SW Series Inverter/Chargers
With Revision 4.01 Software
Owner’s Manual
2001 Xantrex Technology, Inc
Telephone 360/435-8826
2001 Xantrex Technology, Inc
5916 - 195th Street N. E
Arlington, WA
PRODUCT MATERIALS PACKAGE
Telephone 360/435-8826
2001 Xantrex Technology, Inc
5916 - 195th Street N. E
Arlington, WA
TABLE OF CONTENTS
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS
CONTROLS, INDICATORS AND COMPONENTS
WARRANTY/REPAIR INFORMATION
TABLE OF CONTENTS
APPENDIX
INDEX
INDEX OF FIGURES
TABLE OF CONTENTS
Figure 1, Identification Label
INDEX OF TABLES
TABLE OF CONTENTS
Table 1, AC Input and Output Wiring Connections
GENERAL PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS
Safety
SAVE THESE INSTRUCTIONS
SPECIAL NOTICES
IMPORTANT SAFETY INSTRUCTIONS
WARNING - RISK OF EXPLOSIVE GASSES
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PERSONAL PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS
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IMPORTANT SAFETY INSTRUCTIONS
2001 Xantrex Technology, Inc
Telephone 360/435-8826
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INTRODUCTION INTRODUCTION
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INTRODUCTION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
MODEL NUMBER
UNIT IDENTIFICATION UNIT IDENTIFICATION
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Figure 1, Identification Label
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UNIT IDENTIFICATION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
CONTROL PANEL
CONTROLS, INDICATORS AND COMPONENTS
DISPLAY
Figure 2, SW Series Inverter/Charger
LED STATUS INDICATORS
RESET TO FACTORY DEFAULTS BUTTON
MENU ACCESS/ADJUSTMENT BUTTONS Black
CONTRAST CONTROL
AC1 IN GOOD Green
ERROR Red
AC2 IN GOOD Green
BULK Yellow
REMOTE PORT
AC SIDE
STACKING PORT
INVERTER/CHARGER CIRCUIT BREAKER
Figure 5, Internal Components and Indicators
INTERNAL COMPONENTS AND INDICATORS
LED INDICATORS
RY7 Yellow LED
AC SAFETY GROUND
BATTERY TERMINALS
AUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS
Figure 6, Auxiliary and Generator Control Relay Connectors
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INSTALLATION INSTALLATION
QUICK INSTALL
INSTALLATION
MOUNTING
DC CABLING
UNPACKING
COMPLETE INSTALL
LOCATION
INSTALLATION
VENTILATION
AC WIRING
FLOW
Figure 8, Air Flow Intake Location
Table 1, AC Input and Output Wiring Connections
Figure 9, AC Input/Output Power Connection
WIRE COLOR
AC IN
IMPORTANT PRECAUTION
AC INSTALLATION GUIDELINES
EXTERNAL TRANSFER RELAYS
INSTALLATION
WARNING LABEL
120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’S
Figure 10, Warning Label
INSTALLATION
BATTERY CABLE SIZING
DC WIRING
Table 2, Minimum Recommended Battery Cable Size vs. Cable Length
INVERTER MODEL
DC DISCONNECT AND OVERCURRENT PROTECTION
Table 3, Battery Cable To Maximum Breaker/Fuse Size
CABLE SIZE REQUIRED
RATING IN
Figure 11, Battery to Inverter Cable Connection
BATTERY CABLE CONNECTIONS
INSTALLATION PROCEDURE - BATTERY CABLES
INSTALLATION
GEN CONTROL WIRING
CONTROL WIRING
AUX RELAY WIRING
REMOTE CONTROL WIRING
EQUIPMENT OR CHASSIS GROUNDS
SYSTEM GROUNDING
GROUNDING ELECTRODES/GROUND RODS
BONDING THE GROUNDING SYSTEM
NEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONS
INSTALLATION
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AC SOURCE
Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To Ground
INSTALLATION
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ONE GROUND FOR ALL EQUIPMENT
GROUNDING VS. LIGHTNING
KEEP EQUIPMENT CLOSE TOGETHER
Figure 15, Multiple Point Ground System
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INSTALLATION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
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FUNCTIONAL TEST FUNCTIONAL TEST
