Manuals / Xantrex Technology / Lawn and Garden / Portable Generator

Xantrex Technology 120 VAC/60 Table Of Contents, Appendix, Warranty/Repair Information, Index

Models: 120 VAC/60

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TABLE OF CONTENTS

APPENDIX	128
OPTIONS	128
OTHER PRODUCTS	129
REFERENCE TABLES AND GRAPHS	130
STORAGE CHECKLIST	133
WARRANTY/REPAIR INFORMATION	135
LIMITED WARRANTY	135
WARRANTY REGISTRATION	135
LIFE SUPPORT POLICY	135
WARRANTY OR REPAIR SERVICE REQUIRED	136
INDEX	137

 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

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Contents

Owner’s Manual With Revision 4.01 SoftwareSW Series Inverter/Chargers  2001 Xantrex Technology, Inc5916 - 195th Street N. E  2001 Xantrex Technology, IncTelephone 360/435-8826 Arlington, WAPRODUCT MATERIALS PACKAGE 5916 - 195th Street N. E  2001 Xantrex Technology, IncTelephone 360/435-8826 Arlington, WAIMPORTANT SAFETY INSTRUCTIONS TABLE OF CONTENTSTABLE OF CONTENTS CONTROLS, INDICATORS AND COMPONENTSAPPENDIX TABLE OF CONTENTSWARRANTY/REPAIR INFORMATION INDEXINDEX OF FIGURES TABLE OF CONTENTSFigure 1, Identification Label INDEX OF TABLES TABLE OF CONTENTSTable 1, AC Input and Output Wiring Connections Safety IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONSGENERAL PRECAUTIONS SAVE THESE INSTRUCTIONSWARNING - RISK OF EXPLOSIVE GASSES IMPORTANT SAFETY INSTRUCTIONSSPECIAL NOTICES PagePERSONAL PRECAUTIONS IMPORTANT SAFETY INSTRUCTIONSPage  2001 Xantrex Technology, Inc IMPORTANT SAFETY INSTRUCTIONSPage Telephone 360/435-8826INTRODUCTION INTRODUCTION Page 2001 Xantrex Technology, Inc INTRODUCTIONPage Telephone 360/435-8826Page UNIT IDENTIFICATION UNIT IDENTIFICATIONMODEL NUMBER Figure 1, Identification Label 2001 Xantrex Technology, Inc UNIT IDENTIFICATIONPage Telephone 360/435-8826DISPLAY CONTROLS, INDICATORS AND COMPONENTSCONTROL PANEL Figure 2, SW Series Inverter/ChargerMENU ACCESS/ADJUSTMENT BUTTONS Black RESET TO FACTORY DEFAULTS BUTTONLED STATUS INDICATORS CONTRAST CONTROLAC2 IN GOOD Green ERROR RedAC1 IN GOOD Green BULK YellowSTACKING PORT AC SIDEREMOTE PORT INVERTER/CHARGER CIRCUIT BREAKERLED INDICATORS INTERNAL COMPONENTS AND INDICATORSFigure 5, Internal Components and Indicators RY7 Yellow LEDAUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS BATTERY TERMINALSAC SAFETY GROUND Figure 6, Auxiliary and Generator Control Relay ConnectorsINSTALLATION INSTALLATION PageMOUNTING INSTALLATIONQUICK INSTALL DC CABLINGLOCATION COMPLETE INSTALLUNPACKING INSTALLATIONFLOW AC WIRINGVENTILATION Figure 8, Air Flow Intake LocationWIRE COLOR Figure 9, AC Input/Output Power ConnectionTable 1, AC Input and Output Wiring Connections AC INEXTERNAL TRANSFER RELAYS AC INSTALLATION GUIDELINESIMPORTANT PRECAUTION INSTALLATIONFigure 10, Warning Label 120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’SWARNING LABEL INSTALLATIONTable 2, Minimum Recommended Battery Cable Size vs. Cable Length DC WIRINGBATTERY CABLE SIZING INVERTER MODELCABLE SIZE REQUIRED Table 3, Battery Cable To Maximum Breaker/Fuse SizeDC DISCONNECT AND OVERCURRENT PROTECTION RATING ININSTALLATION PROCEDURE - BATTERY CABLES BATTERY CABLE CONNECTIONSFigure 11, Battery to Inverter Cable Connection INSTALLATIONAUX RELAY WIRING CONTROL WIRINGGEN CONTROL WIRING REMOTE CONTROL WIRINGGROUNDING ELECTRODES/GROUND RODS SYSTEM