Owner’s Guide Freedom HW 1000 Inverter/Charger
Freedom HW 1000 Inverter/Charger Owner’s Guide
About Xantrex Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in the development, manufacturing and marketing of advanced power electronic products and systems for the renewable and mobile power markets. The company's products convert and control raw electrical power from any central, distributed, renewable, or backup power source into high-quality power required by electronic equipment and the electricity grid.
About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for operating, maintaining, and troubleshooting a Freedom HW Installation*. For complete information to help in setting up a Freedom HW Installation see the Freedom HF Inverter/Charger Installation Guide (Doc. Part Number: 975-0468-01-01). * Recreational or Fleet Vehicle installation. Scope The Guide provides safety guidelines, as well as information about operating and troubleshooting the installation.
About This Guide Chapter 4 explains how to operate the Freedom HW efficiently and effectively. Chapter 5 describes how to troubleshoot the Freedom HW Inverter/ Charger during operation. Appendix A contains electrical performance information and product specifications. Conventions Used The following conventions are used in this guide.
Important Safety Instructions READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE REFERENCE. This chapter contains important safety and operating instructions for the Freedom HW Inverter/Charger unit. WARNING: Limitations on use The Freedom HW is not intended for use in connection with life support systems or other medical equipment or devices. 1. Before installing and using the Freedom HW, read all instructions and cautionary markings on the Freedom HW, the batteries, and all appropriate sections of this guide.
Safety 6. Do not disassemble the Freedom HW. It contains no user-serviceable parts. See Warranty for instructions on obtaining service. Attempting to service the Freedom HW yourself may result in a risk of electrical shock or fire and will void your warranty. Internal capacitors remain charged after all power is disconnected. 7.
Safety Personal Precautions When Working With Batteries WARNING: BATTERIES PRESENT RISK OF ELECTRICAL SHOCK, BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE OR EXPLOSION FROM VENTED GASES. OBSERVE PROPER PRECAUTIONS. 1. Study and follow all of the battery manufacturer's specific precautions, such as removing or not removing cell caps while charging, and recommended rates of charge. 2. Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer.
Safety 10. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately. 11. If you need to remove a battery, always remove the ground terminal from the battery first. Make sure all accessories are off so you don’t cause an arc. 12. Never charge a frozen battery. 13. Clean battery terminals.
Safety Precautions for Using Rechargeable Appliances CAUTION: Equipment damage Most rechargeable battery-operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage charging output. Some chargers for small rechargeable batteries can be damaged if connected to the Freedom HW.
x
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Introduction Freedom HW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Independent Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 2 Features Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Default Settings for the Freedom HW System -
Contents Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9 Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9 Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9 Inverter Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10 Overload Conditions - - - - - - - - - - - - - - - - - - - -
Contents A Specifications Electrical Specifications: Inverter Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Specifications: Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents xiv 975-0467-01-01
Figures Figure 2-1 Figure 3-1 Figure 3-2 Figure 4-1 What’s In The Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Dip Switches (Factory Setting Shown) - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Three-stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12 975-0467-01-01 xv
xvi
Tables Table 2-1 Table 3-1 Table 4-1 Table 4-2 Table 4-3 Table 5-1 Table 5-2 Table A-1 Freedom HW Default Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Charging Current Guidelines- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Status LED during Inverter Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6 Battery Charging Status LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–13 Battery Charging Voltage and Current Settings - - - - - -
xviii
1 Introduction Chapter 1 introduces you to the Freedom HW, explains the inverting, charging, and power system management functions. It covers the following: • Freedom HW’s major features, and • Freedom HW’s function as an independent power system.
Freedom HW Inverter/Charger Congratulations on your purchase of the Freedom HW Inverter/Charger (Freedom HW). As part of the Xantrex Inverter/Charger family, the Freedom HW gives you quality power, worry-free operation, and outstanding reliability. The Freedom HW’s integrated inverting–charging functions and numerous power management features make it ideal for recreational and commercial vehicles.
Independent Power System Overload Alarm and Shutdown During Inverter mode, the Freedom HW automatically alerts you if the loads that are connected and drawing power from the unit are close to the maximum operating limit. The Freedom HW automatically shuts down when the maximum operating limit is exceeded. Over-temp Alarm and Shutdown During Inverter mode, the Freedom HW automatically alerts you if it is overheating and approaching the over-temperature shutdown limit.
