Xantrex Trace DR Series Page 44 Installation & Operator'S Manual Download

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3.0 OPERATION

Front Panel Controls and Indicators

All operating controls, indicators and sense connectors are located on the front panel of the unit.

The controls are easily accessible, and the LEDs provide inverter/charger status at a glance.

POWER ON/OFF Switch

The POWER ON/OFF control is a momentary contact switch that turns the inverter/charger

ON or OFF by pressing it once. When the inverter is first connected to the batteries, it will run

through a self test consisting of flashing the LEDs in sequence, operating the cooling fan

momentarily and switching the transfer relay three times. Once the self test has successfully

completed, the POWER ON/OFF switch is activated. Pressing the switch once turns the inverter

ON. Another press turns the inverter OFF.

Ports

There are two ports on the inverter/charger. Both ports are RJ11 type telephone style

connectors and are used for controlling the inverter and regulating the charger voltage based on

temperature.

COM PORT

COM PORT (J1) is a dual function RJ11 (6-pin) connector. Its primary function is to

provide serial communications to an optional Trace remote control unit (RC4 or RC8). The

port also acts as a stacking interface control when two DR Series inverters are used in a

series configuration. When two inverters are stacked, a remote control cannot be used with

either unit.

Remote Controls (RC4 or RC8)

DR Series inverters are designed to operate with either an RC4 or RC8 remote control

units. Both remotes incorporate a membrane switch with a single red LED display

combination to start and stop the inverter, as well as provide overall system operating status.

Solid

With AC line power present, the unit is charging the batteries while directing AC to

the load. With no AC line power present, the inverter is running on the batteries and

supplying AC to the load.

Blinking Slow (1 to 3 flashes @ 1 second intervals)

The inverter is in search mode (no load connected).

Blinking Fast (3 to 5 flashes @ 1 second intervals)

The inverter is charging the batteries.

Flickering (3 to 5 flashes @ 1 second intervals)

The inverter has detected an over-current error. The LED (and inverter) will turn OFF

whenever an over-current condition exceeds eight seconds.

Erratic Blinking (0 to 3 and 2 to 5 flashes @ 2 second intervals)

The inverter has detected an error condition caused by overheating, low battery

voltage, or high battery voltage.

OFF

The inverter is OFF.

The remote control must be connected prior to switching the inverter ON; otherwise, the

micro-controller will not recognize (or respond to) the remote. If the remote is not recognized,

switch the inverter OFF and then ON using the inverters front panel POWER ON/OFF

switch.

Stacking Interface

Whenever two DR Series inverters are used in a series (stacked) configuration, one unit

(primary) controls the other unit (secondary). Communication between the two inverters is done

via the COM port (J1). The first unit switched ON, using its front panel POWER ON/OFF switch,

becomes the controlling (primary) inverter.

Summary of Contents for Trace DR Series

Page 1: ...Installation Operator s Manual DR Series Inverter Charger ...

Page 2: ......

Page 3: ... 5 Pre installation 6 Location 6 Mounting 6 Ventilation 6 Tools Required 7 Hardware Materials Required 7 Wiring 7 AC Connections 7 DC Connections 7 Grounding 7 AC Grounding 7 DC Grounding 7 Batteries 8 Battery Location 8 Battery Temperature 8 Main Service Panel 10 Sub Panel 10 AC Circuit Breakers 10 DC Disconnect 10 Wire Routing 10 Inverter Mounting 11 Wiring 13 DC Wiring Batteries 13 Battery Cabl...

Page 4: ...AC Generator Hookup non utility applications only 31 Basic 120 VAC Utility Generator Hookup 32 Generator Connections to manual bypass switch 32 Utility Connections to manual bypass switch 32 Inverter Connections to manual bypass switch 32 Sub panel Connections 32 Series Stacking 34 3 0 OPERATION 36 Front Panel Controls and Indicators 36 Power ON OFF Switch 36 Ports 36 COM Port 36 Remote Controls 3...

