2001 Xantrex Technology, Inc
With Revision 4.01 Software
SW Series Inverter/Chargers
Owner’s Manual
Arlington, WA
2001 Xantrex Technology, Inc
Telephone 360/435-8826
5916 - 195th Street N. E
PRODUCT MATERIALS PACKAGE
Arlington, WA
2001 Xantrex Technology, Inc
Telephone 360/435-8826
5916 - 195th Street N. E
CONTROLS, INDICATORS AND COMPONENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS
INDEX
TABLE OF CONTENTS
WARRANTY/REPAIR INFORMATION
APPENDIX
Figure 1, Identification Label
INDEX OF FIGURES
TABLE OF CONTENTS
Table 1, AC Input and Output Wiring Connections
INDEX OF TABLES
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS
GENERAL PRECAUTIONS
Safety
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IMPORTANT SAFETY INSTRUCTIONS
SPECIAL NOTICES
WARNING - RISK OF EXPLOSIVE GASSES
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PERSONAL PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS
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IMPORTANT SAFETY INSTRUCTIONS
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2001 Xantrex Technology, Inc
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INTRODUCTION INTRODUCTION
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INTRODUCTION
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2001 Xantrex Technology, Inc
Figure 1, Identification Label
UNIT IDENTIFICATION UNIT IDENTIFICATION
MODEL NUMBER
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Telephone 360/435-8826
UNIT IDENTIFICATION
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2001 Xantrex Technology, Inc
Figure 2, SW Series Inverter/Charger
CONTROLS, INDICATORS AND COMPONENTS
CONTROL PANEL
DISPLAY
CONTRAST CONTROL
RESET TO FACTORY DEFAULTS BUTTON
LED STATUS INDICATORS
MENU ACCESS/ADJUSTMENT BUTTONS Black
BULK Yellow
ERROR Red
AC1 IN GOOD Green
AC2 IN GOOD Green
INVERTER/CHARGER CIRCUIT BREAKER
AC SIDE
REMOTE PORT
STACKING PORT
RY7 Yellow LED
INTERNAL COMPONENTS AND INDICATORS
Figure 5, Internal Components and Indicators
LED INDICATORS
Figure 6, Auxiliary and Generator Control Relay Connectors
BATTERY TERMINALS
AC SAFETY GROUND
AUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS
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INSTALLATION INSTALLATION
DC CABLING
INSTALLATION
QUICK INSTALL
MOUNTING
INSTALLATION
COMPLETE INSTALL
UNPACKING
LOCATION
Figure 8, Air Flow Intake Location
AC WIRING
VENTILATION
FLOW
AC IN
Figure 9, AC Input/Output Power Connection
Table 1, AC Input and Output Wiring Connections
WIRE COLOR
INSTALLATION
AC INSTALLATION GUIDELINES
IMPORTANT PRECAUTION
EXTERNAL TRANSFER RELAYS
INSTALLATION
120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’S
WARNING LABEL
Figure 10, Warning Label
INVERTER MODEL
DC WIRING
BATTERY CABLE SIZING
Table 2, Minimum Recommended Battery Cable Size vs. Cable Length
RATING IN
Table 3, Battery Cable To Maximum Breaker/Fuse Size
DC DISCONNECT AND OVERCURRENT PROTECTION
CABLE SIZE REQUIRED
INSTALLATION
BATTERY CABLE CONNECTIONS
Figure 11, Battery to Inverter Cable Connection
INSTALLATION PROCEDURE - BATTERY CABLES
REMOTE CONTROL WIRING
CONTROL WIRING
GEN CONTROL WIRING
AUX RELAY WIRING
BONDING THE GROUNDING SYSTEM
SYSTEM GROUNDING
EQUIPMENT OR CHASSIS GROUNDS
GROUNDING ELECTRODES/GROUND RODS
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NEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONS
INSTALLATION
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Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To Ground
AC SOURCE
INSTALLATION
Figure 15, Multiple Point Ground System
GROUNDING VS. LIGHTNING
ONE GROUND FOR ALL EQUIPMENT
KEEP EQUIPMENT CLOSE TOGETHER
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INSTALLATION
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2001 Xantrex Technology, Inc
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FUNCTIONAL TEST FUNCTIONAL TEST
