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Xantrex RS3000, Installation Manual

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Xantrex RS3000 Installation Manual Download Page 30

Installation

14

975-0171-01-01

DC Cabling

Definition

DC cabling includes all of the cables and connectors between the batteries, the DC 
disconnect and over-current protection device, and the inverter/charger. 

Type

All installations require multi-strand insulated cables. 

The DC cables must be 

copper and must be rated 105 °C minimum.

Size and Length

See Table 3 for required DC cable length, cable size and required fuse size for the 
RS3000. Wire size is usually marked on the cables. 

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.

Important:

Using a smaller gauge cable or a longer cable may cause the inverter to 

shut down under heavy load.

Table 3

Recommended DC Input Cable and Fuse Size

Maximum DC Cable 
Length: Battery to 
RS3000 (one way)

Total Length 
(two way)

Minimum 
Recommended 
Cable Size 

Maximum 
Battery Fuse or 
Breaker

10 feet (3 meters) 

20 feet (6 meters)

No. 4/0 AWG

400A class T

Summary of Contents for RS3000

Page 1: ...RS3000 Sine Wave Inverter Charger Installation Guide RS3000 ...

Page 2: ......

Page 3: ...RS3000 Sine Wave Inverter Charger Installation Guide ...

Page 4: ...owners and are used herein for identification purposes only Notice of Copyright RS3000 Sine Wave Inverter Charger Installation Guide December 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 RS3000 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: ...e CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important Important notes provide information that is important for you to know They are not as critical as Cautions or Warnings In this guide Important information warnings or cautions On the product Important information warnings or cautions with further explanation in the product guide...

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...

Page 8: ...iv 975 0171 01 01 ...

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: ...r 8 To reduce 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 openi...

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: ...ze and Length of DC Cables 5 Mounting Location of the RS3000 5 Planning 6 AC DC and Network Components 6 AC Components 8 AC Input 8 AC Output 8 AC Loads 8 AC Disconnect and Over Current Protection Device 9 Distribution Panels 10 AC Wiring 10 AC Output Neutral Bonding 12 DC Components 13 Batteries 13 DC Disconnects and Over Current Devices 13 DC Cabling 14 DC Grounding 14 Unpacking and Inspecting t...

Page 14: ...ry Temperature Sensor BTS 30 Mounting Options 30 Mounting to the Negative Battery Terminal 31 Mounting to the Side of the Battery Case 33 Step 6 Connecting to the Network 34 Step 7 Performing Checks Prior to Initial Start Up 35 Step 8 Testing Your Installation 36 Testing in Invert Mode 36 Testing in Charge Mode and AC Bypass Mode 37 Installation Complete 37 Inverter Charger Physical Specifications...

Page 15: ...igure 8 Completed DC Wiring and DC Grounding 29 Figure 9 BTS with Cable 30 Figure 10 BTS Mounted on the Negative Battery Terminal 31 Figure 11 Connecting the BTS Cable to Battery Temp jack 32 Figure 12 BTS Mounted on the Battery Case 33 Figure 13 Connecting to a Network Jack 34 Figure 14 RS3000 Front Panel 36 Figure 15 Inverter Charger Dimensions 39 Figure 16 Batteries Connected in Parallel 44 Fig...

Page 16: ...xii ...

Page 17: ...mation 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 AC and DC components required a list of installation tools and materials detailed procedures for a typical installat...

Page 18: ...tallation 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 WARNING Electrical shock and fire hazards Xantrex recommends all wiring be done by qualified perso...

Page 19: ...vides power in a Xanbus system 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 RS3000 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 than the basic ...

Page 20: ...e 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 available from any authorize...

Page 21: ...h of DC Cables To select the appropriate size and length of DC cables see DC Cabling on page 14 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 22: ...ing 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 System Control Panel and Automatic Generator Start if installing Detailed information on planning and installing your network is available in the Xanbus System Installation Guide Ref...

Page 23: ... protection Sensing and control Xanbus enabled Devices Generator Isolator 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 UtilityPower Inverter AC Panel Alternator TEST MONTHLY RESETR E SET TESTT E ST ...

Page 24: ...nes are in phase not out of phase and must come from the same source The voltage between the two lines is zero The voltage between each line and 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 c...