Page 5: ... 55 Flooded Lead Acid FLA 55 RV and Marine 55 Golf Cart 55 Industrial electric forklift 55 Sealed Batteries 55 Gel Cell 55 Absorbed Glass Mat 55 NiCad and NiFe Batteries 56 Battery Bank Sizing 57 Estimating Battery Requirements 57 Example 58 Typical Appliance Wattages 60 Battery Care and Maintenance 61 Charge Rate 61 Bulk Charge 61 Float Voltage 61 Temperature Compensation 61 Equalization Charging...

Page 6: ... methods of installation operation use and maintenance of the unit are beyond the control of Xantrex Technology Inc the company does not assume responsibility and expressly disclaims liability for loss damage or expense arising out of or any way connected with such installation operation use or maintenance ...

Page 7: ... important Follow instructions closely NOTE Cette déclaration est importante Suivre les instructions de près All electrical work must be done in accordance with local national and or international electrical codes Before installing or using this device read all instructions and cautionary markings located in or on the manual the inverter the controller the batteries and the PV array Do not expose ...

Page 8: ...ldup of explosive gasses If the batteries are installed inside an enclosure vent its highest point to the outdoors When installing batteries allow at least 1 inch of air space between batteries to promote cooling and ventilation NEVER smoke in the vicinity of a battery or generator Always connect the batteries first then connect the cables to the inverter or controller This will greatly reduce the...

Page 9: ...erator power while charging the batteries When utility power fails the battery backup system keeps your appliances powered until utility power is restored Internal protection circuits prevent over discharge of the batteries by shutting down the inverter when a low battery condition occurs When utility or generator power is restored the inverter transfers to the AC source and recharges the batterie...

Page 10: ... the unit should require warranty service Save the original shipping carton and packing materials If the inverter ever needs to be returned for service it should be shipped in the original carton This is also a good way to protect the inverter if it ever needs to be moved Record the unit s model serial number and date of purchase in the appropriate fields in section 10 0 SERVICE INFORMATION NOTE D...

Page 11: ...The model number describes the type of inverter the output specifications the required battery voltage and the output voltage and frequency DR indicates the type of inverter charger DR Series 15 the first two digits of the numerical designator indicate the inverter s output power 1500 Watts 12 the second two digits indicate the required nominal battery bank voltage 12 VDC E the letter suffix code ...

Page 12: ...verter charger has been tested to nationally recognized safety standards UL for the US and CSA for Canada and have been found to be free from reasonably foreseeable risk of fire electric shock and related hazards The inverter charger is intended to be used for residential or commercial applications Do NOT use this unit for applications for which it is not listed i e land vehicles or marine craft I...

Page 13: ...ble time The built in fully automatic AC transfer relay automatically transfers power from the utility to the inverter and handles a full 60 amps of current at 120 VAC 30 amps for pass through plus 30 amps for charging Simplicity The DR Series is simple to operate All inverter and battery charger controls are located on the front panel High Efficiency The inverter charger operates at over 90 effic...

Page 14: ...by connecting the battery cables or switching a relay could ignite this mixture Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable NOTE Inverters can generate RFI Radio Frequency Interference Locate any sensitive electronic equipment susceptible to RFI as far away from the inverter as possible This includes radios and TVs Mounting UL Standard 1741 requires the inve...

Page 15: ...both AC and DC cables in conduit Refer to the Figure 25 page 29 for an example of AC wiring to the sub panel for 120 VAC circuits AC Connections Use 6 AWG THHN wire for all AC wiring DC Connections Battery to inverter cabling should be only as long as required If 4 0 AWG cables are used for example do not exceed 5 feet one way in 12 VDC systems do not exceed 10 feet one way in 24 VDC systems For o...

Page 16: ...ure Install an intake vent at the bottom of the enclosure to promote air circulation These vents exhaust explosive hydrogen gases and must not be overlooked when designing an enclosure The enclosure should be made of an acid resistant material or have a finish that resists acid to prevent corrosion It should be capable of holding the electrolyte from at least one battery should a leak occur Place ...

Page 17: ...TTERY ENCLOSURE if used 975 0012 001 DC DISCONNECT VENT outlet VENT inlet MAIN PANEL SUB PANEL INVERTER CHARGER AC CONDUIT AC CONDUIT TO SUB PANEL DC CONDUIT if used CONDUIT BOX if used BATTERIES BATTERY ENCLOSURE if used 975 0012 002 DC DISCONNECT VENT outlet VENT inlet DC GROUND MANUAL AC TRANSFER SWITCH AC GENERATOR externally located DC DISCONNECT AND PVGFP DC CHARGE CONTROLLER ALTERNATE DC EN...