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FUNCTIONAL TEST
2001 Xantrex Technology, Inc
Telephone 360/435-8826
MENU SYSTEM MENU SYSTEM
OVERVIEW
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USER MENU MAP
MENU SYSTEM
MENU HEADINGS
MENU ITEMS
MENU SYSTEM
SETUP MENU MAP
MENU HEADINGS
MENU ITEMS
MENU HEADINGS
USER MENU
MENU SYSTEM
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GENERATOR MODE 2 MENU HEADING
INVERTER MODE 1 MENU HEADING
Move cursor to Inverter OFF to reset Overcurrent
INFORMATION DISPLAY
Generator sync errorNO
Generator start errorNO
Gen max run time errorNO
MENU SYSTEM
5916 195th St NE Arlington, WA 98223 USA
TRACE ENGINEERING 3 MENU HEADING
MENU SYSTEM
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NOTE The meters do not display a + symbol for positive values
METERS 4 MENU HEADING
MENU SYSTEM
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AC1 & AC2 volts valid only when inverter synced to that input
ERROR CAUSES 5 MENU HEADING
MENU SYSTEM
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Battery voltage was above the HIGH BATTERY CUT OUT VDC setting. This can be caused by the solar array or other charging source not being regulated. Check the controller for proper operation. Some controllers have a “equalize” setting which over-rides the normal operation, allowing the battery voltage to be unregulated. Return the controller to the “normal” setting and check for proper operation. If you are using NiCad type batteries, you will need to increase the HIGH BATTERY CUT OUT VDC setting. The inverter will automatically reset once the battery voltage has dropped 1.5 volts below the HBCO setting for a 12 VDC system, 3 volts for a 24 VDC system and 6 volts for a 48 VDC system
MENU SYSTEM
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To defeat timers set start = end
GENERATOR TIMER 7 MENU HEADING
TIME OF DAY 6 MENU HEADING
Gen doesn’t run during quiet time unless batt volts is less than
MENU SYSTEM
SETUP MENU
MENU HEADINGS
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MENU SYSTEM
INVERTER SETUP 9 MENU HEADING
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Set Grid Usage FLT SELL SLT LBX
This setting controls when the inverter turns off due to a low battery voltage condition. The inverter will turn off only after this level has been reached for the period of time set by the following item. When the automatic generator control system is used, the generator will be started when the battery voltage has dropped below this value for 30 seconds continuously. This will occur even during the quiet time period. This setting is not temperature compensated
MENU SYSTEM
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battery temperature if the BTS sensor is installed
BATTERY CHARGING 10 MENU HEADING
MENU SYSTEM
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Sets the maximum amount of AC input current that the battery charger will use to charge the battery. This can be used to limit the charger output as well. The charger will “back-off” if the combination of AC loads and the charger reaches the AMPS AC setting of the AC INPUT connected to prevent overloading the source or tripping breakers. This process occurs automatically
AC INPUTS 11 MENU HEADINGS
MENU SYSTEM
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Sets the AC load current that will initiate the automatic generator control system when the current remains above this setting continuously for the LOAD START DELAY MIN period
GEN AUTO START SETUP 12 MENU HEADING
MENU SYSTEM
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MENU SYSTEM
GEN STARTING DETAILS 13 MENU HEADING
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INFORMATION DISPLAY
MENU SYSTEM
AUXILIARY RELAYS 14 MENU HEADING
