DR1512 DR2412 DR1524 DR2424 DR3624 DR1512W DR1524W DR1512E DR1524E DR1548E DR2424E Installation and Operations Manual DR Inverter/Charger
DR Inverter/Charger Installation and Operation Manual
About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Manual Purpose The purpose of this Installation and Operation Manual is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the DR Inverter/Charger. Scope The Manual provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the unit. It does not provide details about particular brands of batteries.
About This Manual Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions for all DR Inverter/Charger models that shall be followed during installation and maintenance of the inverter. General 1. Before installing and using the DR Inverter/Charger, read all instructions and cautionary markings on the DR Inverter/Charger and all appropriate sections of this guide. Be sure to read all instructions and cautionary markings for any equipment attached to this unit. 2.
Safety Wiring Requirements 1. All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70 (Current Edition). When sizing conductors and conduits interfacing to the DR Inverter, both shall be in accordance with the National Electric Code ANSI/NFPA 70, as well as all state and local code requirements. 2. This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI/NFPA 70 (current edition).
Safety Precautions When Working With Batteries WARNING: Explosion or Fire Hazard Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed. 1. Make sure the area around the battery is well ventilated. 2. Never smoke or allow a spark or flame near the engine or batteries. 3. Use caution to reduce the risk or dropping a metal tool on the battery.
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Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Introduction Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Cable Sizi
Contents Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Charger Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Equalize Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16 3–17 3–17 3–18 4
Contents Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C B–13 B–13 B–15 B–16 Multi-wire
Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 Figure 2-22 Figure 2-23 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Front Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Figures Figure 3-9 Figure 3-10 Figure 3-11 Figure 3-12 Figure 3-13 Figure 3-14 Figure 3-15 Figure 3-16 Figure 3-17 Figure B-1 Figure B-2 Figure B-3 Figure B-4 Figure B-5 Figure B-6 Figure B-7 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure C-5 xiv Battery Capacity Potentiometer (new) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12 Battery Capacity Potentiometer (old)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12 LED Indicators - - - - - - - - - - - -
Tables Table 1-1 Table 1-2 Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 4-1 Table A-1 Table A-2 Table A-3 Table A-4 Table B-1 Table B-2 Table B-3 Table B-4 Table B-5 Table B-6 Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Letter Suffix Code Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Peak Input Filtrate versus Charging Current - - - - - - -
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1 Introduction Chapter 1, “Introduction” contains information about the features and functions of the DR Inverter/Charger.
Introduction Introduction Thank you for purchasing the DR Inverter/Charger from Xantrex Technology Inc. The DR Inverter is one of the finest inverter/chargers on the market today, incorporating state-of-the-art technology and high reliability. The inverter features an AC pass-through circuit, powering your home appliances from utility or generator power while charging the batteries. When utility power fails, the battery backup system keeps your appliances powered until utility power is restored.
Features AC End DC End COM Port Front Panel Controls and Indicators Battery Sense Port Battery Caps Figure 1-1 Front Panel Features AC Side The AC side of the DR Inverter has one 30-amp breaker for pass-thru AC Input, and one 30-amp (20 amp in certain models) breaker for charger AC input. 30 Amp Breaker for Pass-thru AC Input 20 or 30 Amp Breaker for Charger AC Input Ventilation Holes Cover plate is not shown in this photo.
Introduction DC Side The DC side of the DR Inverter has the equipment ground lug, the positive (+) battery terminal, and the negative (–) battery terminal. Battery Positive (+) Terminal Ventilation Holes Battery Negative (–) Terminal Ventilation Holes Ground Lug Figure 1-3 DC Side of the DR Inverter Optional Equipment The following options are available for the DR Inverter/Chargers.
Features Important: The unit weighs 35–45 lb/15.9–20.4 kg (depending on model). Have additional help available if necessary, to assist in lifting the unit during installation. ❐ Verify all of the items listed on the packing material sheet are present. Please call Xantrex Customer Service at (800) 670-0707 if any items are missing. ❐ Save your proof-of-purchase. This is required if the unit should require warranty service.
Introduction Table 1-2 Letter Suffix Code Definitions Letter Suffix Output Voltage Output frequency (no letter) 120 Vac 60 Hz E 230 Vac 50 Hz J 105 Vac 50 Hz K 105 Vac 60 Hz W 220 Vac 60 Hz Figure 1-5 Model Number Sticker Regulatory The 120 Vac/60 Hz models of the DR Series inverter/charger (models DR1512, DR1524, DR2412, DR2424, and DR3624) are ETL Listed to UL Standard 1741, (First Edition) Power Conditioning Units for use in Residential and Commercial Photovoltaic Power Systems.