Page 18: ...an accidental short Size the breaker in accordance with the battery cables Switch this breaker OFF whenever servicing the batteries Wire Routing Determine all wire routes both to and from the inverter and which knockouts are best suited for connecting the AC conduits Possible routing scenarios include AC Input wiring from the main utility service panel to the inverter charger AC Input wiring from ...

Page 19: ...E ON HAND TO ASSIST IN LIFTING THE INVERTER INTO POSITION WHILE IT IS BEING SECURED Procedure Locate the studs and mark their location on the wall Measure the desired height from the floor for the inverter to be mounted Using a level run a horizontal line The length of the line must span at least 3 studs Place a pre cut 2 x 4 on the marked location and drill pilot holes through the 2 x 4 s and stu...

Page 20: ...r mounted directly to the plywood using 1 4 inch diameter lag bolts and washers The plywood must span three studs for adequate support 20 175 inches 51 244 cm 1 90 inches 4 83 cm 7 00 inches 17 8 cm 7 00 inches 17 8 cm 16 00 inches 40 64 cm 14 00 inches 35 56 cm 8 00 inches 20 32 cm 7 640 inches 19 40 cm 8 370 inches 21 25 cm TERMINAL TERMINAL 1 00 inches 2 54 cm 0 365 inches 0 93 cm DC SIDE AC SI...

Page 21: ...d at the inverter s peak power rating exceeding one hour larger cables and disconnects MUST be used see Tables 1 and 2 NOTE If the system includes a large battery bank or large DC source such as a micro hydroelectric plant or wind generator increasing the size of the cables and disconnects will greatly reduce the number of nuisance outages associated with breaker tripping and open fuses Table 1 pr...

Page 22: ... for long cable runs Also the plastic red and black covers on the DC inverter inputs are not designed to accommodate dual cables If dual cables are used the optional conduit box DRCB must be used Some installations may not require conduit or a disconnect device although over current protection is still required Xantrex offers a fuse block TFB providing the code required inverter over current prote...

Page 23: ...the battery cables to the DR Series inverter charger terminals 2 0 Copper Compression Lug 2 0 Aluminum Mechanical Lug Do not place anything between battery cable lug and terminal surface Assemble exactly as shown Figure 9 Battery Cable Connections to Inverter CAUTION THE INVERTER IS NOT REVERSE POLARITY PROTECTED REVERSING THE BATTERY POLARITY ON THE DC INPUT CONNECTIONS WILL CAUSE PERMANENT DAMAG...

Page 24: ...ile starting battery and deep discharge applications Only the deep discharge types are recommended for inverter applications Choose the batteries best suited for the inverter installation and cost Use only the same battery type for all batteries in the bank For best performance all batteries should be from the same lot and date This information is usually printed on a label located on the battery ...

Page 25: ...ng Batteries in Series Wiring the batteries in a series configuration increases the voltage of the battery string 6 volt batteries can be combined to form 12 V 24 V or 48 V battery banks In the same way 12 volt batteries connected in series form 24 V or 48 V battery banks The total current capacity of the bank does not increase and it retains the same amp hour rating as a single battery Figure 12 ...

Page 26: ...g Batteries in Series Parallel Wiring the batteries in a series parallel configuration increases the current and voltage of the battery bank Series parallel wiring is more complicated and care should be taken when wiring these banks To construct a series parallel battery bank follow these instructions Step 1 First wire the batteries in series voltage adds with the positive terminal of one battery ...

Page 27: ...a fused device Connect the NEGATIVE terminal of the second battery string to the inverter s NEGATIVE DC terminal NOTE Connecting the positive and negative wires to the inverter from different strings ensures a balanced charge discharge through the batteries resulting in longer run times and improved battery life Figure 16 Step 3 Series Parallel Configuration Wired to the Inverter 12 V 12 V 3597 F0...

Page 28: ...ore these dashed lines 6 V 6 V 3597 F00 D32 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V 6 V Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie cable not required Cross tie ...

