Xantrex DR1512W Installation And Operation Manual Download

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DR Inverter/Charger

DR1512
DR2412
DR1524
DR2424
DR3624
DR1512W
DR1524W
DR1512E
DR1524E
DR1548E
DR2424E

Installation and Operations Manual

Summary of Contents for DR1512W

Page 1: ...DR Inverter Charger DR1512 DR2412 DR1524 DR2424 DR3624 DR1512W DR1524W DR1512E DR1524E DR1548E DR2424E Installation and Operations Manual...

Page 2: ......

Page 3: ...DR Inverter Charger Installation and Operation Manual...

Page 4: ...sed herein for identification purposes only Notice of Copyright DR Inverter Charger Installation and Operations Manual March 2005 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICAL...

Page 5: ...es Chapter 1 Introduction contains information about the features and functions of the DR Inverter Charger Chapter 2 Installation contains information about how to plan for and install the DR Inverter...

Page 6: ...y conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warnin...

Page 7: ...ric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the DR Inverter Charger with damaged or substandard wiring 6 Do not operate the DR Inverter...

Page 8: ...quipment contains components which tend to produce arcs or sparks To prevent fire or explosion do not install the DR Inverter Charger in compartments containing batteries or flammable materials or in...

Page 9: ...e eye protection and clothing protection Avoid touching your eyes while working near batteries 8 If battery acid contacts skin or clothing wash immediately with soap and water If acid enters your eye...

Page 10: ...viii...

Page 11: ...2 2 Mounting 2 3 Ventilation 2 3 Tools Required 2 3 Hardware Materials Required 2 4 Wiring Considerations 2 4 DC Terminal Connections 2 4 Grounding Considerations 2 4 AC Grounding 2 4 DC Grounding 2...

Page 12: ...pplications using a 120 Vac Generator 2 28 AC Input Wiring Off Grid Applications using a 240 Vac Generator for 120 Vac Loads 2 29 Series Stacking 120 Vac 60 Hz Models only 2 30 3 Operation Front Panel...

Page 13: ...le Devices 4 5 Undersized Loads 4 5 A Specifications Specifications of the DR Inverter A 2 B Battery Information Introduction B 2 Battery Types B 2 Deep cycle Flooded Lead Acid FLA B 2 Sealed Batterie...

Page 14: ...arging B 13 Equalization Charging B 15 General Maintenance B 16 C Multi wire Branch Circuit Wiring Multi wire Branch Circuits C 2 Identifying Multi wire Branch Circuits C 4 Correcting Multi wire Branc...

Page 15: ...2 14 Connecting the BTS to the DR Inverter 2 21 Figure 2 15 AC Side Cover Panels 2 23 Figure 2 16 AC Terminals for AC Input to the Inverter 2 24 Figure 2 17 AC Terminals for AC output to the Sub panel...

Page 16: ...Battery Wiring Series Configuration B 8 Figure B 2 12 volt Battery Wiring Series Configuration B 9 Figure B 3 Battery Wiring in Parallel B 9 Figure B 4 Battery Wiring 24 volt Parallel Configuration St...

Page 17: ...3 10 Table 3 4 AC Pass through Circuit Breakers 3 15 Table 3 5 Battery Charger Circuit Breakers 3 15 Table 4 1 Troubleshooting the DR Inverter 4 2 Table A 1 Electrical Specifications for the DR Invert...

Page 18: ...xvi...

Page 19: ...1 Introduction Chapter 1 Introduction contains information about the features and functions of the DR Inverter Charger...

Page 20: ...utility grid power returns the batteries are quickly recharged to ensure they will be ready to supply backup power during the next outage Accessories allow the DR Series to also serve as a central hu...

Page 21: ...certain models breaker for charger AC input Figure 1 1 Front Panel Features DC End Front Panel Controls and Indicators Battery Caps AC End Battery Sense Port COM Port Figure 1 2 AC Side of the DR Inv...

Page 22: ...mpatible with the RC4 the predecessor to the RC8 although the RC4 is no longer available for purchase from Xantrex Stacking Interface DRI The DRI stacking interface provides 3 wire 120 240 Vac at twic...

Page 23: ...d frequency punch holes The inverter also has a letter designator followed by 4 or 5 digits depending on revision The model number describes the type of inverter the output specifications the required...

Page 24: ...S and have been found to be free from reasonably foreseeable risk of fire electric shock and related hazards The DR Inverter Charger is intended to be used for residential or commercial applications D...