2 Installation Chapter 2, “Installation” contains information about how to plan for and install the DR Inverter/Charger.
Installation Pre-installation Planning Important: Before installing and using the DR Inverter/Charger, read all instructions and cautionary markings on the DR Inverter/Charger and all appropriate sections of this guide. Be sure to read all instructions and cautionary markings for any equipment attached to this unit. Take some time prior to installing the equipment to pre-plan the installation. Location, mounting, and ventilation should be taking into consideration before any cabling can be done.
Pre-installation Planning Mounting The National Building Code requires the inverter be mounted on a vertical surface (or wall). The keyhole slots must not be used as the only method of mounting. The purpose of the wall mounting requirement is to orient the inverter so that its bottom cover, which has no holes, will not allow burning material to be ejected in the event of an internal fire. Use 0.25-inch diameter bolts for mounting.
Installation Hardware / Materials Required The following hardware or materials may be required to complete this installation. ❐ 4 ft. x 4 ft. sheet of 3/4" plywood or 2 x 4’s studding material ❐ #12 wood screws (or 1/2" x 1-1/4" lag bolts) ❐ Conduit and appropriate fittings ❐ Wire nuts Wiring Considerations All wiring and installation methods should conform to applicable electrical and building codes. Pre-plan the wire and conduit runs. • • The AC terminals accept cable sizes up to #6 AWG.
Pre-installation Planning Wire Routing Determine all wire routes both to and from the inverter and which knockouts are best suited for connecting the AC conduits.
Installation Battery Location Locate the batteries in an accessible location. Two feet clearance above the batteries is recommended for access to the battery caps. They should be located as close to the inverter as possible without limiting access to the inverter’s disconnects. Install the batteries to the left of a wall mounted inverter for easy access to the DC side of the inverter and shorter cable runs.
Pre-installation Planning Figure 2-1 On-Grid Basic Configuration (Utility Backup) Figure 2-2 Off-Grid Configuration (Generator only) 975-0012-01-02 Rev A 2–7
Installation Figure 2-3 On-Grid Configuration - with Renewable Energy Sources 2–8 975-0012-01-02 Rev A
Pre-installation Planning Figure 2-4 Off-Grid Configuration - with Renewable Energy Sources 975-0012-01-02 Rev A 2–9
Installation Generators An AC generator can be used as an input source instead of the utility power, or can be connected (using additional hardware) to power the loads when utility is not present (utility outage), and to charge the batteries. The generator must be of the permanently installed type and not a portable type unit used for emergency power.
Pre-installation Planning Inverter Mounting The DR Series inverter can weigh as much as 45 lb. (20.4 kg). Wallboard is not strong enough to support its weight so additional support must be used or added. The inverter can be mounted directly to the wall studs if the wall studs are 16" apart. If not, then 2x4’s or plywood can be used. WARNING: Personal Injury Use appropriate lifting techniques. Have extra people on hand to assist in lifting the inverter into position while it is being secured.
Installation 3. Secure the 2 x 4 with #10 wood screws (length to penetrate 1½ inches into the studs) as shown in Figure 2-7. 4. Measure 7 5/8" from the center of the first 2 x 4 and draw another level line. Place the center of the second 2 x 4 over this line and secure to the wall as described in Step 5. 5. Using the dimensions illustrated in Figure 2-6, drill mounting holes into the center of the 2 x 4’s for the inverter. 6. Secure the inverter to the 2 x 4’s using ¼ x 1½ inch lag bolts and washers.
DC Wiring DC Wiring This section describes the DC wiring requirements and how to make the connections. It provides the required cable and wire sizes, recommended lengths for cables, and disconnect/circuit breaker requirements. DC Circuit Grounding Grounding is an important part of the system installation and must be performed correctly to ensure safe operation of the equipment. Grounding requirements vary by country and application. Consult the NEC for specific requirements.
Installation Figure 2-9 DC Grounding 2–14 975-0012-01-02 Rev A
DC Wiring Batteries The DR Inverter can support either 12-volt battery banks or 24-volt battery banks. Before proceeding, ensure you have the appropriate sized batteries for this inverter. Battery Types Batteries are available in different sizes, amp-hour ratings, voltage, liquid or gel, vented or non-vented, chemistries, etc. They are also available for starting applications (such as an automobile starting battery) and deep discharge applications.
Installation Battery Cable Sizing Proper cable sizing (diameter and length) is critical to the safe and efficient operation of an inverter system. Larger diameter cables (smaller AWG number) have less voltage drop and are, therefore, more efficient when transferring power to and from the batteries. If a cable is undersized (diameter too small), it could potentially overheat, creating a fire hazard. Cable length is another important factor. Runs should be kept as short as practical.