1–4
2 Features Chapter 2 contains information and labeled illustrations to help identify the various features of the Freedom HW.
Materials List Your Freedom HW Inverter/Charger package includes the items listed below. • • • • • • • • Freedom HW Inverter/Charger unit display panel (p/n: 808-9557) with 7-inch (0.
Default Settings for the Freedom HW System Default Settings for the Freedom HW System Table 2-1 lists the default settings for the Freedom HW system. You may record your settings in the right-hand column after you have configured the Freedom HW. Table 2-1 Freedom HW Default Values Item Default Setting Alarm* ON Charger Current* 55A Battery Type ** Flooded(14.4/13.5) Your Setting * adjustable from the display panel. ** adjustable from the main unit behind the display panel assembly.
Side Panel 1 2 3 Feature Description 1 30 A supplementary protector provides overload protection for the AC output. 2 Grounding stud provides a ground path for the Freedom HW chassis to the DC system ground. 3 Main cooling fan turns on when powering loads above 500 W or when the internal temperature reaches a set point temperature. Rear Panel 2 3 1 4 Feature 2–4 Description 1 Negative DC cabling terminal connects to the negative terminal of the battery using a battery cable.
Display Panel Display Panel 3 1 2 FREEDOM 4 STATUS Utility Battery Select Fault Feature Input Voltage (V) Input Current (A) Output Power (kW) HW 1000 Description 1 Power button is the main unit switch that turns the Freedom HW’s inverter function ON or OFF and is also used to select unit feature settings. See page 4–2 for additional information. 2 Three-digit LED display screen shows status information and fault codes. See page 4–2 for additional information.
2–6
3 Configuration Chapter 3 explains how to configure the Freedom HW to best meet your electrical system requirements. It covers the following: • Setting battery types on the main unit and • Adjusting unit settings.
Setting Battery Types on the Main Unit You can attach different types of lead-acid batteries to the Freedom HW. Before installing batteries make sure that you configure the unit to optimize the charging process. WARNING: Fire hazard Incorrectly setting the battery type can lead to battery damage and a risk of fire. The settings can be changed by adjusting the dip switches found on the main unit behind the display panel.
Viewing Inverter/Charger Information Viewing Inverter/Charger Information The LED screen displays inverter/charger information as well as feature settings in coordination with the LED lights underneath the screen. ◆ Press the Select button to toggle between the following information: Info and Setting LED Screen Info and Settings LED DC Input Voltage 12.8 (example) Solid – Input Voltage (V) DC Input Current 11 (example) AC Output Power 0.
To cycle through the various feature settings: 1. Press and hold the Power button for five seconds to enter the feature settings mode. 2. Press the Power button to toggle between the following information: By default the charging current is set to 55 A. Setting LED Screen Charging Current Setting Cur Inverter Mode Setting IN Alarm Setting aL Shutdown Setting sd Factory Setting def To change the charger’s charging current setting: 1. Press and hold the Power button for five seconds.
Adjusting Feature Settings Table 3-1 Charging Current Guidelines AC Input Circuit Breaker Charger DC Current or fuse size Setting (Amps) (Amps) Maximum By-pass AC Current Available (Amps) 15 20 30 By default the inverter mode is set to ON. 5 12.5 15 9.5 35 4.0 55 0 5 17.5 15 14.5 35 9.0 55 5.0 5 27.5 15 24.5 35 19.0 55 15.0 To change the inverter mode setting: ON (“In1”) will put the inverter on standby.
4. Continue pressing the Select button to cycle through the two settings – “In1” and “In0” until you reach the desired setting. 5. Press and hold the Select button for five seconds to make the setting permanent. By default the alarm is set to ON. To adjust the alarm setting: ON (“AL1”) will sound the alarm on all warning and fault conditions. OFF (“AL0”) will mute the alarm. 1. Press and hold the Power button for five seconds. 2. Press the Power button twice. The LED screen will flash “AL” intermittently.
Adjusting Feature Settings To return all feature settings to factory default settings: 1. Press and hold the Power button for five seconds. 2. Press the Power button four times. The LED screen will flash “def” intermittently. 3. Press and hold the Select button for five seconds to return all feature settings to their factory default settings.