Page 25: ...2 Installation Chapter 2 Installation contains information about how to plan for and install the DR Inverter Charger...

Page 26: ...ccumulated an arc caused by connecting the battery cables or switching a relay could ignite this mixture Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable Important B...

Page 27: ...lation Install the inverter in a well ventilated area enclosure for proper operation The inverter s thermal shutdown point will be reached sooner than normal in a poorly ventilated environment resulti...

Page 28: ...run both AC and DC cables in conduit DC Terminal Connections Battery to inverter cabling should be only as long as required For Example If 4 0 AWG cables are used do not exceed 5 feet one way in 12 Vd...

Page 29: ...ions for routing wiring cables Electrical Panels and Circuit Breaker Requirements The following electrical panels and circuit breakers may be required for this installation AC Distribution Panel Sub P...

Page 30: ...baking soda on the shelves to neutralize any acid that may be spilled in the future lead acid batteries only Enclosures located outside must be rainproof and screened to prevent access by rodents or i...

Page 31: ...Pre installation Planning 975 0012 01 02 Rev A 2 7 Figure 2 1 On Grid Basic Configuration Utility Backup Figure 2 2 Off Grid Configuration Generator only...

Page 32: ...Installation 2 8 975 0012 01 02 Rev A Figure 2 3 On Grid Configuration with Renewable Energy Sources...

Page 33: ...Pre installation Planning 975 0012 01 02 Rev A 2 9 Figure 2 4 Off Grid Configuration with Renewable Energy Sources...

Page 34: ...ine wave small variations in peak voltage result in large variations in the amount of energy to the charger The charger s rated output is based on a utility voltage of 120 Vac RMS the usual measured v...

Page 35: ...mounted 3 Using a level run a horizontal line The length of the line must span at least three studs 4 Using the dimensions illustrated in Figure 2 6 drill mounting holes into the center of the studs...

Page 36: ...e center of the second 2 x 4 over this line and secure to the wall as described in Step 5 5 Using the dimensions illustrated in Figure 2 6 drill mounting holes into the center of the 2 x 4 s for the i...

Page 37: ...below for a portion of the NEC code General DC Grounding Requirements This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI N...

Page 38: ...Installation 2 14 975 0012 01 02 Rev A Figure 2 9 DC Grounding...

Page 39: ...The larger the battery bank the longer the run time Size the battery bank to the AC load requirements and length of time required to run from the batteries In general the battery bank should not be d...

Page 40: ...d for the amperage of the inverter and batteries WARNING Fire Hazard Undersized cables can overheat and melt creating a fire hazard when subjected to heavy peak loads Important Run the positive and ne...

Page 41: ...trex offers a fuse block TFB providing the code required inverter over current protection for these applications Refer to the table below for the proper size disconnect device for specific cable diame...

Page 42: ...oper method to connect the battery cables to the DR Inverter s DC terminals Figure 2 10 Battery Cable Connections CAUTION Equipment Damage The inverter is not reverse polarity protected Reversing the...

Page 43: ...commendations 5 Install the over current device fuse or circuit breaker between the battery s positive terminal and the inverter s positive terminal as close to the batteries as possible 6 Connect the...

Page 44: ...12 Install the battery terminal connection covers red for positive black for negative over the inverter s DC terminals and secure with the screws and washers provided Important The next step may caus...

Page 45: ...warm temperatures and undercharging in cold temperatures To install the Battery Temperature Sensor 1 Run the battery temperature sensor wire in the DC conduit if used and route the RJ11 connector end...

Page 46: ...eing used in a stacked configuration install a double pole circuit breaker for 240 Vac service Accessing the AC Terminals All AC wiring connects to the terminal block located on the right hand side of...

Page 47: ...Recommended Wire Size Torque Values Input and Output and Maximum Output Breaker Size Inverter Model AC Input AC Output Torque Value for Terminal Connections Maximum Output Breaker Size 120 Vac 220 24...

Page 48: ...ng to the AC source is performed after all connections have been made in the inverter a Connect the GROUND green wire to the inverter s AC GROUND terminal b Connect the NEUTRAL white wire from the AC...

Page 49: ...ock connections to 16 in lbs 1 8 nm 5 Refer to the sub panel manufacturer s specifications for wire torque requirements to sub panel terminals Important The ground and neutral must be bonded at one pl...