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FUNCTIONAL TEST
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2001 Xantrex Technology, Inc
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MENU SYSTEM MENU SYSTEM
OVERVIEW
MENU ITEMS
MENU SYSTEM
USER MENU MAP
MENU HEADINGS
MENU ITEMS
SETUP MENU MAP
MENU SYSTEM
MENU HEADINGS
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USER MENU
MENU HEADINGS
MENU SYSTEM
INFORMATION DISPLAY
INVERTER MODE 1 MENU HEADING
GENERATOR MODE 2 MENU HEADING
Move cursor to Inverter OFF to reset Overcurrent
MENU SYSTEM
Generator start errorNO
Generator sync errorNO
Gen max run time errorNO
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TRACE ENGINEERING 3 MENU HEADING
5916 195th St NE Arlington, WA 98223 USA
MENU SYSTEM
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METERS 4 MENU HEADING
NOTE The meters do not display a + symbol for positive values
MENU SYSTEM
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ERROR CAUSES 5 MENU HEADING
AC1 & AC2 volts valid only when inverter synced to that input
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
Gen doesn’t run during quiet time unless batt volts is less than
GENERATOR TIMER 7 MENU HEADING
To defeat timers set start = end
TIME OF DAY 6 MENU HEADING
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SETUP MENU
MENU SYSTEM
MENU HEADINGS
Set Grid Usage FLT SELL SLT LBX
INVERTER SETUP 9 MENU HEADING
MENU SYSTEM
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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 CHARGING 10 MENU HEADING
battery temperature if the BTS sensor is installed
MENU SYSTEM
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AC INPUTS 11 MENU HEADINGS
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
MENU SYSTEM
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GEN AUTO START SETUP 12 MENU HEADING
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
MENU SYSTEM
INFORMATION DISPLAY
GEN STARTING DETAILS 13 MENU HEADING
MENU SYSTEM
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Set Pre Crank seconds10
AUXILIARY RELAYS 14 MENU HEADING
MENU SYSTEM
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Relays have 2 seconds delay on close, 0.1 sec delay on open
Close on batt setpoint. Open on batt setpoint - hys
MENU SYSTEM
MENU SYSTEM
BULK CHARGE TRIGGER TIMER 15 MENU HEADING
LOW BATTERY TRANSFER 16 MENU HEADING
See menu 9 to enable LBX mode Make sure LBX is above LBCO volts
SELL mode
BATTERY SELLING 17 MENU HEADING
GRID USAGE TIMER 18 MENU HEADING
See menu 9 to enable SELL mode. Make sure LBX is above LBCO volts
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INFORMATION FILE BATTERY 19 MENU HEADING
Sell and float modes use timer. SLT and LBX mode ignore timer
MENU SYSTEM
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MENU SYSTEM
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2001 Xantrex Technology, Inc
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Figure 17, Trace SW Series Inverter Simple Block Diagram
OPERATION OPERATION
THEORY OF OPERATION
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OPERATION
Figure 18, Trace SW Series Inverter Output Waveform
SW4548E
POWER VS. EFFICIENCY
SW3024E / SW3048E
SW4024 / SW4048
Figure 20, Inverter Capacity vs. Temperature
INVERTER CAPACITY VS TEMPERATURE
power
Temperature C
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ADDITIONAL FEATURES
OPERATING MODES
OPERATION
SETTING SEARCH MODE WATTS
INVERTER MODE
SEARCH MODE CONTROL
BATTERYDC
OPERATION
LOW BATTERY PROTECTION
SETTING SEARCH MODE SPACING
ADJUSTING THE LOW BATTERY PROTECTION
THREE STAGE CHARGING PROCESS
CHARGER MODE
BATTERY
Figure 21, Three-Stage Battery Charging
AC INPUT REQUIREMENTS
BATTERY TEMPERATURE SENSOR BTS
Figure 22, BTS Battery Temperature Sensor
CHARGER ONLY OPERATION
FREQUENCY
RECOMMENDED BATTERY CHARGER SETTINGS
