Xantrex Technology SW Plus 2524, SW Plus 2548, SW Plus 4024, SW Plus 4048, SW Plus 5548 - page 48

System Configuration

2–14 976-0043-01-02

and inverter amperage per NEC/CEC guidelines. It is recommended that

the cable has battery acid resistant insulation and is rated for 90°C

(32 °F) or better.

Be sure to check with any local regulatory agencies for additional

requirements.

Battery cable lugs Battery cables must have crimped copper compression lugs or crimped

and soldered copper compression lugs. Soldered connections alone are

not acceptable.

High quality battery cables are available from Xantrex i n an assor tment of

lengths from 1½ to 10 feet in #2/0 AWG and from 1½ to 15 feet in

#4/0 AWG sizes. These cables are color-coded with pressure crimped,

sealed ring terminals.

Overcurrent

protection For safety and compliance with regulations, battery overcurrent

protection is required. Fuses and disconnects must be sized to protect the

wiring in the system and are required to open before the wire reaches its

maximum current carrying capability.

Xantrex DC175 and

DC250 The NEC/CEC requires both overcurrent protection and a disconnect

switch for residential and commercial electrical syste ms. T hes e item s are

not supplied as part of the inverter. However, Xantrex offers a DC circui t

breaker disconnect module specifically designed for use with Xantrex

Table 2-2

Recommendced Battery Cable Size Versus Length

Inverter

Model

Maximum

Continuous

DC ampsa

a. “Maximum Continuous DC amps”, as shown in this table , is bas ed o n low

battery voltage with an efficiency of 85%.

NEC

ampsb

b. “NEC amps”, as shown in this table, is based on low battery voltage, and

efficiency of 85%, and a 125% NEC derating.

Up to 5 Feet

One-way

Up to 10 Feet

One-way

Up to 15 Feet

One-way

2524 134 167 #2/0 AWG

(67.4 mm2)

#4/0 AWG

(107 mm2)

Not

Recommended

2548 67 84 #2/ 0 AWG

(67.4 mm2)

#4/0 AWG

(107 mm2)

#4/0 AWG x 2

(107 mm2 x 2)

4024 214 267 #4/0 AWG

(107 mm2)

#4/0 AWG x 2

(107 mm2 x 2)

Not

Recommended

4048 107 134 #2/0 AWG

(67.4 mm2)

#4/0 AWG

(107 mm2)

Not

Recommended

5548 147 184 #4/0 AWG

(107 mm2)

#4/0 AWG x 2

(107 mm2 x 2)