GROUNDINGEQUIPMENT OR CHASSIS GROUNDS BONDING THE GROUNDING SYSTEMNEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONS INSTALLATIONPage INSTALLATION Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To GroundAC SOURCE PageKEEP EQUIPMENT CLOSE TOGETHER GROUNDING VS. LIGHTNINGONE GROUND FOR ALL EQUIPMENT Figure 15, Multiple Point Ground System 2001 Xantrex Technology, Inc INSTALLATIONPage Telephone 360/435-8826FUNCTIONAL TEST FUNCTIONAL TEST Page 2001 Xantrex Technology, Inc FUNCTIONAL TESTPage Telephone 360/435-8826MENU SYSTEM MENU SYSTEM OVERVIEWPage MENU HEADINGS MENU SYSTEMUSER MENU MAP MENU ITEMSMENU HEADINGS SETUP MENU MAPMENU SYSTEM MENU ITEMSMENU SYSTEM USER MENUMENU HEADINGS PageMove cursor to Inverter OFF to reset Overcurrent INVERTER MODE 1 MENU HEADINGGENERATOR MODE 2 MENU HEADING INFORMATION DISPLAYGen max run time errorNO Generator start errorNOGenerator sync errorNO MENU SYSTEMMENU SYSTEM TRACE ENGINEERING 3 MENU HEADING5916 195th St NE Arlington, WA 98223 USA PageMENU SYSTEM METERS 4 MENU HEADINGNOTE The meters do not display a + symbol for positive values PageMENU SYSTEM ERROR CAUSES 5 MENU HEADINGAC1 & AC2 volts valid only when inverter synced to that input PageBattery 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 TIME OF DAY 6 MENU HEADING GENERATOR TIMER 7 MENU HEADINGTo defeat timers set start = end Gen doesn’t run during quiet time unless batt volts is less thanMENU HEADINGS SETUP MENUMENU SYSTEM PagePage INVERTER SETUP 9 MENU HEADINGMENU SYSTEM Set Grid Usage FLT SELL SLT LBXThis 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 MENU SYSTEM BATTERY CHARGING 10 MENU HEADINGbattery temperature if the BTS sensor is installed PageMENU SYSTEM 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 PageMENU SYSTEM 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 PagePage GEN STARTING DETAILS 13 MENU HEADINGMENU SYSTEM INFORMATION DISPLAYPage AUXILIARY RELAYS 14 MENU HEADINGMENU SYSTEM Set Pre Crank seconds10MENU SYSTEM Relays have 2 seconds delay on close, 0.1 sec delay on openClose on batt setpoint. Open on batt setpoint - hys PageSee menu 9 to enable LBX mode Make sure LBX is above LBCO volts BULK CHARGE TRIGGER TIMER 15 MENU HEADINGLOW BATTERY TRANSFER 16 MENU HEADING MENU SYSTEMSee menu 9 to enable SELL mode. Make sure LBX is above LBCO volts BATTERY SELLING 17 MENU HEADINGGRID USAGE TIMER 18 MENU HEADING SELL modeMENU SYSTEM INFORMATION FILE BATTERY 19 MENU HEADINGSell and float modes use timer. SLT and LBX mode ignore timer Page 2001 Xantrex Technology, Inc MENU SYSTEMPage Telephone 360/435-8826THEORY OF OPERATION Figure 17, Trace SW Series Inverter Simple Block DiagramOPERATION OPERATION PageOPERATION Figure 18, Trace SW Series Inverter Output WaveformPage SW4024 / SW4048 POWER VS. EFFICIENCYSW3024E / SW3048E SW4548ETemperature C INVERTER CAPACITY VS TEMPERATUREpower Figure 20, Inverter Capacity vs. TemperatureOPERATION ADDITIONAL FEATURESOPERATING MODES PageBATTERYDC INVERTER MODESEARCH MODE CONTROL SETTING SEARCH MODE WATTSADJUSTING THE LOW BATTERY PROTECTION LOW BATTERY PROTECTIONSETTING SEARCH MODE SPACING OPERATIONFigure 21, Three-Stage Battery Charging CHARGER MODEBATTERY THREE STAGE CHARGING PROCESSCHARGER ONLY OPERATION BATTERY TEMPERATURE SENSOR BTSFigure 22, BTS Battery Temperature Sensor AC INPUT REQUIREMENTSAC CURRENT LEVEL RECOMMENDED