Page 29: ...d Cross tie cable not required Cross tie cable not required Cross tie cable not required Fuse Block Disconnect 12 V 12 V 3597 F00 D34 12 V 12 V Cross tie cable not required Cross tie cable not required Fuse Block Disconnect 24 V INVERTER Total battery capacity 100 Ah Figure 18 12 Volt Battery Wiring Series Parallel Configuration with optional cross tie wiring Wiring continued Cross Tying Series Pa...

Page 30: ...s recommendations Ensure the correct polarity of the cables with a DC voltmeter DVM Observing battery polarity connect the positive battery cable from the over current device to the inverter s positive terminal NOTE The next step may cause a small spark and snapping sound when connecting the cable to the inverter This is normal and is caused by the inverter s capacitors charging up Observing batte...

Page 31: ...ing to NEC 250 95 see table below for a portion of the NEC code Size of Over current Device Protecting the Conductor Minimum Size of Copper Ground Wire 30 or 60 amp 10 AWG 100 amp 8 AWG 200 amp 6 AWG 300 amp 4 AWG 400 amp 3 AWG 3597 000 018 Table 3 Safety Ground Wire Size General DC Grounding Requirements Connect the negative terminal of the battery bank to an appropriately sized conductor and con...

Page 32: ...ing overcharging in warm temperatures and undercharging in cold temperatures Installing the sensor Run the battery temperature sensor wire in the DC conduit if used and route the RJ11 connector end to the BATTERY SENSE jack located on the front of the inverter Secure the sensor to one of the batteries located in the center the battery pack Figure 20 BTS RJ11 Jack Location Figure 21 BTS Installed o...

Page 33: ... stacked configuration install two 60 amp circuit breakers for 240 VAC service one in each leg of the circuit for L1 and L2 Input to the Inverter CAUTION THE INVERTER S AC OUTPUT MUST NEVER BE WIRED TO THE UTILITY OR GENERATOR OUTPUT THIS WILL CAUSE SEVERE DAMAGE TO THE INVERTER WHICH IS NOT COVERED UNDER WARRANTY All AC wiring connects to the terminal block located on the right hand side of the i...

Page 34: ...2 8 or 6 AWG 10 AWG 12 AWG 16 AWG DR2412 6 AWG 10 AWG 10 AWG 14 AWG DR1524 8 or 6 AWG 10 AWG 12 AWG 16 AWG DR2424 8 AWG 10 AWG 10 AWG 14 AWG DR3624 6 AWG Not Available 8 AWG Not Available 975 0012 007 AC Wiring Before wiring the input of the inverter refer to the table below for the minimum recommended wire size NOTE Refer to the NEC for actual wire sizes for specific installations ...

Page 35: ...nstall a 60 amp circuit breaker in the utility service panel This will serve as both an AC disconnect and over current protection Feed the HOT NEUTRAL and GROUND wires via conduit from the inverter to the main utility box Leave several inches of extra wire at each end Make the connections to the inverter first Wiring to the utility breaker box is performed after all connections have been made in t...

Page 36: ...e to the inverter s AC GROUND chassis terminal Connect the other end of this wire to the GROUND bus in the sub panel Connect the NEUTRAL white wire to the inverter s NEUTRAL OUTPUT terminal Connect the other end of this wire to the NEUTRAL bus in the sub panel Connect the HOT black wire to the inverter s terminal labeled AC HOT OUTPUT Connect the other end of this wire to the sub panel s input cir...

Page 37: ...P POWER TO LOAD 120 VAC 120 VAC 240 VAC GROUND CAUTION NEUTRAL BONDED TO GROUND IN MAIN PANEL ONLY NEUTRAL 3597 W00 C06 Figure 25 Single Inverter 120 VAC Wiring Diagram AC Wiring continued AC Input Wiring to the Main Utility Breaker Box single inverter installations WARNING MAKE CERTAIN THE POWER TO THE MAIN UTILITY BOX IS DISCONNECTED NEVER WORK ON LIVE CIRCUITS Remove the MAIN UTILITY BOX s cove...

