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Contents

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976-0043-01-02

Generator start types   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–20

Additional/Optional Equipment Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–22

AC Conduit Box (ACCB)   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–22
DC Conduit Box (DCCB)   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–23

Fuse Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–24

DC Disconnect Boxes (DC175/DC250)  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–24
Battery Status Meter (TM500A)   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–25
Remote Monitors   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–26

Inverter Control Module (ICM)  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–27
Inverter Communications Adapter (ICA)   - - - - - - - - - - - - - - - - - - - - - - - - - -  2–27

Generator Start Module (GSM)  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–28
Auxiliary Load Module (ALM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–28
240 Vac Application Requirements  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–29
Autotransformer for 240 VAC Applications (T240)  - - - - - - - - - - - - - - - - - - - - - -  2–29
Inverter Stacking Control – Series (ISC-S) Cable - - - - - - - - - - - - - - - - - - - - - - - -  2–29
Renewable Energy DC Input Sources   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–30

Off-Grid Applications  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–32

Renewable Energy Systems with/without Generator Backup  - - - - - - - - - - - - - - - -  2–32

Single-Inverter Configurations (120 Vac)  - - - - - - - - - - - - - - - - - - - - - - - - - -  2–32
Single-Inverter Configurations (120/240 Vac)  - - - - - - - - - - - - - - - - - - - - - - -  2–32
Dual-Inverter Configurations (240 Vac)  - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–34

Generator-Only Systems   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–36

Single-Inverter Configurations   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–36
Dual-Inverter Configurations   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–38
240 Vac-only Input Source  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–38

On-Grid Applications  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–40

Backup Systems  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–40

Single-Inverter Configurations (120 Vac)  - - - - - - - - - - - - - - - - - - - - - - - - - -  2–40
Single-Inverter Configurations (240 Vac)  - - - - - - - - - - - - - - - - - - - - - - - - - -  2–40
Dual-Inverter Configurations (240 Vac)  - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–42

Energy Management  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–44

RE Backup with Utility (SB Mode)  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–44
Peak Load Management  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–44
Time-of-Use (TOU) Metering  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–45
AC Load Support   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  2–46
Renewable Energy with Grid Backup (BX Mode)   - - - - - - - - - - - - - - - - - - - -  2–47

3

Installation

Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Summary of Contents for SW Plus 2524

Page 1: ...Sine Wave Plus Inverter Charger Owner s Manual SW Plus 2524 SW Plus 2548 SW Plus 4024 SW Plus 4048 SW Plus 5548...

Page 2: ......

Page 3: ...Sine Wave Plus Inverter Charger Owner s Manual...

Page 4: ...Plus Inverter Charger Owner s Manual September 2003 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS...

Page 5: ...detailed planning and setup information procedures for installing the inverter as well as information about operating and troubleshooting the unit It does not provide details about particular brands...

Page 6: ...ter 8 Operation explains how to operate the Sine Wave Plus Inverter Charger It also explains how to read the LED indicators and User Menus to determine system status Chapter 9 Troubleshooting contains...

Page 7: ...ergency Power Off Switch Glossary contains a glossary of technical terms used in this manual The glossary also defines some common electrical terms It also provides a list of acronyms used in this man...

Page 8: ...ion Guide Inverter Stacking Control Series ISC S Cable Owner s Guide Inverter Communications Adapter ICA Owner s Guide Inverter Control Module ICM Installation Guide AC Conduit Box ACCB Owner s Guide...

Page 9: ...t multi wire branch circuits 5 Do not operate the inverter if it has been damaged in any way If the unit is damaged see the Warranty and Product Information section at the end of this manual 6 This un...

Page 10: ...acturer and the manufacturer of the equipment in which the battery is installed FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital dev...

Page 11: ...2 2 System Output Requirements 2 4 System Input Requirements 2 4 Location Considerations 2 5 Mounting Considerations 2 6 Ventilation Requirements 2 6 Grounding Considerations 2 7 DC System Grounding 2...

Page 12: ...2 30 Off Grid Applications 2 32 Renewable Energy Systems with without Generator Backup 2 32 Single Inverter Configurations 120 Vac 2 32 Single Inverter Configurations 120 240 Vac 2 32 Dual Inverter C...

Page 13: ...ng 3 26 Accessing the AC Terminal Block and Ground Bar 3 28 AC Wiring for Single Inverter Systems 3 30 Manual and Auto Start Generators 3 30 Install AC Output Wiring to the Inverter AC Distribution Pa...

Page 14: ...ramming 6 8 DC Amps verses AC Amps 6 8 Basic Setup Process 6 9 Accessing the Basic Setup Menu 6 10 Menu Item Descriptions 6 11 10 Time of Day Setup Menu 6 11 10A Set Hour 6 11 10B Set Minute 6 11 10C...

Page 15: ...ced Setup Advanced Setup Summary 7 2 Before You Begin Advanced Programming 7 10 Accessing the Advanced Setup Menu 7 11 Menu Item Descriptions 7 13 20 Silent Setup Menu 7 13 20A Refloat High Volts DC 7...

Page 16: ...25B Gen Warm up Seconds minutes 7 37 25C Pre Crank Seconds 7 37 25D Max Cranking Seconds 7 37 25E Post Crank Seconds 7 37 26 Gen Auto Run Setup Menu 7 38 26A Load Start Amps AC 7 38 26B Load Start De...

Page 17: ...e Run 8 19 02E Gen Start Run Time 8 19 02F Days Left To Gen Exercise 8 19 03 Time Of Day Menu 8 20 03A SW Plus Software Level 8 20 03B System Information 8 20 03C Company Name and Address 8 20 03D Cit...

Page 18: ...elected 8 30 6F Battery VDC LBCO 8 30 6G Battery VDC HBCO 8 30 06H EPO Shutdown 8 30 07 GSM ALM Options Menu 8 30 07A RY7 GSM Energized 8 30 07B RY8 GSM Energized 8 31 07C RY9 ALM Energized 8 31 07D R...

Page 19: ...6 Amp Hour Example Worksheet C 7 Battery bank size worksheet C 8 Battery Configurations C 9 Wiring Batteries in Series C 9 Wiring Batteries in Parallel C 10 Wiring Batteries in Series Parallel C 11 B...

Page 20: ...ch Circuits F 4 Correcting Multi wire Branch Circuit Wiring F 5 G Emergency Power Off Switches The Purpose of an EPO switch G 2 How to use the EPO Port for an EPO Switch G 4 Warranty and Product Infor...

Page 21: ...Communications Adapter 2 27 Figure 2 11 Generator Start Module 2 28 Figure 2 12 Auxiliary Load Module 2 28 Figure 2 13 T240 Autotransformer 2 29 Figure 2 14 ISC S Cable 2 29 Figure 2 15 Xantrex C Seri...

Page 22: ...Figure 3 18 AC Input and Output Wiring to a Single Inverter with an Auto Start AC Generator 3 32 Figure 3 19 AC Output Wiring to the Inverter AC Panel 3 34 Figure 3 20 Generator Input Wiring to a Sin...

Page 23: ...ection 7 35 Figure 7 10 RY7 RY8 Sequence of Events for GS Selection 7 36 Figure 8 1 LED Indicators 8 3 Figure 8 2 Inverter Operation Status LEDs 8 4 Figure 8 3 AC Status LEDs 8 5 Figure 8 4 Charge Sta...

Page 24: ...onfiguration Wired to the Inverter C 12 Figure C 7 Example of Battery Connections for Stacked Inverters 24 Vdc shown C 12 Figure E 1 Overvoltage using a C Series Charge Controller E 2 Figure E 2 Diver...

Page 25: ...for a 48 volt 350 amp hour Battery 6 23 Table 6 8 Calculating the Bulk Done Amps for a 24 volt 700 amp hour Battery 6 24 Table 6 9 Calculating the Bulk Done Amps for a 48 volt 350 amp hour Battery 6 2...

Page 26: ...B 10 Table B 6 Advanced Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models B 12 Table B 7 Advanced Setup Default and User Settings for the Sine Wave Plus 5548 Model B 14 Tabl...

Page 27: ...1 Introduction Chapter 1 Introduction lists and describes the basic features and parts of the Sine Wave Plus Inverter Charger...

Page 28: ...LCD for easy programming and troubleshooting light emitting diode LED display of system operational status automatic on off control of electric start generators requires additional equipment remote m...