DC Wiring DC Disconnect and Over-current Protection For safety and to comply with regulations, battery over-current 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. The National Electrical Code (NEC) requires both over-current protection and a disconnect switch for residential and commercial electrical systems. These items are not supplied as part of the inverter.
Installation Battery Cable Connections Battery cables must have crimped (or preferably, soldered and crimped) copper compression lugs unless aluminum mechanical lugs are used. Soldered connections alone are not acceptable. High quality, UL-listed battery cables are available from Xantrex in an assortment of lengths: 1½ to 10 feet, and in #2/0 AWG or #4/0 AWG sizes. These cables are color-coded with pressure crimped, sealed ring terminals.
DC Wiring Positive (+) Battery Terminal Negative (–) Battery Terminal Torque the Positive (+) Battery terminal to 10-15 ft-lbs (13.6 to 20.3 nm) Torque value for the Ground Lug is 10-15 in-lbs (1.1 to 1.7 nm) Torque the Negative (–) Battery terminal to 10-15 ft-lbs (13.6 to 20.3 nm) Ground Lug Figure 2-11 DC Terminals on the DR Inverter Connecting the Battery Bank to the Inverter Follow the procedure below to connect the battery bank to the inverter.
Installation 8. Observing battery polarity, connect the positive battery cable (from the over-current device) to the inverter’s positive terminal. Important: The next step may cause a small spark and snapping sound when connecting the cable to the inverter. This is normal, and is caused by the inverter’s capacitors charging up. 9. Observing battery polarity, connect the negative battery cable to the inverter’s negative terminal. 10.
DC Wiring Installing a Battery Temperature Sensor A battery temperature sensor (BTS) option can easily be installed in the system to ensure proper charging of the batteries based on temperature. Installing a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures. To install the Battery Temperature Sensor: 1.
Installation AC Wiring This section describes the AC wiring requirements and how to make the connections. It provides the required wire sizes, recommended lengths for conductors, and disconnect/circuit breaker requirements. Important: The installation of sub-panels and wiring should be performed by a qualified person or a licensed electrician following all local and NEC codes.
AC Wiring Important: The lower AC cover varies depending on the model. DR24XX and DR36XX models are equipped with a conduit box and not a plate. The conduit box is required for the larger diameter wire providing ample bending radius. Screws Standard Cover Plate High Power Conduit Box DR24XX and DR36XX models DR15XX Figure 2-15 AC Side Cover Panels Before wiring the input of the inverter, refer to Table 2-5 below for the minimum recommended wire size.
Installation Important: The U.S. requires conduit be used in this type of installation. Refer to the NEC and local codes. Conduit fittings can be replaced with strain reliefs where code permits. WARNING: Shock Hazard Disconnect the battery cables from the inverter if they are already connected. To connect the AC Input to the Inverter: 1. Disconnect the main breaker at the main electrical service panel (if used) or disconnect the AC generator. 2.
AC Wiring AC Output Wiring to the AC Distribution Panel (Sub-panel) Important: The ground and neutral must be bonded at one place, and only one place, in the system. If the generator is the main source of power, (i.e., no utility grid power) then the neutral and ground connections are bonded at the generator. If the generator is acting as a backup for the utility grid, then the bond should be at the main utility service entrance box. In this case, ensure that no bond exists at the generator output.
Installation The following diagrams illustrate the AC wiring for the following basic 120/240 Vac scenarios. Consult your system design for other possible configurations.
AC Wiring AC Input Wiring using a Generator in an On-Grid Application If a generator is used as a backup for the utility, then a manual transfer switch must be added to provide a means to switch the generator power to the inverter’s inputs. The generator can be used during extended outages to recharge the batteries and provide pass through power for the loads. Start and stop the generator manually using the generator’s pull-cord, ON/OFF switch, etc.
Installation AC Input Wiring - Off-Grid Applications using a 120 Vac Generator Follow the example below to complete the wiring for an off-grid application.
AC Wiring AC Input Wiring - Off-Grid Applications using a 240 Vac Generator for 120 Vac Loads Follow the example below to complete the wiring for an off-grid application.
Installation Series Stacking (120 Vac/60 Hz Models only) This COM port allows two DR Inverters (120 Vac/60 Hz models only) to be used in the same system in a “SERIES” configuration to operate 240 Vac loads. Series stacking can also be used to connect to 240 Vac only power systems providing both 120 and 240 Vac outputs. A series stacking interface cable (DRI) is required to connect the series stacking port of the inverters.
