Xantrex MS2000 User Manual Download

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MS2000 Sine Wave Inverter/Charger

Installation Guide

MS2000

Summary of Contents for MS2000

Page 1: ...MS2000 Sine Wave Inverter Charger Installation Guide MS2000 ...

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Page 3: ...MS2000 Sine Wave Inverter Charger Installation Guide ...

Page 4: ...e owners and are used herein for identification purposes only Notice of Copyright MS2000 Sine Wave Inverter Charger Installation Guide August 2004 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS ...

Page 5: ...ling the inverter charger It does not provide information on operation configuration troubleshooting and warranty and product information Refer to the MS2000 Sine Wave Inverter Charger Operation Guide This guide does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience The Installation Guide is intended for qual...

Page 6: ...life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes contain information that is important for you to know but is not as critical as a caution or warning In this guide Important information warnings or cautions On the product Important information warnings or cautions with further explanation in the product guides A...

Page 7: ...stem Control Panel Owner s Guide 975 0083 01 01 Xanbus System Installation Guide 975 0136 01 01 More information about Xantrex Technology Inc as well as its products and services including a complete list of Xanbus enabled devices is available at www xantrex com Contact Information Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 3...

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Page 9: ...cal and national electrical codes applicable in your application 3 To avoid a risk of fire and electric shock make sure that the existing wiring is in good condition and that the wire is not undersized Do not operate the inverter charger with damaged or substandard wiring 4 To reduce risk of damage and injury charge only rechargeable lead acid batteries flooded gel or absorbed glass mat AGM types ...

Page 10: ... the risk of electric shock disconnect all sources of AC and DC power from the inverter charger before attempting any maintenance or cleaning Turning off controls will not reduce this risk 9 The inverter charger must be provided with equipment grounding conductors connected to the AC input ground and chassis ground terminals To reduce the risk of overheating keep the ventilation openings clear and...

Page 11: ... when you work near a lead acid battery 2 Have plenty of fresh water and soap nearby in case battery acid contacts your skin clothing or eyes 3 Wear complete eye protection and clothing protection Avoid touching your eyes while working near batteries 4 If battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flood the eye with running ...

Page 12: ...fill Carefully follow the manufacturer s recharging instructions FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment This equipment generates u...

Page 13: ...g Location of the MS2000 5 AC DC and Network Components 6 AC Components 8 AC Input 8 Disconnect and Over Current Protection Device 8 Distribution Panels 9 AC Wiring 9 AC Output Neutral Bonding 9 DC Components 11 Batteries 11 DC Disconnects and Over Current Devices 11 DC Cabling 11 DC Grounding 12 Unpacking and Inspecting the Inverter Charger 13 Materials List 13 Installation Tools and Materials 14...

Page 14: ...ttery Temperature Sensor BTS 31 Mounting Options 32 Mounting to the Negative Battery Terminal 32 Mounting to the Side of the Battery Case 34 Step 7 Connecting to the Network 35 Step 8 Performing Checks Prior to Initial Start Up 36 Step 9 Testing Your Installation 37 Testing in Invert Mode 37 Testing in Charge Mode 37 Testing in AC Bypass Mode 38 Testing the Echo Charger 38 Inverter Charger Physica...

Page 15: ...ning Batteries 49 Clothing 49 Tools 49 Equipment 49 Supplies 49 Maintaining and Cleaning 50 Battery Enclosure and Batteries 50 Terminals Lugs 50 Battery Cables 51 Cabling Hook up Configurations 52 Parallel Connection 52 Series Connection 53 Series Parallel Connections 54 Index 55 ...

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Page 17: ...mpleted DC Wiring 27 Figure 10 Completed DC Grounding 28 Figure 11 Echo Charger Port 29 Figure 12 Inserting Cable into the Echo Charger Connector 30 Figure 13 BTS with Cable 31 Figure 14 BTS Mounted on the Negative Battery Terminal 32 Figure 15 Connecting the BTS Cable to Battery Temp jack 33 Figure 16 BTS Mounted on the Battery Case 34 Figure 17 Connecting to a Network Jack 35 Figure 18 Inverter ...