Page 29: ...The front of the Sine Wave Plus has the following features the Inverter Control Module ICM Display the AC Access Cover Figure 1 1 The Sine Wave Plus Figure 1 2 The Front Side of the Sine Wave Plus AC...

Page 30: ...y Power Off EPO switch Certification Label The Grid Tie Interface Port The Grid Tie feature is currently not available with the Sine Wave Plus models However the port has been included in the event th...

Page 31: ...icated EPO port on the AC left side of the inverter See Appendix G Emergency Power Off Switches for additional information about this feature and how to prepare a cable for it Certification Label The...

Page 32: ...following features the positive battery terminal the negative battery terminal the battery temperature sensor port the chassis ground lug Figure 1 5 The DC side of the Sine Wave Plus Positive Battery...

Page 33: ...a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures If more than one BTS is being used install them adjacent to each other so that they a...

Page 34: ...ot a branch circuit rated breaker Separate output breakers are still required If the button is protruding from the chassis as shown in Figure 1 7 it means the circuit breaker has tripped open Press th...

Page 35: ...2 System Configuration Chapter 2 System Configuration contains information to help you plan for a Sine Wave Plus installation in an off grid on grid or backup power application...

Page 36: ...onsider the following issues as you design your system System output How much power will be required and how it will be produced Single or dual inverters based on output voltage and output watts requi...

Page 37: ...ing type i e ground bar ground bus or ground rod Neutral to ground bonding requirements Lightning and surge protection See Grounding Considerations on page 2 7 for additional information Battery What...

Page 38: ...oads which would be on at once to determine continuous power requirements Add the surge current of all loads which might start at once to determine surge requirements e g washer spinner waterpump and...

Page 39: ...Inverters can generate radio frequency interference RFI Locate any sensitive electronic equipment susceptible to RFI as far away from the inverter as possible This includes radios and televisions Elec...

Page 40: ...ting surface Use all ten mounting holes and all four keyhole slots for securing the unit and use 0 25 inch diameter bolts for mounting Ventilation Requirements Location Install the inverter in a well...

Page 41: ...This is the most common form of grounding methods used for residential and commercial applications The Sine Wave Plus meets FCC part 15 Class B regulations in a negative grounded system See FCC Inform...

Page 42: ...is recommended that the size and gauge of grounding wire should be more than the NEC CEC minimum requirements when installing power sources such as inverter chargers or generators WARNING Shock Hazard...

Page 43: ...8 feet 2 meters long and driven into the earth It is also common to use copper wire placed in the concrete foundation of the building as a grounding system Either method may be acceptable but the loc...

Page 44: ...ding is located at the utility panel after the power has gone through the kilowatt hour meter of the utility if present Renewable energy systems Renewable energy systems with no grid connection can be...

Page 45: ...s the batteries should be housed in an enclosure or dedicated room that can be locked or screened and ventilated It should be vented to the outside by a 1 inch minimum vent pipe located at the top of...

Page 46: ...ce and ensure the safety of the system Larger diameter cables smaller AWG number have less voltage drop and are therefore more efficient when transferring power to and from the batteries The use of ov...

Page 47: ...another important factor Runs should be kept as short as practical Longer cable runs increase resistance thus lowering the overall efficiency of the system This is especially true in lower voltage sys...

Page 48: ...e wire reaches its maximum current carrying capability Xantrex DC175 and DC250 The NEC CEC requires both overcurrent protection and a disconnect switch for residential and commercial electrical system...

Page 49: ...endent on the quality and maintenance of the DC connections Stacked inverter sets are far less forgiving to long undersized uneven and or poor connections than are single inverters Dual inverters not...

Page 50: ...as the batteries become charged The bonding jumpers allow the inverters to agree better on what the voltage actually is The longer the DC cables are the more likely you will need bonding jumpers Shun...

Page 51: ...are installed in a cold environment insulation should be installed to protect the batteries from the cold The insulation will act as a barrier to the cold and also keeps the heat generated by the batt...

Page 52: ...the inverter wiring from becoming energized in the event that an electric start generator starts unexpectedly while the inverter is being serviced Subpanel Inverter Panel In on grid applications load...

Page 53: ...cables Remote ICM cable to the inverter charger if used Load circuit wiring rerouted from the main service panel to the subpanel on grid applications only Generator Considerations Purpose An engine g...

Page 54: ...Vac only depending on the overall needs of the system The generator must be large enough to provide adequate power to charge the batteries and support a certain amount of AC loads If the generator is...

Page 55: ...these protection features they are designed for unattended starting and operation and may be compatible with the Sine Wave Plus with the optional GSM Be sure to locate an auto start generator in a pl...

Page 56: ...ay be required depending upon the intended use of the inverter to make the installation code compliant These components are not provided with the inverter and must be purchased separately AC Conduit B...

Page 57: ...iderations 976 0043 01 02 2 23 DC Conduit Box DCCB The DC Conduit Box DCCB connects to the DC side of the inverter and accepts DC conduit runs Figure 2 4 DC Conduit Box Figure 2 5 Sine Wave Plus with...

Page 58: ...ector s on the ends known as C type or stripped end battery cables The TFBxxx fuse block has stainless steel bolt connections for cables with ring terminals known as ring lugged battery cables Both fu...

Page 59: ...ged Cumulative amp hours Recharge indicator Low voltage indicator Full charge indicator The unit is configurable for specific system or application functions such as setting the CHARGED indication par...

Page 60: ...the inverter site and the ICA Note The ICM and the ICA use the same input port on the inverter Both of these options cannot be used at the same time Figure 2 8 Accessories for Remote Monitoring CAUTIO...

Page 61: ...the Inverter Communications Adapter ICA Inverter Communications Adapter ICA The ICA allows the inverter to be connected directly to a PC for monitoring and adjustment The ICA comes with a 50 foot cabl...

Page 62: ...generators and Appendix D Generators for additional information regarding generator types Auxiliary Load Module ALM The ALM is an accessory that enables the inverter to start and stop auxiliary loads...

Page 63: ...ake 240 Vac from a generator and step down the voltage to 120 Vac for the single inverter For step up and step down functions two T240s will be required A T240 Autotransformer can optimize the generat...

Page 64: ...enly removed from them This can happen if the DC disconnect should open trip or the batteries are fully charged and no other DC loads are connected in the system A diversion load controller prevents d...

Page 65: ...e the possibility of a fire resulting from ground faults in a PV array in accordance with NEC CEC for rooftop mounted PV systems on dwellings It is not designed or intended to prevent electrical shock...

Page 66: ...ent to power the required loads or keep the batteries charged a generator can be used to supplement the system Single Inverter Configurations 120 Vac If only 120 Vac output is required from the system...

Page 67: ...llustration to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inverter...

Page 68: ...is an excellent choice for providing power to multi wire branch circuits where single 120 Vac inverters may require extensive rewiring within the building See Figure 2 18 for an example of this config...

Page 69: ...lustration to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inverter s...

Page 70: ...nsiderations on page 2 19 and Appendix D Generators for additional information regarding using generators for system input Single Inverter Configurations A single inverter system is usually adequate t...

Page 71: ...lustration to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inverter s...

Page 72: ...ding See Appendix F Multi wire Branch Circuit Wiring for information on identifying and correcting multi wire branch circuit wiring See Figure 2 20 for an illustration of a 240 Vac Generator Only Syst...

Page 73: ...his illustration to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inve...

Page 74: ...provide backup power in the event of a grid failure Batteries can be charged by the utility grid when available RE sources or with a backup generator Single Inverter Configurations 120 Vac If only 120...

Page 75: ...ation to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inverter site 5...

Page 76: ...wire branch circuits where stand alone 120 Vac inverters may require extensive rewiring within the building See Appendix F Multi wire Branch Circuit Wiring regarding multi wire branch circuits See Fi...

Page 77: ...llustration to demonstrate a single point ground 4 If using a PC to monitor the system the Xantrex ICA is required If using a PC to monitor from off site an external modem is required at the inverter...

Page 78: ...the RE can provide the inverter will automatically bring in enough AC power from the grid to power the loads See SB Standby Utility Backup on page 7 17 for instructions for setting these parameters Pe...

Page 79: ...on page 7 16 for instructions for setting these parameters Energy management determines when utility power is used Start and Stop times are programmed into Menu Items 21B and 21C depending on when you...

