Installation Guide Freedom HW 1000 Inverter/Charger
Freedom HW 1000 Inverter/Charger Installation Guide This guide for use by qualified installers only
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 Installation Guide is to provide explanations and procedures for setting up and installing a Freedom HW Installation*. For complete information on how to operate, maintain, and troubleshoot the Freedom HW unit, see the Freedom HF Inverter/Charger Owner’s Guide (Doc. Part Number: 975-0467-01-01) * Recreational or Fleet Vehicle.
About This Guide 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. Related Information You can find more information about Xantrex Technology Inc.
Important Safety Instructions READ AND SAVE THIS INSTALLATION 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.
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.
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.
12. Never charge a frozen battery. 13. Clean battery terminals. Be careful to keep corrosion from coming into contact with your eyes. 14. Locate the Freedom HW unit away from batteries in a separate, well ventilated compartment. 15. Never place the Freedom HW unit directly above batteries; gases from a battery will corrode and damage the unit 16. Never allow battery acid to drip on the unit when reading gravity, or filling battery. 17.
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Installation Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Installation Tools and Materials - - - - - - -
2 Specifications Electrical Specifications: Inverter Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Specifications: Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 Installation Chapter 1 provides information to help in installing a Freedom HW Inverter/Charger Installation. It covers the following: • Materials list. • Safety instructions and various installation codes that may be applicable to your installation. • Sample installation tools and materials. • High level overview of installation steps. • Installation procedures starting on page 1–5 including mounting and connecting the equipment ground, AC cabling, DC cabling, and grounding steps.
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.
Safety Instructions Safety Instructions WARNING: Shock hazard Xantrex Technology recommends that all wiring be done by a certified technician or electrician to ensure adherence to the applicable electrical safety wiring regulations. • • Before you begin the installation, review the “Important Safety Instructions” on page v, and read this entire “Installation” section so you can plan your installation from beginning to end. Disconnect all AC and DC power sources to prevent accidental shock.
Installation Tools and Materials You will need the following to install the Freedom HW: ❐ Wire stripper ❐ Mounting screws or bolts ❐ #2 Phillips screwdriver ❐ Wrench for DC terminals (1/2 inch or 13mm or adjustable) ❐ AC cable (i.e. 2-conductor-plus-ground cable), sized appropriately for load and application ❐ Wire nuts or crimp connectors for AC wire and appropriate tools ❐ DC cable, sized appropriately for load and application ❐ Lugs for DC cables to fit 8 mm (5/16 in.
Basic Installation Procedures Basic Installation Procedures Xantrex recommends that you have your installation performed by a qualified technician or electrician. This section provides sample installation information as a guide for your installation. For your convenience, the overall procedure is divided into ten main steps: ❐ Step 1: Designing an installation. (Start on page 1–6.) ❐ Step 2: Choosing a location for the Freedom HW. (Start on page 1–12.) ❐ Step 3: Mounting the Freedom HW.
Step 1: Designing the Installation Most Freedom HW installations share common components, and some of these are briefly described below. Figure 1-2 shows some components and their relationship to each other in a typical recreational vehicle or fleet vehicle installation.
Basic Installation Procedures AC shore power A source of 120 V, 60Hz sine wave alternating current is needed to provide energy to charge batteries and pass power through to AC loads. This source is usually the utility grid (power company) or an AC generator. An automatic or manual AC source selector switch can be used to switch between the multiple sources of shore power to the Freedom HW system. The AC source feeding the Freedom HW must have the neutral conductor bonded to ground.
AC Output: The circuit breaker or fuse must be rated at no more than the rating of the input breaker in the installation and must be approved for use on 120 Vac branch circuits. The wire used between the Freedom HW and the AC output breaker must be of adequate size to match the AC input circuit breaker’s rating. The wiring from each AC output breaker to each of the loads must be adequately sized to carry the current rating of the individual AC output breaker.
Basic Installation Procedures AC breakers and fuses must be sized to adequately protect the wiring that is installed on the input and output AC circuits of the Freedom HW. All breakers and wiring must be sized and connected in accordance with the electrical codes or regulations applicable to your installation. Table 1-1 gives some examples of wiring sizes based on the U.S. National Electrical Code and the Canadian Electrical Code.