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Page 19: ...us 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 diagram of a typical Xanbus system information on additional AC and DC components required a list of installation tools and materials detailed procedures for a typical installation installation testing procedures battery in...

Page 20: ...ocation 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 American Boat and Yacht Council ABYC standards for installation on boats External connections to the inverter charger shall comply with the United States Coast Guard electrical regulations 33CFR 183 Sub Part 1 WARNING Electrical ...

Page 21: ...em The System Control Panel provides configuration and monitoring capability for each device connected to the Xanbus system such as the Automatic Generator Start and the MS2000 In Figure 1 network connections are represented by dotted lines and conventional electrical connections are represented by solid lines No attempt has been made to show polarity of electrical connections Your system requirem...

Page 22: ...rence 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 that are Xanbus enabled include the System Control Panel and Automatic Generator Start These system accessories are available from any author...

Page 23: ...ct the appropriate size and length of DC cables see DC Cabling on page 11 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 battery cables are in excess of 10 feet each 10 feet for the positive cable and 10 feet for the negative cable or not of sufficient size the vo...

Page 24: ...on panels DC components include Sources of DC power batteries for example DC cables DC over current protection and disconnect devices Network considerations include Cables connectors network connectors and terminators for the System Control Panel and Automatic Generator Start if installing See Figure 1 Detailed information on planning and installing your network is available in the Xanbus System I...

Page 25: ...all required grounding or overcurrent protection Echo Charger Engine Negative Terminal Bus Generator Non Inverter Loads Automatic Generator Start System Control Panel Sine Wave Inverter Charger Engine Battery Transfer Switch AC Main Panel AC In AC Out DC DC DC Fuse House Battery Battery Temperature Sensor AC Input Shore Power Inverter AC Panel Alternator RESET TEST GFCI ...

Page 26: ...must be rated no more than 30 amps and must be approved for use on 120 VAC branch circuits If the AC input power rating is more than 30 amps you need to add an additional 30 amp breaker or fuse at the electrical panel to which the MS2000 AC input is wired AC Output The circuit breaker or fuse must be rated at no more than 30 amps and must be approved for use on 120 VAC branch circuits GFCI Require...

Page 27: ...ut stranded wire is required if single conductors are used All wiring must be rated 90 C or higher Size Wire size has to be coordinated with the overcurrent protection provided ahead of the wire involved in accordance with the electrical codes or regulations applicable to your installation The wiring used between the AC input circuit breaker and the inverter charger input must be sized to match th...

Page 28: ...connected to ground in one place at any one time Suitability This automatic neutral to ground bonding system is suited for installations in which the AC input source is known to have a bonded neutral This will be the case in most situations in a utility feed at an external AC hook up or a generator with a bonded neutral If not have an electrician look into bonding the source s neutral to ground Se...

Page 29: ...er must be equipped with a disconnect and over current protection device Refer to your applicable installation code This usually consists of a circuit breaker a fused disconnect or a separate fuse and DC disconnect Do not confuse AC circuit breakers with DC circuit breakers They are not interchangeable The rating of the fuse or breaker must be matched to the size of cables used in accordance with ...

Page 30: ...Echo Charger to engine battery Maximum DC Cable Length one way 10 feet 3 meters 20 feet 6 meters Maximum Total Length two way 20 feet 6 meters n a Minimum Recommended Cable Size No 4 0 AWG 14 AWG Maximum Battery Fuse or Breaker 300 A class T 15 A DC 1 Per ABYC E 11 which requires No 2 0 AWG DC supply conductors for the MS2000 but allows a DC grounding conductor one size smaller than the DC supply ...

Page 31: ... anything is missing from the shipping box contact Xantrex Customer Service See Contact Information on page iii 2 Record the serial number of the MS2000 and other purchase information in the Warranty and Product Information section of the MS2000 Sine Wave Inverter Charger Operation Guide You will be asked for this product information if you need to call Xantrex Customer Service WARNING Heavy load ...