Page 38: ...f energy to the charger The charger s rated output is based on a utility voltage of 120 VACrms which has a peak voltage of 169 VACp 230 VACrms has a peak voltage of 325 VACp Low power generators may not produce enough voltage under heavy load conditions to fully charge the batteries as the voltage peaks may be clipped limiting the maximum charge rate Size the generator appropriately for the system...

Page 39: ...the output of the generator only if used in non utility installations or in the MAIN SERVICE PANEL not both Drive a ground rod 6 8 feet into the ground and connect the generator s ground to the ground rod NOTE The ground and neutral must be bonded at one place and only one place in the system If the generator is the main source of power i e no utility grid power then the neutral and ground connect...

Page 40: ...MAIN UTILITY PANEL and the GROUND terminal in the manual bypass switch Connect a white wire between the NEUTRAL bus in the MAIN UTILITY PANEL and the NEUTRAL bus in the manual bypass switch Connect a black wire between the inverter circuit breaker in the MAIN UTILITY PANEL and the UTILITY HOT contact in the manual bypass switch Inverter Connections to manual bypass switch Connect a green wire betw...

Page 41: ... HOT NEUTRAL Isolated Neutral Bus Isolated Neutral Bus Isolated Neutral Bus Bonded Neutral Ground Bus House Ground HOT NEUTRAL HOT NEUTRAL GROUND UTILITY HOT CONTACT GENERATOR HOT CONTACT 975 0012 008 COMMOMN CONTACT to inverter AC Input AC Output Main Utility Circuit Breaker Inverter Circuit Breaker N E U T R A L G R O U N D Bond Wire U G C Main Input Breaker Figure 27 Basic 120 VAC Utility Gener...

Page 42: ...AC operation Both units can charge the batteries or provide battery backup power during a utility outage The following illustrations provide a general overview of AC and DC wiring configurations and output voltages supplied by stacked inverters Detailed wiring and operating instructions are provided with the DRI interface kit available from Xantrex Technology Inc NOTE Only 120 VAC 60 Hz models can...

Page 43: ...ect 120 VAC 60 Hz models only Figure 30 Stacking Port and Battery Wiring with Two Disconnects 120 VAC 60 Hz models only DC Disconnect Negative Tie Series Stacking Cable DRI 975 0012 009 Positive Tie Inverter 1 L1 Inverter 2 L2 DC Disconnect Negative Tie Series Stacking Cable DRI 975 0012 010 DC Disconnect Inverter 1 L1 Inverter 2 L2 ...

Page 44: ...ers are designed to operate with either an RC4 or RC8 remote control units Both remotes incorporate a membrane switch with a single red LED display combination to start and stop the inverter as well as provide overall system operating status Solid With AC line power present the unit is charging the batteries while directing AC to the load With no AC line power present the inverter is running on th...

Page 45: ...he batteries receive a full charge and lowers it during warm temperatures reducing battery gassing and providing overcharge protection Refer to the Installation section for the BTS location on the battery Front Panel Controls and Indicators continued Figure 33 Front Panel Controls and Indicators COM PORT POWER ON OFF Switch INVERTER MODE LED SEARCH MODE WATTS OVER TEMP OVERLOAD BATTERY HIGH RED LE...

Page 46: ... recommendation for Float and Bulk settings 3 Not Specified Provides an additional set of Bulk and Float voltages Switch Position Description 12 Volt Models 24 Volt Models Equalize Float Voltage Bulk Equalize Voltage Float Voltage Bulk Equalize Voltage Charge Rate Time 0 Equalize 1 13 2 15 0 26 4 30 0 Battery Capacity Setting C 40 6 hours minimum 12 hours maximum 1 Equalize 2 13 2 15 5 26 4 31 0 B...

Page 47: ...4 GEL Cell 2 Recommended for gel cell batteries that specify high float voltages Check with the battery s manufacturer 5 GEL Cell 1 Typical gel cell setting 6 PbCa Lead Calcium Use this setting for sealed type car batteries 7 Deep Cycle Lead Acid Factory setting for typical deep cycle lead acid batteries 8 NiCad 1 Use for NiCad battery systems 9 NiCad 2 Recommended for use with nickel iron batteri...