Not

Recommended

Contents

Main Page Page Page About This Manual Organization Conventions Used CAUTION Related Information Important Safety Instructions Explosive gas precautions FCC Information to the User Contents Important Safety Instructions 1 2 Introduction 3 Installation 4 Functional Test 5 Navigation 6 Basic Setup Programming 7 Advanced Setup 8 Operation Page 9 Troubleshooting A. Inverter Specifications Page Page Figures Page Page Page Tab les Page Page Basic Features Front Panel AC Side Emergency Power Off (EPO) Option Certification Label DC Side Battery Temperature Sensor (BTS) Top Page Pre-Configuration Planning Types of Applications System Considerations Important: Page System Output Requirements System Input Requirements Important: Location Considerations WARNING: Explosion and Corrosion Hazard CAUTION: Damage to Inverter Mounting Considerations Ventilation Requirements Grounding Considerations DC System Grounding Inverter Grounding Note: WARNING: Explosion Hazard Equipment or Chassis Grounding Grounding Electrodes/Ground Rods Bonding the Grounding System Battery Considerations Important: Battery Bank Requirements Battery Cable Requirements Page Page Battery Requirements for Dual Inverter Systems Important: Page Battery Temperature Wiring Considerations Generator Considerations Note: Important: Types of Generators Generator start types Page Additional/Optional Equipmen t Considerations AC Conduit Box (ACCB) Important: Page Fuse Block DC Disconnect Boxes (DC175/DC250) Battery Status Meter (TM 500A) Remote Monitors Note: Inverter Control Module (ICM) Inverter Communicati ons Adapter (ICA) CAUTION: Damage to PC Generator Start Module (GSM) Auxiliary Load Module (ALM) 240 Vac Application Requirements Autotransformer for 240 VAC Applications (T240) Inverter Stacking Contro l Series (ISC-S) Cable Renewable Energy DC Input Sources Important: Page Off-Grid Applications Renewable Energy Systems with/without Generator Backup Single-Inverter Configurations (120 Vac) Single-Inverter Configurations (120/240 Vac) 976-0043-01-02 233 Figure 2-17 Off-Grid Application Renewable Energy System using a Single Inverter NOTES: Dual-Inverter Configurations (240 Vac) 976-0043-01-02 235 Figure 2-18 N Off-Grid Application Renewable Energy System using Dual Inverters OTES: Generator-Only Systems Single-Inverter Configurations 976-0043-01-02 237 Figure 2-19 Off Grid Application - Generator-only System using a Single Inverter NOTES: Dual-Inverter Configurations 240 Vac-only Input Source 976-0043-01-02 239 Figure 2-20 Off Grid Application Generator-only System using Dual Inverters, Series-stacked NOTES: On-Grid Applications Backup Systems Single-Inverter Configurations (120 Vac) Single-Inverter Configurations (240 Vac) On-Grid Applications Figure 2-21 On-Grid Application Backup System using a Single Inverter NOTES: Dual-Inverter Configurations (240 Vac) On-Grid Applications 976-0043-01-02 243 Figure 2-22 On-Grid Application Backup System using Dual Inverters, Series-stacked NOTES: Energy Management RE Backup with Utility (SB Mode) Peak Load Management Time-of-Use (TOU) Metering AC Load Support Note: Renewable Energy with Grid Backup (BX Mode) Note: Page Page Pre-Installation Tool s Re qu ire d Hardware / Materials Required Optional System Accessories Battery Bank Preparation Unpacking and Inspecting the Inverter Page Knockout Preparation Important: Mounting Shelf-Mounting WARNING: Personal Injury Hazard 976-0043-01-02 39 Figure 3-3 ***NOT TO SCALE*** Keyhole slots Mounting Holes* Wall-Mounting 976-0043-01-02 311 Figure 3-4 Wall-Mounting Method using 2x 4s Page 976-0043-01-02 313 Figure 3-5 Wall Mounting using Plywood DC Wiring Preparing the Battery Ba nk Grounding the DC System Page Page Connecting DC Input Sources Renewable Energy Configurations Installing the Battery Temperature Sensor (BTS) Page Page Page Procedure for Single Inverter Systems Page Procedure for Dual-Inverter Systems Page AC Wiring Table 3-1 AC Disconnect and Wire Sizing CAUTION: Damage to the Inverter Accessing the AC Terminal Block and Ground Bar Page AC Wiring for Single Inverter Systems Manual and Auto Start Generators Page Page Install AC Output Wiring to the Inverter AC Distribution Panel CAUTION: Equipment Damage Page Install Generator Wiring to the Inverter Important: Page AC Wiring 976-0043-01-02 337 Generator Input Wiring to a Single Inverter Figure 3-20 Sine Wave Plus Inverter/Charger Generator connections using a T240, a generator disconnect and a 120/240 Vac Generator Generator connections using a generator disconnect and a 120 Vac Generato