficients on a 12 volt battery are as follows Flooded 27 mV 25 C BTS C Gel 27 mV 25 C BTS C AGM 21 mV 25 C BTS C The temperature compensation coefficients on a 24 volt battery are...

Page 87: ...or transfer 85 VAC Maximum AC input voltage for transfer 135 VAC Minimum AC input frequency for transfer 45 Hz Maximum AC input frequency for transfer 70 Hz Cooling Fan cooled temperature controlled R...

Page 88: ...170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com...

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