Page 80: ...s The Sine Wave Plus is designed to assist the generator when heavy current demands load down the generator by supplying additional power from the batteries In this way the generator can operate loads...

Page 81: ...he renewable energy sources the inverter transfers from the utility grid to inverter supplied AC power See 22 Battery Xfer BX Menu on page 7 18 for instructions for setting these parameters Figure 2 2...

Page 82: ...2 48...

Page 83: ...3 Installation Chapter 3 Installation describes how to mount and install the Sine Wave Plus Inverter Charger and perform wiring and cabling procedures for various configurations...

Page 84: ...vel pencil and utility knife Slotted screw driver Wire strippers Assorted open end wrenches Torque wrench Socket wrench and sockets Electrical tape Multi meter AC DC volts Important Be sure to obtain...

Page 85: ...em accessories can be used in the installation of the Sine Wave Plus These accessories are available from any authorized Xantrex dealer Consult with your local system designer to determine what option...

Page 86: ...nformation see Appendix C Battery Information Prepare the battery bank as follows 1 Determine the type of batteries to be used See Battery Types on page C 2 in Appendix C for information on types of b...

Page 87: ...ect for shipping damage and contact the shipping company if there is damage Verify that all of the following items are present Please call your authorized Xantrex dealer if any items are missing The S...

Page 88: ...the Warranty and Product Information section at the back of this manual Model Number information can be found on the Certification Label located on the AC end of the unit See Figure 3 1 for the locati...

Page 89: ...logo on the certification label indicates the need to add overcurrent protection It shall be installed at the battery as part of the installation in accordance with your local electrical code Table 2...

Page 90: ...1 Ensure that the desired shelf location is strong enough to support the inverter weight and allows adequate clearance for ventilation and access to the indicators and controls 2 Drill mounting holes...

Page 91: ...le slots Keyhole slots 21 533 cm 16 406 cm 6 165 cm 1 1 1 14 8 3 15 1 8 4 102 cm 10 267 cm 2 17 432 cm 8 3 18 467 cm 8 3 20 508 cm Mounting Holes NOT TO SCALE 6 165 cm 10 cm 25 cm 38 cm 38 cm 38 cm 38...

Page 92: ...ngth of the line must span at least 3 studs 4 Place a pre cut 2 x 4 on the marked location and drill pilot holes through the 2 x 4 s and studs 5 Secure the 2 x 4 with 10 wood screws length to penetrat...

Page 93: ...ure 3 4 Wall Mounting Method using 2 x 4 s Wall studs 16 inches oncenter Wallboard Floor Ceiling 14 3 8 c c SetInv erter OFFSRC H ON CHG Sine Wave Plus Inverter Charger Approx 4 5 ft 2 x 4 mounting su...

Page 94: ...hods Be sure to use all the mounting holes and keyhole slots for mounting a Using the measurements from Figure 3 3 drill out the mounting hole locations for the inverter b Create a cardboard template...

Page 95: ...976 0043 01 02 3 13 Figure 3 5 Wall Mounting using Plywood Wall studs 16 inches on center Wallboard Floor Ceiling Plywood SetIn ve rte r OFFSRCH ONCHG Sine Wave Plus Inverter Charger Mounting Holes 10...

Page 96: ...Bank Prepare the battery bank according to type of battery selected and configure the battery bank to optimize voltage output according to system requirements See your battery manufacturer s installa...

Page 97: ...rounding procedures and can be used as the DC disconnect as shown in Figure 3 7 on page 3 16 WARNING Fire Hazard Undersized cables can overheat and melt creating a fire hazard when subjected to heavy...

Page 98: ...electrode in accordance with local and national electrical codes 2 Connect the NEGATIVE terminal of the battery bank to the ground bond inside the DC disconnect 3 Connect an appropriately sized GROUN...

Page 99: ...es 2 Connect the NEGATIVE terminal of the battery bank to the ground bond inside the DC disconnect 3 Connect an appropriately sized GROUND wire from the Chassis Bonding Lug on the L1 inverter DC end t...

Page 100: ...e level so as to measure the average battery temperature If using multiple charging devices inverters and charge controllers install all sensors together with each other so they all measure the same t...

Page 101: ...DC Wiring 976 0043 01 02 3 19 Figure 3 9 BTS RJ11 Port Location and Installation BTS RJ11 Port DC End of the Inverter...

Page 102: ...the DC end of the inverter Figure 3 10 shows the locations of the DC connectors WARNING Shock Hazard Before making any connections verify that the DC disconnect device is switched OFF Figure 3 10 DC...

Page 103: ...on CAUTION Damage to Equipment Do not put anything between the battery cable lug and the terminal surface Overheating of the terminal may occur Do not apply any type of antioxidant paste until after t...

Page 104: ...reaker in the DC disconnect torque to manufacturer s recommendations The DC disconnect should be located as close to the batteries as possible b Connect another cable from the other side of the same c...

Page 105: ...DC Wiring 976 0043 01 02 3 23 Figure 3 13 DC Connections to a Single Inverter...

Page 106: ...onnect c a third cable from the first circuit breaker in the DC disconnect to the L1 inverter POSITIVE terminal d a fourth cable from the second DC disconnect to the L2 inverter POSITIVE terminal 2 Co...

Page 107: ...DC Wiring 976 0043 01 02 3 25 Figure 3 14 DC Connections to Dual Inverters...

Page 108: ...this input The AC2 GEN input is intended to be used with AC generators and the inverter can do generator features auto start with this input The inverter will accept and use AC power on either of thes...

Page 109: ...aining multi wire branch circuits See Appendix F Multi wire Branch Circuit Wiring which describes how to check for multi wire branch circuits in the load center and offers some possible solutions alte...

Page 110: ...omewhere safe where it will not be lost 2 Slide the access cover off of the front panel To replace the AC access cover 1 Slide the access cover back into place 2 Replace the Phillips screw that was re...

Page 111: ...AC Wiring 976 0043 01 02 3 29 Figure 3 16 AC Input Output Wiring Terminals AC Terminal Block AC Terminal Block Enlargement...

Page 112: ...nnect switch are optional but the generator disconnect switch is strongly recommended Manual and Auto Start Generators Some generators must be started manually at the generator These kinds of generato...

Page 113: ...generator This will remind the operator that AC power may still be supplied from the generator and additional steps may be required to make the panel and the generator safe Figure 3 17 Connecting the...

Page 114: ...Installation 3 32 976 0043 01 02 Figure 3 18 AC Input and Output Wiring to a Single Inverter with an Auto Start AC Generator...

Page 115: ...ked by the inverter s and remove their wires from the main panel c Reroute these wires to the new inverter subpanel 5 Remove unused breakers from utility panel It is now safe to re energize the main u...

Page 116: ...o the inverter panel GROUND bar 2 Connect the NEUTRAL white wire a from the inverter NEUTRAL OUT terminal b to the inverter panel NEUTRAL bus 3 Connect the HOT black wire a from the inverter AC OUT te...

Page 117: ...the power from the generator to the inverter input and to loads that cannot be powered by the inverter Loads such as air conditioners large well pumps and arc welders are typically better suited to ru...

Page 118: ...enerator disconnect switch NEUTRAL connector to the inverter NEUTRAL 2 terminal 3 Connect HOT black wires a from the generator L1 HOT OUT to the Step down autotrans former L1 HOT IN b and from the gen...

Page 119: ...ave Plus Inverter Charger Generator Disconnect Switch Optional G N GROUND NEUTRAL GEN HOT OUT 120 240 Vac GENERATOR L1 L2 G HOT OUT N HOT IN 1a 2a 3a Step down Autotransformer Optional 2b 3b 3c AC GRO...

Page 120: ...ity panel GROUND bar 3 Connect a NEUTRAL white wire a from the inverter NEUTRAL 1 terminal and b to the utility panel NEUTRAL bus 4 Connect a HOT black wire a from the inverter AC1 GRID terminal and b...

Page 121: ...ports on the AC end of the Sine Wave Plus This cable is not provided with the inverter and must be purchased separately Install this cable prior to making the AC wiring connections For complete insta...

Page 122: ...The following diagram is for connecting the cable to the inverters only For information on wiring dual stacked inverter systems please refer to the ISC S Cable Owner s Guide CAUTION Equipment Damage D...

Page 123: ...pecific installation instructions for installing the ICA To install the remote monitor s cable Connect the appropriate end of the cable from the remote monitor of choice to the REMOTE port on the AC e...