Page 32: ...AC terminals Slot screwdriver 1 8 wide blade max for Echo Charger connector Needle nose pliers Wrench for DC terminals 7 16 Wrench for DC grounding connection 5 16 Materials You will need the following materials to complete your installation Strain relief clamp s for AC cables 3 4 and or 1 DC battery cables sized according to Table 2 on page 12 Terminals and or crimp connectors for DC cables for 3...

Page 33: ...all procedure is divided into nine steps 1 Choosing a location 2 Mounting the inverter charger 3 Connecting the AC input wires and AC output wires 4 Connecting the DC cables 5 Connecting the Echo Charger 6 Connecting the battery temperature sensor 7 Connecting to the network 8 Performing checks prior to initial start up 9 Testing your installation ...

Page 34: ...n openings Do not install this equipment in a compartment with limited airflow Overheating may result Ventilated Do not operate the inverter charger in a closed in area or restrict ventilation in any way The inverter charger requires air circulation to maintain optimum operating temperature and provide best performance If the unit has inadequate ventilation it may shut down due to overheating The ...

Page 35: ... gases Never place the inverter charger directly above the batteries gases from battery will corrode and damage the inverter charger Never allow battery acid to drip on the inverter charger or its wiring when filling the batteries or reading their specific gravity Orientation To meet regulatory requirements the MS2000 must be mounted in an approved mounting orientation See Figure 4 on page 19 Thes...

Page 36: ...onents are present and record relevant product information on form WA 4 in the MS2000 Sine Wave Inverter Charger Operation Guide 4 Select an appropriate mounting location and orientation To meet regulatory requirements the MS2000 must be mounted in one of the two orientations shown in Figure 4 5 Use the packaging board as a template to mark the position of the mounting screws or refer to Figure 18...

Page 37: ...4 Approved Mounting Orientations Table 3 Description of Approved Mounting Orientations Number Approved Mounting Orientation 1 Desktop 2 Wall mount orientation on a vertical surface with DC terminals facing down 1 Desktop mount 2 Wall mount ...

Page 38: ...input and output neutrals to a common neutral bus AC Wiring Compartment For your reference the AC wiring compartment is shown in Figure 5 AC Knockouts There are two 3 4 trade size knockouts on the front panel for AC wiring as shown in Figure 5 For easier wiring access there are also knockouts on either side of the unit not shown The side knockouts are 1 trade size knockouts Use the same trade size...

Page 39: ... 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 three wires 7 Using the 1 4 blade slot screwdriver loosen the wire attachment screws on the terminals Do not remove the screws 8 Insert the line wire into L the neutral wire into N and the ground wire into ground as shown in Fig...

Page 40: ...e the screws 6 Insert the line wire into L the neutral wire into N and the ground wire into ground as shown in Figure 6 Observe the color codes described in Table 4 7 Tighten the wire attachment screws Leave some slack wire inside the wiring box 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 outg...

Page 41: ...ble 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 3 8 stud size to connect to the MS2000 If 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 enoug...

Page 42: ... regular intervals To ensure maximum performance from the inverter 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 i...

Page 43: ... fuse or breaker Observe polarity carefully while completing 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 5 Connect one connector on the NEGATIVE cable to the NEGATIVE DC terminal on the inverter charger as shown in Figure 7 The connector goes o...

Page 44: ...the other end of the NEGATIVE cable to the NEGATIVE terminal on the battery 8 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 9 Attach the DC terminal covers using the screws provided to protect the DC terminals as shown in Figure 8 Figure 7 DC Cable Connections Important The next step is the last cable connection you need to make A spark is no...

Page 45: ...Installation 975 0126 02 01 27 Figure 9 Completed DC Wiring ...

Page 46: ...liant DC supply cable and fuse sizes indicated in this Installation Guide 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 10 2 Connect the DC grounding cable No 1 0 AWG or larger copper cable between the chassis ground point and the DC groun...