Page 50: ...Grid using with a generator Backup See Figure 2 19 On Grid Dual Inverter Application See Figure 2 20 Off Grid Application using a 120 Vac Generator See Figure 2 21 Off Grid Application using a 240 Va...

Page 51: ...er switch must be added to provide a means to switch the generator power to the inverter s inputs The generator can be used during extended outages to recharge the batteries and provide pass through p...

Page 52: ...12 01 02 Rev A AC Input Wiring Off Grid Applications using a 120 Vac Generator Follow the example below to complete the wiring for an off grid application Figure 2 20 AC Wiring using a 120 Vac Generat...

Page 53: ...t Wiring Off Grid Applications using a 240 Vac Generator for 120 Vac Loads Follow the example below to complete the wiring for an off grid application Figure 2 21 AC Wiring using a 240 Vac Generator w...

Page 54: ...this mode one of the inverters will function as the primary and the other inverter becomes the secondary The first unit switched ON becomes the primary and ensures the secondary s output is 180 degre...

Page 55: ...AC Wiring 975 0012 01 02 Rev A 2 31 Figure 2 22 AC Wiring for dual inverters On Grid Application 120 Vac models only...

Page 56: ...Installation 2 32 975 0012 01 02 Rev A Figure 2 23 Wiring for dual inverters On Grid Application 120 Vac models only...

Page 57: ...3 Operation Chapter 3 Operation contains information about how to operate the DR Inverter Charger...

Page 58: ...e When the inverter is first connected to the batteries it will run through a self test consisting of flashing the LEDs in sequence operating the cooling fan momentarily and switching the transfer rel...

Page 59: ...an optional Xantrex remote control unit RC4 or RC8 The port also acts as a stacking interface control when two DR Inverters are used in a series configuration When two inverters are stacked a remote...

Page 60: ...e first unit switched ON using its front panel POWER ON OFF switch becomes the controlling primary inverter Controls There are several controls on the inverter s front panel that provide adjustments f...

Page 61: ...aximum 2 Deep Cell Lead Acid 2 13 3 15 0 26 6 30 0 Provides an additional Float and Bulk settings for deep cycle lead acid batteries Refer to the battery manufacturer s recommendation for Float and Bu...

Page 62: ...s 2 3 times a second indicating the inverter is in the SEARCH MODE 4 Slowly turn the potentiometer CCW toward MIN when the proper setting is found the lamp and INVERTER MODE LED will light steady 5 Tu...

Page 63: ...harge rate of 70 amps a Battery bank amp hour capacity is 250 amp hours using gel cell batteries b Divide the amp hour capacity by 5 250 5 50 c Set the potentiometer to approximately 71 50 amps Import...

Page 64: ...isabled Important The potentiometer does not have an arrow to indicate its position Use a small blade screwdriver and rotate the control completely CCW to find the start position Rotate the potentiome...

Page 65: ...mportant The range of set points between 2 and 5 o clock also determine the low AC Transfer Voltage This must be considered when adjusting this potentiometer with ODP enabled see Table 3 3 Important W...

Page 66: ...depending upon the position of the potentiometer Important There are 6 settings available for the AC Transfer Voltage for both ODP OFF and ON as shown in the Table 3 3 below Important To achieve the...

Page 67: ...entiometer toward MAX allows the inverter to transfer to battery power providing full AC output during these periods Important When setting the AC Transfer Voltage potentiometer for generator applicat...

Page 68: ...If the system s battery bank is larger than 1000 amp hours set the potentiometer for 1K Important If using dual inverters configurations set each charger for half the value Important Most battery man...

Page 69: ...a safe level the LED turns OFF If the condition persists the inverter will shut down cool and then restart Whenever the current draw exceeds a value programmed into the micro controller the LED lights...

Page 70: ...ated to the system Important In renewable energy applications solar wind hydro etc the DC charge controllers must be set to a level below the inverter s maximum input voltage or the inverter shuts OFF...

Page 71: ...charger circuit The breakers are rated for the maximum charge rate and pass through current allowed according to the rating of the internal relay Table 3 4 AC Pass through Circuit Breakers Models DR1...

Page 72: ...The voltage should be 120 Vac 230 Vac for E models 220 Vac for W models or 105 Vac for J and K models Non true RMS meters register from 90 to 110 Vac 6 Switch the AC disconnect circuit breaker to OFF...

Page 73: ...40 set with the BATTERY BANK CAPACITY potentiometer the charger switches to the third stage float Float Charge Float charge the final stage of battery charging maintains a charge to the batteries whe...

