With Revision 4.01 Software
SW Series Inverter/Chargers
Owner’s Manual
2001 Xantrex Technology, Inc
2001 Xantrex Technology, Inc
Telephone 360/435-8826
5916 - 195th Street N. E
Arlington, WA
PRODUCT MATERIALS PACKAGE
2001 Xantrex Technology, Inc
Telephone 360/435-8826
5916 - 195th Street N. E
Arlington, WA
TABLE OF CONTENTS
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS
CONTROLS, INDICATORS AND COMPONENTS
TABLE OF CONTENTS
WARRANTY/REPAIR INFORMATION
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
IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS
GENERAL PRECAUTIONS
Safety
SAVE THESE INSTRUCTIONS
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
Telephone 360/435-8826
INTRODUCTION INTRODUCTION
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INTRODUCTION
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2001 Xantrex Technology, Inc
Telephone 360/435-8826
UNIT IDENTIFICATION UNIT IDENTIFICATION
MODEL NUMBER
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Figure 1, Identification Label
UNIT IDENTIFICATION
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2001 Xantrex Technology, Inc
Telephone 360/435-8826
CONTROLS, INDICATORS AND COMPONENTS
CONTROL PANEL
DISPLAY
Figure 2, SW Series Inverter/Charger
RESET TO FACTORY DEFAULTS BUTTON
LED STATUS INDICATORS
MENU ACCESS/ADJUSTMENT BUTTONS Black
CONTRAST CONTROL
ERROR Red
AC1 IN GOOD Green
AC2 IN GOOD Green
BULK Yellow
AC SIDE
REMOTE PORT
STACKING PORT
INVERTER/CHARGER CIRCUIT BREAKER
INTERNAL COMPONENTS AND INDICATORS
Figure 5, Internal Components and Indicators
LED INDICATORS
RY7 Yellow LED
BATTERY TERMINALS
AC SAFETY GROUND
AUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS
Figure 6, Auxiliary and Generator Control Relay Connectors
INSTALLATION INSTALLATION
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INSTALLATION
QUICK INSTALL
MOUNTING
DC CABLING
COMPLETE INSTALL
UNPACKING
LOCATION
INSTALLATION
AC WIRING
VENTILATION
FLOW
Figure 8, Air Flow Intake Location
Figure 9, AC Input/Output Power Connection
Table 1, AC Input and Output Wiring Connections
WIRE COLOR
AC IN
AC INSTALLATION GUIDELINES
IMPORTANT PRECAUTION
EXTERNAL TRANSFER RELAYS
INSTALLATION
120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’S
WARNING LABEL
Figure 10, Warning Label
INSTALLATION
DC WIRING
BATTERY CABLE SIZING
Table 2, Minimum Recommended Battery Cable Size vs. Cable Length
INVERTER MODEL
Table 3, Battery Cable To Maximum Breaker/Fuse Size
DC DISCONNECT AND OVERCURRENT PROTECTION
CABLE SIZE REQUIRED
RATING IN
BATTERY CABLE CONNECTIONS
Figure 11, Battery to Inverter Cable Connection
INSTALLATION PROCEDURE - BATTERY CABLES
INSTALLATION
CONTROL WIRING
GEN CONTROL WIRING
AUX RELAY WIRING
REMOTE CONTROL WIRING
SYSTEM GROUNDING
EQUIPMENT OR CHASSIS GROUNDS
GROUNDING ELECTRODES/GROUND RODS
BONDING THE GROUNDING SYSTEM
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
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GROUNDING VS. LIGHTNING
ONE GROUND FOR ALL EQUIPMENT
KEEP EQUIPMENT CLOSE TOGETHER
Figure 15, Multiple Point Ground System
INSTALLATION
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2001 Xantrex Technology, Inc
Telephone 360/435-8826
FUNCTIONAL TEST FUNCTIONAL TEST
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FUNCTIONAL TEST
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2001 Xantrex Technology, Inc
Telephone 360/435-8826
MENU SYSTEM MENU SYSTEM
OVERVIEW
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MENU SYSTEM
USER MENU MAP
MENU HEADINGS
MENU ITEMS
SETUP MENU MAP
MENU SYSTEM
MENU HEADINGS
MENU ITEMS
USER MENU
MENU HEADINGS
MENU SYSTEM
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INVERTER MODE 1 MENU HEADING
GENERATOR MODE 2 MENU HEADING
Move cursor to Inverter OFF to reset Overcurrent
INFORMATION DISPLAY
Generator start errorNO
Generator sync errorNO
Gen max run time errorNO
MENU SYSTEM
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
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GENERATOR TIMER 7 MENU HEADING
To defeat timers set start = end