Page 124: ...et points for energizing and de energizing the relays are adjustable as are the time delays To connect the ALM to the Sine Wave Plus Connect the ALM communications cable from the ALM to the AUX port o...

Page 125: ...are a cable for it EPO Port The EPO switch is connected to the Sine Wave Plus with a telephone cord RJ11 type connector to the dedicated EPO port on the AC left side of the inverter Important The purp...

Page 126: ...3 44...

Page 127: ...4 Functional Test Chapter 4 Functional Test explains how to conduct a functional test of the inverter...

Page 128: ...y battery power to the inverter 1 Before applying DC power to the inverter measure the voltage and polarity of the cables measure at the battery side of the disconnect or breaker 2 Apply battery DC po...

Page 129: ...ter charger is in the Search Mode and is looking for an AC load greater than the Search Watts setting default 8 watts On The inverter charger is on The inverter will produce a low audible buzz and is...

Page 130: ...ating correctly Depending on your configuration provide AC power to the AC1 GRID and AC1 NEU or AC2 GEN and AC2 NEU The AC1 or AC2 green LED will initially blink until AC power has synchronized and th...

Page 131: ...o inverter mode immediately This will be indicated by the INVERT yellow LED illuminating The inverter will begin to produce an low audible buzz as it takes power from the batteries and uses it to powe...

Page 132: ...4 6...

Page 133: ...5 Navigation Chapter 5 Navigation explains how to navigate through the Sine Wave Plus Inverter Charger menus using the Control Module and the menu maps...

Page 134: ...Sine Wave Plus 4024 and 4048 Models on page 7 5 Table 7 3 Advanced Setup Default Settings for the Sine Wave Plus Plus 5548 Models on page 7 7 Record changes If your installation will require that the...

Page 135: ...ush buttons eight Light Emitting Diodes LEDs one contrast adjustment and one Liquid Crystal Display LCD on the front of the ICM The push buttons are grouped into sets depending on their function The L...

Page 136: ...e Advanced Setup Menu One push button is available for resetting factory defaults ON OFF Menu Buttons These push buttons directly access either the Inverter User Menu or the Generator User Menu INV ON...

Page 137: ...ess the Menu Heading button to move forward Press the Menu Heading button to move backward Menu Item Buttons Below the Menu Headings are subdirectories called Menu Items Menu Items contain the selecta...

Page 138: ...ctory Defaults The Reset Defaults push button at the bottom of the ICM refreshes the LCD display Pressing this button when the Press Resets for Factory Default menu is displayed resets the unit to the...

Page 139: ...sic Setup Menu The Basic Setup Menu contains the basic setup information to run the equipment in basic inverter charger Mode Basic programming includes setting the time of day clock configuring the in...

Page 140: ...These Menu Headings do not set configuration parameters but do provide system performance information See The User Menu Summary on page 8 11 for a summary of the default settings and display descript...

Page 141: ...Menu Map 976 0043 01 02 5 9 Figure 5 10 User Menu Map Part 2...

Page 142: ...s required for system configuration and modes of operation Establishing these parameters upon initial power up will be required See Basic Setup Process on page 6 9 for overview instructions on program...

Page 143: ...Menu Map 976 0043 01 02 5 11 Figure 5 12 Basic Setup Menu Map Part 2...

Page 144: ...ator starting details auxiliary load usage and energy management grid usage parameters See Advanced Setup Summary on page 7 2 for a listing of all the default settings for this menu structure See Acce...

Page 145: ...Menu Map 976 0043 01 02 5 13 Figure 5 14 Advanced Setup Menu Map Part 2...

Page 146: ...Navigation 5 14 976 0043 01 02 Figure 5 15 Complete User Menu Map...

Page 147: ...Menu Map 976 0043 01 02 5 15 Figure 5 16 Complete Basic Setup Menu Map...

Page 148: ...Navigation 5 16 976 0043 01 02 Figure 5 17 Complete Advanced Setup Menu Map...

Page 149: ...6 Basic Setup Programming Chapter 6 Basic Setup Programming explains how to program the Sine Wave Plus Inverter Charger to operate under basic conditions...

Page 150: ...8 Models on page B 5 Table B 3 Basic Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models on page B 6 Table B 4 Basic Setup Default and User Settings for the Sine Wave Plus 5548...

Page 151: ...00 00 to 23 50 02 00 page 6 24 12H Max Bulk EQ Timer 00 00 to 23 50 05 00 00 00 to 23 50 05 00 page 6 25 12I Temp Comp LeadAcid NiCad LeadAcid LeadAcid NiCad LeadAcid page 6 25 End Menu 12 13 AC Input...

Page 152: ...nu on page 6 12 for details 11A High Battery Cut Out Vdc 16 1 to 34 0 32 0 32 2 to 68 0 64 0 page 6 12 11B Low Battery Cut In Vdc 16 1 to 33 9 26 0 32 2 to 67 8 52 0 page 6 12 11C Low Battery Cut Out...

Page 153: ...AC 00 to 60 30 00 to 60 30 page 6 27 13C Input Upper Limit Vac 125 to 150 130 125 to 150 130 page 6 28 13D Input Lower Limit Vac 80 to 115 110 80 to 115 110 page 6 28 End Menu 13 14 Save Restore Sett...

Page 154: ...64 0 page 6 12 11B Low Battery Cut In Vdc 32 2 to 67 8 52 0 page 6 12 11C Low Battery Cut Out Vdc 32 0 to 67 8 44 0 page 6 13 11D LBCO Delay Minutes 01 to 255 15 page 6 13 11E Search Watts SRCH 00 to...

Page 155: ...enu 13 14 Save Restore Settings Menu See 14 Save Restore Settings Menu on page 6 29 for details 14A Push INV now to save settings Push INV now to save settings page 6 29 14B Push GEN to restore settin...

Page 156: ...es although small in the power conversion process Actual AC Voltage Actual DC Voltage Amp ratio There are two rules of thumb using this inverter to estimate the amperages If you are running on battery...

Page 157: ...nverter operating functions See 11 Inverter Setup Menu on page 6 12 for instructions on setting the Inverter functions 3 Selecting Charger functions This selects the basic charger functions See 12 Bat...

Page 158: ...USER MENU is displayed 3 Press and hold down the green GEN button 4 While holding the green GEN button down press the red INV button to move into the Basic Setup Menu Figure 6 1 Accessing the Basic S...

Page 159: ...change the time displayed The minute section of the display will change in 10 minute increments 3 Keep pressing the SET POINT buttons until the appropriate hour is displayed 10B Set Minute To set the...

Page 160: ...tery dealer installer 11A High Battery Cut Out VDC This voltage level is the maximum voltage the batteries will be allowed to reach If the battery voltage exceeds this limit for more than 1 minute the...

Page 161: ...either a generator or grid power This is the lowest voltage level acceptable for battery use by the inverter 11D LBCO Delay Minutes Menu item 11D LBCO Delay Minutes is used to set the length of time i...

Page 162: ...ds are present If a water pump is driven by the inverter for only one hour total per day then the other twenty three hours out of the day the inverter is using 8 watts per hour just to sit there and d...

Page 163: ...panion load whose only purpose is to be switched on to wake up the inverter to power the load that is unable to bring the inverter out of Search Mode Guidelines for setting this menu item Setting this...

Page 164: ...re appropriate for your installation If not you will need to adjust the settings according to the battery manufacturer s recommendations The following information is provided to help you make the nece...

Page 165: ...a bulk and absorption charge cycle is complete the charger will shut down go silent AC voltage on the inverter s input will pass through to the loads The charger continues to monitor the battery volta...

Page 166: ...until the time set in 20F Must Float Time and the level set in 20E Float Done Amps have been reached In Silent Mode the transfer time between utility power and the inverter is slower than in Float Mod...

Page 167: ...information on the Silent Mode programming CAUTION Damage to DC Loads and Batteries DC loads should be disconnected from the batteries during equalization charging to protect DC loads from high batte...

Page 168: ...For Setting Charging Parameters on page 6 21 for recommended float voltages 12D Equalize Volts DC This the voltage level at which the charger performs an equalize charge on the batteries The factory d...

Page 169: ...7 6 Vdc 26 8 Vdc 53 6 Vdc Not recommended consult manufacturer LeadAcid Deep cycle Liquid Electrolyte Lead Antimony Battery 29 2 Vdc 58 4 Vdc 26 8 Vdc 53 6 Vdc Charge to 31 0 Vdc 24 volt models or 62...