r Install Utility Wiring to the Inverter Input (On-Grid Applications only) Optional Equipment Stacking Dual Inverter Systems Installing the ISC-S Cable CAUTION: Equipment Damage Remote Monitoring Options Auxiliary Load Module (ALM) Emergency Power Off (EPO) EPO Port Important: Page Page Basic Functional Test Confirm all Connections Important: Applying Battery Power to the Inverter Turning ON the Inverter AC Voltage Check Important: Confirming Battery Charger Operation Confirming Inverter Operation Page Page Navigating the Sine Wave Plus The Inverter Control Module (ICM) Inverter Control Module Features The display The cursor Display contrast Push-buttons ON/OFF Menu Buttons Page Set Point Buttons Reset Factory Defaults CAUTION: Equipment Damage Menu Map Page Page Page Page Page Page Page Page Page Page Basic Setup Summary Table 6-1 Basic Setup Menu Default Settings for the Sine Wave Plus 2524 and 2548 Models Table 6-2 Table 6-1 Basic Setup Menu Default Settings for the Sine Wave Plus 4024 and 4048 Models Basic Setup Menu Default Settings for the Sine Wave Plus 2524 and 2548 Models Table 6-2 Basic Setup Menu Default Settings for the Sine Wave Plus 4024 and 4048 Models Table 6-3 Basic Setup Menu Default Settings for the Sine Wave Plus 5548 Model Table 6-3 Basic Setup Menu Default Settings for the Sine Wave Plus 5548 Model Before You Begin Programming DC Amps verses AC Amps Note: Basic Setup Process Accessing the Basic Setup Menu Menu Item Descriptions 10 Time of Day Setup Menu 10A Set Hour 10B Set Minute 10C Set Seconds 11 Inverter Setup Menu 11A High Battery Cut Out VDC 11B Low Battery Cut In VDC 11C Low Battery Cut Out VDC 11D LBCO Delay Minutes 11E Search Watts Note: Battery Charger Functions Note: Multi-Stage Charging Process Note: Equalize Charging the Batteries Notes: WARNING: Explosion Hazard 12 Battery Charging Menu 12A Finish Stage CAUTION: Damage to DC Loads and Batteries 12B Bulk Volts DC 12C Float Volts DC 12D Equalize Volts DC Table 6-4 Table 6-5 Battery Voltages For Setting Charging Parameters Battery Charging Current and Timer Default Settings 12E Max Charge Amps AC 12F Bulk Done Amps AC 12G EQ VDC Done Timer 12H Max Bulk/EQ Timer h:m 12I Temp Comp 13 AC Inputs Menu Note: 13A Grid (AC1) Amps AC 13B Gen (AC2) Amps AC 13C Input Upper Limit VAC 13D Input Lower Limit VAC CAUTION: Damage to Loads 14 Save/Restore Settings Menu 14A Push INV now to Save Settings 14B Push GEN to Restore Settings Note: 14C Push GEN for Factory Defaults End Basic Setup Men u Page Advanced Setup Summary Table 7-1 Advanced Setup Default Settings for the Sine Wave Plus 2524and 2548 Models Table 7-1 Advanced Setup Default Settings for the Sine Wave Plus 2524and 2548 Models Page Page Page Page Page Before You Begin Advanced Programming Accessing the Advanced Se tup Menu OR Menu Item Descriptions 20 Silent Setup Menu Page 20A Refloat High Volts DC 20B Refloat Low Volts DC 20C Float Done Amps AC Note: 20D Must Float Time Min 21 Grid (AC1) Usage Menu 21A Grid Usage 21B Grid Usage Begin h:m 21C Grid Usage End H:M 22 Battery Xfer (BX) Menu Note: 22A High Xfer (HBX) VDC 22B Low Xfer (LBX) VDC 23 ALM Relays Menu 23A RY9 VDC Energized 23B RY9 VDC DeEnergized 23C RY9 Delay At DeEngz. Min 23D RY10 VDC Energized 23E RY10 Vdc DeEnergized 23F RY10 Delay at Engz. Min 23G RY11 Mode Page Generator Starting Scen arios Manual Generator Control CAUTION: Damage to Generator Automatic Generator C ontrol Page 24 Generator Timers Menu Notes: 24A Gen Run Time Start h:m 24B Gen Run Time Stop H:M 24C Quiet Time Begin h:m 24D Quiet Time End h:m 24E Gen Exercise Period Days 24F Gen Exercise Timer Min 24G Gen Cooldown Timer Min 24H RN2/Max Gen Run h:m 25 Gen Starting Details Menu Generator Start Module (GSM) 25A RY7 Mode Page Page Menu Item Descriptions 976-0043-01-02 733 Figure 7-7 Wiring examples of Honda and Onan Generators Advanced Setup 734 976-0043-01-02 Figure 7-8 RY7 and RY8 Tim ing Di agra m RN2 GS RY7 Page Page 25B Gen Warm-up Seconds/minutes 25C Pre Crank Seconds 25D Max Cranking Seconds 25E Post Crank Seconds 26 Gen Auto Run Setup Menu 26A Load Start Amps AC 26B Load Start Delay Min 26C Load Stop Delay Min 26D 24 Hr Start Volts DC 27 Save/Restore Settings Menu 27A Push INV now to Save Settings Note: 27B Push GEN to Restore Settings 27C Push GEN for Factory Defaults End Advanced Setup Menu Page Operating the Sine Wave Plus Operational Status Indicators LED Indicators Inverter Operation Status (Yellow) AC Input Status (Green) Charge Status (Yellow and Green) Operational Status Indication (Red and Yellow) Error LED Reset LED Summary