AC Wiring Figure 2-22 AC Wiring for dual-inverters - On-Grid Application (120 Vac models only) 975-0012-01-02 Rev A 2–31
Installation Figure 2-23 Wiring for dual-inverters - On-Grid Application (120 Vac models only) 2–32 975-0012-01-02 Rev A
3 Operation Chapter 3, “Operation” contains information about how to operate the DR Inverter/Charger.
Operation Front Panel Controls and Indicators All operating controls, indicators and sense connectors are located on the front panel of the unit. The controls are easily accessible, and the LEDs provide inverter/charger status at a glance.
Front Panel Controls and Indicators Ports There are two ports on the inverter/charger. Both ports are RJ11 type telephone style connectors. One is used for connecting a remote control to the inverter. The other is used for regulating the charger voltage based on the temperature of the battery bank. BATTERY SENSE Port The BATTERY SENSE Port is used for connecting a battery temperature sensor (BTS) to control the charging rate based on battery temperature.
Operation • • Erratic Blinking (0 to 3 and 2 to 5 flashes @ 2 second intervals) - The inverter has detected an error condition caused by overheating, low battery voltage, or high battery voltage. OFF - The inverter is OFF. The remote control must be connected prior to switching the inverter ON; otherwise, the micro-controller will not recognize (or respond to) the remote. If the remote is not recognized, switch the inverter OFF and then ON using the inverter’s front panel POWER ON/OFF switch.
Front Panel Controls and Indicators Table 3-1 Battery Type Selector Switch Settings 12-volt Models Switch Position Description 24-volt Models Charge Function Float Voltage Bulk/ Equalize* Voltage Float Voltage Bulk/ Equalize* Equalize Charge Rate Voltage Equalize Time 0 Equalize 1 equalizes at a rate equal to the battery bank capacity (in amphours) divided by 40. 13.2 *15.0 26.4 *30.0 Battery Capacity Setting (C/40) 6 hrs. minimum 12 hrs.
Operation Important: 1. Switch positions “0” and “1” are for monthly battery maintenance only. Return the switch to the appropriate position for the system’s batteries when Equalize charging has completed. NEVER EQUALIZE GEL BATTERIES! Use together with BATTERY CHARGER RATE potentiometer (position1) or BATTERY CAPACITY potentiometer (position 0). 2. Equalize voltages are displayed in the table with an asterisk (*) - Switch positions “0” and “1” only. 3.
Front Panel Controls and Indicators Important: Some loads constantly draw power even though they are switched OFF. These include: TVs with instant-ON circuits, microwaves with digital displays, VCRs, etc. It is best to operate these devices from another circuit or install a switch to turn these OFF completely or don’t use the Search Mode. Important: When the SEARCH MODE is used with series stacked inverters, only 120 Vac loads connected to the “master” inverter will bring the unit out of the search mode.
Operation Use Table 3-2 to find the approximate setting of the Battery Charge Rate potentiometer. The settings do not need to be exact, but should be as close as possible to the actual value required. Important: The potentiometer does not have an arrow to indicate its position. Use a small blade screwdriver and rotate the control completely CCW to find the start position. Rotate the potentiometer CW to the desired position (i.e., halfway between the stops for a 50% setting).
Front Panel Controls and Indicators Over Discharge Protection (ODP) When enabled, ODP shuts down the inverter at a specified voltage (low battery cutoff) to protect the batteries from over discharge damage. The inverter circuitry calculates the lowest (safe) DC voltage (leaving approximately 20% battery capacity) based on the position the Battery Type Selector switch and the amount of current drawn by the load. Under no-load conditions this level is typically between 11.8 and 12.
Operation AC Transfer Voltage During normal operation, the inverter supplies AC power to the applied loads through the pass-through circuit and simultaneously charges the system batteries. Whenever the external AC source drops below the AC Transfer Voltage (set by the potentiometer), the inverter switches to battery power in order to maintain the connected load. Examples (120 Vac inverter system): 1. The AC Transfer Voltage potentiometer is set to 9:00 o’clock with ODP disabled.
Front Panel Controls and Indicators Maximum (105 Vac for 120 Vac models) AC Transfer Voltage (Adjustable) with ODP Disabled Maximum (105 Vac for 120 Vac models) Minimum (45 Vac for 120 Vac models) AC Transfer Voltage (Adjustable) with ODP Enabled Minimum (45 Vac for 120 Vac models) Figure 3-7 ODP Enabled/Disabled Positions Important: Most AC appliances will operate properly with an AC pass-through voltage between 95 and 105 volts.
