Manuals / Xantrex Technology / Lawn and Garden / Portable Generator

Xantrex Technology 120 VAC/60 Page 127, Technical Information,  2001 Xantrex Technology, Inc

Models: 120 VAC/60

1 152

Page 135

TECHNICAL INFORMATION

 2001 Xantrex Technology, Inc.	Telephone: 360/435-8826	SW Series Inverter/Charger
5916 - 195th Street N. E.	Fax: 360/435-2229	Part No. 2031-5
Arlington, WA 98223	www.traceengineering.com	Rev. C: February 2001

Page

127

Page 135

Image 135

Xantrex Technology 120 VAC/60 Page 127, Technical Information,  2001 Xantrex Technology, Inc, Telephone 360/435-8826

Contents

 2001 Xantrex Technology, Inc With Revision 4.01 SoftwareSW Series Inverter/Chargers Owner’s ManualArlington, WA  2001 Xantrex Technology, IncTelephone 360/435-8826 5916 - 195th Street N. EPRODUCT MATERIALS PACKAGE Arlington, WA  2001 Xantrex Technology, IncTelephone 360/435-8826 5916 - 195th Street N. ECONTROLS, INDICATORS AND COMPONENTS TABLE OF CONTENTSTABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONSINDEX TABLE OF CONTENTSWARRANTY/REPAIR INFORMATION APPENDIXINDEX OF FIGURES TABLE OF CONTENTSFigure 1, Identification Label INDEX OF TABLES TABLE OF CONTENTSTable 1, AC Input and Output Wiring Connections SAVE THESE INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONSGENERAL PRECAUTIONS SafetyPage IMPORTANT SAFETY INSTRUCTIONSSPECIAL NOTICES WARNING - RISK OF EXPLOSIVE GASSESPERSONAL PRECAUTIONS IMPORTANT SAFETY INSTRUCTIONSPage Telephone 360/435-8826 IMPORTANT SAFETY INSTRUCTIONSPage  2001 Xantrex Technology, IncPage INTRODUCTION INTRODUCTIONTelephone 360/435-8826 INTRODUCTIONPage  2001 Xantrex Technology, IncFigure 1, Identification Label UNIT IDENTIFICATION UNIT IDENTIFICATIONMODEL NUMBER PageTelephone 360/435-8826 UNIT IDENTIFICATIONPage  2001 Xantrex Technology, IncFigure 2, SW Series Inverter/Charger CONTROLS, INDICATORS AND COMPONENTSCONTROL PANEL DISPLAYCONTRAST CONTROL RESET TO FACTORY DEFAULTS BUTTONLED STATUS INDICATORS MENU ACCESS/ADJUSTMENT BUTTONS BlackBULK Yellow ERROR RedAC1 IN GOOD Green AC2 IN GOOD GreenINVERTER/CHARGER CIRCUIT BREAKER AC SIDEREMOTE PORT STACKING PORTRY7 Yellow LED INTERNAL COMPONENTS AND INDICATORSFigure 5, Internal Components and Indicators LED INDICATORSFigure 6, Auxiliary and Generator Control Relay Connectors BATTERY TERMINALSAC SAFETY GROUND AUXILIARY AND GENERATOR CONTROL RELAY CONNECTORSPage INSTALLATION INSTALLATIONDC CABLING INSTALLATIONQUICK INSTALL MOUNTINGINSTALLATION COMPLETE INSTALLUNPACKING LOCATIONFigure 8, Air Flow Intake Location AC WIRINGVENTILATION FLOWAC IN Figure 9, AC Input/Output Power ConnectionTable 1, AC Input and Output Wiring Connections WIRE COLORINSTALLATION AC INSTALLATION GUIDELINESIMPORTANT PRECAUTION EXTERNAL TRANSFER RELAYSINSTALLATION 120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’SWARNING LABEL Figure 10, Warning LabelINVERTER MODEL DC WIRINGBATTERY CABLE SIZING Table 2, Minimum Recommended Battery Cable Size vs. Cable LengthRATING IN Table 3, Battery Cable To Maximum Breaker/Fuse SizeDC DISCONNECT AND OVERCURRENT PROTECTION CABLE SIZE REQUIREDINSTALLATION BATTERY CABLE CONNECTIONSFigure 11, Battery to Inverter Cable Connection INSTALLATION PROCEDURE - BATTERY CABLESREMOTE CONTROL WIRING CONTROL WIRINGGEN CONTROL WIRING AUX RELAY WIRINGBONDING THE GROUNDING SYSTEM SYSTEM GROUNDINGEQUIPMENT OR CHASSIS GROUNDS GROUNDING ELECTRODES/GROUND RODSNEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONS INSTALLATIONPage Page Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To GroundAC SOURCE INSTALLATIONFigure 15, Multiple Point Ground System GROUNDING VS. LIGHTNINGONE GROUND FOR ALL EQUIPMENT KEEP EQUIPMENT CLOSE TOGETHERTelephone 360/435-8826 INSTALLATIONPage  2001 Xantrex Technology, IncPage FUNCTIONAL TEST FUNCTIONAL TESTTelephone 360/435-8826 FUNCTIONAL TESTPage  2001 Xantrex Technology, IncMENU SYSTEM MENU SYSTEM OVERVIEWPage MENU ITEMS MENU SYSTEMUSER MENU MAP MENU HEADINGSMENU ITEMS SETUP MENU MAPMENU SYSTEM MENU HEADINGSPage USER MENUMENU HEADINGS MENU SYSTEMINFORMATION DISPLAY INVERTER MODE 1 MENU HEADINGGENERATOR MODE 2 MENU HEADING Move cursor to Inverter OFF to reset OvercurrentMENU SYSTEM Generator start errorNOGenerator sync errorNO Gen max run time errorNOPage TRACE ENGINEERING 3 MENU HEADING5916 195th St NE Arlington, WA 98223 USA MENU SYSTEMPage METERS 4 MENU HEADINGNOTE The meters do not display a + symbol for positive values MENU SYSTEMPage ERROR CAUSES 5 MENU HEADINGAC1 & AC2 volts valid only when inverter synced to that input MENU SYSTEMBattery 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 SYSTEMPage Gen doesn’t run during quiet time unless batt volts is less than GENERATOR TIMER 7 MENU HEADINGTo defeat timers set start = end TIME OF DAY 6 MENU HEADINGPage SETUP MENUMENU SYSTEM MENU HEADINGSSet Grid Usage FLT SELL SLT LBX INVERTER SETUP 9 MENU HEADINGMENU SYSTEM PageThis 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 SYSTEMPage Page BATTERY CHARGING 10 MENU HEADINGbattery temperature if the BTS sensor is installed MENU SYSTEMPage AC INPUTS 11 MENU HEADINGSSets 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 SYSTEMPage GEN AUTO START SETUP 12 MENU HEADINGSets 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 SYSTEMINFORMATION DISPLAY GEN STARTING DETAILS 13 MENU HEADINGMENU SYSTEM PageSet Pre Crank seconds10 AUXILIARY RELAYS 14 MENU HEADINGMENU SYSTEM PagePage Relays have 2 seconds delay on close, 0.1 sec delay on openClose on batt setpoint. Open on batt setpoint - hys MENU SYSTEMMENU SYSTEM BULK CHARGE TRIGGER TIMER 15 MENU HEADINGLOW BATTERY TRANSFER 16 MENU HEADING See menu 9 to enable LBX mode Make sure LBX is above LBCO voltsSELL mode BATTERY SELLING 17 MENU HEADINGGRID USAGE TIMER 18 MENU HEADING See menu 9 to enable SELL mode. Make sure LBX is above LBCO voltsPage INFORMATION FILE BATTERY 19 MENU HEADINGSell and float modes use timer. SLT and LBX mode ignore timer MENU SYSTEMTelephone 360/435-8826 MENU SYSTEMPage  2001 Xantrex Technology, IncPage Figure 17, Trace SW Series Inverter Simple Block DiagramOPERATION OPERATION THEORY OF OPERATIONOPERATION Figure 18, Trace SW Series Inverter Output WaveformPage SW4548E POWER VS. EFFICIENCYSW3024E / SW3048E SW4024 / SW4048Figure 20, Inverter Capacity vs. Temperature INVERTER CAPACITY VS TEMPERATUREpower Temperature CPage ADDITIONAL FEATURESOPERATING MODES OPERATIONSETTING SEARCH MODE WATTS INVERTER MODESEARCH MODE CONTROL BATTERYDCOPERATION LOW BATTERY PROTECTIONSETTING SEARCH MODE SPACING ADJUSTING THE LOW BATTERY PROTECTIONTHREE STAGE CHARGING PROCESS CHARGER MODEBATTERY Figure 21, Three-Stage Battery ChargingAC INPUT REQUIREMENTS BATTERY TEMPERATURE SENSOR BTSFigure 22, BTS Battery Temperature Sensor CHARGER ONLY OPERATIONFREQUENCY RECOMMENDED BATTERY CHARGER