Table 1-2 Recommended Cable Sizes Inverter/Charger Freedom HW Cable Length: Battery to Inverter (one way) Less than 5 feet (1.5 meters) Minimum Cable Size Maximum battery Fuse Size No. 2 AWG 150 Adc Note: Xantrex recommends not using a cable longer than 5 feet (1.5 meters) in each direction. Cable sizes above are based on the US National Electrical Code Table 310.17 - 75C cables, assuming an ambient temperature of 30 °C cables.
Basic Installation Procedures Ground Fault Circuit Interrupters (GFCIs) A GFCI is a device that de-energizes a circuit when a current to ground exceeds a specified value that is less than that required to blow the circuit breaker. GFCIs are intended to protect people from electric shocks and are usually required in wet or damp locations. Installations in recreational vehicles require GFCI protection of branch circuits connected to the AC output of the Freedom HW.
Step 2: Choosing a Location for the Freedom HW WARNING: Fire and explosion hazard This equipment contains components that tend to produce arcs or sparks. To prevent fire or explosion, do not install the Freedom HW in compartments containing batteries or flammable materials, or in locations that require ignitionprotected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, or joints, fittings, or other connections between components of the fuel system.
Basic Installation Procedures Step 3: Mounting the Freedom HW To mount the Freedom HW: 1. Remove the Freedom HW from its shipping container, verify that all components are present, and record relevant product information on Freedom HF Inverter/Charger Owner’s Guide (Doc. Part Number: 975-0467-01-01) Warranty section. 2. Select an appropriate mounting location and orientation. (See Figure 1-3 below.
Connecting the Equipment Ground WARNING: Fire hazard Never operate the Freedom HW without properly connecting the equipment ground. A fire hazard could result from improper grounding. The Freedom HW has a ground stud on the side of the unit as shown in Figure 1-4. Follow the guidelines in “Grounding Locations” to connect the inverter’s chassis to the ground.
Basic Installation Procedures Step 4: Connecting the AC Input Wires WARNING: Fire, Shock and Energy hazards Make sure wiring is disconnected from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes. Do not connect the output terminals of the Freedom HW to any incoming AC source.
Table 1-4 Required AC wire size vs. required breaker rating Freedom HW Required Breaker Size Required Wire Size 30 A maximum 10 AWG There are two knockouts on the front panel for AC input and output wiring. CAUTION: Equipment damage The AC wiring terminal block is split into input and output sections. Damage to the inverter will occur if the unit is wired incorrectly.
Basic Installation Procedures AC input ground screw AC output ground screw S TATUS U til i t y B a tte r y Inpu t Voltag e ( V ) S el ec t Fault Inpu t C u rre n t (A) Outpu t P o w e r ( W ) HW FREEDOM HW 1000 AC knockout AC INPUT GND AC OUTPUT N L Do not connect the AC OUT to any other source of power . Damage to unit may occur . CAUTION! N L GND AC knockout Figure 1-5 Freedom HW AC Wiring Compartment 6. Strip about 2 inches (50 mm) from the jacket of the AC input cable.
Step 5: Connecting AC Output to an Existing AC Circuit WARNING: Shock, fire, and energy hazards Make sure wiring is disconnected from all electrical sources before handling. All wiring must be done in accordance with applicable local and national electrical wiring codes. WARNING: Shock hazard and equipment damage Do not connect any AC source (such as a generator or utility power) to the AC wiring output of the Freedom HW.
Basic Installation Procedures WARNING: Shock, fire, and energy hazards Make sure wiring is disconnected from all electrical sources before handling. All wiring must be done in accordance with applicable local and national electrical wiring codes. Do not connect the output leads of the inverter to any incoming AC source. To make a permanent connection to existing AC wiring (continuing from # 13 of “Step 4: Connecting the AC Input Wires” on page 1–15): 1. Ensure that AC and DC power are both OFF. 2.