Table 8 -1 summarizes the LED indicators. Table 8-1 LED Summary Table Table 8-1 LED Summary Table The User Menu Summary 02 Generator ON/OFF Menu Page Page Accessing the User Menu User Menu Description 01 Inverter ON/OFF Menu 01A Inverter 01B EQ Charge OFF ON 01C Search Watts (SRCH) Note: 01D Bypass Mode 02 Generator ON/OFF Menu CAUTION: Damage to AC Loads 02A Generator Note: 02B Gen Start Load Amps 02C Gen Start Volts/Manual 02D Gen Start Exercise Run 02E Gen Start Run Time 02F Days Left To Gen Exercise 03 Time Of Day Menu 03A SW Plus Software Level 03B System Information 03C Company Name and Address 03D City, State, and Zip Code Press Reset for Factory Defaults 04 Meters Menu 04A Battery Actual Vdc Note: 04B Battery Comp Vdc 04C Inverter/Charger Amps AC 04D Input Amps AC 04E Load Amps AC 04F Inverter Volts AC Page 05 Error Causes Menu 05A Over Current 05B Transformer Overtemp 05C Heatsink Overtemp 05D Low Battery Voltage 05E High Battery Voltage 05F External Err (Stacked) 05G Input Relay Failure 05H Gen Failed to Start 05I Gen Stopped Due to V/F 06 Status Menu 06A Bypass Mode Selected 06B Chr Selected (No Backup) 06C Gen Signaled to Run 06D Gen In Cooldown 06E EQ Charge Selected 07 GSM/ALM Options Menu 07A RY7 (GSM) Energized Page Page Page Inverter Troubleshooting Page Battery Charger Troubleshooting Page Page Error Causes Page Page Electrical Specifications Page Mechanical Specifications Page Theory of Operation Page Power Versus Efficiency Power Versus Efficiency 976-0043-01-02 A9 Figure A-4 Power Versus Efficiency Cur ves for All Models Measurements made us i ng resi stive load bank and Yokogawa WT 2030 D i gital Power Meter Efficiency Output Power in Watts Figure A-5 Measur ements mad e using r esist ive loa d bank and Yok ogawa P Z400 0 Powe r Analy zer A10 976-0043-01-02 Sine Wave Plus Efficiency Curve for the SW Plus 2548 Figure A-6 Figure A-7 Analyzer Efficiency Output Powe r in Watts 976-0043-01-02 A11 Inverter Capacity versus Temperature Time versus Current Page Page Page Page User Menu Settings 02 Generator ON/OFF Menu Page Page Basic Setup Menu Basic Setup Default and User Settings for the Sine Wave Plus 2524 and 2548 Models Table B-3 Table B-2 Basic Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models Basic Setup Default and User Settings for the Sine Wave Plus 2524 and 2548 Models Table B-3 Basic Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models Table B-4 Basic Setup Default and User Settings for the Sine Wave Plus 5548 Model Page Advanced Setup Menu Advanced Setup Default and User Settings for the Sine Wave Plus 2524 and Page Page Page Page Page Page Page Introduction Battery Types Deep-cycle Flooded Lead Acid (FLA) Sealed Batteries (Gel and AGM) NiCad and NiFe Batter ies Understanding Battery Capacity Ratings Battery Bank Sizing Understanding Amp-hour Requirements Calculating Amp Hours Amp Hour Example Worksheet Battery bank size worksheet Battery Configurations Wiring Batteries in Series Battery Information C10 976-0043-01-02 Wiring Batteries in Parallel r 12-volt Battery Wiring - Series Configuration Figure C-2 +- Wiring Batteries in Series-Parallel Battery Connections for Stacked Inverters Battery Maintenance Battery charging Table C-4 Table C-5 Variances in Charging Voltage based on Battery Temperature Temperature Compensation Calculation Equalization Chargi ng Note: CAUTION: Damage to DC Loads CAUTION: Damage to Batteries General Maintenance WARNING: Shock Hazard CAUTION: Damage to Batteries Page Page Page Two-Wire Start Circuits Three-Wire Start Circuits Honda 3-Wire Type Generators Onan 3-Wire Type Generators 3-2 Wire Converters Page E Overvoltage Protection using a Charge Controller Diversion Load Control Page F Multi-wire Branch Circuits Multi-wire Branch Circuits Figure F-2 120 Vac 120 Vac 976-0043-01-02 F3 Multi-wire Branch Circuit Wiring and Current Flow 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit Identifying Multi-wire Branch Circui ts Correcting Multi-wire Branch C ircuit Wiring Multi-wire Branch Circuit Wiring F6 976-0043-01-02 Figure F-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring Load Center 120 Vac 120 Vac Neutral Ground Page The Purpose of an EPO switch Page How to use the EPO Port for an EPO Switch Glossary Glossary of Terms Page Page Page Abbreviations and Acronyms Page Warranty and Product Information Warra nty Disclaimer Product Exclusions Warning: Limitations On Use Return Material Authorization Policy Return Procedure Out of Warranty Service Information About Your System Page Page Page Page Page Page Xantrex Technology Inc.