Page 25: ...ratings of the two breakers must not exceed 50A For example if Line 1 has a 30A breaker the Line 2 breaker cannot exceed 20A The sum of the breakers can exceed 50A if both are fed from a common feeder line protected at no more than 50A for example a 50A breaker feeding a pair of 30A breakers AC Output Protection The breaker between the RS3000 AC output and the AC loads must be rated to protect the...

Page 26: ...e inverter charger and the loads the AC load panel The AC source panel includes a main circuit breaker which serves as over current protection for the panel Additional circuit breakers serve individual circuits one of which serves the inverter charger AC Wiring Definition AC wiring includes input wiring all the wires and connectors between the AC source and the inverter charger input and output wi...

Page 27: ...ut wiring is dual input and the output wiring is single input the following rules apply If the input breaker on L1 is greater than 25 A the wire size must be coordinated for that amperage If the input breaker on L1 is less than 25 A the wire size must be coordinated for 25 A The wire size must not be sized for anything lower than 25 A If both the input and the output wiring are dual input the outp...

Page 28: ...es that require AC sources such as inverters and generators to have their neutral conductors tied to ground at the source of power in the same way that the neutral conductor from the utility is tied to ground These same codes specify that the neutral can only be connected to ground in one place at any one time Suitability This automatic neutral to ground bonding system requires AC input sources wi...

Page 29: ...need to consult individual battery manufacturers for this information DC Disconnects and Over Current Devices The DC circuit from the battery to the inverter charger must be equipped with a disconnect and over current protection device Refer to your applicable installation code Type This device usually consists of a circuit breaker a fused disconnect or a separate fuse and DC disconnect Do not con...

Page 30: ...ize for the RS3000 Wire size is usually marked on the cables 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 Important Using a smaller gauge cable or a longer cable may cause the inverter to shut down under heavy load Table 3 Recommended DC ...

Page 31: ...ssing from the shipping box contact Xantrex Customer Service See Contact Information on page ii 2 Record the serial number of the RS3000 and other purchase information in the Warranty and Product Information section of the RS3000 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 The RS3000 Sine ...

Page 32: ...ench for DC terminals 9 16 Materials You will need the following materials to complete your installation p Strain relief clamp s for AC cables 3 4 and or 1 p DC battery cables sized according to Table 3 on page 14 p Terminals and or crimp connectors for DC cables for 3 8 stud size p Copper wire for DC grounding No 8 AWG See DC Grounding on page 14 p Terminal or crimp connector for DC grounding cab...

Page 33: ...d only be installed in a location that meets the following requirements WARNING Risk of fire or explosion This equipment contains components that could produce arcs or sparks To reduce the risk of fire or explosion do not install this equipment in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing ga...

Page 34: ...gth and size of your DC cables will affect performance Use the DC cables recommended in Table 3 on page 14 The unit should not be installed in the battery 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 cha...

Page 35: ...nt product information on form WA 4 in the RS3000 Sine Wave Inverter Charger Operation Guide 3 Select an appropriate mounting location and orientation To meet regulatory requirements the RS3000 must be mounted in one of the orientations shown in Figure 4 on page 20 4 Mark the position of the mounting holes Refer to Figure 15 on page 39 5 Pilot drill the six mounting holes 6 Fasten the inverter cha...

Page 36: ...rface with DC terminals facing left Wall Mount DC on Right Maybe On a vertical surface with DC terminals facing down This orientation is suitable only for applications with no risk of condensation or dripping water Wall Mount DC Up Maybe On vertical surface with DC terminals facing up This orientation is suitable only for applications with no risk of condensation or dripping water Wall Mount DC Do...

Page 37: ...e AC input and output neutrals to a common neutral bus AC Wiring Compartment For your reference the AC wiring compartment is shown in Figure 5 on page 22 AC Knockouts There are two 3 4 trade size knockouts on the front panel for AC wiring For easier wiring access there are also 1 trade size knockouts on either side of the unit not shown Use the same trade size of strain relief as the trade size of...

Page 38: ...anel and remove the four screws 2 Remove the cover panel from the unit to access the wiring compartment 3 Remove one of the AC knockouts from the 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...

