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Installation &

Operators Manual

DR Series

Inverter/Charger

Содержание DR - REV A

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

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Страница 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...

Страница 4: ...C 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 C...

Страница 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 Estim...

Страница 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...

Страница 7: ...portant Follow instructions closely NOTE Cette d claration est importante Suivre les instructions de pr s All electrical work must be done in accordance with local national and or international electr...

Страница 8: ...dup 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 prom...

Страница 9: ...rator 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 disc...

Страница 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...

Страница 11: ...he 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 fi...

Страница 12: ...erter 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 rela...

Страница 13: ...le 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...

Страница 14: ...y 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...

Страница 15: ...oth 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 Bat...

Страница 16: ...re 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 sh...

Страница 17: ...TERY 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 BATTE...

Страница 18: ...n 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...

Страница 19: ...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 inve...

Страница 20: ...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...

Страница 21: ...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 micr...

Страница 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...

Страница 23: ...he 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 exact...

Страница 24: ...le 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...

Страница 25: ...g 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 wa...

Страница 26: ...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 b...

Страница 27: ...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 e...

Страница 28: ...re 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 cabl...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...ng 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 3...

Страница 32: ...ng 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...

Страница 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...

Страница 34: ...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...

Страница 35: ...stall 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...

Страница 36: ...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...

Страница 37: ...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 Wir...

Страница 38: ...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 no...

Страница 39: ...he 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...

Страница 40: ...AIN 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 b...

Страница 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...

Страница 42: ...C 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 ou...

Страница 43: ...ct 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 In...

Страница 44: ...rs 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...

Страница 45: ...e 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 batt...

Страница 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 E...

Страница 47: ...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 sea...

Страница 48: ...erter 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 s...

Страница 49: ...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...

Страница 50: ...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 Bat...

Страница 51: ...ect 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 a...

Страница 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...

Страница 53: ...ble 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...

Страница 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...

Страница 55: ...re 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 prolong...

Страница 56: ...cuit 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 Cir...

Страница 57: ...eck 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 mod...

Страница 58: ...y 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 the...

Страница 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 f...

Страница 60: ...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...

Страница 61: ...C 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 gr...

Страница 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 ra...

Страница 63: ...r 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...

Страница 64: ...d 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...

Страница 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 mu...

Страница 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 int...

Страница 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 dete...

Страница 68: ...ance 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 Co...

Страница 69: ...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 auto...

Страница 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 t...

Страница 71: ...ess 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 I...

Страница 72: ...nexpensive 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 freque...

Страница 73: ...f 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 vo...

Страница 74: ...using 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 neut...

Страница 75: ...RFORMED 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...

Страница 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 m...

Страница 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 responsibili...

Страница 78: ...nowingly 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 ass...

Страница 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 _______________________________________________...

Страница 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...

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Страница 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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