DELAY PERIOD
AC CURRENT LEVEL
EQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLY
Table 4, Charging Setpoints For Common Battery Types
TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES
Battery Type
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To start the equalization process either manually or automatically
OPERATION
UTILITY GRID AC AC GENERATOR
INVERTER/CHARGER MODE
TRANSFERRING UPON AVAILABILITY OF AC POWER
TRANSFERRING BASED ON BATTERY VOLTAGE
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TRANSFER TIME
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
OPERATION
OPERATION
GENERATOR SUPPORT MODE
GENERATOR
BATTERY
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GENERATOR SUPPORT/OVERLOAD PROTECTION
120 VAC VS. 120/240 VAC GENERATORS
OPERATION
INVERTER/ CHARGER
AUTOMATIC GENERATOR CONTROL MODE
DC BATTERY
AC GENERATOR CONTROL
OPERATION
GEN CONTROL RELAYS
GENERATOR STARTING SCENARIOS
AUTOMATICALLY
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GENERATOR STARTING AND STOPPING CONFIGURATIONS
MANUALLY
OPERATION
GENERATOR AUTO START REQUIREMENTS AND TYPES
TWO WIRE START GENERATORS
2 WIRE TYPE GENERATOR
Figure 23, Two Wire Start Wiring Diagram
OPERATION
THREE-WIRE START GENERATORS
Figure 25, Three-Wire Start Wiring Diagram ONAN Type
HONDA TYPE GENERATOR
OPERATION
3-TO-2 WIRE CONVERTERS
GENERATOR CONTROL SEQUENCE
Figure 26, Relay RY7 and RY8 Sequence
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GENERATOR ERROR CAUSES
GENERATOR STOP COOL DOWN PERIOD
OPERATION
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EQUALIZATION CHARGING, AUTOMATIC GENERATOR CONTROL SYSTEM
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
OPERATION
MAIN
UTILITY BACKUP MODE
GENERATOR AC INVERTER/ CHARGER DC BATTERY
UTILITY GRID
OPERATION
USING SLT MODE SILENT MODE
BATTERY REQUIREMENTS
UTILITY SUPPORT/OVERLOAD PROTECTION
MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UP
UTILITY INTERACTIVE MODE
GROUND FAULT
UTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT
OPERATION
THEORY OF OPERATION
UTILITY INTERACTIVE ISLANDING PROTECTION
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
POSITIVE + = Inverter is drawing power from grid
SELLING POWER - FROM A DC CHARGING SOURCE
Battery Sell Volts
DC Setting
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SELLING POWER - STORED IN THE BATTERIES
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
OPERATION
OPERATION
BATTERY REGULATION LEVEL - SELL MODE
15 menu heading is used to trigger a bulk charge cycle
BATTERY REQUIREMENTS
LINE-TIE SYSTEM WITH
UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUP
BACKUP OF CRITICAL AC
UTILITY INTERACTIVE
SOLAR ARRAY
OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE
BATTERY BANK
Figure 30, Overvoltage Protection for Battery
IN BRIEF
ENERGY MANAGEMENT MODE
INVERTER/ CHARGER DC BATTERY
OPERATION
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OPERATION
OPERATION
PEAK LOAD SHAVING MODE
IN BRIEF
INVERTER/ CHARGER DC BATTERY
AC LOADS SUB-PANEL AC INVERTER CHARGER
LOW BATTERY TRANSFER LBX MODE
SOLAR ARRAY DC GROUND FAULT PROTECTION
UTILITY GRID kWH METER AC AC LOADSAC MAIN PANEL
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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
OPERATION
USING MULTIPLE INVERTERS
INPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS
“SERIES” STACKED OPERATION
OPERATION
GENERATOR CONTROL SETTINGS
“PARALLEL” STACKED OPERATION
240 VAC/60 HZ ONLY ELECTRICAL SYSTEMS
OPERATION
BATTERY CHARGING WITH MULTIPLE INVERTERS
AUTOMATIC GENERATOR CONTROL 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
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OPERATION
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2001 Xantrex Technology, Inc
TELEPHONE COMPANY BATTERY
BATTERY TYPE
SELECTION OF BATTERY TYPE
STARTING BATTERY
SEALED LEAD ACID BATTERIES