Page 47: ...ance the DC cable 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 Although the Echo Charger output is limited to 10 A it is recommended to use No 14 AWG 90 C cable to minimize voltage drops To prepare the Echo Charger cable 1 Cut the cable to the required length Strip off 1 4 insul...

Page 48: ...cable 4 To secure the cable remove the screwdriver to release the tension clip 5 Install the disconnect and 15 A DC over current protection between the other end of the cable and the battery positive terminal as close as possible to the battery in accordance with codes 6 Open the disconnect switch or remove the fuse Important The right side hole on the Echo Charger connector does not connect to an...

Page 49: ... engine battery including start current not just the Echo Charger Step 6 Connecting the Battery Temperature Sensor BTS Installing a battery temperature sensor BTS extends the life of the house battery bank by preventing overcharging in warm temperatures and undercharging in cold temperatures With a BTS monitoring the battery temperature the voltage delivered to the house battery bank is adjusted a...

Page 50: ... which is directly connected to the inverter charger 2 Switch off all devices operating from the battery or open the battery switch if present to disconnect the battery 3 Wait 10 minutes for any explosive battery gases to dissipate 4 Remove the nut that connects the existing wiring ring terminals to the battery negative terminal stud 5 Move or reorient the existing wiring ring terminals on the bat...

Page 51: ...it in Step 2 9 Route the sensor cable to the inverter charger and plug it into the Battery Temp jack as shown in Figure 15 Secure the cable along its length WARNING Fire hazard In this procedure you must install the DC wire on the battery terminal first Then the sensor is installed on top of the DC wire This sequence is required to provide the best connection to the battery and to ensure correct p...

Page 52: ...e 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 sensor 5 Press the sensor firmly against the clean side of the b...

Page 53: ...Guide Refer to the this guide to determine the type 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 CAUTION Equipment Damage Connect the MS2000 only to other Xanbus compatible devices Although the cabling and connectors used in this network system are the same as Ethernet connectors this...

Page 54: ...nnect switch or DC circuit breaker Negative battery cable is connected to the house bank negative battery terminal House battery voltage is within the proper range for this unit 10 3 15 3 volts DC DC disconnect switch or breaker is turned off Echo Charger disconnect switch is off or fuse is removed Echo Charger connections are correct positive cable runs from the Echo Charger to the positive termi...

Page 55: ... only if the Invert Enable button light is also illuminated If the unit is powered up for the first time the Inverter On light will be off To turn the inverter on press the Invert Enable button 3 Connect the MS2000 to the test light by closing the AC breaker that contols the circuit that the test light is connected to If the light bulb illuminates the installation has been successful Testing in Ch...

Page 56: ...he System Control Panel verify that the Echo Charger is enabled 4 If the Echo Charger is enabled verify that the MS2000 advanced menu is displaying the Echo Charger current and voltage The current displayed will depend on the voltage level of the house bank and the voltage difference between the house battery bank and the engine battery Inverter Charger Physical Specifications For complete inverte...

Page 57: ...Installation 975 0126 02 01 39 Figure 18 Inverter Charger Dimensions 14 2 361 ...

Page 58: ...ies Plates Made of lead and connected to the battery terminals These are the terminals inside each cell of the battery The essential chemical reactions of the battery occur at the plates and they are the source of the current voltage produced by the battery Sulfation As a battery discharges its plates become covered with lead sulfate With regular recharging the lead sulfate leaves the plates and r...

Page 59: ...Cranking Amps is a measure of the amperage output of a battery intended for starting or cranking an engine Starting batteries use many thin plates to maximize the surface area of the battery This allows very high starting current In a deep cycle application these batteries will limit the number of cycles that can be supported before the battery needs to be replaced Deep Cycle Batteries Deep cycle ...

Page 60: ...r requires topping up Battery caps are not removable The sealed construction allows the batteries to be mounted in any position without spilling The advantages are no maintenance to the battery itself the system still requires routine maintenance long life 800 cycles claimed and low self discharge The disadvantages are high initial cost and the possibility of damage from overcharging While many ma...

