Xantrex FREEDOM SW 3000 Installation Manual Download Page 17

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975-0546-01-01

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Installation Information

Before You Begin the Installation

Before beginning your installation:

•

Read the entire Installation Guide so you can plan the installation from
beginning to end.

•

Read the

Xanbus System Installation Guide

to plan your network

requirements.

•

Assemble all the tools and materials you require for the installation.

•

Review the Important Safety Instructions on page iv.

•

Be aware of all safety and electrical codes which must be met.

Installation Codes

Applicable installation codes vary depending on the specific location and
application of the installation. Some examples are:

•

The U.S. National Electrical Code (NEC)

•

The Canadian Electrical Code (CEC)

•

Canadian Standards Association (CSA) and RV Industry Association
(RVIA) for installation in RVs.

ELECTRICAL SHOCK AND FIRE HAZARDS

•

All wiring should be done by qualified personnel to ensure
compliance with all applicable installation codes and regulations.

•

Disconnect all AC and DC power sources.

•

Disable and secure all AC and DC disconnect devices and automatic
generator starting devices.

Failure to follow these instructions will result in death or serious
injury.

Summary of Contents for FREEDOM SW 3000

Page 1: ... nec ted to this equ ipm ent Ref er to ma nua l Cha rge onl y lea d a cid bat teri es Oth er bat tery typ es ma y bur st cau sin g per son al inju ry and dam age No min al DC Op era tin g Vo lta ge 12 Vdc No min al AC Ou tpu t Vo lta ge 120 Vac 1Ø No min al AC Ou tpu t Fre que ncy 60 Hz Ma x Con tin uou s AC Ou tpu t Cur ren t 25 A Ma x Op era tin g DC Inp ut Cur ren t 320 A Ma x Con tin uou s AC ...

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Page 3: ...onsent of Xantrex Technology Inc 161 G South Vasco Road Livermore California USA 94551 Xantrex Technology Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHN...

Page 4: ...d experience in installing electrical equipment knowledge of the applicable installation codes and awareness of the hazards involved in performing electrical work and how to reduce those hazards A qualified technician or electrician has this knowledge and experience Conventions Used The following conventions are used in this guide STATEMENT OF HAZARD Contains statements of avoidance or strict comp...

Page 5: ...nstaller should have knowledge and experience in installing electrical equipment knowledge of the applicable installation codes and awareness of the hazards involved in performing electrical work and how to reduce those hazards A qualified technician or electrician has this knowledge and experience STATEMENT OF HAZARD Contains statements of avoidance or strict compliance Failure to follow these in...

Page 6: ...ctrical shock hazard ELECTRICAL SHOCK HAZARD Do not expose the Freedom SW 3000 to rain snow spray or bilge water This inverter charger is designed for indoor use only Do not operate the inverter charger if it has received a sharp blow been dropped has cracks or openings in the enclosure including if the fuse cover has been lost damaged or will not close or otherwise damaged in any other way Do not...

Page 7: ...struct the air intake vent openings and or install in a zero clearance compartment Do not use transformerless battery chargers in conjunction with the inverter charger due to overheating Failure to follow these instructions will result in death or serious injury EXPLOSION HAZARD Charge only properly rated such as 12 V lead acid GEL AGM Flooded or lead calcium rechargeable batteries because other b...

Page 8: ... cause an explosion 6 Batteries can produce a short circuit current high enough to weld a ring or metal bracelet or the like to the battery terminal causing a severe burn 7 When removing a battery always remove the negative terminal from the battery first for systems with grounded negative If it is grounded positive remove the positive terminal first Make sure all loads connected to the battery an...

Page 9: ...When Placing the Inverter Charger EXPOSURE TO CHEMICALS AND GASES HAZARD Make sure the area around the battery is well ventilated Make sure the voltage of the batteries matches the output voltage of the inverter charger Be careful to keep corrosion from coming into contact with your eyes and skin when cleaning battery terminals Failure to follow these instructions can result in death or serious in...

Page 10: ... be used for residential or commercial applications It is not intended for other applications as it may not comply with the additional safety code requirements needed for those other applications See Limitations On Use below LIMITATIONS ON USE Do not use in connection with life support systems or other medical equipment or devices Do not use in ambulances or other life saving emergency vehicles Fa...