TIME OF DAY 6 MENU HEADING
Gen doesn’t run during quiet time unless batt volts is less than
SETUP MENU
MENU SYSTEM
MENU HEADINGS
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INVERTER SETUP 9 MENU HEADING
MENU SYSTEM
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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 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
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GEN STARTING DETAILS 13 MENU HEADING
MENU SYSTEM
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INFORMATION DISPLAY
AUXILIARY RELAYS 14 MENU HEADING
MENU SYSTEM
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Set Pre Crank seconds10
Relays have 2 seconds delay on close, 0.1 sec delay on open
Close on batt setpoint. Open on batt setpoint - hys
MENU SYSTEM
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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
MENU SYSTEM
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
SELL mode
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
Telephone 360/435-8826
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
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POWER VS. EFFICIENCY
SW3024E / SW3048E
SW4024 / SW4048
SW4548E
INVERTER CAPACITY VS TEMPERATURE
power
Temperature C
Figure 20, Inverter Capacity vs. Temperature
ADDITIONAL FEATURES
OPERATING MODES
OPERATION
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INVERTER MODE
SEARCH MODE CONTROL
BATTERYDC
SETTING SEARCH MODE WATTS
LOW BATTERY PROTECTION
SETTING SEARCH MODE SPACING
ADJUSTING THE LOW BATTERY PROTECTION
OPERATION
CHARGER MODE
BATTERY
Figure 21, Three-Stage Battery Charging
THREE STAGE CHARGING PROCESS
BATTERY TEMPERATURE SENSOR BTS
Figure 22, BTS Battery Temperature Sensor
CHARGER ONLY OPERATION
AC INPUT REQUIREMENTS
RECOMMENDED BATTERY CHARGER SETTINGS
DELAY PERIOD
AC CURRENT LEVEL
FREQUENCY
Table 4, Charging Setpoints For Common Battery Types
TYPICAL BULK AND FLOAT 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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INVERTER/CHARGER MODE
TRANSFERRING UPON AVAILABILITY OF AC POWER
TRANSFERRING BASED ON BATTERY VOLTAGE
UTILITY GRID AC AC GENERATOR
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
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GENERATOR SUPPORT MODE
GENERATOR
BATTERY
OPERATION
GENERATOR SUPPORT/OVERLOAD PROTECTION
120 VAC VS. 120/240 VAC GENERATORS
OPERATION
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AUTOMATIC GENERATOR CONTROL MODE
DC BATTERY
AC GENERATOR CONTROL
INVERTER/ CHARGER
GEN CONTROL RELAYS
GENERATOR STARTING SCENARIOS
AUTOMATICALLY
OPERATION
GENERATOR STARTING AND STOPPING CONFIGURATIONS
MANUALLY
OPERATION
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TWO WIRE START GENERATORS
2 WIRE TYPE GENERATOR
Figure 23, Two Wire Start Wiring Diagram
GENERATOR AUTO START REQUIREMENTS AND TYPES
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
OPERATION
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
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UTILITY BACKUP MODE
GENERATOR AC INVERTER/ CHARGER DC BATTERY
UTILITY GRID
MAIN
USING SLT MODE SILENT MODE
BATTERY REQUIREMENTS
UTILITY SUPPORT/OVERLOAD PROTECTION
OPERATION
UTILITY INTERACTIVE MODE
GROUND FAULT
UTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT
MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UP
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
OPERATION
SELLING POWER - FROM A DC CHARGING SOURCE
Battery Sell Volts
DC Setting
POSITIVE + = Inverter is drawing power from grid
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
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BATTERY REGULATION LEVEL - SELL MODE
15 menu heading is used to trigger a bulk charge cycle
BATTERY REQUIREMENTS
OPERATION
UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUP
BACKUP OF CRITICAL AC
UTILITY INTERACTIVE
LINE-TIE SYSTEM WITH
OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODE
BATTERY BANK