Page 170: ...ror condition The following settings are guidelines only Refer to your battery vendor for specific settings and battery maintenance guidelines Calculating Maximum Charging Amps To calculate the 12E Ma...

Page 171: ...rger will continue to charge at the bulk voltage until the 12G Max Bulk EQ Timer h m period is reached and switches the charger out of the bulk stage To calculate the 12F Bulk Done Amps AC 1 Multiply...

Page 172: ...2D Equalize Volts DC Table 6 8 Calculating the Bulk Done Amps for a 24 volt 700 amp hour Battery Step Instruction Equation 1 Multiply the total battery amp hours by 2 3 4 700 x 2 3 4 14 21 28 AC Bulk...

Page 173: ...pensation reduces the battery charge voltage when the environmental temperature is hot to prevent battery over gassing or overcharging In cold temperatures the voltage is increased to assure complete...

Page 174: ...These settings provide the limit at which the inverter will start drawing power from the batteries in order to meet the demand of the AC loads Configuring the AC inputs includes determining the follow...

Page 175: ...l at which point the inverter starts drawing power from the batteries to add to the generator power to meet the demand of the loads This is the AC load support feature If the loads exceed this setting...

Page 176: ...ries to aid to the grid power AC1 or GEN AC2 power depending on which one is being used to meet the demands of the loads When the AC voltage reaches this level the inverter stops battery charging and...

Page 177: ...settings currently programmed into the inverter To save settings 1 Press the button until 14A Push Inv Now to Save Settings is displayed 2 Press the red INV button to save the settings 14B Push GEN t...

Page 178: ...N button to restore the factory default settings End Basic Setup Menu You have reached the end of the Basic Setup Menu To exit the Basic Setup Menu and go on to the Advanced Setup Menu 1 Press the Men...

Page 179: ...Chapter 7 Advanced Setup explains how to program the Sine Wave Plus Inverter Charger to operate under special advanced conditions such as automatic generator starting energy management and auxiliary l...

Page 180: ...B 10 Table B 6 Advanced Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models on page B 12 Table B 7 Advanced Setup Default and User Settings for the Sine Wave Plus 5548 Model o...

Page 181: ...1 Mode Cooldown Error Error Cooldown Error Error page 7 21 End Menu 23 24 Generator Timers Menu See 24 Generator Timers Menu on page 7 26 for details 24A Gen Run Time Start h m 00 00 to 23 50 08 00 00...

Page 182: ...C 10 0 to 35 5 24 6 20 0 to 71 0 49 2 page 7 38 26E 2 hr Start Volts DC 10 0 to 35 5 23 6 20 0 to 71 0 47 2 page 7 38 26F 15 min Start Volts DC 10 0 to 35 5 22 6 20 0 to 71 0 45 2 page 7 39 26G Read L...

Page 183: ...End h m 00 00 to 23 50 21 00 00 00 to 23 50 21 00 page 7 18 End Menu 21 22 Battery Xfer BX Menu See 22 Battery Xfer BX Menu on page 7 18 for details 22A High Xfer HBX Vdc 16 1 to 33 9 27 0 32 2 to 67...

Page 184: ...25D Max Cranking Seconds 01 to 15 10 01 to 15 10 page 7 37 25E Post Crank Seconds 00 to 255 30 00 to 255 30 End Menu 25 26 Gen Auto Run Setup Menu See 26 Gen Auto Run Setup Menu on page 7 38 for deta...

Page 185: ...Refloat Low Volts DC 32 2 to 67 8 50 0 page 7 15 20C Float Done Amps AC 00 to 40 10 page 7 15 20D Must Float Time Min 00 to 255 05 page 7 15 End Menu 20 21 Grid AC1 Usage Menu See 21 Grid AC1 Usage Me...

Page 186: ...n h m 00 00 to 23 50 08 00 page 7 27 24D Quiet Time End h m 00 00 to 23 50 08 00 page 7 28 24E Gen Exercise Period Days 00 to 255 30 page 7 28 24F Gen Exercise Timer Min 00 to 255 15 page 7 28 24G Gen...

Page 187: ...c Start LBCO setting 11C 44 0 Read Only page 7 39 End Menu 26 27 Save Restore Settings Menu See 27 Save Restore Settings Menu on page 7 39 for details 27A Push INV now to save Settings Push INV now to...

Page 188: ...nformation on programming this features AUXILIARY LOADS Sets the parameters by which the relays in the ALM are used This feature is programmed in Menu Heading 23 See 23 ALM Relays Menu on page 7 19 fo...

Page 189: ...ld down the green GEN button 3 While holding the green GEN button down press the red INV button to move into the BEGIN BASIC SETUP MENU 4 Release the GEN and INV buttons Figure 7 1 Accessing the Advan...

Page 190: ...EN button 7 While holding the green GEN button down press the red INV to move into the ADVANCDED SETUP MENU Figure 7 2 Accessing the Advanced Setup Menu Method 2 Press the green GEN button and hold do...

Page 191: ...r to the batteries such as a PV array wind generator micro hydro generator etc When this level is met or exceeded the unit turns on the charger and directs the excess DC power to the AC loads and atte...

Page 192: ...output loads If the external current source provides more current that what is needed to maintain the batteries at the float voltage and power the inverter loads the battery voltage will rise The inv...

Page 193: ...hat point the current supplied to the batteries is allowed to decrease to in order to trigger the Silent mode The 20C Float Done Amps AC setting is usually set to 1 of the total battery bank capacity...

Page 194: ...ge parameters the Advanced Setup Menu Headings 21 Grid AC1 Usage Menu and 22 Battery Xfer Menu are used Table 7 4 Calculating the Float Done Amps for a 24 volt 700 amp hour Battery Step Instruction Eq...

Page 195: ...the settings in menu 22B Low Xfer LBX VDC and then transfers to the utility Utility grid power is then used as a backup source to keep the loads powered When the batteries have recharged from an exter...

Page 196: ...etting only operates with the AC1 input grid input 22 Battery Xfer BX Menu This menu heading provides settings that determine the transfer levels when the loads will be powered from the inverter or fr...

Page 197: ...ensated 23 ALM Relays Menu Auxiliary load functions are controlled by setting parameters in Menu Heading 23 ALM Relays Using this feature requires the additional purchase of a Xantrex Auxiliary Load M...

Page 198: ...ime period set in menu 23C RY9 Delay At DeEngz Min the relay de energizes and closes the contacts between the N C and COM terminals This setting is not temperature compensated when a BTS is installed...

Page 199: ...use the cooldown selection to enable an external contactor to allow both legs of a generator to go through a cooldown period When using the generator AUTO selection and connecting two inverters in a...

Page 200: ...Advanced Setup 7 22 976 0043 01 02 Figure 7 3 Relay 11 Wiring Example to Dual Inverters with Cooldown selected...

Page 201: ...erator based on type of generator used See 25 Gen Starting Details Menu on page 7 29 for specific instructions on programming these menu items into the Sine Wave Plus 26 GEN Auto Run Setup Menu This M...

Page 202: ...whenever the current demand through the inverter to the AC loads remains above the 26A Load Start Amps AC setting for the selected 26B Load Start Delay Min period The current can be monitored by the 0...

Page 203: ...reached the 24B Gen Run Time Stop h m value Exercise Period Days The generator is automatically started at a pre selected time based on the 24D Quiet Time End h m whenever it exceeds a set number of...

Page 204: ...utomatic cooldown period and continue to run 4 During Quiet Time the auto start generator is prevented from automatically starting unless the battery voltage reaches the LBCO setting for the LBCO dela...

Page 205: ...30 seconds If you want to override this generator start feature and not have the generator start select OFF in the 02A Generator ON OFF menu item During quiet time the automatic generator start syste...

Page 206: ...ternal counter reaches the number of days set the generator starts at the end of the quiet time setting If the generator is run for 5 minutes at any time during this period this counter resets and the...

Page 207: ...Y7 and RY8 provide the control signals for the generator RY7 provides either a STOP or a RUN signal It can also provide a GLOW signal for diesel generator engines This mode is selected in menu item 25...

Page 208: ...RN2 Since there is no monitoring of the generator by the inverter in this mode only one attempt is made to start the generator GS This selection GlowStop provides a momentary contact closure between c...