Page 11: ...he Xanbus System 4 Xanbus Enabled 5 System Accessories 5 Planning the Installation 6 Two Key Performance Factors 6 Size and Length of DC Cables 6 Mounting Location of the Freedom SW 3000 6 Planning 7 AC DC and Network Components 7 AC Components 9 AC Input 9 AC Output 9 AC Loads 9 AC Disconnect and Over Current Protection Device 10 Distribution Panels 11 AC Wiring 11 AC Output Neutral Bonding 12 Co...

Page 12: ...cation for the Inverter Charger 18 Step 2 Mounting the Inverter Charger 20 Considerations 20 Step 3 Connecting the AC Input and AC Output Wires 23 General AC Wiring Considerations 23 Connecting AC Input Wires 24 Connecting the AC Output Wires 25 Step 4 Connecting the DC Cables 27 DC Connection Precautions 27 Recommended Cable Sizes and Lengths and Fuse Size 27 Preparing the Cables 27 Guidelines fo...

Page 13: ...l Start Up 37 Step 8 Testing Your Installation 38 Testing in Invert Mode 38 Testing in Charge Mode and AC Bypass Mode 39 Installation Complete 39 Inverter Charger Physical Specifications 40 Battery Information 41 Battery Bank Sizing 41 Estimating Battery Requirements 41 Calculating Battery Size 41 Battery Banks 43 Battery Bank Sizing Worksheet 43 Restrictions on Motor Size 43 Cabling and Hook up C...

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Page 15: ...Xanbus system The Freedom SW 3000 is a Xanbus enabled device that typically powers the Xanbus system For information on installing the Xanbus system see the Xanbus System Installation Guide which is available for download at www xantrex com This Installation Guide provides safety instructions that must be observed during installation a typical Xanbus system diagram information on additional requir...

Page 16: ...s for the DC terminals NOTE If any of the items are missing contact Xantrex or any authorized Xantrex dealer for replacement See Contact Information on page i IMPORTANT Keep the carton and packing material in case you need to return the Freedom SW 3000 for servicing Figure 1 Materials List RE M BT S FR EED OMSW 300 0 In ve rter Res et Ena ble Inv erte r AC On C ha rge Fau lt X anbu s I n ter fa ce...

Page 17: ...s which must be met Installation Codes Applicable installation codes vary depending on the specific location and application of the installation Some examples are The U S National Electrical Code NEC The Canadian Electrical Code CEC Canadian Standards Association CSA and RV Industry Association RVIA for installation in RVs ELECTRICAL SHOCK AND FIRE HAZARDS All wiring should be done by qualified pe...

Page 18: ...ides power in a Xanbus system The System Control Panel SCP provides configuration and monitoring capability for each device connected to the Xanbus system such as the Automatic Generator Start AGS and the Freedom SW 3000 In Figure 1 network connections are represented by dotted lines and conventional electrical connections are represented by solid lines Your system requirements may be more complex...

Page 19: ...ss susceptible to interference and line loss Upgradeable Firmware upgrades mean your purchase will remain up to date For detailed instructions and a complete list of Xanbus enabled devices visit the website at www xantrex com System Accessories System accessories currently available which are Xanbus enabled include the System Control Panel and Automatic Generator Start These system accessories are...

Page 20: ...th of DC Cables To select the appropriate size and length of DC cables see DC Cabling on page 13 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 long battery cables which are in excess of 10 feet each and not of sufficient size the voltage drop across the...

Page 21: ...Distribution Panels AC Wiring AC Output Neutral Bonding DC components include Batteries DC Disconnects and Over Current Devices DC Cabling DC Grounding Network considerations include Cables connectors network connectors and terminators for the SCP and Automatic Generator Start if installing Detailed information on planning and installing your network is available in the Xanbus System Installation ...

Page 22: ...ger Engine Battery AC Main Panel AC In AC Out DC DC D System Control Panel SCP Automatic Generator Start AGS C Fuse House Battery Battery Temperature Sensor Inverter AC Panel Alternator RESET TEST Generator Transfer Switch UtilityPower Low Voltage DC Xanbus enabled Devices IMPORTANT Figure 2 does not show all required grounding or overcurrent protection ...