Operation Battery Capacity The Battery Capacity potentiometer is used to set the correct charge profile for the battery capacity (amp-hours) used with the inverter (see illustration below). The setting allows the inverter to calculate over-discharge protection values and also the end of the Bulk/Absorption charge mode, at which point the inverter switches to the Float mode of battery charging.
Front Panel Controls and Indicators LED Indicators There are four LEDs on the inverter’s front panel, indicating inverter status, battery condition, over temperature/overload conditions and charger status. These LEDs blink or change color depending on the condition or function they are displaying.
Operation Important: In renewable energy applications (solar, wind, hydro, etc.) the DC charge controllers must be set to a level below the inverter’s maximum input voltage or the inverter shuts OFF. Whenever the battery voltage drops to its lowest (safe) level (as calculated by the ODP), the LED lights green to indicate the condition. If the condition persists, the inverter will shut down until the battery voltage returns to a safe level and then restart.
Front Panel Controls and Indicators Circuit Breakers The DR Inverter contains two circuit breakers located on the right-hand side of the chassis, directly above the AC input terminal block. The pass-through AC input circuit breaker protects the AC wiring and connected load. The charger AC input circuit breaker protects the charger circuit. The breakers are rated for the maximum charge rate and pass-through current allowed according to the rating of the internal relay.
Operation Start-up Once the inverter is properly connected to the batteries, AC source, and loads (using a sub-panel) the inverter is ready for operation. Recheck the controls and ensure they are in the proper position. Recheck all wiring and ensure it is correct. Starting the inverter: 1. Apply DC power to the inverter by switching on the DC disconnect circuit breaker. The inverter will go through a self-test and then shut OFF. 2. Press the ON/OFF button once. The inverter will sound an audible chirp. 3.
Charger Mode Charger Mode 3-Stage Charging Process The charging cycle uses a 3-stage charging process to maintain the batteries. Whenever nominal AC is present at the inverter’s input, it passes power through to the connected load and begins charging the batteries, indicated by the dual color BATTERY CHARGER LED. Bulk Charge Bulk charge is the first stage in the charging process and provides the batteries with a controlled, constant current. A solid orange BATTERY CHARGER LED indicates bulk charge.
Operation Battery Charger LED Solid Orange = Bulk Blinking Orange = Absorption Solid Green = Float Battery Capacity Figure 3-14 Charger Controls and Indicators Equalize Charging Equalize charging is a special mode of battery charging. During use, the battery’s cells can become unequal in the voltage and current they can deliver. This is due to a buildup of sulfate on the plates as well as stratified electrolyte. Sulfate prevents the cells from receiving or delivering full power.
Charger Mode Important: Recheck the water the level after equalize charging and refill if necessary. 4. Set the BATTERY TYPE SELECTOR switch to position “0” or “1”. To start the equalization charging process, cycle the AC power (i.e., disconnect and then reconnect the AC source). A solid orange BATTERY CHARGER LED indicates equalize charge.
Operation See Table 3-1 Switch Position “1”. Figure 3-16 Equalize 1 Battery Charger Rate Potentiometer (Position “1”) See Table 3-1 Switch Position “0”.
4 Troubleshooting Chapter 4, “Troubleshooting” contains information about how to troubleshoot possible error conditions while using the DR Inverter/Charger.
Troubleshooting Troubleshooting the DR Inverter Table 4-1 provides a list of possible error conditions that may occur, their possible causes, and possible solutions to resolve the error condition. Table 4-1 Troubleshooting the DR Inverter Error Condition Possible Cause Solution No AC output voltage and no warning LEDs on ON. Battery voltage at the inverter terminals is too high or low. Check the battery voltage, fuses or breakers, and cable connections.
Problem Loads Table 4-1 Troubleshooting the DR Inverter Error Condition Possible Cause Solution - indicates charging, but no charge is going to the batteries. Circuit Breaker on the side of the inverter is open. Reset the AC CHARGER circuit breaker on the side of the unit. - is ON, but there is no output power. No AC voltage on inverter’s AC terminal block. Check “AC PASS-THRU” Circuit Breaker on the side of the inverter. Good AC voltage on inverter’s AC terminal block.
Troubleshooting Clocks The inverter’s crystal controlled oscillator keeps the frequency accurate to within a few seconds a day; however, external loads in the system may alter the inverter’s output waveform causing clocks to run at different speeds. There may be periods where clocks keep time and then mysteriously do not. This is because most clocks do not draw enough power to trigger the load sensing circuit.