BATTERY CHARGER SETTINGSDELAY PERIOD FREQUENCYBattery Type Table 4, Charging Setpoints For Common Battery TypesTYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES EQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLYTo start the equalization process either manually or automatically OPERATIONPage TRANSFERRING BASED ON BATTERY VOLTAGE INVERTER/CHARGER MODETRANSFERRING UPON AVAILABILITY OF AC POWER UTILITY GRID AC AC GENERATOROPERATION 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 PageBATTERY GENERATOR SUPPORT MODEGENERATOR OPERATIONOPERATION GENERATOR SUPPORT/OVERLOAD PROTECTION120 VAC VS. 120/240 VAC GENERATORS PageAC GENERATOR CONTROL AUTOMATIC GENERATOR CONTROL MODEDC BATTERY INVERTER/ CHARGERAUTOMATICALLY GEN CONTROL RELAYSGENERATOR STARTING SCENARIOS OPERATIONOPERATION GENERATOR STARTING AND STOPPING CONFIGURATIONSMANUALLY PageFigure 23, Two Wire Start Wiring Diagram TWO WIRE START GENERATORS2 WIRE TYPE GENERATOR GENERATOR AUTO START REQUIREMENTS AND TYPESHONDA TYPE GENERATOR THREE-WIRE START GENERATORSFigure 25, Three-Wire Start Wiring Diagram ONAN Type OPERATIONFigure 26, Relay RY7 and RY8 Sequence 3-TO-2 WIRE CONVERTERSGENERATOR CONTROL SEQUENCE OPERATIONOPERATION GENERATOR ERROR CAUSESGENERATOR STOP COOL DOWN PERIOD PageOPERATION 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 PageUTILITY GRID UTILITY BACKUP MODEGENERATOR AC INVERTER/ CHARGER DC BATTERY MAINUTILITY SUPPORT/OVERLOAD PROTECTION USING SLT MODE SILENT MODEBATTERY REQUIREMENTS OPERATIONUTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT UTILITY INTERACTIVE MODEGROUND FAULT MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UPWhen 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 THEORY OF OPERATIONUTILITY INTERACTIVE ISLANDING PROTECTION OPERATIONDC Setting SELLING POWER - FROM A DC CHARGING SOURCEBattery Sell Volts POSITIVE + = Inverter is drawing power from gridOPERATION 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 PageBATTERY REQUIREMENTS BATTERY REGULATION LEVEL - SELL MODE15 menu heading is used to trigger a bulk charge cycle OPERATIONUTILITY INTERACTIVE UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUPBACKUP OF CRITICAL AC LINE-TIE SYSTEM WITHFigure 30, Overvoltage Protection for Battery OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODEBATTERY BANK SOLAR ARRAYOPERATION ENERGY MANAGEMENT MODEINVERTER/ CHARGER DC BATTERY IN BRIEFOPERATION PageINVERTER/ CHARGER DC BATTERY PEAK LOAD SHAVING MODEIN BRIEF OPERATIONUTILITY GRID kWH METER AC AC LOADSAC MAIN PANEL LOW BATTERY TRANSFER LBX MODESOLAR ARRAY DC GROUND FAULT PROTECTION AC LOADS SUB-PANEL AC INVERTER CHARGEROnce 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 “SERIES” STACKED OPERATION USING MULTIPLE INVERTERSINPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS OPERATION240 VAC/60 HZ ONLY ELECTRICAL SYSTEMS GENERATOR CONTROL SETTINGS“PARALLEL” STACKED OPERATION OPERATIONThe 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 BATTERY CHARGING WITH MULTIPLE INVERTERSAUTOMATIC GENERATOR CONTROL WITH MULTIPLE INVERTERS OPERATION 2001 Xantrex Technology, Inc OPERATIONPage Telephone 360/435-8826STARTING BATTERY BATTERY TYPESELECTION OF BATTERY TYPE TELEPHONE COMPANY BATTERYPage 100 NICAD AND NICKEL IRON NIFE BATTERYTECHNICAL INFORMATION SEALED LEAD ACID BATTERIESPage 101 BATTERY SIZINGESTIMATING BATTERY