Page 23: ...d the neutral is 120 VAC and the voltage between the neutral and ground is approximately zero Because the two lines are in phase the currents from each line add together in the neutral For example if Line 1 is supplying 20A and Line 2 is supplying 15A the current in the neutral will be 35A AC Output AC output from the Freedom SW 3000 is 120 VAC and can be wired as single output or dual output AC L...

Page 24: ...e AC output wire size used If the AC output wiring is based on the full 30A pass through rating then a 30A output breaker is acceptable If the AC output wiring is smaller then the breaker size will have to be smaller as well in accordance with applicable electrical installation codes GFCI Requirements A GFCI ground fault circuit interrupter is a device that deenergizes a circuit when a current to ...

Page 25: ...g must be rated 90 C or higher Size of AC Input Wiring Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved in accordance with the electrical codes or regulations applicable to your installation Therefore the wiring used between the AC input circuit breaker and the inverter charger input must be sized to match the input breaker rating For dual input the...

Page 26: ...breaker and your loads must be sized to match the output breaker AC Output Neutral Bonding The AC source must have its neutral conductor bonded to ground Bonding system The Freedom SW 3000 provides a system that automatically connects the neutral conductor of the inverter s AC output circuit to safety ground bonding it while the inverter charger is inverting and disconnects it unbonding it when th...

Page 27: ...disconnect Do not confuse AC circuit breakers with DC circuit breakers They are not interchangeable Rating The rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes Location The breaker or fuse and disconnect should be located as close as possible to the battery in the positive cable Applicable codes may limit how far the prot...

Page 28: ...ation Guide Planning DC Grounding The inverter charger DC chassis ground terminal needs to be connected to the vehicle chassis by a minimum No 8 AWG copper conductor that is either insulated green wire rated 90 C or bare copper ...

Page 29: ...eipt is required if the inverter charger should need warranty service 4 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 Freedom SW 3000 in the original shipping carton is also a good way to protect the inverter charger if it ever needs to be moved HEAVY LOAD The Freedom SW 3000 ...

Page 30: ...ry cables sized according to Table 3 on page 13 Terminals and or crimp connectors for DC cables for 3 8 stud size Copper wire for DC grounding No 8 AWG See DC Grounding on page 14 Terminal or crimp connector for DC grounding cable for 1 4 stud size AC and DC disconnect switches and over current protective devices and connectors as required See page 13 AC output and input wire See Figure 2 on page ...

Page 31: ... overall procedure is divided into eight steps Step 1 Choosing a Location for the Inverter Charger Step 2 Mounting the Inverter Charger Step 3 Connecting the AC Input and AC Output Wires Step 4 Connecting the DC Cables Step 5 Connecting the Battery Temperature Sensor BTS Step 6 Connecting to the Network Step 7 Performing Checks Prior to Initial Start Up Step 8 Testing Your Installation ...

Page 32: ...follow these instructions will result in death or serious injury HEAT HAZARD Do not cover or obstruct the ventilation openings Do not install this equipment in a compartment with limited airflow Overheating may result Failure to follow these instructions will result in death or serious injury Ventilated Do not operate the inverter charger in a closed in area or restrict ventilation in any way The ...

Page 33: ...tery compartment due to the possible presence of explosive hydrogen gas from the batteries Protected from battery acid and gases Never place the inverter 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 solid gas impermeable wall dividing the two compar...

Page 34: ...ant product information on form WA 4 in the Freedom SW 3000 Sine Wave Inverter Charger Owner s Guide 3 Select an appropriate mounting location and orientation To meet regulatory requirements the Freedom SW 3000 must be mounted in one of the orientations shown in Figure 3 on page 21 4 Mark the position of the mounting holes 5 Pilot drill the six mounting holes 6 Fasten the inverter charger to the m...

Page 35: ...or non marine applications with no risk of condensation or dripping water Wall Mount DC on Left Yes for non marine applications only On a vertical surface with DC terminals facing left This orientation is suitable only for non marine applications with no risk of condensation or dripping water FREEDOM SW 3000 Inverter Reset Enable Inverter AC On Charge Fault Xanbus Interface FREEDOM SW 3000 Inverte...