Problem Loads Printers Most inkjet type printers work well in inverter applications. Laser printers, however, require high current for their fusing circuit and are not recommended for use with an inverter. Rechargeable Devices When first using a rechargeable device, monitor its temperature for 10 minutes to ensure it does not become abnormally hot. Excessive heat will indicate that it is incompatible with the inverter.
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A Specifications Appendix A, “Specifications” contains information about the electrical specifications and environmental specifications of the DR Inverter/Charger.
Specifications Specifications of the DR Inverter Table A-1 provides the electrical specifications for the DR Inverter/Charger (120 Vac/60 Hz. models). Table A-2 provides the electrical specifications for the DR Inverter/Charger (220 Vac/60 Hz. models). Table A-3 provides the electrical specifications for the DR Inverter/Charger (230 Vac/50 Hz. models). Table A-4 provides the environmental specifications for all models of the DR Inverter/Charger.
Specifications of the DR Inverter Table A-1 Electrical Specifications for the DR Inverter/Chargera - 120 Vac/60 Hz Models Model DR1512 DR2412 DR1524 DR2424 DR3624 DC Input Voltage (nominal)c 12.6 Vdc 12.6 Vdc 25.2 Vdc 25.2 Vdc 25.2 Vdc DC Input Voltage Range 10.8 to 15.5 Vdc 10.8 to 15.5 Vdc 21.6 to 31.0 Vdc 21.6 to 31.0 Vdc 21.6 to 31.
Specifications Table A-2 Electrical Specifications for the DR Inverter/Chargersa - 220 Vac/60 Hz Models Model DR1512W DR2412W AC Input Voltage 220 Vac 220 Vac AC Input Low Transfer Voltage 80 to 210 Vac 80 to 210 Vac AC Input Currentb 45 amps 55 amps Continuous Power (@ 25°C) 1500 VA 2400 VA Continuous Output (@25 °C) 6.8 amps AC 6.8 amps AC Efficiency 94% max 94% max AC Output Voltage (rms) 220 Vac 220 Vac Frequency: (± 0.04% Crystal controlled) 60 Hz. 60 Hz.
Specifications of the DR Inverter Table A-2 Electrical Specifications for the DR Inverter/Chargersa - 220 Vac/60 Hz Models Model DR1512W Temperature Comp Probe (BTS) optional Remote Control (RC8)d optional DR2412W a.Specifications subject to change without notice. b.This is the minimum AC current required to obtain full pass-through and maximum battery charging. c.Product may not meet voltage regulation specifications at other than "Input Nominal" at full-rated load. d.Also compatible with the RC4.
Specifications Table A-3 Electrical Specifications for the DR Inverter/Chargera - 230 Vac/50 Hz Models Model DR1512E DR1524E DR1548E DR2424E Auto Low Battery Protection enabled 11 V 11 V 22 V 22 V DC Charger Rate (Adjustable) 0 to 70 amps 0 to 35 amps 0 to 17.5 amps 0 to 70 amps Common Specifications: Voltage Regulation (maximum) ± 5% Voltage Regulation (Typical) ±2. 5% Waveform modified sine wave Load Power Factor (allowed) 0.5 to 1.
Specifications of the DR Inverter Table A-4 Environmental Specifications for the DR Inverter/Chargera Model DR1512 DR2412 DR1524 DR2424 DR3624 Dimensionsb 8.5" w x 7.25" H x 21" D (21.6 cm W x 18.4 cm H x 54.
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B Battery Information Appendix B, “Battery Information” supplies general information about batteries such as battery types, battery bank sizing, battery configurations, and battery care. For detailed information, see your battery manufacturer or your system designer.
Battery Information Introduction Batteries Batteries are available in different sizes, amp-hour ratings, voltage, liquid or gel, vented or non-vented, chemistries, etc. They are also available for starting applications (such as an automobile starting battery) and deep discharge applications. Recommendations Consider the following recommendations for battery use. • • • Use only the deep discharge types for inverter applications. Use the same battery type for all batteries in the bank.
Battery Types Sealed Batteries (Gel and AGM) Description Gel Cell and absorbed glass mat (AGM) batteries are sealed and do not require the addition of distilled water. Since these batteries are valve regulated, over-charging can cause irreversible damage.
Battery Information Understanding Battery Capacity Ratings Discharge rate Deep cycle batteries have their amp-hour rating expressed as “at the x-hour rate”. The hour rating refers to the time it takes to discharge the batteries. A faster hour rate (6 hour rate) means more current is withdrawn from the batteries during their discharge period.
