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Xantrex Technology 120 VAC/60 owner manual

Models: 120 VAC/60

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5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229

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Xantrex Technology 120 VAC/60 owner manual

Contents

With Revision 4.01 Software SW Series Inverter/ChargersOwner’s Manual  2001 Xantrex Technology, Inc 2001 Xantrex Technology, Inc Telephone 360/435-88265916 - 195th Street N. E Arlington, WAPRODUCT MATERIALS PACKAGE  2001 Xantrex Technology, Inc Telephone 360/435-88265916 - 195th Street N. E Arlington, WATABLE OF CONTENTS TABLE OF CONTENTSIMPORTANT SAFETY INSTRUCTIONS CONTROLS, INDICATORS AND COMPONENTSTABLE OF CONTENTS WARRANTY/REPAIR INFORMATIONAPPENDIX INDEXFigure 1, Identification Label INDEX OF FIGURESTABLE OF CONTENTS Table 1, AC Input and Output Wiring Connections INDEX OF TABLESTABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS GENERAL PRECAUTIONSSafety SAVE THESE INSTRUCTIONSIMPORTANT SAFETY INSTRUCTIONS SPECIAL NOTICESWARNING - RISK OF EXPLOSIVE GASSES PagePage PERSONAL PRECAUTIONSIMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS Page 2001 Xantrex Technology, Inc Telephone 360/435-8826INTRODUCTION INTRODUCTION PageINTRODUCTION Page 2001 Xantrex Technology, Inc Telephone 360/435-8826UNIT IDENTIFICATION UNIT IDENTIFICATION MODEL NUMBERPage Figure 1, Identification LabelUNIT IDENTIFICATION Page 2001 Xantrex Technology, Inc Telephone 360/435-8826CONTROLS, INDICATORS AND COMPONENTS CONTROL PANELDISPLAY Figure 2, SW Series Inverter/ChargerRESET TO FACTORY DEFAULTS BUTTON LED STATUS INDICATORSMENU ACCESS/ADJUSTMENT BUTTONS Black CONTRAST CONTROLERROR Red AC1 IN GOOD GreenAC2 IN GOOD Green BULK YellowAC SIDE REMOTE PORTSTACKING PORT INVERTER/CHARGER CIRCUIT BREAKERINTERNAL COMPONENTS AND INDICATORS Figure 5, Internal Components and IndicatorsLED INDICATORS RY7 Yellow LEDBATTERY TERMINALS AC SAFETY GROUNDAUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS Figure 6, Auxiliary and Generator Control Relay ConnectorsINSTALLATION INSTALLATION PageINSTALLATION QUICK INSTALLMOUNTING DC CABLINGCOMPLETE INSTALL UNPACKINGLOCATION INSTALLATIONAC WIRING VENTILATIONFLOW Figure 8, Air Flow Intake LocationFigure 9, AC Input/Output Power Connection Table 1, AC Input and Output Wiring ConnectionsWIRE COLOR AC INAC INSTALLATION GUIDELINES IMPORTANT PRECAUTIONEXTERNAL TRANSFER RELAYS INSTALLATION120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’S WARNING LABELFigure 10, Warning Label INSTALLATIONDC WIRING BATTERY CABLE SIZINGTable 2, Minimum Recommended Battery Cable Size vs. Cable Length INVERTER MODELTable 3, Battery Cable To Maximum Breaker/Fuse Size DC DISCONNECT AND OVERCURRENT PROTECTIONCABLE SIZE REQUIRED RATING INBATTERY CABLE CONNECTIONS Figure 11, Battery to Inverter Cable ConnectionINSTALLATION PROCEDURE - BATTERY CABLES INSTALLATIONCONTROL WIRING GEN CONTROL WIRINGAUX RELAY WIRING REMOTE CONTROL WIRINGSYSTEM GROUNDING EQUIPMENT OR CHASSIS GROUNDSGROUNDING ELECTRODES/GROUND RODS BONDING THE GROUNDING SYSTEMPage NEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONSINSTALLATION Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To Ground AC SOURCEINSTALLATION PageGROUNDING VS. LIGHTNING