3–8
4 Operation Chapter 4 explains how to operate the Freedom HW efficiently and effectively. It covers the following: • Procedures for operating the inverter from the display panel, • Operating limits and inverter loads, • Battery charging, and • Information about routine maintenance.
Display Panel Operation The Freedom HW features a display panel with three-digit LED display screen to show inverter, AC source, and battery status information. 3 1 2 FREEDOM 4 Info and Settings LED lights STATUS Utility Battery Select Fault Feature 4–2 Input Voltage (V) Input Current (A) Output Power (kW) HW 1000 Description 1 Power button • Press and hold for one second to turn the Freedom HW’s Inverter function ON or OFF (when AC Shore Power is NOT present.
Operating in Shore Power Mode Operating in Shore Power Mode The Freedom HW operates in shore power mode when an AC source (a generator or utility power) is present at the AC input terminals. When the AC source is within operating range, the Freedom HW unit bypasses inverter function and provides the same AC source power to the AC output terminals. AC power will automatically pass through the Freedom HW.
Operating in Inverter Mode The Freedom HW is in inverter mode when shore power is not presently available and the unit is using the battery (inverting DC to AC) to power the appliances connected to the Freedom HW. The Yellow status LED lights up to indicate the Freedom HW is using the battery to power the appliances. Table 4-1 below illustrates the battery status during inverter mode as shown on the display panel.
Operating in Inverter Mode Operating Several Loads at Once If you are going to operate several loads from the Freedom HW, turn them on one at a time after you have turned the inverter on. Turning loads on separately helps to ensure that the inverter does not have to deliver the starting current for all the loads at once, and will help prevent an overload shutdown. Adjusting the Audible Alarm The Freedom HW’s audible alarm can be enabled or disabled. See “To adjust the alarm setting:” on page 3–6.
Status LED During Inverter Mode The following summarizes the behavior of the Status LED during Inverter mode. Table 4-1 Status LED during Inverter Mode Status LED Display Screen Condition Solid YELLOW 12.8 Select button is pressed to display Input Battery Voltage. The Input Battery Voltage LED lights up. Value in display screen is shown as Volts. (where 12.8 is an example of battery voltage) 11 (where 11 is an example of current) 0.85 (where 0.
Operating in Inverter Mode Table 4-1 Status LED during Inverter Mode Status LED Display Screen Condition Solid RED E01 through e04 Fault condition detected and AC output power is not available. The unit will sound an alarm and will shutdown completely within 30 seconds. See Table 5-1, “Error Codes Displayed on the Display Panel Screen” on page 5–5. Off Off Inverter is OFF. Off (or Yellow) 00.
Operating During Transition Between Shore Power and Inverter Mode The Freedom HW’s advanced power management is capable of transitioning power from an AC source to DC source within a fraction of a second and vice-versa. The Freedom HW automatically detects when shore power is present and when it becomes unavailable or when shore power drops to less than 95 Vac.
Operating Limits Operating Limits Power Output The Freedom HW can deliver up to 1000 watts continuous power. The wattage rating applies to resistive loads such as incandescent lights. Input Voltage The allowable Freedom HW input voltage ranges are shown in the following table: Operating Condition Voltage Range Normal 11–15.0 V Optimum Performance 12.0–13.
Inverter Loads The Freedom HW will operate most AC loads within its power rating of 1000 watts. However, some appliances and equipment may be difficult to operate, and other appliances may actually be damaged if you try to operate them with the Freedom HW. Please read “High Surge Loads” and “Trouble Loads” carefully. Overload Conditions There are two kinds of overload conditions: Overload Warning Overload Shutdown • An overload warning and • An overload shutdown.
Inverter Loads Trouble Loads CAUTION Some equipment may be damaged by the Freedom HW’s modified sine wave output, which has a different wave form than utility-supplied electricity. Some appliances, including the types listed below, may be damaged if they are connected to the Freedom HW: • • • Speed controllers found in some fans, power tools, kitchen appliances, and other loads may be damaged. Some chargers for small rechargeable batteries can be damaged.
Battery Charging Battery charging is possible only when shore power is present and the Freedom HW unit is connected to a battery (or battery bank). The frequency of battery charging is determined by how much energy in the battery is used up during inverting. Whenever the Freedom HW detects a battery voltage that falls below 12.8 Vdc, the unit will begin charging the battery, i.e., enter into bulk and absorption stages then settle in float stage.