Page 36: ...n is suitable only for non marine applications with no risk of condensation or dripping water 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 requirements Orientation Approved Mounting Orientation Comment M O D E E R F SW 0 0 0 3 M O D E E R F SW 0 0 0 3 M O D E E R F SW 0 0 0 3...

Page 37: ...common point For example do not route the AC input and output neutrals to a common neutral bus AC Wiring Compartment For your reference the AC wiring compartment is shown in Figure 4 on page 24 AC Knockouts There are two dual 1 0 3 4 trade size knockouts on the side panel for AC wiring Use the same trade size of strain relief as the trade size of the knockout s you are using AC Wiring Terminals Th...

Page 38: ...he front or side of the unit Do not leave the knockout inside the wiring compartment 4 Install a strain relief clamp in the AC knockout 5 Run the AC wiring through the strain relief clamp 6 Strip approximately 2 inches 50 mm off the jacket from the AC cable and separate the wires 7 Using a 1 4 blade slot screwdriver loosen the terminal screws on the terminals Do not remove the screws Figure 4 AC W...

Page 39: ...utput wiring connections 1 Remove one of the AC knockouts from the front or side of the unit Do not leave the knockout inside the wiring compartment 2 Install a strain relief clamp in the AC knockout and run the AC wiring through the strain relief clamp 3 Strip approximately 2 inches 50 mm off the jacket from the AC cable and separate the wires 4 Using a 1 4 blade slot screwdriver loosen the termi...

Page 40: ...wire can be connected directly under the screw heads If stranded ground wire is being used ring terminals must also be used 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 equipped with circuit breakers Terminals Line for Dual Output Lines for Single Output N ...

Page 41: ... a crimp 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 terminals you will be using Xantrex recommends the use of crimp connectors The connector should be designed for a 1 4 stud size to connect to the Freedom SW 3000 If a crimp connector is used it sho...

Page 42: ...maximum performance from the inverter charger do not route your DC cables through a DC distribution panel battery isolator or other device that will cause additional voltage drops The exception is the DC fuse and Disconnect or the DC circuit breaker which is required at the battery to protect the DC wiring To help avoid damage caused by reverse polarity battery connection it is a good idea to mark...

Page 43: ...mpleting the installation Use a wrench to tighten the bolt to a torque of 15 16 ft lbs 20 4 21 7 Nm at the inverter charger end Observe the fuseholder or breaker manufacturer s recommendation at the other end 6 Connect one connector on the NEGATIVE cable to the NEGATIVE DC terminal on the inverter charger as shown in Figure 5 The connector goes on first then the flat washer steel lock washer steel...

Page 44: ...charger 8 Connect the other end of the cable to the NEGATIVE terminal on the battery 9 Use a wrench to tighten the bolt to a torque of 15 16 ft lbs 20 4 21 7 Nm at the inverter charger end 10 To protect the DC terminals attach the DC terminal covers Figure 6 to the inverter charger using the screws provided Figure 5 DC Cable Connections IMPORTANT The next step is the last cable connection you need...

Page 45: ...ble and fuse sizes indicated on page 13 If you are using different sizes refer to the applicable code for DC grounding detail To connect the chassis ground 1 Using the appropriate wrench loosen the bolt on the chassis ground point shown in Figure 7 2 Connect the grounding cable between the chassis ground point and the DC grounding point for your system In an RV or vehicle installation the DC groun...

Page 46: ...tery is adjusted according to the battery s actual temperature The BTS has a self adhesive 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 post allows the internal battery temperature to be sensed and provides the most accurate results Attaching the s...

Page 47: ...al 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 downward to allow the sensor to seat flush to the top surface of the upper ring terminal 6 Mount the sensor directly on top of the ring terminal as shown in Figure 9 and firmly tighten the terminal nut 7 Check to ensure that the sensor and all wires are held...

Page 48: ... the Battery Temp jack as shown in Figure 10 Secure the cable along its length Figure 10 Connecting the BTS Cable to BTS Jack FREEDOMSW 3000 In ve rte r Re se t En ab le In ve rt er AC On C ha rg e Fa ult nte rfa ce SW 3000 REM BTS FREEDOMSW 3 ve rte r En ab le In ve rt er AC On C ha rg e Fa ult In v Re se t te rfa ce SW 3000 3 REM BTS ...