Page 61: ...ystem is going to be located a heated equipment room should be considered Benefits of insulated enclosure If the system is located in an unheated space an insulated enclosure is highly recommended for the batteries During the charging process the batteries release heat due to the internal resistance of the battery If the batteries are insulated the heat can be kept in the batteries to keep them wa...

Page 62: ...acity is a measure of how long a battery can deliver a certain amount of current usually 25 amps For example a battery with a reserve capacity of 180 minutes can deliver 25 amps for 180 minutes before it is completely discharged Amp hour capacity is a measure of how many amps a battery can deliver for a specified length of time usually 20 hours A typical marine or RV battery rated for 100 Ah can d...

Page 63: ...ATT HOURS 10 for a 12 volt battery or BATTERY AMP HOURS USED AC WATT HOURS 20 for a 24 volt battery For example a 100 W light bulb that is used for 4 hours will use 400 watt hours Wh and the inverter will consume approximately 40 Ah from a 12 volt battery or 20 Ah from a 24 volt battery Another useful rule of thumb is that the current drawn from the battery can be estimated from the AC output watt...

Page 64: ...s increase you may need to use more than one battery to obtain sufficient capacity Batteries can be connected in parallel in series or in series parallel to create higher capacity systems It is not recommended to connect batteries from different manufacturers different types or that have different amp hour ratings in parallel Improper charging and decreased battery life will result See Cabling Hoo...

Page 65: ...Worksheet Appliance A Power Consumption Watts B Operating Time per Day Hours Daily watt hours needed 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...

Page 66: ...to prevent dirt from entering the cell Fill the cell to just above the plates Don t overfill the batteries or the electrolyte will leak out when the batteries are being charged Check the water level in the batteries frequently when performing an equalize charge and add water if necessary Check battery connections for good contact with the terminals See Checking battery connections on page 50 Maint...

Page 67: ...e so wear something you can discard just in case you splash some acid on yourself Be sure to wear rubber gloves and eye protection Tools Adjustable wrench or appropriately sized ratchet and sockets for battery terminals Adjustable and or locking pliers Torque wrench suggested not required Soft bristled brush a discarded toothbrush works fine 6 scrub brush Inexpensive 1 2 chip brush or soldering br...

Page 68: ...nals and cable lugs exposed to open air corrode rapidly The corrosion appears as a white powder or granular foam on the terminals and on any nearby exposed metal parts This is actually a crystallized form of sulfuric acid If the corrosive contacts your skin it will cause burns unless you rinse it off immediately Most textiles that are exposed to this corrosive eventually dissolve The most common c...

Page 69: ...y anything between the battery terminal and the cable lugs the connection should be metal to metal The liquid neoprene cures to form an airtight protective layer and reduce the amount of corrosion on the battery terminals If liquid neoprene is not available use a light coating of white lithium grease or other sealant Battery Cables Inspect all of the battery cables for missing or damaged insulatio...

Page 70: ...rconnects 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 parallel when all the po...

Page 71: ...inal 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 Figure 20 Figure 20 Batteries Connected in Series ...

Page 72: ...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 Figure 21 Figure 21 Batteries in Series Parallel Connections ...

Page 73: ... to battery case 34 BTS See battery temperature sensor 31 C Canadian Electrical Code CEC 2 Canadian Standards Association CSA 2 clearance around unit recommended 16 connecting to the network 35 Customer Service contact information iii D DC cables preparing 23 required size and length 12 DC cabling required 11 DC disconnect device 11 DC fuse size 12 DC grounding 12 DC over current device 11 deep cy...

Page 74: ...er specifications 38 inverter charger heavy load precaution 18 K key performance factors 5 L liquid neoprene 49 51 lithium grease 49 M maintaining batteries 48 materials list 13 materials required for installation 14 mounting orientations 18 P parallel battery connection 52 physical specifications 38 plates 40 preparing Echo Charger cable 29 preparing ground cable 23 R related product literature i...

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Page 76: ... Technology 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 0126 02 01 Printed in Canada ...

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