NICAD AND NICKEL IRON NIFE BATTERY
TECHNICAL INFORMATION
Page 100
Table 5, Typical Wattage Of Common Appliances
BATTERY SIZING
ESTIMATING BATTERY REQUIREMENTS
Page 101
5,139
BATTERY BANK SIZING
EXAMPLE
Page 102
WATTS
WORKSHEET
Page 103
TECHNICAL INFORMATION
TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES
BATTERY CARE AND MAINTENANCE
Table 6, Battery Charging Charging Setpoints
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MONTHLY MAINTENANCE
BATTERY STATE OF CHARGE
Table 7, Battery State of Charge Voltage
Page 106
BATTERY INSTALLATION
BATTERY ENCLOSURES
BATTERY TEMPERATURE
Total Battery Capacity
BATTERY HOOK-UP CONFIGURATIONS
Each individual 6-volt battery capacity = 100 amp hours
Figure 31, Series Configuration 6-Volt Battery Wiring
SERIES - PARALLEL CONNECTION
Each individual 12-volt battery capacity = 50 amp hours
Figure 33, Parallel Configuration 12-Volt Battery Wiring
PARALLEL CONNECTION
6V 6V
Total Battery Capacity
Figure 35, Series-Parallel Configuration 12-Volt Battery Wiring
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BATTERY CABLE INDUCTANCE
Distance Between Battery Cables Inductance in micro-Henries
Table 8, Battery Cable Inductance
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APPLICATIONS
RESISTIVE LOADS
INDUCTIVE LOADS
SOLUTION
TROUBLESHOOTING GUIDE
INVERTER - If ERROR LED comes on, see ERROR CAUSES section
PROBLEM
TROUBLESHOOTING GUIDE
BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES section
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TECHNICAL INFORMATION
Page 114
TROUBLESHOOTING GUIDE
SOLUTION
TECHNICAL INFORMATION
INVERTER/CHARGER TERMINOLOGY
Page 115
Digital VoltMeter DVM
TECHNICAL INFORMATION
Page 116
Figure 36, AC Waveforms
TECHNICAL INFORMATION
Page 117
Stacking
MODEL
SPECIFICATIONS AND FEATURES 60 Hz Models
Note All specifications are subject to change without notice
Page 118
SW3024E SW3048E SW4548E SW3024J SW4048J SW4548A
SPECIFICATIONS AND FEATURES 50 Hz Models
Page 119
SW2612E
2001 Xantrex Technology, Inc
DIMENSIONS
Page 120
TECHNICAL INFORMATION
TECHNICAL INFORMATION
INSTALLATION DIAGRAMS
Page 121
Telephone 360/435-8826
Page 122
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
SW Series Inverter/Charger - Model SW
USER SETTINGS WORKSHEETS
USER MENU
Page 123
USER SETTINGS
SETUP MENU - 12 VDC 120 VAC/60HZ MODELS
Page 124
DEFAULT SETTINGS
USER SETTINGS
SETUP MENU - 24 VDC 120 VAC/60HZ MODELS
Page 125
DEFAULT SETTINGS
USER SETTINGS
SETUP MENU - 48 VDC 120 VAC/60HZ MODELS
Page 126
DEFAULT SETTINGS
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Page 127
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
SWCA
APPENDIX
OPTIONS
SWRC
C40 MULTI-FUNCTION CONTROLLER
SW SERIES POWER PANEL SYSTEMS
TM500 TRACE METER BATTERY STATUS MONITOR
OTHER PRODUCTS
Page 130
Table 9, Power Consumption Of Common Appliances
Table 10, AWG to Metric Wire Conversion Chart
REFERENCE TABLES AND GRAPHS
NEC AMPS2
Table 11, Minimum Recommended Battery Cable Size vs. Cable Length
Table 12, Battery Cable to Maximum Breaker/Fuse Size
Page 131
Minimum Size of Copper Ground Wire
Table 13, Recommended Minimum AC Wire Sizes 75 C
Table 15, Safety Ground Wire Size Table
Battery DC Disconnect Size
Interior Storage
Storage Checklist
Preparation for Storage
Page 133
Telephone 360/435-8826
Page 134
APPENDIX
2001 Xantrex Technology, Inc
LIFE SUPPORT POLICY
WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATION
LIMITED WARRANTY
WARRANTY REGISTRATION
Page 136
WARRANTY/REPAIR INFORMATION
WARRANTY OR REPAIR SERVICE REQUIRED
INDEX
INDEX
Page 137
Hook Up Configurations
INDEX
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Output Waveform
Page 139
Low Battery Cut Out VDC
INDEX
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INDEX
Stored In The Batteries
Page 141
Installation Guidelines
INDEX
INDEX
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