Page 209: ...cranking signal period Check with the generator s manufacturer for specific details The RN1 setting requires AC2 input to sense the generator output to stop cranking The RN2 setting does NOT require A...

Page 210: ...The inverter attempts to start the generator up to six times Guidelines for setting this menu item If the required voltage level is not reached relay RY7 closes in the GS mode to stop the generator b...

Page 211: ...rators GENERATOR START MODULE RY7 STOP SWITCH CONTACTS ONAN TYPE GENERATOR COM N O N C RY8 COM N O N C START SWITCH CONTACTS 5 AMP FUSE 5 AMP FUSE RY7 RUN STOP SWITCH CONTACTS HONDA TYPE GENERATOR COM...

Page 212: ...amps reaches the 26A LOAD START AMPS AC setting and remains longer than the period set in 26B LOAD START DELAY MINUTES 4 If the time set for the generator to run in 24A GEN RUN TIME START H M is reac...

Page 213: ...NC C NO 80 Vac on AC2 Input GeneratorOFF 25C Pre Crank Seconds 25DMaxCranking Seconds GeneratorRun Period BEGIN and continue clockwise 1 Manual turn OFF 2 Load is reduced 3 Charger finishes a RN1 fin...

Page 214: ...r Run Period 1 Manual turn ON 2 Load Start 3 Voltage Start 4 Exercise Start 5 Gen Run Start Time Command to Start OFF OFF OFF ON Y E L L E D R Y 7 NC C NO G R N L E D R Y 8 NC C NO OFF OFF Y E L L E D...

Page 215: ...is connected to the automatic start system 25D Max Cranking Seconds This menu item sets the maximum number of seconds the starter is cranked during the starting sequence by engaging relay RY8 Guideli...

Page 216: ...of time the generator continues to run after the load current determined by the 04E Load Amps AC meter decreases below the 26A Load Start Amps AC setting 26D 24 Hr Start Volts DC This menu item sets t...

Page 217: ...0 second start attempts to auto start the generator even if the quiet time as set in menu 24 Generator Timers Menu is enabled This is a read only display 27 Save Restore Settings Menu This menu provid...

Page 218: ...ults This menu item provides the means to restore the factory default settings To restore the factory default settings 1 Press the button to select 27C Push Gen For Factory Defaults 2 Press the green...

Page 219: ...8 Operation Chapter 8 Operation explains how to operate the Sine Wave Plus Inverter Charger It also explains how to read the LED indicators and User Menus to determine system status...

Page 220: ...mance throughout it s operation Check the LED indicators for system status information See LED Indicators on page 8 3 for the description of their meaning Check the 04 Meters Menu to confirm current v...

Page 221: ...status LEDs indicate the various operating conditions of the inverter Unless otherwise indicated the LEDs will be ON solid and not flashing or blinking The LEDs also are grouped by function LEDs prov...

Page 222: ...T LED indicates the inverter is operational and inverter power to the AC output is available to power the load if needed Therefore this LED will be illuminated during normal operation Search Mode Indi...

Page 223: ...g BX Modeor the Grid Usage Timer this LED will continue to blink even if the source is within tolerance AC2 Generator LED The AC2 LED indicates power has been applied to the inverter s AC2 generator i...

Page 224: ...mer h m value which ever comes first The inverter then switches over to the FINISH stage of charging This LED is also used to indicate an equalization charge When this LED is blinking it indicates the...

Page 225: ...determine which error condition has occurred Error conditions include Over current menu item 05A Transformer Over temp menu item 05B Heatsink Over temp menu item 05C Low Battery Voltage menu item 05D...

Page 226: ...ndition but an indication that the inverter charger is in a special mode or condition i e such as Bypass Mode Charger only Mode Generator Cooldown Period etc Status conditions include Bypass Mode was...

Page 227: ...frequency limits and is providing pass thru power to the loads or AC1 is selected under the 01D Bypass Mode menu item AC power is present on the AC1 input terminal The AC power may not be within volta...

Page 228: ...Error If the Error LED flashes and no Error cause is displayed in 05 Error Causes then the AC input frequency is in need of adjustment STATUS LED yellow No Status condition has been detected A Status...

Page 229: ...Inverter OFF SRCH ON CHR OFF OFF SRCH ON CHR OFF page 8 15 01B EQ Charge OFF ON OFF OFF ON OFF page 8 16 01C Search Watts SRCH 00 to 248 08 00 to 248 08 page 8 16 01D Bypass Mode AC1 NORM AC2 NORM AC1...

Page 230: ...to 163 Read Only 00 to 163 Read Only page 8 23 04G Grid AC1 Volts AC 00 to 163 Read Only 00 to163 Read Only page 8 24 04H Gen AC2 Volts AC 00 to 163 Read Only 00 to 163 Read Only page 8 24 04I Frequen...

Page 231: ...tery Vdc LBCO NO YES Read Only NO YES Read Only page 8 30 06G Battery Vdc HBCO NO YES Read Only NO YES Read Only page 8 30 06H EPO shutdown NO YES Read Only NO YES Read Only page 8 30 End Menu 06 07 G...

Page 232: ...access the 01A Inverter User Menu Press the red INV button to go directly to 01A Inverter To directly access the 02 Generator User Menu Press the green GEN button to go directly to 02A Generator Figur...

Page 233: ...wer is not present on the inverter s input the inverter will not provide an output voltage to the load until the load exceeds the value set for the 01C Search Watts and 11E Search Watts setting Use th...

Page 234: ...inished the generator is stopped after cooldown if started automatically and the cursor returns to OFF A BULK charge can be initiated by moving the cursor to ON then OFF 01C Search Watts SRCH This men...

Page 235: ...omatically based on programmed usage parameters This menu heading also provides generator status menus 02B through 02F to help determine why a generator started 01D Bypass Mode AC1 NORM AC2 Important...

Page 236: ...turn off when the current as shown on the 04E Load Amps AC display decreases below the 26A Load Start Amps setting for the 26C Load Stop Delay Min period If the generator started automatically based o...

Page 237: ...art Exercise Run A YES displayed in this menu item indicates the generator has or is about to start because the 24E Exercise Period Days setting in menu item 24E has been reached The generator will co...

Page 238: ...ding on your model either 2 5 KVA 4 0 KVA or 5 5 KVA will be displayed in this menu item 03C Company Name and Address Menu item 03C displays the company name and street address where the Sine Wave Plu...

Page 239: ...tings Only the system clock will remain unchanged using the reset function It also runs an LED and relay test which allows users to check the LEDs on the inverter display and the relays and LEDs on an...

Page 240: ...ttery Actual Vdc This menu item displays the actual DC battery voltage This value is used for setting the following menu items 11C Low Battery Cut Out Vdc 11A High Battery Cut Out Vdc 22B Low Battery...

Page 241: ...the other unit is using a large amount of current to keep the battery charged 04C Inverter Charger Amps AC This menu item displays the AC amperage A positive amp reading indicates the inverter charge...

Page 242: ...ency of the AC source 04J Max Bulk EQ Time h m This menu item display shows the time the system has been charging the batteries in either bulk absorption or equalize mode 04K Battery Temp Degrees C Th...

Page 243: ...ceeded their designed operating temperature and the inverter will shut off If the unit is operating as a battery charger when this error condition occurs the inverter stops charging to prevent further...

Page 244: ...y Voltage If yes is visible in this display the battery voltage has dropped below the 11C Low Battery Cutout VDC setting continuously for the 11D LBCO Delay Minutes period When a battery protection fa...

Page 245: ...e AC source is within acceptable tolerances 05F External Err Stacked If Yes is displayed then the inverter showing the error Inverter 1 has received a shutdown command from the stacked inverter Invert...

Page 246: ...ates the error Whenever this error occurs the inverter is prevented from starting the generator until this error is cleared To clear this error select OFF from menu item 02A Generator Determine and co...

Page 247: ...g a float charge if Float is selected or a silent charge as necessary if Silent is selected 06C Gen Signaled to Run If Yes is displayed the generator was issued a command to start This menu item only...

Page 248: ...he inverter has received an Emergency Power OFF Shutdown command from an externally located shut off switch to the inverter s EPO Port 07 GSM ALM Options Menu The 07 GSM ALM Options Menu displays the...

Page 249: ...en displayed at or below the level set in menu item 23B RY9 DeEnergized 07E RY10 ALM Energized If Yes is displayed the inverter has sent out a command to energize the RY10 relay between the N O to COM...