SETTINGSDELAY PERIOD AC CURRENT LEVELEQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLY Table 4, Charging Setpoints For Common Battery TypesTYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES Battery TypeTo start the equalization process either manually or automatically OPERATIONPage UTILITY GRID AC AC GENERATOR INVERTER/CHARGER MODETRANSFERRING UPON AVAILABILITY OF AC POWER TRANSFERRING BASED ON BATTERY VOLTAGEPage TRANSFER TIMEWhile 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 OPERATIONOPERATION GENERATOR SUPPORT MODEGENERATOR BATTERYPage GENERATOR SUPPORT/OVERLOAD PROTECTION120 VAC VS. 120/240 VAC GENERATORS OPERATIONINVERTER/ CHARGER AUTOMATIC GENERATOR CONTROL MODEDC BATTERY AC GENERATOR CONTROLOPERATION GEN CONTROL RELAYSGENERATOR STARTING SCENARIOS AUTOMATICALLYPage GENERATOR STARTING AND STOPPING CONFIGURATIONSMANUALLY OPERATIONGENERATOR AUTO START REQUIREMENTS AND TYPES TWO WIRE START GENERATORS2 WIRE TYPE GENERATOR Figure 23, Two Wire Start Wiring DiagramOPERATION THREE-WIRE START GENERATORSFigure 25, Three-Wire Start Wiring Diagram ONAN Type HONDA TYPE GENERATOROPERATION 3-TO-2 WIRE CONVERTERSGENERATOR CONTROL SEQUENCE Figure 26, Relay RY7 and RY8 SequencePage GENERATOR ERROR CAUSESGENERATOR STOP COOL DOWN PERIOD OPERATIONPage EQUALIZATION CHARGING, AUTOMATIC GENERATOR CONTROL SYSTEMAn 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 OPERATIONMAIN UTILITY BACKUP MODEGENERATOR AC INVERTER/ CHARGER DC BATTERY UTILITY GRIDOPERATION USING SLT MODE SILENT MODEBATTERY REQUIREMENTS UTILITY SUPPORT/OVERLOAD PROTECTIONMAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UP UTILITY INTERACTIVE MODEGROUND FAULT UTILITY GRID kWh METER AC OUTDOOR AC DISCONNECTOPERATION THEORY OF OPERATIONUTILITY 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 gridPOSITIVE + = Inverter is drawing power from grid SELLING POWER - FROM A DC CHARGING SOURCEBattery Sell Volts DC SettingPage SELLING POWER - STORED IN THE BATTERIESPower 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 OPERATIONOPERATION BATTERY REGULATION LEVEL - SELL MODE15 menu heading is used to trigger a bulk charge cycle BATTERY REQUIREMENTSLINE-TIE SYSTEM WITH UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUPBACKUP OF CRITICAL AC UTILITY INTERACTIVESOLAR ARRAY OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODEBATTERY BANK Figure 30, Overvoltage Protection for BatteryIN BRIEF ENERGY MANAGEMENT MODEINVERTER/ CHARGER DC BATTERY OPERATIONPage OPERATIONOPERATION PEAK LOAD SHAVING MODEIN BRIEF INVERTER/ CHARGER DC BATTERYAC LOADS SUB-PANEL AC INVERTER CHARGER LOW BATTERY TRANSFER LBX MODESOLAR ARRAY DC GROUND FAULT PROTECTION UTILITY GRID kWH METER AC AC LOADSAC MAIN PANELOnce 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 OPERATIONPage OPERATION USING MULTIPLE INVERTERSINPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS “SERIES” STACKED OPERATIONOPERATION GENERATOR CONTROL SETTINGS“PARALLEL” STACKED OPERATION 240 VAC/60 HZ ONLY ELECTRICAL SYSTEMSOPERATION BATTERY CHARGING WITH MULTIPLE INVERTERSAUTOMATIC 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 connectTelephone 360/435-8826 OPERATIONPage  2001 Xantrex Technology, IncTELEPHONE COMPANY BATTERY BATTERY TYPESELECTION OF BATTERY TYPE STARTING BATTERYSEALED LEAD ACID BATTERIES NICAD AND NICKEL IRON NIFE BATTERYTECHNICAL INFORMATION Page 100Table 5, Typical