Figure 30, Overvoltage Protection for Battery
SOLAR ARRAY
ENERGY MANAGEMENT MODE
INVERTER/ CHARGER DC BATTERY
OPERATION
IN BRIEF
OPERATION
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PEAK LOAD SHAVING MODE
IN BRIEF
INVERTER/ CHARGER DC BATTERY
OPERATION
LOW BATTERY TRANSFER LBX MODE
SOLAR ARRAY DC GROUND FAULT PROTECTION
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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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
OPERATION
OPERATION
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2001 Xantrex Technology, Inc
Telephone 360/435-8826
BATTERY TYPE
SELECTION OF BATTERY TYPE
STARTING BATTERY
TELEPHONE COMPANY BATTERY
NICAD AND NICKEL IRON NIFE BATTERY
TECHNICAL INFORMATION
Page 100
SEALED LEAD ACID BATTERIES
BATTERY SIZING
ESTIMATING BATTERY REQUIREMENTS
Page 101
Table 5, Typical Wattage Of Common Appliances
BATTERY BANK SIZING
EXAMPLE
Page 102
5,139
WORKSHEET
Page 103
TECHNICAL INFORMATION
WATTS
BATTERY CARE AND MAINTENANCE
Table 6, Battery Charging Charging Setpoints
Page 104
TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES
MONTHLY MAINTENANCE
BATTERY STATE OF CHARGE
Table 7, Battery State of Charge Voltage
Page 105
BATTERY INSTALLATION
BATTERY ENCLOSURES
BATTERY TEMPERATURE
Page 106
BATTERY HOOK-UP CONFIGURATIONS
Each individual 6-volt battery capacity = 100 amp hours
Figure 31, Series Configuration 6-Volt Battery Wiring
Total Battery Capacity
Each individual 12-volt battery capacity = 50 amp hours
Figure 33, Parallel Configuration 12-Volt Battery Wiring
PARALLEL CONNECTION
SERIES - PARALLEL CONNECTION
Total Battery Capacity
Figure 35, Series-Parallel Configuration 12-Volt Battery Wiring
Page 109
6V 6V
BATTERY CABLE INDUCTANCE
Distance Between Battery Cables Inductance in micro-Henries
Table 8, Battery Cable Inductance
Page 110
APPLICATIONS
RESISTIVE LOADS
INDUCTIVE LOADS
Page 111
TROUBLESHOOTING GUIDE
INVERTER - If ERROR LED comes on, see ERROR CAUSES section
PROBLEM
SOLUTION
BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES section
Page 113
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TROUBLESHOOTING GUIDE
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
TECHNICAL INFORMATION
SPECIFICATIONS AND FEATURES 60 Hz Models
Note All specifications are subject to change without notice
Page 118
MODEL
SPECIFICATIONS AND FEATURES 50 Hz Models
Page 119
SW2612E
SW3024E SW3048E SW4548E SW3024J SW4048J SW4548A
DIMENSIONS
Page 120
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
INSTALLATION DIAGRAMS
Page 121
TECHNICAL INFORMATION
Page 122
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
USER SETTINGS WORKSHEETS
USER MENU
Page 123
SW Series Inverter/Charger - Model SW
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
USER SETTINGS
Page 127
TECHNICAL INFORMATION
2001 Xantrex Technology, Inc
Telephone 360/435-8826
APPENDIX
OPTIONS
SWRC
SWCA
SW SERIES POWER PANEL SYSTEMS
TM500 TRACE METER BATTERY STATUS MONITOR
OTHER PRODUCTS
C40 MULTI-FUNCTION CONTROLLER
Table 9, Power Consumption Of Common Appliances
Table 10, AWG to Metric Wire Conversion Chart
REFERENCE TABLES AND GRAPHS
Page 130
Table 11, Minimum Recommended Battery Cable Size vs. Cable Length
Table 12, Battery Cable to Maximum Breaker/Fuse Size
Page 131
NEC AMPS2
Table 13, Recommended Minimum AC Wire Sizes 75 C
Table 15, Safety Ground Wire Size Table
Battery DC Disconnect Size
Minimum Size of Copper Ground Wire
Storage Checklist
Preparation for Storage
Page 133
Interior Storage
Page 134
APPENDIX
2001 Xantrex Technology, Inc
Telephone 360/435-8826
WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATION
LIMITED WARRANTY
WARRANTY REGISTRATION
LIFE SUPPORT POLICY
WARRANTY/REPAIR INFORMATION
WARRANTY OR REPAIR SERVICE REQUIRED
Page 136
INDEX
Page 137
Hook Up Configurations
INDEX
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INDEX
Page 139
Low Battery Cut Out VDC
INDEX
Output Waveform
INDEX
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Page 141
Installation Guidelines
INDEX
Stored In The Batteries
Page 142
INDEX