Page 39: ...5 on page 22 Connect Line 1 to L1 Neutral to N Line 2 to L2 9 Tighten the terminal screws Leave some slack wire inside the wiring box 10 Connect the ground wires to a free position on the ground bus Figure 5 on page 22 If solid ground wire is being used the wire can be connected directly under the screw heads If stranded ground wire is being used ring terminals must also be used 11 Secure the stra...

Page 40: ...he terminal screws Leave some slack wire inside the wiring box 7 Connect the ground wires to a free position on the ground bus Figure 5 on page 22 If solid ground wire is being used the 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 compart...

Page 41: ...00 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 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 RS3000 If a crimp connector is used it should ...

Page 42: ...intervals To ensure 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...

Page 43: ...se 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 6 Connect one connector on the NEGATIVE cable to the NEGATIVE DC terminal on the inverter charger as shown in Figure 6 The connector goes on f...

Page 44: ...EGATIVE 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 7 to the inverter charger using the screws provided The completed DC terminal wiring with covers is shown in Figure 8 Figure 6 DC Cable Connections Important The next step is the last cable connec...

Page 45: ...izes indicated on page 14 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 8 2 Connect the grounding cable see page 25 between the chassis ground point and the DC grounding point for your system In an RV or vehicle installation the DC groundi...

Page 46: ...ure 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 as shown in Figure 9 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 sensor to the side of the battery using...

Page 47: ...he 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 10 and firmly tighten the terminal nut 7 Check to ensure that the sensor and all wires are held firmly and cannot be moved 8 Turn the battery switc...

Page 48: ...Installation 32 975 0171 01 01 Figure 11 Connecting the BTS Cable to Battery Temp jack ...

Page 49: ...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 sensor 5 Press the sensor fir...

Page 50: ...n the Xanbus System Installation 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 RS3000 only to other Xanbus compatible devices Although the cabling and connectors used in this network system are the...

Page 51: ... correctly on the terminal block and not reversed p Positive battery cable is connected to the positive battery terminal through the DC fuse and disconnect switch or DC circuit breaker p Negative battery cable is connected to the negative battery terminal p Battery voltage is within the proper range for this unit 10 3 15 3 volts DC p DC disconnect switch or breaker is turned off p AC input and out...

Page 52: ...ing 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 RS3000 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 RS3000 is correct as described in Step 7 Performing ...

Page 53: ...t 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 illuminate in sequence To verify that RS3000 correctly switches to Bypass mode 3 Press the Charger Enable button to disable the charger Verify that...

Page 54: ...fications refer to the RS3000 Sine Wave Inverter Charger Operation Guide The physical specifications of the RS3000 are shown in Figure 15 on page 39 and described in Table 4 Table 4 RS3000 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: ...Installation 975 0171 01 01 39 Figure 15 Inverter Charger Dimensions 14 2 361 ...

Page 56: ...iver during a specified number of hours It is represented by the product of the two 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 g...

Page 57: ... the battery Even though you calculated the amp hour requirements appropriately the 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 1 1 Battery Sizing Example This example illustrates how quickly your battery needs can escalate To reduce the required batte...

Page 58: ... 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 RS3000 can handle surges to 7500 VA for 5 seconds which translates to a locked rotor amp on the motor of no more than 60 A The locked rotor amp may be specified on the motor nameplate as LRA ...

Page 59: ...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 60: ...terconnects 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 ...

Page 61: ...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 17 Figure 17 Batteries Connected in Series ...

Page 62: ...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 18 Figure 18 Batteries in Series Parallel Connections ...

Page 63: ...device 13 F FCC regulations viii G gases hydrogen 18 GFCI 9 GFCI models tested 10 ground fault circuit interrupter See GFCI 9 I installation approved mounting orientations 19 approved mounting orientations illustrated 20 choosing a location for inverter charger 17 connecting AC input wires 21 connecting AC output wires 21 connecting BTS cable to BTS jack 33 connecting cables to inverter charger 27...

Page 64: ...Index 48 975 0171 01 01 T tools installation 16 two key performance factors 5 V ventilation openings recommended clearance 18 X Xanbus enabled designation meaning of 3 Xantrex web site iii ...

Page 65: ......

Page 66: ...x 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 0171 01 01 Printed in China ...

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