Wattage Of Common Appliances BATTERY SIZINGESTIMATING BATTERY REQUIREMENTS Page 1015,139 BATTERY BANK SIZINGEXAMPLE Page 102WATTS WORKSHEETPage 103 TECHNICAL INFORMATIONTYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES BATTERY CARE AND MAINTENANCETable 6, Battery Charging Charging Setpoints Page 104Page 105 MONTHLY MAINTENANCEBATTERY STATE OF CHARGE Table 7, Battery State of Charge VoltagePage 106 BATTERY INSTALLATIONBATTERY ENCLOSURES BATTERY TEMPERATURETotal Battery Capacity BATTERY HOOK-UP CONFIGURATIONSEach individual 6-volt battery capacity = 100 amp hours Figure 31, Series Configuration 6-Volt Battery WiringSERIES - PARALLEL CONNECTION Each individual 12-volt battery capacity = 50 amp hoursFigure 33, Parallel Configuration 12-Volt Battery Wiring PARALLEL CONNECTION6V 6V Total Battery CapacityFigure 35, Series-Parallel Configuration 12-Volt Battery Wiring Page 109Page 110 BATTERY CABLE INDUCTANCEDistance Between Battery Cables Inductance in micro-Henries Table 8, Battery Cable InductancePage 111 APPLICATIONSRESISTIVE LOADS INDUCTIVE LOADSSOLUTION TROUBLESHOOTING GUIDEINVERTER - If ERROR LED comes on, see ERROR CAUSES section PROBLEMTROUBLESHOOTING GUIDE BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES sectionPage 113 PageTECHNICAL INFORMATION Page 114TROUBLESHOOTING GUIDE SOLUTIONTECHNICAL INFORMATION INVERTER/CHARGER TERMINOLOGYPage 115 Digital VoltMeter DVMPage 116 Figure 36, AC WaveformsTECHNICAL INFORMATION Page 117 StackingTECHNICAL INFORMATION MODEL SPECIFICATIONS AND FEATURES 60 Hz ModelsNote All specifications are subject to change without notice Page 118SW3024E SW3048E SW4548E SW3024J SW4048J SW4548A SPECIFICATIONS AND FEATURES 50 Hz ModelsPage 119 SW2612E 2001 Xantrex Technology, Inc DIMENSIONSPage 120 TECHNICAL INFORMATIONINSTALLATION DIAGRAMS Page 121TECHNICAL INFORMATION Telephone 360/435-8826 Page 122TECHNICAL INFORMATION  2001 Xantrex Technology, IncSW Series Inverter/Charger - Model SW USER SETTINGS WORKSHEETSUSER MENU Page 123USER SETTINGS SETUP MENU - 12 VDC 120 VAC/60HZ MODELSPage 124 DEFAULT SETTINGSUSER SETTINGS SETUP MENU - 24 VDC 120 VAC/60HZ MODELSPage 125 DEFAULT SETTINGSUSER SETTINGS SETUP MENU - 48 VDC 120 VAC/60HZ MODELSPage 126 DEFAULT SETTINGSTelephone 360/435-8826 Page 127TECHNICAL INFORMATION  2001 Xantrex Technology, IncSWCA APPENDIXOPTIONS SWRCC40 MULTI-FUNCTION CONTROLLER SW SERIES POWER PANEL SYSTEMSTM500 TRACE METER BATTERY STATUS MONITOR OTHER PRODUCTSPage 130 Table 9, Power Consumption Of Common AppliancesTable 10, AWG to Metric Wire Conversion Chart REFERENCE TABLES AND GRAPHSNEC AMPS2 Table 11, Minimum Recommended Battery Cable Size vs. Cable LengthTable 12, Battery Cable to Maximum Breaker/Fuse Size Page 131Minimum Size of Copper Ground Wire Table 13, Recommended Minimum AC Wire Sizes 75 CTable 15, Safety Ground Wire Size Table Battery DC Disconnect SizeInterior Storage Storage ChecklistPreparation for Storage Page 133Telephone 360/435-8826 Page 134APPENDIX  2001 Xantrex Technology, IncLIFE SUPPORT POLICY WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATIONLIMITED WARRANTY WARRANTY REGISTRATIONWARRANTY/REPAIR INFORMATION WARRANTY OR REPAIR SERVICE REQUIREDPage 136 INDEX INDEXPage 137 Hook Up ConfigurationsINDEX PageOutput Waveform Page 139Low Battery Cut Out VDC INDEXPage INDEXStored In The Batteries Page 141Installation Guidelines INDEXINDEX Page 142