Page 49: ...must be in direct internal contact 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 the sensor from adhering to the battery case Allow the battery case to dry thoroughly 4 Peel the protective backing from the self adhesive strip on the rear of the se...

Page 50: ...ype of network layout to install as well as guidelines for installing the network The Xanbus System Installation Guide is available for download at www xantrex com EQUIPMENT DAMAGE Connect the Freedom SW 3000 only to other Xanbus compatible devices Although the cabling and connectors used in this network system are the same as Ethernet connectors this network is not an Ethernet system Equipment da...

Page 51: ...ons and AC output connections are wired correctly 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 cable is connected to the negative battery terminal Battery voltage is within the proper range for this unit 10 16 volts DC DC disconnect switch or breaker is tu...

Page 52: ...o test the Freedom SW 3000 in invert mode using a 100 watt light bulb as the test load 1 Close the DC disconnect switch or the DC circuit breaker to supply DC power to the Freedom SW 3000 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 light does not come on make sure the voltage at the DC terminals on the...

Page 53: ...e the AC supply breaker to supply AC power to the unit To verify that the Freedom SW 3000 starts charging 2 After a few seconds verify that the Bulk light illuminates Over a period of time the Absorption or Float light illuminates as charging progresses In three stage charging the Bulk Absorption and Float lights illuminate in sequence In two stage charging the Bulk and Absorption lights illuminat...

Page 54: ...specifications refer to the Freedom SW 3000 Sine Wave Inverter Charger Owner s Guide The physical specifications of the Freedom SW 3000 are described in Table 4 below Table 4 Freedom SW 3000 Physical Specifications Length 16 19 inches 411 mm Width 14 20 inches 361 mm Height 8 1 inches 208 mm Weight 75 lb 34 kg ...

Page 55: ...amps multipled by hours A typical marine or RV battery rated for 100 Ah can deliver 5 amps for 20 hours 5A 20 hours 100 Ah This same battery can deliver a higher or lower current for less or more time limited approximately by the 100 Ah figure 50 A for 2 hours or 200 A for 1 2 hour but usually the capacity figure given is only accurate for the specified duration 20 hours Estimating Battery Require...

Page 56: ...startup of a large motor makes high demands on the battery You may find that adding more amp hours in the form of extra batteries or replacement with a bigger battery solves the problem Table 5 Battery Sizing Example This example illustrates how quickly your battery needs can escalate To reduce the required battery bank size you can either conserve energy by eliminating or reducing the use of some...

Page 57: ...mating the time for which you will run each of the loads to ensure sufficient battery capacity Restrictions on Motor Size An appliance may require three to six times its normal running current in order to start The Freedom SW 3000 can handle surges to 6000 watts for ten seconds which translates to a locked rotor amp rating of no more than 50 A The locked rotor amp may be specified on the motor nam...

Page 58: ...ed for this appliance 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 charges Wh Battery Ah used between charges divide by 10 for 12 volt system divide by 20 for 24 volt system Ah Recommended Battery Bank Size in Ah multiply by 2 Ah ...

Page 59: ... AWG the 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 improve the overall performance Consult your battery supplier for more information regarding the hook up configuration required for your system Parallel Connection Batteries are connected in par...

Page 60: ... with the positive terminal of one battery to the negative terminal of the next battery they are connected in series In a series configuration the battery bank has the same Ah rating of a single battery but an overall voltage equal to the sum of the individual batteries See below Figure 15 Batteries Connected in Series ...

Page 61: ...ination The result is an increase in both the voltage and the capacity of the total battery bank This is common with all battery inverter system voltages The smaller lower voltage batteries are first connected in series to obtain the necessary voltage and then these batteries connected in series sets are connected in parallel to increase the battery bank capacity See below Figure 16 Batteries in S...

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Page 64: ...Xantrex Technology Inc 1 800 670 0707 Tel toll free 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free customerservice xantrex com www xantrex com 975 0546 01 01 Printed in China ...

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