Page 250: ...8 32...

Page 251: ...9 Troubleshooting Chapter 9 Troubleshooting contains information and procedures for solving possible problems with the Sine Wave Plus...

Page 252: ...INVERT LED is on with no ERROR LED Open AC output breakers or fuses and bad output wire connections Look at the ICM display under 04F Inverter Volts AC and check AC voltage on the inverter AC terminal...

Page 253: ...uorescent Bulbs These work the opposite of incandescent light bulbs If the inverter is set to detect a 30 watt load and a 40 watt fluorescent is switched on the inverter will not detect it This is bec...

Page 254: ...hronize and charge unless you are within the 21 Grid Usage timer period AC1 or AC2 LED is flashing but will not start charging allow 40 seconds to synchronize AC frequency at the AC input terminal may...

Page 255: ...reaker on top of unit press on breaker button to ensure it is engaged Cool the unit down or check the inverter cooling fan or check for anything preventing air flow Charger drops off before full charg...

Page 256: ...e if your voltage returns to the bulk float voltage The red Error LED and the STATUS LED illuminate at the same time and the inverter shuts down The inverter has detected a low battery voltage conditi...

Page 257: ...w intake may be blocked Charging setting is too high based on ambient temperature around inverter Check for high input AC voltage Remove excessive loads Let inverter cooldown and try restarting Hold a...

Page 258: ...FF selection If you do have an automatic start generator that is started by the inverter test by selecting ON Measure the AC voltage on the AC2 input terminals while the generator is starting Check th...

Page 259: ...A Inverter Specifications Appendix A Inverter Specifications provides the electrical and environmental specifications of this inverter...

Page 260: ...0 Vac Inverter Voltage Regulation 3 3 Frequency Nominal 0 04 Crystal Controlled Invert Mode 60 Hz 60 Hz Continuous Output 25 C 21 amps rms 21 amps rms Surge Capability 25 C 5 second rating resistive 8...

Page 261: ...c Inverter Voltage Regulation 3 3 3 Frequency Nominal 0 04 Crystal Controlled Invert Mode 60 Hz 60 Hz 60 Hz Continuous Output 25 C 33 amps rms 33 amps rms 46 amps rms Surge Capability 25 C 5 second ra...

Page 262: ...to 284 F 55 C to 140 C Enclosure Type Indoor ventilated Galvaneel steel chassis with powder coat finish Indoor ventilated Galvaneel steel chassis with powder coat finish Unit Weight 105 lb 48 kg 105 l...

Page 263: ...aneel steel chassis with powder coat finish Indoor ventilated Galvaneel steel chassis with powder coat finish Indoor ventilated Galvaneel steel chassis with powder coat finish Unit Weight 117 lb 53 kg...

Page 264: ...ch is typically 3 5 The multi stepped output is formed by modulation of the voltage through mixing of the transformers in a specific order Anywhere from 34 52 steps per AC cycle are present in the wav...

Page 265: ...the AC source Bi Directional Topology The inverter s power topology is bi directional If the waveform created by the inverter has a higher voltage than the paralleled AC source then power flows from...

Page 266: ...oads Inductive loads such as motors are run less efficiently due to the impact of power factor losses The Sine Wave Plus offers an extremely good efficiency curve The inverter reaches high efficiency...

Page 267: ...3500 4000 4500 5000 5500 Output Power in Watts Efficiency Measurement smade using resistiveload bank and Yokogawa WT2030 Digit al Power Meter or Yokogawa PZ4000 Power Analyzer SWPlus2524 SWPlus5548 S...

Page 268: ...ve 0 10 20 30 40 50 60 70 80 90 100 0 500 1000 1500 2000 2500 Output Power in Watts Efficiency M easurements made using resistive load bank and Yokogawa WT 2030 Digital Power M eter SW Plus 4024 Effic...

Page 269: ...30 40 50 60 70 80 90 100 0 500 1000 1500 2000 2500 3000 3500 4000 Output Power in Watts Efficiency M easurements made using resistive load bank and Yokogawa PZ4000 Power Analyzer SW Plus 5548 Efficien...

Page 270: ...a lower current as the temperature rises Therefore the surge ability of the unit decreases with increased temperature This table refers to output VA only Testing was conducted in a thermal chamber wi...

Page 271: ...ir continuous power ratings This graph shows how loads that are larger than the inverter can sustain continuously can be operated for useful periods of time The length of time that the inverter can op...

Page 272: ...Inverter Specifications A 14 976 0043 01 02 Figure A 10 Time versus Current for the Sine Wave Plus 2548 Figure A 11 Time versus Current for the Sine Wave Plus 4024...

Page 273: ...Time versus Current 976 0043 01 02 A 15 Figure A 12 Time versus Current for the Sine Wave Plus 4048 Figure A 13 Time versus Current for the Sine Wave Plus 5548...

Page 274: ...A 16...

Page 275: ...B Configuration Settings Appendix B Configuration Settings provides worksheets for programming your inverter charger for user specific parameters...

Page 276: ...01B EQ Charge OFF ON OFF OFF ON OFF 01C Search Watts SRCH 00 to 248 08 00 to 248 08 01D Bypass Mode AC1 NORM AC2 NORM AC1 NORM AC2 NORM 02 Generator ON OFF Menu See 02 Generator ON OFF Menu on page 8...

Page 277: ...0 00 to 23 50 Read Only 00 00 to 23 50 Read Only 04K Battery Temp Degrees C 28 to 60 OL Read Only 28 to 60 OL Read Only 04L Fan Speed 00 01 02 03 04 Read Only 00 01 02 03 04 Read Only 05 Error Causes...

Page 278: ...own NO YES Read Only NO YES Read Only 07 GSM ALM Menu See 07 GSM ALM Options Menu on page 8 30 for details 07A RY7 GSM Energized NO YES Read Only NO YES Read Only 07B RY8 GSM Energized NO YES Read Onl...

Page 279: ...00 to 00 09 00 00 00 00 10C Set Second 00 to 59 00 00 00 00 to 59 00 00 00 11 Inverter Setup Menu See 11 Inverter Setup Menu on page 6 12 for details 11A High Battery Cut Out Vdc 16 1 to 34 0 32 0 32...

Page 280: ...4024 Sine Wave Plus 4048 User Settings Basic Setup Menus Range Display Default Range Display Default 10 Time of Day Setup Menu See 10 Time of Day Setup Menu on page 6 11 for details 10A Set Hour 00 0...

Page 281: ...d LeadAcid LeadAcid NiCad LeadAcid 13 AC Inputs Menu See 13 AC Inputs Menu on page 6 26 for details 13A Grid AC1 Amps AC 00 to 60 60 00 to 60 60 13B Gen AC2 Amps AC 00 to 60 30 00 to 60 30 13C Input U...

Page 282: ...67 8 44 0 11D LBCO Delay Minutes 01 to 255 15 11E Search Watts SRCH 00 to 248 08 12 Battery Charging Menu See 12 Battery Charging Menu on page 6 19 for details 12A Finish Stage SILENT FLOAT FLOAT 12B...

Page 283: ...Settings 14B Push GEN to restore settings Push GEN to restore settings 14C Push GEN for factory defaults Push GEN for factory defaults Table B 4 Basic Setup Default and User Settings for the Sine Wave...

Page 284: ...Done Amps AC 00 to 40 10 00 to 40 10 20D Must Float Time Min 00 to 255 05 00 to 255 05 21 Grid AC1 Usage Menu See 21 Grid AC1 Usage Menu on page 7 16 for details 21A Grid Usage SB BX SB BX SB SB BX S...

Page 285: ...1 RN2 GS GS RN1 RN2 GS 25B Gen Warmup Second Minute 0 to 127 0 to 127 10 Seconds 0 to 127 0 to 127 10 Seconds 25C Pre Crank Seconds 00 to 255 10 0 to 255 10 25D Max Crank Seconds 01 to 15 10 01to15 10...

Page 286: ...Setup Menus Sine Wave Plus 4024 Sine Wave Plus 4048 User Settings Range Display Default Settings Range Display Default Settings 20 Silent Setup Menu See 20 Silent Setup Menu on page 7 13 for details...