Page 74: ...the sulfate from the plates Equalizing the batteries every month or two depending on usage prolongs the life of the batteries and provides better battery performance To Set the Equalize Charge 1 Remov...

Page 75: ...ge condition is met and 6 hours have elapsed the charger will switch to the float mode If the condition is not met i e the current draw is above the rate set with the BATTERY CAPACITY potentiometer po...

Page 76: ...0012 01 02 Rev A Figure 3 16 Equalize 1 Battery Charger Rate Potentiometer Position 1 See Table 3 1 Switch Position 1 Figure 3 17 Equalize 2 Battery Capacity Rate Potentiometer Position 0 See Table 3...

Page 77: ...4 Troubleshooting Chapter 4 Troubleshooting contains information about how to troubleshoot possible error conditions while using the DR Inverter Charger...

Page 78: ...ions Check all AC output connections Use a True RMS voltmeter Charger is inoperative AC voltage has dropped out of tolerance Loose AC input connections Check the AC voltage for proper voltage and freq...

Page 79: ...ng the inverter out of its search mode Also when using a computer avoid starting large loads Consumer Electronics AM radios tend to pick up inverter noise especially on the lower half of their band In...

Page 80: ...Switches Most dimmer switches lose their ability to dim the lights when used with an inverter and operate only in the fully ON or OFF position Newer microprocessor controlled dimmers tend to work bett...

Page 81: ...mperature for 10 minutes to ensure it does not become abnormally hot Excessive heat will indicate that it is incompatible with the inverter Undersized Loads If the power consumed by a device is less t...

Page 82: ...4 6...

Page 83: ...A Specifications Appendix A Specifications contains information about the electrical specifications and environmental specifications of the DR Inverter Charger...

Page 84: ...0 105 Vac 40 105 Vac AC Input Currentb 45 amps 55 amps 45 amps 55 amps 55 amps Continuous Power 25 C 1500 VA 2400 VA 1500 VA 2400 VA 3600 VA Continuous Output 25 C 12 5 amps AC 20 amps AC 12 5 amps AC...

Page 85: ...1 0 leading or lagging Adjustable Load Sensing Range 5 watts minimum to 100 watts maximum Series Operation Yes Force Air Cooling Variable speed fan AutomaticTransfer Relay 30 amps Number of Charging...

Page 86: ...Mode 0 045 amps 0 055 amps Full Voltage 0 700 amps 0 900 amps DC Current at Rated Power 150 amps 80 amps Short Circuit Current 400 amps 800 amps DC Input Voltage nominal c 12 6 Vdc 12 6 Vdc DC Input V...

Page 87: ...230 Vac 230 Vac 230 Vac 230 Vac AC Input Low Transfer Voltage 80 to 210 Vac 80 to 210 Vac 80 to 210 Vac 80 to 210 Vac AC Input Currentb 55 amps 55 amps 55 amps 55 amps Continuous Power 25 C 1500 VA 1...

Page 88: ...NO Force Air Cooling Variable speed fan Automatic Transfer Relay 20 amps Number of Charging Profiles 10 Three stage Charging Yes float absorption bulk Temperature Comp Probe BTS optional Remote Contr...

Page 89: ...extensions such as mounting rails DC terminals and front panel controls 8 5 w x 7 25 H x 21 D 21 6 cm W x 18 4 cm H x 54 6 cm D Unit Weight 35 lbs 16 kg 45 lbs 21 kg 35 lbs 16 kg 40 lbs 16 kg 45 lbs 2...

Page 90: ...A 8...

Page 91: ...x B Battery Information supplies general information about batteries such as battery types battery bank sizing battery configurations and battery care For detailed information see your battery manufac...

Page 92: ...battery types recommended for use in an inverter system are Flooded Lead Acid FLA Sealed Gel Cells GEL Sealed Absorbed Glass Mat AGM and alkaline types Nickel iron NiFe and Nickel Cadmium NiCad Start...

Page 93: ...must therefore be adjusted for a 24 and 48 volt system i e 20 cells for a 24 volt system and 40 cells for a 48 volt system Alkaline batteries require a higher charge voltage to fully recharge and dro...

Page 94: ...batteries expresses battery capacity in terms of its ability to provide large amounts of current for intervals measured in minutes not hours This is why starting batteries are not appropriate for inv...

Page 95: ...ases an appliance which draws a large wattage may not consume as many amp hours as a load drawing fewer watts but running for a longer period of time For Example A circular saw draws 1500 watts or 125...