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Set Pre Crank seconds10
Close on batt setpoint. Open on batt setpoint - hys
Relays have 2 seconds delay on close, 0.1 sec delay on open
MENU SYSTEM
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LOW BATTERY TRANSFER 16 MENU HEADING
BULK CHARGE TRIGGER TIMER 15 MENU HEADING
See menu 9 to enable LBX mode Make sure LBX is above LBCO volts
MENU SYSTEM
GRID USAGE TIMER 18 MENU HEADING
BATTERY SELLING 17 MENU HEADING
See menu 9 to enable SELL mode. Make sure LBX is above LBCO volts
SELL mode
Sell and float modes use timer. SLT and LBX mode ignore timer
INFORMATION FILE BATTERY 19 MENU HEADING
MENU SYSTEM
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MENU SYSTEM
2001 Xantrex Technology, Inc
Telephone 360/435-8826
OPERATION OPERATION
Figure 17, Trace SW Series Inverter Simple Block Diagram
THEORY OF OPERATION
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OPERATION
Figure 18, Trace SW Series Inverter Output Waveform
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SW3024E / SW3048E
POWER VS. EFFICIENCY
SW4024 / SW4048
SW4548E
power
INVERTER CAPACITY VS TEMPERATURE
Temperature C
Figure 20, Inverter Capacity vs. Temperature
OPERATING MODES
ADDITIONAL FEATURES
OPERATION
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SEARCH MODE CONTROL
INVERTER MODE
BATTERYDC
SETTING SEARCH MODE WATTS
SETTING SEARCH MODE SPACING
LOW BATTERY PROTECTION
ADJUSTING THE LOW BATTERY PROTECTION
OPERATION
BATTERY
CHARGER MODE
Figure 21, Three-Stage Battery Charging
THREE STAGE CHARGING PROCESS
Figure 22, BTS Battery Temperature Sensor
BATTERY TEMPERATURE SENSOR BTS
CHARGER ONLY OPERATION
AC INPUT REQUIREMENTS
DELAY PERIOD
RECOMMENDED BATTERY CHARGER SETTINGS
AC CURRENT LEVEL
FREQUENCY
TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES
Table 4, Charging Setpoints For Common Battery Types
Battery Type
EQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLY
To start the equalization process either manually or automatically
OPERATION
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TRANSFERRING UPON AVAILABILITY OF AC POWER
INVERTER/CHARGER MODE
TRANSFERRING BASED ON BATTERY VOLTAGE
UTILITY GRID AC AC GENERATOR
While connected to the utility, the battery charger will be engaged. Some applications may want to allow the alternate power source solar, wind or hydro to recharge the battery instead of allowing the utility to provide the power. The only option is to program the SET MAX CHARGE AMPS AC menu item under the BATTERY CHARGING 10 menu heading to the minimum value, 1 amp AC, and set the BULK VOLTS and FLOAT VOLTS settings, also under the BATTERY CHARGING 10 menu heading, to a low value
TRANSFER TIME
OPERATION
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GENERATOR
GENERATOR SUPPORT MODE
BATTERY
OPERATION
120 VAC VS. 120/240 VAC GENERATORS
GENERATOR SUPPORT/OVERLOAD PROTECTION
OPERATION
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DC BATTERY
AUTOMATIC GENERATOR CONTROL MODE
AC GENERATOR CONTROL
INVERTER/ CHARGER
GENERATOR STARTING SCENARIOS
GEN CONTROL RELAYS
AUTOMATICALLY
OPERATION
MANUALLY
GENERATOR STARTING AND STOPPING CONFIGURATIONS
OPERATION
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2 WIRE TYPE GENERATOR
TWO WIRE START GENERATORS
Figure 23, Two Wire Start Wiring Diagram
GENERATOR AUTO START REQUIREMENTS AND TYPES
Figure 25, Three-Wire Start Wiring Diagram ONAN Type
THREE-WIRE START GENERATORS
HONDA TYPE GENERATOR
OPERATION
GENERATOR CONTROL SEQUENCE
3-TO-2 WIRE CONVERTERS
Figure 26, Relay RY7 and RY8 Sequence
OPERATION
GENERATOR STOP COOL DOWN PERIOD
GENERATOR ERROR CAUSES
OPERATION
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An automatic equalization charge process is available in the SW Series Inverter/Charger. To start the equalization process, select EQ from the SET GENERATOR menu item, accessible by pressing the green GEN MENU button on the Control Panel