Page 48: ...verter is in the SEARCH MODE Slowly turn the potentiometer CCW toward MIN when the proper setting is found the lamp and INVERTER MODE LED will light steady Turn the lamp OFF for a moment the inverter should switch back to the SEARCH MODE Turn the lamp ON ensure the inverter comes out of the Search Mode Adjust the potentiometer up or down as necessary NOTE The Search Mode only activates when the un...

Page 49: ...l batteries Divide the amp hour capacity by 5 250 5 50 Set the potentiometer to approximately 71 50 amps Use the table below to find the approximate setting of the Battery Charge Rate potentiometer The settings do not need to be exact but should be as close as possible to the actual value required NOTE The potentiometer does not have an arrow to indicate its position Use a small blade screwdriver ...

Page 50: ...w battery cutoff to protect the batteries from over discharge damage The inverter circuitry calculates the lowest safe DC voltage leaving approximately 20 battery capacity based on the position the Battery Type Selector switch and the amount of current drawn by the load Under no load conditions this level is typically between 11 8 and 12 0 VDC for a 12 volt battery bank NOTE The range of set point...

Page 51: ...fect the operation of the AC Transfer Voltage ODP is either ON or OFF depending upon the position of the potentiometer NOTE There are 6 settings available for the AC Transfer Voltage for both ODP OFF and ON as shown in the Table 9 below NOTE To achieve the fastest transfer time typically less than 16 ms set the AC Transfer Voltage potentiometer near the 2 00 o clock position with the ODP enabled o...

Page 52: ... between these values will allow the incoming source voltage to drop to this level and still operate the connected appliances load If the appliances do not operate properly at the lower AC utility pass through voltage increasing the setting of the potentiometer toward MAX allows the inverter to transfer to battery power providing full AC output during these periods NOTE When setting the AC Transfe...

Page 53: ...ible to the actual capacity of the battery bank for optimum charging If the system s battery bank is larger than 1000 amp hours set the potentiometer for 1K NOTE Most battery manufacturers list the amp hour rating on the battery label Figure 41A Battery Capacity Potentiometer New Figure 41B Battery Capacity Potentiometer Old 50 amp hours small battery bank 1000 amp hours use for 1000 amp hour or l...

Page 54: ... Overload LED Red Green error condition The Over Temp Overload LED is a dual color dual function indicator When the inverter s temperature is too high for safe operation the LED lights red to indicate the Over Temp condition When the temperature returns to a safe level the LED turns OFF If the condition persists the inverter will shut down cool and then restart Whenever the current draw exceeds a ...

Page 55: ...are detected LOW HIGH BATTERY OVER TEMPERATURE or a quick duration SHORTED OUTPUT or OVER CURRENT The inverter shuts OFF and requires a MANUAL restart if the following conditions are detected a prolonged overload condition approximately 10 seconds or the inverter s output is connected directly to an AC power source utility grid or generator Charger LED Orange Green The Charger LED is a dual color ...

Page 56: ...rcuit breaker protects the charger circuit The breakers are rated for the maximum charge rate and pass through current allowed according to the rating of the internal relay Table 11 Battery Charger Circuit Breakers Table 10 AC Pass through Circuit Breakers AC Pass through Circuit Breaker Charger AC Input Circuit Breaker Figure 43 AC Pass through and Charger AC Input Circuit Breakers Models DR15xx ...

Page 57: ...heck the output voltage of the inverter This voltage can be checked at either the AC terminal block or in the sub panel between the HOT and NEUTRAL lines The voltage should be 120 VAC 230 VAC for E models 220 VAC for W models or 105 VAC for J and K models Switch the AC disconnect circuit breaker to OFF The inverter will go into the inverter mode if a sufficient load is applied to the AC output whi...

Page 58: ...ly decreases When the current equals the programmed return amps value battery bank capacity 40 set with the BATTERY BANK CAPACITY potentiometer the charger switches to the third stage float NOTE If there are DC loads connected to the battery the current may never decrease to the level to initiate the float stage The inverter charger incorporates a timer circuit which starts counting when AC voltag...

Page 59: ... Charge Remove all DC loads connected to the batteries Remove all battery vent caps Check the battery water level it should be just over the top of the plates do not overfill Use only distilled water for filling batteries NOTE Recheck the water the level during equalize charging and refill if necessary Set the BATTERY TYPE SELECTOR switch to position 0 or 1 to start the equalization charging proce...