REQUIREMENTS Table 5, Typical Wattage Of Common AppliancesPage 102 BATTERY BANK SIZINGEXAMPLE 5,139TECHNICAL INFORMATION WORKSHEETPage 103 WATTSPage 104 BATTERY CARE AND MAINTENANCETable 6, Battery Charging Charging Setpoints TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPESTable 7, Battery State of Charge Voltage MONTHLY MAINTENANCEBATTERY STATE OF CHARGE Page 105BATTERY TEMPERATURE BATTERY INSTALLATIONBATTERY ENCLOSURES Page 106Figure 31, Series Configuration 6-Volt Battery Wiring BATTERY HOOK-UP CONFIGURATIONSEach individual 6-volt battery capacity = 100 amp hours Total Battery CapacityPARALLEL CONNECTION Each individual 12-volt battery capacity = 50 amp hoursFigure 33, Parallel Configuration 12-Volt Battery Wiring SERIES - PARALLEL CONNECTIONPage 109 Total Battery CapacityFigure 35, Series-Parallel Configuration 12-Volt Battery Wiring 6V 6VTable 8, Battery Cable Inductance BATTERY CABLE INDUCTANCEDistance Between Battery Cables Inductance in micro-Henries Page 110INDUCTIVE LOADS APPLICATIONSRESISTIVE LOADS Page 111PROBLEM TROUBLESHOOTING GUIDEINVERTER - If ERROR LED comes on, see ERROR CAUSES section SOLUTIONPage BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES sectionPage 113 TROUBLESHOOTING GUIDESOLUTION Page 114TROUBLESHOOTING GUIDE TECHNICAL INFORMATIONDigital VoltMeter DVM INVERTER/CHARGER TERMINOLOGYPage 115 TECHNICAL INFORMATIONPage 116 Figure 36, AC WaveformsTECHNICAL INFORMATION Page 117 StackingTECHNICAL INFORMATION Page 118 SPECIFICATIONS AND FEATURES 60 Hz ModelsNote All specifications are subject to change without notice MODELSW2612E SPECIFICATIONS AND FEATURES 50 Hz ModelsPage 119 SW3024E SW3048E SW4548E SW3024J SW4048J SW4548ATECHNICAL INFORMATION DIMENSIONSPage 120  2001 Xantrex Technology, IncINSTALLATION DIAGRAMS Page 121TECHNICAL INFORMATION  2001 Xantrex Technology, Inc Page 122TECHNICAL INFORMATION Telephone 360/435-8826Page 123 USER SETTINGS WORKSHEETSUSER MENU SW Series Inverter/Charger - Model SWDEFAULT SETTINGS SETUP MENU - 12 VDC 120 VAC/60HZ MODELSPage 124 USER SETTINGSDEFAULT SETTINGS SETUP MENU - 24 VDC 120 VAC/60HZ MODELSPage 125 USER SETTINGSDEFAULT SETTINGS SETUP MENU - 48 VDC 120 VAC/60HZ MODELSPage 126 USER SETTINGS 2001 Xantrex Technology, Inc Page 127TECHNICAL INFORMATION Telephone 360/435-8826SWRC APPENDIXOPTIONS SWCAOTHER PRODUCTS SW SERIES POWER PANEL SYSTEMSTM500 TRACE METER BATTERY STATUS MONITOR C40 MULTI-FUNCTION CONTROLLERREFERENCE TABLES AND GRAPHS Table 9, Power Consumption Of Common AppliancesTable 10, AWG to Metric Wire Conversion Chart Page 130Page 131 Table 11, Minimum Recommended Battery Cable Size vs. Cable LengthTable 12, Battery Cable to Maximum Breaker/Fuse Size NEC AMPS2Battery DC Disconnect Size Table 13, Recommended Minimum AC Wire Sizes 75 CTable 15, Safety Ground Wire Size Table Minimum Size of Copper Ground WirePage 133 Storage ChecklistPreparation for Storage Interior Storage 2001 Xantrex Technology, Inc Page 134APPENDIX Telephone 360/435-8826WARRANTY REGISTRATION WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATIONLIMITED WARRANTY LIFE SUPPORT POLICYWARRANTY/REPAIR INFORMATION WARRANTY OR REPAIR SERVICE REQUIREDPage 136 Hook Up Configurations INDEXPage 137 INDEXPage INDEXINDEX Page 139Low Battery Cut Out VDC Output WaveformINDEX PageINDEX Page 141Installation Guidelines Stored In The BatteriesPage 142 INDEX