EQUALIZATION CHARGING, AUTOMATIC GENERATOR CONTROL SYSTEM
OPERATION
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GENERATOR AC INVERTER/ CHARGER DC BATTERY
UTILITY BACKUP MODE
UTILITY GRID
MAIN
BATTERY REQUIREMENTS
USING SLT MODE SILENT MODE
UTILITY SUPPORT/OVERLOAD PROTECTION
OPERATION
GROUND FAULT
UTILITY INTERACTIVE MODE
UTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT
MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UP
UTILITY INTERACTIVE ISLANDING PROTECTION
THEORY OF OPERATION
When SELL mode is selected from the SET GRID USAGE menu item located under the INVERTER SETUP 9 menu heading in the SETUP MENU, the inverter will move any excess power not required to charge the batteries into the utility grid
OPERATION
Battery Sell Volts
SELLING POWER - FROM A DC CHARGING SOURCE
DC Setting
POSITIVE + = Inverter is drawing power from grid
Power stored in the batteries can also be sold into the utility grid. This can be used together with the solar array or alone without a solar array. The inverter can be programmed to sell the energy in the batteries at a specific time and then to recharge the batteries at another time. Both the discharge level and discharge rate can be adjusted to control the battery selling process
SELLING POWER - STORED IN THE BATTERIES
OPERATION
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15 menu heading is used to trigger a bulk charge cycle
BATTERY REGULATION LEVEL - SELL MODE
BATTERY REQUIREMENTS
OPERATION
BACKUP OF CRITICAL AC
UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUP
UTILITY INTERACTIVE
LINE-TIE SYSTEM WITH
BATTERY BANK
OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE
Figure 30, Overvoltage Protection for Battery
SOLAR ARRAY
INVERTER/ CHARGER DC BATTERY
ENERGY MANAGEMENT MODE
OPERATION
IN BRIEF
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OPERATION
IN BRIEF
PEAK LOAD SHAVING MODE
INVERTER/ CHARGER DC BATTERY
OPERATION
SOLAR ARRAY DC GROUND FAULT PROTECTION
LOW BATTERY TRANSFER LBX MODE
UTILITY GRID kWH METER AC AC LOADSAC MAIN PANEL
AC LOADS SUB-PANEL AC INVERTER CHARGER
Once the system has transferred back to the battery, the battery voltage will continue to increase if the power from the alternative source exceeds the loads. This can result in the battery voltage reaching the HIGH BATTERY CUT OUT VDC setting unless a charge control device limits the battery voltage. Note that the LOW BATTERY CUT IN VDC setting must be set below the external charge controllers regulation setting or the system would never transfer back to the battery. The best compromise involves setting the BULK VOLTS DC equal to the FLOAT VOLTS DC default value, and setting the LOW BATTERY CUT IN VDC setting to the default BULK VOLTS DC setting. Make sure the external charge controller is set slightly higher than the LOW BATTERY CUT IN VDC setting so that the voltage can be reached without the charging source shutting off
OPERATION
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INPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS
USING MULTIPLE INVERTERS
“SERIES” STACKED OPERATION
OPERATION
“PARALLEL” STACKED OPERATION
GENERATOR CONTROL SETTINGS
240 VAC/60 HZ ONLY ELECTRICAL SYSTEMS
OPERATION
AUTOMATIC GENERATOR CONTROL WITH MULTIPLE INVERTERS
BATTERY CHARGING WITH MULTIPLE INVERTERS
The inverters can operate in parallel as battery chargers from the same AC source connected to the same battery. The AC input terminals and DC terminals would all be in parallel. The inverters will synchronize individually to the AC source and then connect
OPERATION
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OPERATION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