Battery Charging Table 4-2 Battery Charging Status LED Status LED Display Screen Condition Solid GREEN FUL Battery is FULL. Flashing GREEN BUL— CHg— 12.8 Battery is in BULK CHARGE. (where 12.8 is an example of battery voltage) ABS— CHg— 14.2 Battery is in ABSORPTION CHARGE. (where 14.2 is an example of battery voltage) Solid RED E10 Solid GREEN or Flashing GREEN 5A or 15A or 35A Select button is pressed to display present Charging Current setting.
Table 4-3 below illustrates the battery charging voltage and current settings. Table 4-3 Battery Charging Voltage and Current Settings Battery Type Bulk/Absorption Voltage (Volts) Float Voltage (Volts) Charge Current (Amps) Float Current (Amps) Flooded 14.4 13.5 5, 15 35, 55 1.5 4.5 GEL 14.2 13.8 5, 15 35, 55 1.5 4.5 AGM 14.3 13.4 5, 15 35, 55 1.5 4.5 Fixed 13.5 13.
5 Troubleshooting Chapter 5 describes how to troubleshoot the Freedom HW Inverter/Charger during operation. It covers the following: • General troubleshooting guidelines, • Common problems, • Warning messages, • Troubleshooting references, and • Inverter applications (loads).
General Troubleshooting Guidelines WARNING: Shock and Energy hazard Do not disassemble the Freedom HW. It does not contain any user-serviceable parts. Attempting to service the unit yourself could result in an electrical shock or burn. Important: If you need to obtain service, see page WA–1. Before you call Xantrex Customer Service, record the information that is asked for in “Information About Your System” on page WA–5. This section will help you narrow down the source of any problem you encounter.
General Troubleshooting Guidelines 3.
Common Problems Buzz in Audio Equipment Some inexpensive stereo systems may emit a buzzing noise from their loudspeakers when operated from the Freedom HW. This occurs because the power supply in the audio system does not adequately filter the modified sine wave produced by the inverter. The only solution is to use a sound system that has a higher quality power supply. Television Reception When the Freedom HW is operating, it can interfere with television reception on some channels.
Warning Messages Warning Messages Warning messages in the form of audible alarms and error codes that appear on the display panel screen to alert you to an impending system change. Warnings do not affect operation. With the exception of the error codes displayed on the screen, only the audible alarm can be enabled or disabled. Follow the steps in “To adjust the alarm setting:” on page 3–6 to change the alarm settings. The error codes are listed in Table 5-1 below.
Table 5-1 Error Codes Displayed on the Display Panel Screen Error Code Condition Mode Action E07 Inverting • Over-temperature warning • • E08 not used E09 not used E10 High battery voltage AC shore (> 15.5 V) power • • E11 Over-temperature detected on the AC transfer relay AC shore power • • • E12 Battery is bad or external DC load is connected to the battery. AC shore power • • • 5–6 Reduce the loads connected to the AC outlet of the unit.
Warning Messages For error codes E01 to E04: • • the unit will stop inverting, and the display screen and the alarm will turn off after 30 seconds. For error codes E10 and E11: • • • the unit will stop charging, but the error code will still show on the display screen and the alarm will remain on, and AC power will continue to pass through to the AC outlets.
Troubleshooting Reference WARNING: Electrical shock and burn hazard Do not disassemble the Freedom HW. It does not contain any user-serviceable parts. Repairing the unit yourself could result in an electrical shock or burn. Table 5-2 Troubleshooting Reference Problem Possible Cause Solution Low output voltage (96 Vac–104 Vac) during Inverter mode. You are using a voltmeter Use a true RMS reading voltmeter such as the Fluke 87. that cannot accurately read the RMS voltage of a modified sine wave.
Troubleshooting Reference Table 5-2 Troubleshooting Reference Problem Possible Cause No output voltage. The Status 30 A supplementary LED is green or yellow. breaker has tripped. Solution Check load and reset the supplementary breaker. Circuit breaker on the AC Reset the circuit breaker or check the AC load panel or AC output output disconnect circuits. disconnect has tripped. Battery voltage is too low to start inverting. Display Check DC connections and cable. screen may show DC Recharge battery.