Battery Bank Sizing Back up power systems which use utility power for recharging should use the estimated number of days of maximum power outage for determining days of autonomy. Understanding Amp-hour Requirements Amp-hours To estimate the battery bank requirements, you must first calculate the amount of power you will draw from the batteries during your period of autonomy. This power draw is then translated into amp hours (Ah)—the unit of measure to express deep-cycle battery capacity.
Battery Information Considerations When calculating battery bank size, consider the following: • • Motors typically require 3 to 6 times their running current when starting. Check the manufacturer’s data sheets for their starting current requirements. If you will be starting large motors from the inverter, increase the battery bank size to allow for the higher start-up current.
Battery Bank Sizing Battery bank size worksheet Calculation To calculate the battery bank size, use the average amp-hours per day that you calculated using Table B-1, then make the other calculation shown in Table B-2 to calculate the battery bank size you need to support your loads. Table B-2 Determining Battery Bank Size Worksheets Average amp hours per day 95 Divided by inverter efficiency (90%) for DR Inverter 0.9 Divided by battery efficiency (usually 0.75) 0.
Battery Information Battery Configurations The battery bank must be wired to match the inverter’s DC input voltage specifications (12 or 24 Vdc). In addition, the batteries can be wired to provide additional run time. The various wiring configurations are: Series Wiring batteries in series increases the total bank output voltage. This voltage MUST match the DC requirements of the inverter or inverter and/or battery damage may occur.
Battery Configurations + - + Each battery's amp-hour rating is 100 Ah. - 12 V 12 V SHUNT DC Disconnect (either a circuit breaker or a fuse with a disconnect) + - 24 V INVERTER (Total battery capacity = 100 Ah) Figure B-2 12-volt Battery Wiring - “Series” Configuration Wiring Batteries in Parallel Effect Wiring the batteries in a parallel configuration increases the current of the battery string. The voltage of the battery bank remains the same as an individual battery.
Battery Information Wiring Batteries in Series-Parallel Effect Wiring the batteries in a series-parallel configuration increases the current and voltage of the battery bank. “Series-parallel” wiring is more complicated and care should be taken when wiring these banks. Steps It is done in three steps; wiring the batteries in series, wiring them in parallel, then wiring the string to the inverter. Series wiring To wire in series: 1.
Battery Configurations Connect to inverter To connect to the inverter: 1. Connect a cable from the positive terminal of the first battery string to the inverter’s positive DC terminal (via a fused device). 2. Connect the negative terminal of the last battery string to the negative terminal of inverter’s DC terminal. Connection from Series String 1 to inverter's positive (+) terminal + – + 6V – + 6V – + 6V – Series String 1 6V Each battery's amp-hour rating is 100 Ah.
Battery Information Battery Connections for Stacked Inverters When using inverters in a stacked configuration, the same battery bank must be used for both inverters. To ensure even charging of the batteries, each inverter must be connected to both strings (i.e., positive cable to string two, and negative cable to string one for inverter 1, and positive cable to string one and negative cable to string two for inverter 2) as shown in the diagram below.
Battery Maintenance Battery Maintenance Maintenance strategy To get the best performance from an inverter system, the batteries must be properly setup and maintained. This includes setting the proper voltages for Bulk and Float charging. See the “CAUTIONS” in the section on Equalization Charging that follows. In addition, the battery terminals should be inspected, cleaned, and re-torqued if necessary. Neglecting any of these items may result in poor inverter performance and greatly reduce battery life.
Battery Information Table B-4 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) Celsius 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 Fahrenheit 140 131 122 113 104 95 86 77 68 59 50 41 32 23 14 5 -4 -13 -22 -31 -40 12-volt units 24-volt units 48-volt units Lead Acid NiCad Lead Acid NiCad (6 cells) (10 cells) (12 cells) (20 cells) -1.05 -0.70 -2.10 -1.40 -0.90 -0.60 -1.80 -1.20 -0.75 -0.50 -1.50 -1.00 -0.60 -0.40 -1.20 -0.80 -0.45 -0.30 -0.
Battery Maintenance Equalization Charging Purpose An equalize charge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells. Effect Equalize charging also produces gassing which stirs up the electrolyte mixture and helps distribute the acid more evenly. Non-equalized batteries Batteries that are not equalize charged can be damaged by sulfate accumulation, thus sealing off a percentage of the plates and reducing battery capacity.
Battery Information General Maintenance Water Levels Flooded lead acid batteries require periodic water refills in each battery cell. Only distilled water should be used in a battery, as tap or mineral water may contain contaminants which will upset the battery chemistry and may damage the battery. When filling the battery, clean the surface first to prevent dirt from entering the cell. Fill the cell to just above the plates or to the bottom of the internal collar inside the battery.