Page 287: ...255 30 00 to 255 30 24F Gen Exercise Timer Min 00 to 255 15 00 to 255 15 24G Gen Cooldown Timer Min 00 to 255 02 00 to 255 02 24H RN2 Gen Run h m 00 00 to 23 50 08 00 00 00 to 23 50 08 00 25 Gen Start...

Page 288: ...dvanced Setup Menus Sine Wave Plus 5548 User Settings Range Display Default Settings 20 Silent Setup Menu See 20 Silent Setup Menu on page 7 13 for details 20A Refloat High Volts DC 32 2 to 67 8 56 8...

Page 289: ...et Time Begin h m 00 00 to 23 50 08 00 24D Quiet Time End h m 00 00 to 23 50 08 00 24E Gen Exercise Period Days 00 to 255 30 24F Gen Exercise Timer Min 00 to 255 15 24G Gen Cooldown Timer Min 00 to 25...

Page 290: ...c Start LBCO setting 11C 44 0 27 Save Restore Setup Menu See 27 Save Restore Settings Menu on page 7 39 for details 27A Push INV now to save Settings Push INV now to save Settings 27B Push GEN to rest...

Page 291: ...x C 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 292: ...of chemistries Batteries can be either sealed or non sealed vented Deep discharge The battery types recommended for use in an inverter system are Flooded Lead Acid FLA Sealed Gel Cells GEL Sealed Abs...

Page 293: ...system and 24 cells for a 48 volt system The number of cells required in a battery bank for alkaline batteries must therefore be adjusted for a 24 and 48 volt system i e 20 cells for a 24 volt system...

Page 294: ...ischarge rate 72 hour rate will result in a larger number of amp hours being available for electrical loads Calculation This calculation shows how to determine the level of current drawn from a batter...

Page 295: ...available energy If an engine generator is part of the system design the days of autonomy can be determined by simply deciding how often you are prepared to run the generator Significant battery cost...

Page 296: ...will use the appliance For example you use the microwave every day but a breadmaker only once a week If you use an appliance for less than an hour express the time as a decimal portion of an hour Amps...

Page 297: ...column 4 Multiply Hours x Days for each load identified to determine the watt hours per week 5 Add the total watt hours per week for all loads then divide by 7 to obtain the average total watt hours p...

Page 298: ...owever you should try to find the exact wattage on the appliance label Table C 2 Determining Battery Bank Size Average amp hours per day 95 Divided by inverter efficiency 90 for Sine Wave Plus 0 9 Div...

Page 299: ...DC requirements and run time for operating the AC loads This voltage must match the DC requirements of the inverter Batteries with more than two or three series strings in parallel often exhibit poor...

Page 300: ...ies in a parallel configuration The Sine Wave Plus is not available in a 12 volt unit Figure C 2 12 volt Battery Wiring Series Configuration 12 V 12 V 48 V INV ERTER Total battery capacity 100 A h 12...

Page 301: ...s 24 volts shown in Figure C 4 and Figure C 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 batteries in paralle...

Page 302: ...tring one and negative cable to string two for inverter 2 as shown in the diagram below Figure C 6 Series Parallel Configuration Wired to the Inverter 12 V 12 V 12 V 12 V 12 V 12 V 12 V 12 V 48 V INVE...

Page 303: ...age 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 volta...

Page 304: ...3 1 20 0 80 2 40 1 60 40 104 0 90 0 60 1 80 1 20 35 95 0 60 0 40 1 20 0 80 30 86 0 30 0 20 0 60 0 40 25 77 0 00 0 00 0 00 0 00 20 68 0 30 0 20 0 60 0 40 15 59 0 60 0 40 1 20 0 80 10 50 0 90 0 60 1 80...

Page 305: ...gets watery This effect is called stratification Frequency Every month or two the batteries should be equalize charged Note If the battery temperature is allowed to fall to extremely cold temperatures...

Page 306: ...s 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 periods...

Page 307: ...batteries in the bank should measure the same voltage this is not an accurate measurement for cross tied batteries as each battery is in parallel with another battery making individual battery measur...

Page 308: ...C 18...

Page 309: ...This information is provided for basic reference only Because of the wide variety of generator circuits available Xantrex cannot be held responsible for the accuracy of the information provided Alway...

Page 310: ...to the generator running when it is in an over temperature or low oil condition etc Since these generators are not designed for unattended operation the generator supplier should be consulted regardin...

Page 311: ...S Many diesel generators are controlled like the Onan 3 wire type with the exception that they also require glow plugs to be operated before a generator start is attempted The inverter s automatic gen...

Page 312: ...D 4...

Page 313: ...charge protection This information is provided for basic reference only Because of the wide variety of over charge protection available Xantrex cannot be held responsible for the accuracy of the info...

Page 314: ...ts the batteries from exceeding a user specified voltage level This preserves and extends the life of the battery by preventing the damage caused by overcharging The charge controller can also take ov...

Page 315: ...nect should open trip or the batteries are fully charged and no other DC loads are connected in the system A diversion load controller prevents damage to the generator system by diverting the power fr...

Page 316: ...E 4...

Page 317: ...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 318: ...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 current b...

Page 319: ...d 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 White N...

Page 320: ...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 haza...

Page 321: ...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 can...

Page 322: ...eutral 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 Br...

Page 323: ...G Emergency Power Off Switches Appendix G Emergency Power Off Switches supplies information about the requirements for installing an Emergency Power Off Switch...

Page 324: ...ts To provide a shutdown solution the Sine Wave Plus includes a feature that when utilized with a properly marked switch can disable and shutdown the system The Sine Wave Plus is one of the first rene...

Page 325: ...nverter output and the sub essential loads panel When the EPO switch is activated as described above the inverter shuts down and a separate set of contacts provides the signal to trip the shunt trip c...

Page 326: ...ignating Shunt Trip Main Disconnect shall be located on the exterior of the building or structure and approximately one foot 1 above and one foot 1 to one side of the shunt trip mechanism Service disc...

Page 327: ...gular intervals For example 120 Vac 60 Hz power reverses flow 60 times a second hence the rating 60 Hz cycles Amp A measurement of the flow of electrical current One amp is equal to the electric force...

Page 328: ...r number of times per second that the flow of AC electricity reverses itself Also referred to as cycles see alternating current High Battery Protection A control circuit that disconnects charge curren...

Page 329: ...modified square wave National Electric Code The electrical wiring and installation standards used in the United States Off Grid An electrical system that is not connected to a utility distribution gr...

Page 330: ...ity being supplied to loads appliances for example from one source of power to another A transfer switch may be used to designate whether power to a distribution panel will come from a generator or in...

Page 331: ...ndards Association DC Direct Current DCCB DC Conduit Box EMI Electro Magnetic Interference EPO Emergency Power Off FLT Float relates to battery charging FCC Federal Communications Commission GEN Gener...

Page 332: ...C Personal Computer PV Photovoltaic solar electric panels PVGFP PV Ground Fault Protection RE Renewable Energy RFI Radio Frequency Interference RMA Return Material Authorization SB Stand By SLT Silent...

Page 333: ...ntrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion...

Page 334: ...uct if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product i...

Page 335: ...may vary from state to state or province to province Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFICALLY PLEASE NOTE THAT THE SINE WAVE...

Page 336: ...ex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any...

Page 337: ...tion e g RV truck ________________________________ Length of time inverter has been installed ________________________________ Battery battery bank size ________________________________ Battery type e...

Page 338: ...I 6...

Page 339: ...correct size 2 13 length requirements 2 13 battery enclosures safety requirements for 2 11 battery status meter features of 2 25 battery temperature sensor location 1 6 purpose 1 7 battery temperatur...

Page 340: ...ding conductor size 2 8 inverter location considerations 2 4 Inverter Mode Theory of Operation Output Waveform A 7 Inverter Panel Mounting 3 33 Inverter Stacking Control Series Cable see ISC S ISC S p...

Page 341: ...on batteries 2 17 Theory of Operation Output Waveform A 7 Three Wire Start Circuits D 2 Time of Use TOU metering applications of 2 45 TM500A features 2 25 Tools 3 2 Two Wire Start Circuits B 1 D 2 E 2...

Page 342: ...Index IX 4 976 0043 01 02...

Page 343: ......

Page 344: ...itish Columbia Canada V5A 4B5 800 670 0707 Tel Toll Free in North America 360 925 5097 Tel direct 800 994 7828 Fax Toll Free in North America 360 925 5143 Fax direct customerservice xantrex com www xa...

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