SELECTION OF BATTERY TYPE
BATTERY TYPE
STARTING BATTERY
TELEPHONE COMPANY BATTERY
TECHNICAL INFORMATION
NICAD AND NICKEL IRON NIFE BATTERY
Page 100
SEALED LEAD ACID BATTERIES
ESTIMATING BATTERY REQUIREMENTS
BATTERY SIZING
Page 101
Table 5, Typical Wattage Of Common Appliances
EXAMPLE
BATTERY BANK SIZING
Page 102
5,139
Page 103
WORKSHEET
TECHNICAL INFORMATION
WATTS
Table 6, Battery Charging Charging Setpoints
BATTERY CARE AND MAINTENANCE
Page 104
TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES
BATTERY STATE OF CHARGE
MONTHLY MAINTENANCE
Table 7, Battery State of Charge Voltage
Page 105
BATTERY ENCLOSURES
BATTERY INSTALLATION
BATTERY TEMPERATURE
Page 106
Each individual 6-volt battery capacity = 100 amp hours
BATTERY HOOK-UP CONFIGURATIONS
Figure 31, Series Configuration 6-Volt Battery Wiring
Total Battery Capacity
Figure 33, Parallel Configuration 12-Volt Battery Wiring
Each individual 12-volt battery capacity = 50 amp hours
PARALLEL CONNECTION
SERIES - PARALLEL CONNECTION
Figure 35, Series-Parallel Configuration 12-Volt Battery Wiring
Total Battery Capacity
Page 109
6V 6V
Distance Between Battery Cables Inductance in micro-Henries
BATTERY CABLE INDUCTANCE
Table 8, Battery Cable Inductance
Page 110
RESISTIVE LOADS
APPLICATIONS
INDUCTIVE LOADS
Page 111
INVERTER - If ERROR LED comes on, see ERROR CAUSES section
TROUBLESHOOTING GUIDE
PROBLEM
SOLUTION
Page 113
BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES section
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TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
Page 114
SOLUTION
TECHNICAL INFORMATION
Page 115
INVERTER/CHARGER TERMINOLOGY
Digital VoltMeter DVM
TECHNICAL INFORMATION
Page 116
Figure 36, AC Waveforms
TECHNICAL INFORMATION
Page 117
Stacking
TECHNICAL INFORMATION
Note All specifications are subject to change without notice
SPECIFICATIONS AND FEATURES 60 Hz Models
Page 118
MODEL
Page 119
SPECIFICATIONS AND FEATURES 50 Hz Models
SW2612E
SW3024E SW3048E SW4548E SW3024J SW4048J SW4548A
Page 120
DIMENSIONS
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
INSTALLATION DIAGRAMS
Page 121
TECHNICAL INFORMATION
TECHNICAL INFORMATION
Page 122
2001 Xantrex Technology, Inc
Telephone 360/435-8826
USER MENU
USER SETTINGS WORKSHEETS
Page 123
SW Series Inverter/Charger - Model SW
Page 124
SETUP MENU - 12 VDC 120 VAC/60HZ MODELS
DEFAULT SETTINGS
USER SETTINGS
Page 125
SETUP MENU - 24 VDC 120 VAC/60HZ MODELS
DEFAULT SETTINGS
USER SETTINGS
Page 126
SETUP MENU - 48 VDC 120 VAC/60HZ MODELS
DEFAULT SETTINGS
USER SETTINGS
TECHNICAL INFORMATION
Page 127
2001 Xantrex Technology, Inc
Telephone 360/435-8826
OPTIONS
APPENDIX
SWRC
SWCA
TM500 TRACE METER BATTERY STATUS MONITOR
SW SERIES POWER PANEL SYSTEMS
OTHER PRODUCTS
C40 MULTI-FUNCTION CONTROLLER
Table 10, AWG to Metric Wire Conversion Chart
Table 9, Power Consumption Of Common Appliances
REFERENCE TABLES AND GRAPHS
Page 130
Table 12, Battery Cable to Maximum Breaker/Fuse Size
Table 11, Minimum Recommended Battery Cable Size vs. Cable Length
Page 131
NEC AMPS2
Table 15, Safety Ground Wire Size Table
Table 13, Recommended Minimum AC Wire Sizes 75 C
Battery DC Disconnect Size
Minimum Size of Copper Ground Wire
Preparation for Storage
Storage Checklist
Page 133
Interior Storage
APPENDIX
Page 134
2001 Xantrex Technology, Inc
Telephone 360/435-8826
LIMITED WARRANTY
WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATION
WARRANTY REGISTRATION
LIFE SUPPORT POLICY
WARRANTY/REPAIR INFORMATION
WARRANTY OR REPAIR SERVICE REQUIRED
Page 136
Page 137
INDEX
Hook Up Configurations
INDEX
INDEX
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Low Battery Cut Out VDC
Page 139
INDEX
Output Waveform
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INDEX
Installation Guidelines
Page 141
INDEX
Stored In The Batteries
INDEX
Page 142
6V