Battery Maintenance State of Charge The battery’s state-of-charge should be checked often and only when the battery at a state of rest (when the battery is not powering loads or actively being charged). First thing in the morning is usually the best time to check the state of charge. If the batteries are readily accessible, measure the voltage across the individual battery terminals. There should be less than a 0.2 volt difference between each battery.
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C Multi-wire Branch Circuit Wiring Appendix C, “Multi-wire Branch Circuit Wiring” supplies information about Multi-wire Branch Circuit Wiring Precautions when using stand-alone 120 Vac inverters or generators. WARNING A possible fire hazard can exist if 120 Vac only sources (such as inverters and generators) are wired incorrectly into 120/240 Vac panels containing multi-wire branch circuits.
Multi-wire Branch Circuit Wiring Multi-wire Branch Circuits Problem A potential safety problem exists when installing stand-alone 120 Vac inverters into existing 120/240 Vac wired panels where multi-wire branch circuit wiring methods were used. Legacy situation Multi-wire branch circuits are wired differently from “home run” type wiring (Figure C-1) in that only one neutral wire is used to provide the neutral-return path for each circuit connected to both phases of the AC grid.
Multi-wire Branch Circuits Load Center 240 Vac from Grid Load Center L1 240 Vac from Grid L2 15 A Breaker (Ganged) Neutral Ground L1 L2 Neutral 15 A Breaker (Ganged) Ground Red - Hot (Current Flow 15 A) Black - Hot (Current Flow 15 A) Single White - Neutral (Current Flow 0 A) 120 Vac Black - Hot (Current Flow 5 A) 120 Vac Single White - Neutral 120 Vac (Current Flow 10 A) Bare - Ground 15 A Breaker (Ganged) Red - Hot (Current Flow 15 A) 120 Vac Bare - Ground Bare - Ground Splice Out-of-
Multi-wire Branch Circuit Wiring Identifying Multi-wire Branch Circuits WARNING: Shock Hazard The next step involves opening the load center, exposing live circuits. This procedure should only be performed by qualified persons or electricians. Identifying characteristic Multi-wire branch circuits can be identified by removing the cover on the load center and inspecting the wiring. Conventional 120 Vac circuits are identified by a 2-wire-plus-ground (black, white, and copper) “romex” for each circuit.
Correcting Multi-wire Branch Circuit Wiring Correcting Multi-wire Branch Circuit Wiring Acceptable options Correcting multi-wire branch circuit wiring is not easy. Two options which will correct multi wiring branch circuit wiring are: • Recommended option Rewire existing multi-wire branch circuits to conventional “home run” wiring. This requires a qualified electrician (knowledgeable about multi-wire branch circuit wiring) and is expensive.
Multi-wire Branch Circuit Wiring NEUTRAL HOT 120 Vac Inverter or Generator T240 AutoTransformer Load Center HOT - L1 L1 HOT - L2 L2 Neutral 15 A Breaker (Ganged) White - Neutral Ground 15 A Breaker (Ganged) Red - Hot (Current Flow 15 A Black - Hot (Current Flow 15 A) Single White - Neutral 120 Vac (Current Flow 0 A) 120 Vac Bare - Ground White - Neutral Splice (Current Flow 15 A) The out-of-phase current SUBTRACTS at this point.
Warranty and Return Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your DR Inverter/Charger. This warranty period lasts for Warranty period from the date of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims.
Warranty and Return What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems.
Warranty and Return Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory "Ship To" address. Products must also be shipped prepaid. Product shipments will be refused and returned at your expense if they are unauthorized, returned without an RMA number clearly marked on the outside of the shipping box, if they are shipped collect, or if they are shipped to the wrong location.
Warranty and Return Information About Your System As soon as you open your DR Inverter/Charger package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number _________________________________ ❐ Purchased From _________________________________ ❐ Purchase Date _________________________________ If you need to contact Customer Service, please record the following details before calling. This information will help our representatives give you better service.
Index A P AM radios 4–3 AWG 2–4 peak output voltage 4–4 Problem Loads 4–3 proof of purchase WA–4 purchase date WA–4 B Batteries Battery Care and Maintenance Equalization Charging B–15 Temperature Compensation B–13 Battery Types Absorbed Glass Mat B–3 Flooded Lead Acid (FLA) B–2 Gel Cell B–3 Golf Cart B–2 Industrial (electric forklift) B–2 NiCad and NiFe B–3 Charging Bulk Voltage B–13 Charge Rates B–13 Float Voltage B–13 batteries first aid when working with vii precautions when working with vii Battery
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Xantrex Technology Inc. 1 800 670 0707 Tel. toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.