ONE GROUND FOR ALL EQUIPMENTKEEP EQUIPMENT CLOSE TOGETHER Figure 15, Multiple Point Ground SystemINSTALLATION Page 2001 Xantrex Technology, Inc Telephone 360/435-8826FUNCTIONAL TEST FUNCTIONAL TEST PageFUNCTIONAL TEST Page 2001 Xantrex Technology, Inc Telephone 360/435-8826Page MENU SYSTEM MENU SYSTEMOVERVIEW MENU SYSTEM USER MENU MAPMENU HEADINGS MENU ITEMSSETUP MENU MAP MENU SYSTEMMENU HEADINGS MENU ITEMSUSER MENU MENU HEADINGSMENU SYSTEM PageINVERTER MODE 1 MENU HEADING GENERATOR MODE 2 MENU HEADINGMove cursor to Inverter OFF to reset Overcurrent INFORMATION DISPLAYGenerator start errorNO Generator sync errorNOGen max run time errorNO MENU SYSTEMTRACE ENGINEERING 3 MENU HEADING 5916 195th St NE Arlington, WA 98223 USAMENU SYSTEM PageMETERS 4 MENU HEADING NOTE The meters do not display a + symbol for positive valuesMENU SYSTEM PageERROR CAUSES 5 MENU HEADING AC1 & AC2 volts valid only when inverter synced to that inputMENU SYSTEM PagePage 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 systemMENU SYSTEM GENERATOR TIMER 7 MENU HEADING To defeat timers set start = endTIME OF DAY 6 MENU HEADING Gen doesn’t run during quiet time unless batt volts is less thanSETUP MENU MENU SYSTEMMENU HEADINGS PageINVERTER SETUP 9 MENU HEADING MENU SYSTEMPage Set Grid Usage FLT SELL SLT LBXPage 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 compensatedMENU SYSTEM BATTERY CHARGING 10 MENU HEADING battery temperature if the BTS sensor is installedMENU SYSTEM PageAC 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 automaticallyMENU SYSTEM PageGEN 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 periodMENU SYSTEM PageGEN STARTING DETAILS 13 MENU HEADING MENU SYSTEMPage INFORMATION DISPLAYAUXILIARY RELAYS 14 MENU HEADING MENU SYSTEMPage Set Pre Crank seconds10Relays have 2 seconds delay on close, 0.1 sec delay on open Close on batt setpoint. Open on batt setpoint - hysMENU SYSTEM PageBULK CHARGE TRIGGER TIMER 15 MENU HEADING LOW BATTERY TRANSFER 16 MENU HEADINGSee menu 9 to enable LBX mode Make sure LBX is above LBCO volts MENU SYSTEMBATTERY SELLING 17 MENU HEADING GRID USAGE TIMER 18 MENU HEADINGSee menu 9 to enable SELL mode. Make sure LBX is above LBCO volts SELL modeINFORMATION FILE BATTERY 19 MENU HEADING Sell and float modes use timer. SLT and LBX mode ignore timerMENU SYSTEM PageMENU SYSTEM Page 2001 Xantrex Technology, Inc Telephone 360/435-8826Figure 17, Trace SW Series Inverter Simple Block Diagram OPERATION OPERATIONTHEORY OF OPERATION PagePage OPERATIONFigure 18, Trace SW Series Inverter Output Waveform POWER VS. EFFICIENCY SW3024E / SW3048ESW4024 / SW4048 SW4548EINVERTER CAPACITY VS TEMPERATURE powerTemperature C Figure 20, Inverter Capacity vs. TemperatureADDITIONAL FEATURES OPERATING MODESOPERATION PageINVERTER MODE SEARCH MODE CONTROLBATTERYDC SETTING SEARCH MODE WATTSLOW BATTERY PROTECTION SETTING SEARCH MODE SPACINGADJUSTING THE LOW BATTERY PROTECTION OPERATIONCHARGER MODE BATTERYFigure 21, Three-Stage Battery Charging THREE STAGE CHARGING PROCESSBATTERY TEMPERATURE SENSOR BTS Figure 22, BTS Battery Temperature SensorCHARGER ONLY OPERATION AC INPUT REQUIREMENTSRECOMMENDED BATTERY CHARGER SETTINGS DELAY PERIODAC CURRENT LEVEL FREQUENCYTable 4, Charging Setpoints For Common Battery Types TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPESBattery Type EQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLYPage To start the equalization process either manually or automaticallyOPERATION INVERTER/CHARGER MODE TRANSFERRING UPON AVAILABILITY OF AC POWERTRANSFERRING BASED ON BATTERY VOLTAGE UTILITY GRID AC AC GENERATORTRANSFER 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 valueOPERATION PageGENERATOR SUPPORT MODE GENERATORBATTERY OPERATIONGENERATOR SUPPORT/OVERLOAD PROTECTION 120 VAC VS. 120/240 VAC GENERATORSOPERATION PageAUTOMATIC GENERATOR CONTROL MODE DC BATTERYAC GENERATOR CONTROL INVERTER/ CHARGERGEN CONTROL RELAYS GENERATOR STARTING SCENARIOSAUTOMATICALLY OPERATIONGENERATOR STARTING AND STOPPING CONFIGURATIONS MANUALLYOPERATION PageTWO WIRE START GENERATORS 2 WIRE TYPE GENERATORFigure 23, Two Wire Start Wiring Diagram GENERATOR AUTO START REQUIREMENTS AND TYPESTHREE-WIRE START GENERATORS Figure 25, Three-Wire Start Wiring Diagram ONAN TypeHONDA TYPE GENERATOR OPERATION3-TO-2 WIRE CONVERTERS GENERATOR CONTROL SEQUENCEFigure 26, Relay RY7 and RY8 Sequence OPERATIONGENERATOR ERROR CAUSES GENERATOR STOP COOL DOWN PERIODOPERATION PageEQUALIZATION 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 PanelOPERATION PageUTILITY BACKUP MODE GENERATOR AC INVERTER/ CHARGER DC BATTERYUTILITY GRID MAINUSING SLT MODE SILENT MODE BATTERY REQUIREMENTSUTILITY SUPPORT/OVERLOAD PROTECTION OPERATIONUTILITY INTERACTIVE MODE GROUND FAULTUTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UPTHEORY OF OPERATION UTILITY INTERACTIVE ISLANDING PROTECTIONWhen 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 OPERATIONSELLING POWER - FROM A DC CHARGING SOURCE Battery Sell VoltsDC Setting POSITIVE + = Inverter is drawing power from gridSELLING 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 processOPERATION PageBATTERY REGULATION LEVEL - SELL MODE 15 menu heading is used to trigger a bulk charge cycleBATTERY REQUIREMENTS OPERATIONUTILITY INTERACTIVE OPERATION WITH UTILITY BACKUP BACKUP OF CRITICAL ACUTILITY INTERACTIVE LINE-TIE SYSTEM WITHOVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE BATTERY BANKFigure 30, Overvoltage Protection for Battery SOLAR ARRAYENERGY MANAGEMENT MODE INVERTER/ CHARGER DC BATTERYOPERATION IN BRIEFOPERATION PagePEAK LOAD SHAVING MODE IN BRIEFINVERTER/ CHARGER DC BATTERY OPERATIONLOW BATTERY TRANSFER LBX MODE SOLAR ARRAY DC GROUND FAULT PROTECTIONUTILITY GRID kWH METER AC AC LOADSAC MAIN PANEL AC LOADS SUB-PANEL AC INVERTER CHARGERPage 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 offOPERATION USING MULTIPLE INVERTERS INPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS“SERIES” STACKED OPERATION OPERATIONGENERATOR CONTROL SETTINGS “PARALLEL” STACKED OPERATION240 VAC/60 HZ ONLY ELECTRICAL SYSTEMS OPERATIONBATTERY CHARGING WITH MULTIPLE INVERTERS AUTOMATIC GENERATOR CONTROL WITH MULTIPLE INVERTERSThe 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 OPERATIONOPERATION Page 2001 Xantrex Technology, Inc Telephone 360/435-8826BATTERY TYPE SELECTION OF BATTERY TYPESTARTING BATTERY TELEPHONE COMPANY BATTERYNICAD AND NICKEL IRON NIFE BATTERY TECHNICAL INFORMATIONPage 100 SEALED LEAD ACID BATTERIESBATTERY SIZING ESTIMATING BATTERY REQUIREMENTSPage 101 Table 5, Typical Wattage Of Common AppliancesBATTERY