Page 60: ...6 6 30 0 3 Not Specified 13 6 14 3 27 2 28 6 4 Gel Cell 2 13 7 14 4 27 4 28 8 5 Gel Cell 1 13 5 14 1 27 0 28 2 6 PbCa Lead Acid 13 2 14 3 26 4 28 6 7 Deep Cycle Lead Acid 1 Default Setting 13 4 14 6 26 6 29 2 8 NiCad 1 14 0 16 0 28 0 32 0 9 NiCad 2 14 5 16 0 29 0 32 0 NOTES Switch positions 0 and 1 are for monthly battery maintenance only Return the switch to the appropriate position for the syste...

Page 61: ...AC DVM and measure the input voltatge Remove excessive loads Let inverter cool down before restarting Check inverter s cooling fan Check for obstructions in air vents Clean if necessary OVERLOAD LED green turns ON after the inverter was running large loads turns ON when the inverter is OFF flickers for 5 10 seconds then turns ON Loud hum when an AC source is connected to the inverter turns ON and ...

Page 62: ... side of the unit Check AC PASS THRU circuit breaker on the side of the inverter Check for open AC output breakers or fuses and AC wiring connections Charger is inoperative or supplying a low charge rate AC voltage has dropped out of tolerance Charger controls are improperly set Low peak AC input voltage 169 VACp required for full charger output AC current supplied from generator is too low Loose ...

Page 63: ...ar in small systems Often referred to as Group 24 or Group 27 batteries Designed for limited cycling Do not last as long as the other true deep cycle batteries Typically rated at 12 volts 80 to 100 amp hours Golf Cart Popular for smaller off grid home systems Many medium sized inverter systems use L16 batteries Rugged long lasting Typically rated at 6 volts 220 to 350 amp hours Industrial electric...

Page 64: ...ed for a 12 24 and 48 volt system i e 10 cells for a 12 volt system 20 cells for a 24 volt system and 40 cells for a 48 volt system Alkaline batteries require a higher charge voltage to fully recharge and drop to a lower voltage during discharge compared to a similarly sized lead acid type battery Another option for 24 volt only alkaline battery banks is to use only 19 cells instead of 20 This all...

Page 65: ... size the batteries at twice this amount to ensure the batteries are not regularly over discharged To compute the amp hour requirements the amp hour ratings of each appliance powered by the inverter must be added together Use the figures from the nameplate label on the appliances then use the formula WATTS VOLTS x AMPS Then divide the calculated wattage of the load by the system battery voltage to...

Page 66: ... Divide the number entered into each row of the Step 4 column by 7 to obtain the AVERAGE DAILY WATT HOURS REQUIRED figure Enter these figures in the Step 5 column Step 6 Add all the figures entered into the AVERAGE DAILY WATT HOURS REQUIRED Step 5 column and enter this number into the TOTAL DAILY WATT HOURS REQUIRED Step 6 column in the second table Step 7 Multiply the TOTAL DAILY WATT HOURS REQUI...

Page 67: ... Step 10 Divide the SAFE BATTERY SIZE WATT HOURS Step 9 figure by the DC system voltage i e 12 24 or 48 volts Enter this number in the SAFE BATTERY SIZE AMP HOURS Step 10 column Use this figure to determine the number of batteries required to reach the amp hour rating Step 1 AC Appliance Step 2 Step3 Step 4 Step 5 Appliance Running Watts x Hours Used Each Day x Days Used Each Week 7 Average Daily ...

Page 68: ...iance Watts Fluorescent type light 10 Blender 400 Computer 200 300 Toaster 1000 Microwave compact 600 800 Hot Plate 1800 Microwave full size 1500 Washer Dryer 375 1000 Stereo or VCR 50 3 8 Drill 500 Color TV 19 150 Hair Dryer or Iron 1000 Refrigerator 3 cu ft 180 Vacuum Cleaner 1200 Refrigerator 12 cu ft 480 Coffee Maker 1200 Refrigerators and icemakers typically run only 1 3 of the time therefore...