Page 96: ...er will power and enter their wattage in the watts column 2 Determine the number of hours or decimal portion of hours the appliance is used each day Enter this figure in the Hours column 3 Determine t...

Page 97: ...es However you should try to find the exact wattage on the appliance label Table B 2 Determining Battery Bank Size Average amp hours per day 95 Divided by inverter efficiency 90 for DR Inverter 0 9 Di...

Page 98: ...he DC requirements of the inverter Batteries with more than two or three series strings in parallel often exhibit poor performance characteristics and shortened life Wiring Batteries in Series Effect...

Page 99: ...tery terminals are connected together and all the positive battery terminals are connected together Wiring example Figure B 3 is an example of how to wire batteries in a parallel configuration Figure...

Page 100: ...nput requirements 24 volts shown in Figure B 4 and Figure B 5 2 Repeat this step for the next battery string Two identical strings of batteries are now wired in series Parallel wiring To wire the batt...

Page 101: ...nfiguration Step 3 Important Connecting the positive and negative wires to the inverter from different strings ensures a balanced charge discharge through the batteries resulting in longer run times a...

Page 102: ...cable to string one and negative cable to string two for inverter 2 as shown in the diagram below Figure B 7 Example of Battery Connections for Stacked Inverters 24 Vdc shown DC CONDUIT FOR INVERTER 1...

Page 103: ...oltage the batteries will be charged to during a normal charge cycle Gel cell batteries are set to a lower value and non sealed batteries are set to a higher voltage setting Float Voltage The Float vo...

Page 104: ...0 00 0 00 20 68 0 15 0 10 0 30 0 20 0 60 0 40 15 59 0 30 0 20 0 60 0 40 1 20 0 80 10 50 0 45 0 30 0 90 0 60 1 80 1 20 5 41 0 90 0 60 1 20 0 80 2 40 1 60 0 32 0 75 0 50 1 50 1 00 3 00 2 00 5 23 0 90 0...

Page 105: ...acid accumulate at the bottom of the battery potentially damaging the plates At the same time the electrolyte at the top of the battery gets watery This effect is called stratification Frequency Every...

Page 106: ...osts Battery posts must be clean to reduce the resistance between the battery post and cable connection A buildup of dirt or oxidation may eventually lead to the cable terminal overheating during peri...

Page 107: ...is not an accurate measurement for cross tied batteries as each battery is in parallel with another battery making individual battery measurements impossible The voltage should match the following ta...

Page 108: ...B 18...

Page 109: ...d alone 120 Vac inverters or generators WARNING A possible fire hazard can exist if 120 Vac only sources such as inverters and generators are wired incorrectly into 120 240 Vac panels containing multi...

Page 110: ...out of phase with each other so the neutral wire never receives more current than it was designed to handle as the current from each circuit subtracts or cancels out leaving only the difference curren...

Page 111: ...nged Load Center L1 L2 Neutral Ground 120 Vac 120 Vac 15 A Breaker Ganged 240 Vac from Grid Bare Ground Single White Neutral Current Flow 10 A Black Hot Current Flow 5 A Red Hot Current Flow 15 A Whit...

Page 112: ...se a 3 wire plus ground arrangement black red white and copper for each circuit run If this arrangement exists in the panel and it is being powered by a stand alone 120 Vac inverter a potential fire h...

Page 113: ...240 Vac split phase configuration This solution may actually be less expensive than having an electrician re wire the multi wire branch circuits It also provides increased power backup protection and...

Page 114: ...2 Neutral Ground 120 Vac 120 Vac 15 A Breaker Ganged Bare Ground Single White Neutral Current Flow 0 A Black Hot Current Flow 15 A Red Hot Current Flow 15 A White Neutral Splice Current Flow 15 A 15 A...

Page 115: ...of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United Sta...

Page 116: ...ANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED...

Page 117: ...elephone number where you can be reached during work hours A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are...

Page 118: ...d __________________________________ Length of time inverter has been installed __________________________________ Battery battery bank size __________________________________ Battery type e g flooded...

Page 119: ...st aid when working with vii precautions when working with vii Battery B 13 C computers 4 3 computers use with inverter 4 3 Customer Service preparing to call WA 4 F first aid vii Fluorescent lights 4...

Page 120: ...IX 2...

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Page 122: ...nology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 975 0012 01 02 Rev A PC Print...

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