BANK SIZING EXAMPLEPage 102 5,139WORKSHEET Page 103TECHNICAL INFORMATION WATTSBATTERY CARE AND MAINTENANCE Table 6, Battery Charging Charging SetpointsPage 104 TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPESMONTHLY MAINTENANCE BATTERY STATE OF CHARGETable 7, Battery State of Charge Voltage Page 105BATTERY INSTALLATION BATTERY ENCLOSURESBATTERY TEMPERATURE Page 106BATTERY HOOK-UP CONFIGURATIONS Each individual 6-volt battery capacity = 100 amp hoursFigure 31, Series Configuration 6-Volt Battery Wiring Total Battery CapacityEach individual 12-volt battery capacity = 50 amp hours Figure 33, Parallel Configuration 12-Volt Battery WiringPARALLEL CONNECTION SERIES - PARALLEL CONNECTIONTotal Battery Capacity Figure 35, Series-Parallel Configuration 12-Volt Battery WiringPage 109 6V 6VBATTERY CABLE INDUCTANCE Distance Between Battery Cables Inductance in micro-HenriesTable 8, Battery Cable Inductance Page 110APPLICATIONS RESISTIVE LOADSINDUCTIVE LOADS Page 111TROUBLESHOOTING GUIDE INVERTER - If ERROR LED comes on, see ERROR CAUSES sectionPROBLEM SOLUTIONBATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES section Page 113Page TROUBLESHOOTING GUIDEPage 114 TROUBLESHOOTING GUIDESOLUTION TECHNICAL INFORMATIONINVERTER/CHARGER TERMINOLOGY Page 115Digital VoltMeter DVM TECHNICAL INFORMATIONTECHNICAL INFORMATION Page 116Figure 36, AC Waveforms TECHNICAL INFORMATION Page 117Stacking SPECIFICATIONS AND FEATURES 60 Hz Models Note All specifications are subject to change without noticePage 118 MODELSPECIFICATIONS AND FEATURES 50 Hz Models Page 119SW2612E SW3024E SW3048E SW4548E SW3024J SW4048J SW4548ADIMENSIONS Page 120TECHNICAL INFORMATION  2001 Xantrex Technology, IncTECHNICAL INFORMATION INSTALLATION DIAGRAMSPage 121 Page 122 TECHNICAL INFORMATION 2001 Xantrex Technology, Inc Telephone 360/435-8826USER SETTINGS WORKSHEETS USER MENUPage 123 SW Series Inverter/Charger - Model SWSETUP MENU - 12 VDC 120 VAC/60HZ MODELS Page 124DEFAULT SETTINGS USER SETTINGSSETUP MENU - 24 VDC 120 VAC/60HZ MODELS Page 125DEFAULT SETTINGS USER SETTINGSSETUP MENU - 48 VDC 120 VAC/60HZ MODELS Page 126DEFAULT SETTINGS USER SETTINGSPage 127 TECHNICAL INFORMATION 2001 Xantrex Technology, Inc Telephone 360/435-8826APPENDIX OPTIONSSWRC SWCASW SERIES POWER PANEL SYSTEMS TM500 TRACE METER BATTERY STATUS MONITOROTHER PRODUCTS C40 MULTI-FUNCTION CONTROLLERTable 9, Power Consumption Of Common Appliances Table 10, AWG to Metric Wire Conversion ChartREFERENCE TABLES AND GRAPHS Page 130Table 11, Minimum Recommended Battery Cable Size vs. Cable Length Table 12, Battery Cable to Maximum Breaker/Fuse SizePage 131 NEC AMPS2Table 13, Recommended Minimum AC Wire Sizes 75 C Table 15, Safety Ground Wire Size TableBattery DC Disconnect Size Minimum Size of Copper Ground WireStorage Checklist Preparation for StoragePage 133 Interior StoragePage 134 APPENDIX 2001 Xantrex Technology, Inc Telephone 360/435-8826WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATION LIMITED WARRANTYWARRANTY REGISTRATION LIFE SUPPORT POLICYPage 136 WARRANTY/REPAIR INFORMATIONWARRANTY OR REPAIR SERVICE REQUIRED INDEX Page 137Hook Up Configurations INDEXPage INDEXPage 139 Low Battery Cut Out VDCINDEX Output WaveformINDEX PagePage 141 Installation GuidelinesINDEX Stored In The BatteriesPage 142 INDEX