Page 69: ...p them in a ready state Temperature Compensation For optimal battery charging the Bulk and Float charge rate should be adjusted according to the temperature of the battery This can be accomplished automatically by using a Battery Temperature Sensor BTS The sensor attaches directly to the side of one of the batteries in the bank and provides precise battery temperature information Equalization Char...

Page 70: ... manual Clean Battery Cables and Posts WARNING BEFORE ATTEMPTING TO CLEAN THE BATTERY POSTS TURN OFF THE DC CIRCUIT BREAKER USE ONLY INSULATED TOOLS AND REMOVE ALL JEWELRY 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 of high current draw Use a st...

Page 71: ...less than a 0 2 volt difference between each battery To determine the individual cell voltage divide the voltage by the number of cells in the battery i e 12 6 V divided by 6 cells 2 1 volts per cell If a greater difference is measured the batteries may need to be equalized liquid lead acid types only or replaced All batteries in the bank should measure the same voltage this is not an accurate mea...

Page 72: ...Inexpensive tape recorders are likely to experience noise as well When using sensitive electronic devices avoid starting large loads Clocks The inverter s crystal controlled oscillator keeps the frequency accurate to within a few seconds a day however external loads in the system may alter the inverter s output waveform causing clocks to run at different speeds There may be periods where clocks ke...

Page 73: ...of power is added Microwave Ovens Microwave ovens are sensitive to peak output voltages The higher the voltage the faster they cook Since the inverter s peak output voltage is dependent upon battery voltage and load size the microwave s cook time may need to be increased Printers Most inkjet type printers work well in inverter applications Laser printers however require high current for their fusi...

Page 74: ...ausing the one neutral wire to now carry the in phase currents for both circuits Since the current is in phase the two circuits add instead of subtract potentially doubling the current flow in the neutral return wire Refer to Figure 51 The branch circuit breakers do not protect the neutral wire from overload under this condition This excess current will overheat the neutral wire potentially creati...

Page 75: ...ERFORMED BY QUALIFIED PERSONS OR ELECTRICIANS Multiwire branch circuits can be identified by removing the cover on the load center and inspecting the wiring Conventional 120 VAC circuits are identified by a 2 wire plus ground black white and copper romex for each circuit Multiwire branch circuits use a 3 wire plus ground arrangement black red white and copper for each circuit run Figure 49 If this...

Page 76: ... protection and can power 240 VAC loads Add a T240 Autotransformer to the output of the inverter to restore the split phase configuration This is the least expensive and easiest method to correct for multiwire branch circuit wiring Refer to Figure 53 Using this method half of the current is supplied to one leg of the circuit and half to the other in a split phase arrangement 180 out of phase This ...

Page 77: ... products must be returned to Xantrex or its Authorized Service Center in the original packaging or equivalent The cost of transportation and insurance on items returned for service is the responsibility of the customer Return transportation UPS Ground or equivalent as well as insurance on all repaired items is paid by Xantrex All remedies and the measure of damages are limited to the above Xantre...

Page 78: ...knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to The Company that a the risks of injury or damage have been minimized b the customer assumes all such risks and c the liability of Xantrex is adequately protected Warranty Registration To ensure proper registration complete the Warranty Card and mail it to Xantrex within 10 days from th...

Page 79: ... Include a telephone number where you can be reached during business hours and a complete return shipping address P O Box numbers are not acceptable Name ______________________________________________________________ Address ____________________________________________________________ City _______________________________________________________________ State Province ______________________________...

Page 80: ... 18 kg 45 lb 21 kg N A Common Specifications Voltage Regulation Max 5 Voltage Regulation Typ 2 5 Waveform modified sine wave Power Factor allowed 0 to 1 Frequency Regulation 60 Hz 0 04 E models 50 Hz 0 04 J models 50 Hz 0 04 K models 50 Hz 0 04 Standard Output Voltage 120 VAC 60 Hz E models 230 VAC 50 Hz W models 220 VAC 60 Hz J models 105 VAC 50 Hz K models 105 VAC 60 Hz Adjustable Load Sensing 5...

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Page 84: ...Xantrex Technology Inc 5916 195th Northeast Arlington WA 98223 U S A t 360 435 8826 f 360 435 3945 www xantrex com Printed in U S A 2000 Xantrex Technology Inc P N 975 0012 01 01 Rev A 12 00 ...

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