CAUTION: Reverse polarity Improper connections (connecting a line conductor to a neutral conductor, for example) will cause the Freedom HW to malfunction and may permanently damage the inverter. Damage caused by a reverse polarity connection is not covered by your warranty. 11. Insert the Line and Neutral wires into the corresponding terminals. 12. Tighten the wire attachment screws to a torque of 15.6–21.6 in-lbf (1.76–2.44 N-m). Leave some wiring slack inside the wiring compartment.
Basic Installation Procedures CAUTION: Equipment damage Do NOT connect the AC OUT Neutral and Line to the AC IN Neutral and Line. See Important note below. See Important note below. GENERATOR INVERTER SUBPANEL See Important note below. TRANSFER SWITCH SHORE POWER MAIN AC PANEL AC OUTLETS (with GFCI) INVERTER LOADS Figure 1-6 AC Wiring Diagram with an Inverter Subpanel In this wiring diagram, the AC input to the Freedom HW comes from the main AC panel which contains the input circuit breaker.
CAUTION: Equipment damage Do NOT connect the AC OUT Neutral and Line to the AC IN Neutral and Line. See Important note below. GENERATOR See Important note below. TRANSFER SWITCH MAIN AC PANEL SHORE POWER Input breakers must be provided by installers. AC OUTLETS (with GFCI) INVERTER LOADS Figure 1-7 AC Wiring Diagram without an Inverter Subpanel In this wiring diagram, the AC input to the Freedom HW comes directly from an AC source.
Basic Installation Procedures Step 6: Connecting the DC Cables CAUTION Before making the final DC connection, check cable polarity at both the battery and the Freedom HW. Positive must be connected to positive; negative must be connected to negative. Reversing the positive and negative battery cables will damage the Freedom HW and void your warranty. This type of damage is easily detected. WARNING: Fire hazard Use only copper wire rated 75 °C minimum.
To make the DC connections Refer to Figure 1-9. 1. Make sure the inverter is off and no AC or DC is connected to the unit. 2. Remove the nuts and washers from the Freedom HW positive and negative DC terminals. 3. Strip 1/2 inch (13 mm) to 3/4 inch (19 mm) insulation from one end of each cable. The amount stripped off will depend on the terminals chosen. 4. Attach the connectors that will secure the cables to the battery, to the disconnect/battery selector switch, and the fuse block.
Basic Installation Procedures 10. Install the lock washer and nut that are supplied with the inverter. Tighten the nut to a torque of 108–120 in-lbf (12.2–13.6 N-m). Make the connection snug enough so the ring terminal does not move around on the DC terminal, but do not overtighten. See Figure 1-9, “DC Cable Connections” on page 1–26. CAUTION Loose connections cause excessive voltage drop and may cause overheated wires and melted insulation. CAUTION Do not over-tighten the nut on the DC input terminals.
13. Install the lock washer and nut that are supplied. Tighten the nut to a torque of 108–120 in-lbf (12.2–13.6 N-m). Make the connection snug enough so the ring terminal does not move around on the DC terminal, but do not overtighten.
Basic Installation Procedures Step 7: Mounting the Display Panel Xantrex has three communications cables of different lengths available for purchase. Choose a 25-foot cable (p/n: 31-6257-00), 50-foot cable (p/n: 31-6262-00), or a 70-foot cable (p/n: 31-6275-00). Flush mounting the panel on a wall or bulkhead requires an opening specified in the display panel mounting template. About 1.5 inches (3.8 cm) of free space is required within the wall to accommodate the depth of the panel.
Step 8: Testing Your Installation WARNING: Shock hazard Pressing the Inverter button to turn OFF the Freedom HW inverter function on display panel does not disconnect DC or AC input power to the Freedom HW. If shore power is present at AC input terminals, it will pass through to the AC output. There are two tests to be performed. The first test verifies that the Freedom HW is inverting DC battery power and delivering AC power to its output.
Basic Installation Procedures Testing in Shore Power Mode To test the Freedom HW in shore power mode: ◆ With the appliance from the previous test still connected and operating, connect the shore power source. The Freedom HW transfers the appliances to shore power. The status LED on the display panel will change from yellow to a ten-second flashing yellow and then green. If the appliance operates, your installation is successful.
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2 Specifications Chapter 2 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.
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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.