Table 5-2 Troubleshooting Reference Problem Possible Cause Solution Battery charging current is lower than the charging set point during bulk charge mode. Ambient (environment) temperature is high. Do not be alarmed, the unit is performing normally. The charging current automatically de-rates or shuts down at high ambient temperature. The charger resumes to normal when the unit’s temperature cools down. Improve ventilation. Make sure the unit’s ventilation openings are not blocked.
Inverter Applications Motor Loads Induction motors (motors without brushes) require two to six times their running current on start up. The most demanding are those that start under load (e.g. compressors and pumps). Of the capacitor start motors (typical in drill presses, band saws, etc.), the largest you can expect to run is ½ to 1 hp (the transfer relays are rated at 2 hp.) Universal motors are generally easier to start.
5–12
A Specifications Appendix A contains electrical performance information and product specifications. Note: Specifications are subject to change without notice.
Electrical Specifications: Inverter Mode DC Input Low operating voltage range “SdL” setting 10.5–15.5 V High operating voltage range “SdH” setting 11.8–15.5 V Under voltage alarm/shutdown Under voltage recovery “SdL” setting 10.5/11.0 V 12.0 V Under voltage alarm/shutdown Under voltage recovery “SdH” setting 11.8/12.3 V 12.6 V Safe non-operating voltage range 0–16 Vdc Normal voltage 12.5V Nominal current at full load 100A AC Output Output voltage 120 Vac Continuous power 1.
Electrical Specifications: Charge Mode Electrical Specifications: Charge Mode AC Input Operating voltage range 95–135 Vac Nominal current 12Aac at 55A charge, 120 Vac in Nominal frequency 60 Hz DC Output Nominal voltage 12.0 Vdc Min battery voltage for charging 0.0 Vdc Max output voltage 14.
Environmental Specifications Operating Temperature Range 32–104 ºF (0–40 ºC), with output derated above 77 ºF (25 °C) Storage Temperature Range -40–158 ºF (-40–70 ºC) Humidity: Operation/Storage 5–95% RH, non-condensing System Specifications Pass-through 120 Vac, 60 Hz, 30 A, 3-hr Max, 24 A continuous Transfer relay rating 30A, 2.
Regulatory Approvals Regulatory Approvals ETL approved to CSA 107.1, UL458 Inverter Overload Operation This graph shows how long (measured in seconds) the Freedom HW will operate for a given output current (measured in Amps). The graph illustrates inverter operation at 25 °C. Time (sec) 4000 . . .
Invert Power Derating vs. Ambient Temperature If the unit is in inverter mode and in elevated ambient temperature above 25 °C, you will have to reduce power draw according to the following chart to avoid over-temperature shutdown. Watts 30 °C @ 12.5 V 1000 900 W @ 11.
Charger Output Current vs. AC Input Voltage Charger Output Current vs. AC Input Voltage When the Freedom HW is charging batteries from a weak shore power source the AC voltage may fall as the Freedom HW draws current.
A–8
Warranty and Return Information Warranty What does this warranty cover and how long does it last? This Limited Warranty is provided by Xantrex Technology Inc. ("Xantrex") and covers defects in workmanship and materials in your Freedom HW Inverter/Charger. This Warranty Period lasts for 12 Months from the date of purchase at the point of sale to you, the original end user customer, unless otherwise agreed in writing. You will be required to demonstrate proof of purchase to make warranty claims.
Warranty and Return Proof of purchase may be in any one of the following forms: • The dated purchase receipt from the original purchase of the product at point of sale to the end user; or • The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status; or • The dated invoice or purchase receipt showing the product exchanged under warranty.
Warranty and Return IN TORT, WHETHER OR NOT ARISING OUT OF XANTREX'S NEGLIGENCE, AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR SYSTEM, AND (C) ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT.
Warranty and Return If you are returning a product from outside of the USA or Canada In addition to the above, you MUST include return freight funds and are fully responsible for all documents, duties, tariffs, and deposits. If you are returning a product to a Xantrex Authorized Service Center (ASC) A Xantrex return material authorization (RMA) number is not required.
Warranty and Return Information About Your System As soon as you open your Freedom HW Inverter/Charger package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number ________________________________ ❐ Product Number 806-1055 ❐ Purchased From ________________________________ ❐ Purchase Date ________________________________ If you need to contact Customer Service, please record the following details before calling.
WA–6
Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free NA customerservice@xantrex.com www.xantrex.
