DR Inverter/Charger

DR1512

DR2412

DR1524

DR2424

DR3624

DR1512W

DR1524W

DR1512E

DR1524E

DR1548E

DR2424E

Installation and Operations Manual

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.

Trademarks

DR Inverter/Charger is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex

International.

Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.

Notice of Copyright

DR Inverter/Charger Installation and Operations Manual © March 2005 Xantrex International. All rights reserved.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY

TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,

INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH

INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision

March 2005 Revision

Part Number

975-0012-01-02 Rev A

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct)

Email:

Web: [email protected]

www.xantrex.com

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. You need to consult individual battery manufacturers for this information.

Audience

The Manual is intended for anyone who needs to install and operate the DR

Inverter/Charger. Installers should be certified technicians or electricians.

Organization

This Manual is organized into four chapters and three appendices.

Chapter 1, “Introduction” contains information about the features and functions of the DR Inverter/Charger.

Chapter 2, “Installation” contains information about how to plan for and install the DR Inverter/Charger.

Chapter 3, “Operation” contains information about how to operate the DR

Inverter/Charger.

Chapter 4, “Troubleshooting” contains information about how to troubleshoot possible error conditions while using the DR Inverter/Charger.

Appendix A, “Specifications” contains information about the electrical specifications and environmental specifications of the DR Inverter/Charger.

Appendix B, “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.”

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.

975-0012-01-02 Rev A iii

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.

Abbreviations and Acronyms

AC

ASC

AHJ

COM

CW

CCW

DC

DR Inverter

DRI

LED

PV

PVGFP

RE

RMA

Alternating Current

Authorized Service Center

Authority Having Jurisdiction

COMmunications Port

Clockwise (rotates to the right)

Counter-clockwise (rotates to the left)

Direct Current

DR Inverter/Charger

DR Interface (for stacking)

Light Emitting Diode

Photovoltaic

PV Ground Fault Protection

Renewable Energy

Return Material Authorization

Related Information

You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com. iv 975-0012-01-02 Rev A

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. This unit is designed for indoor use only. Do not expose the DR Inverter/

Charger to rain, snow, or spray.

3. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the DR Inverter/Charger in a zero-clearance compartment. Overheating may result.

4. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk of fire, electric shock, or injury to persons.

5. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the DR

Inverter/Charger with damaged or substandard wiring.

6. Do not operate the DR Inverter/Charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the DR Inverter/Charger is damaged, see the Warranty section.

7. Do not disassemble the DR Inverter/Charger. It contains no user-serviceable parts. See Warranty for instructions on obtaining service. Attempting to service the DR Inverter/Charger yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.

8. The DR Inverter contains more than one live circuit (batteries and AC line).

Power may be present at more than one source. To reduce the risk of electrical shock, disconnect both AC and DC power from the DR Inverter/Charger before attempting any maintenance or cleaning or working on any circuits connected to the DR Inverter/Charger. Turning off controls will not reduce this risk.

9. Use insulated tools to reduce the chance of short-circuits when installing or working with the inverter, the batteries, or a PV array.

975-0012-01-02 Rev A v

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). This is the single point earth ground for the inverter system.

3. Use copper conductors only with insulation rated for 75 °C.

4. The grounds on the DR Inverter are marked with this symbol:

5. The AC voltage and current on the DR Inverter is marked with this symbol:

6. The DC voltage and current on the DR Inverter is marked with this symbol:

7. Phase on the DR Inverter is marked with this symbol:

WARNING Fire Hazard:

Do not install 120 volt AC stand-alone inverters onto 120/240 volt AC multi-branch circuit wiring. This could pose a fire hazard due to an overloaded neutral return wire in this configuration. See “Multi-wire Branch Circuit Wiring” on page C–1 for details.

Explosive gas precautions

WARNING: Explosion Hazard

Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your DR Inverter/

Charger.

1. This equipment contains components which tend to produce arcs or sparks.

To prevent fire or explosion, do not install the DR Inverter/Charger in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system.

2. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed.

vi 975-0012-01-02 Rev A

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. It could spark or short circuit the battery or other electrical parts and could cause an explosion.

4. Remove all metal items, like rings, bracelets, and watches when working with lead-acid batteries. Lead-acid batteries produce a short circuit current high enough to weld metal to skin, causing a severe burn.

5. Have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery.

6. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

7. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries.

8. 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.

9. If you need to remove a battery, always remove the grounded terminal from the battery first. Make sure all accessories are off so you don’t cause a spark.

10. Always use identical types of batteries.

11. Never install old or untested batteries. Check each battery’s date code or label to ensure age and type.

12. Batteries are temperature sensitive. For optimum performance, the should be installed in a stable temperature environment.

13. Always recycle old batteries. Contact your local recycling center for proper disposal information.

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viii

Contents

Important Safety Instructions

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

1 Introduction

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

DC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Remote Control (RC8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Stacking Interface (DRI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Conduit Box (DRCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Unpacking and Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

2 Installation

Pre-installation Planning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Ventilation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Hardware / Materials Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

DC Terminal Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Grounding Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

AC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Wire Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Electrical Panels and Circuit Breaker Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

AC Distribution Panel (Sub-Panel) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

DC Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

Battery Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

Battery Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

Basic Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

Inverter Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

DC Circuit Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

General DC Grounding Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

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Contents

Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15

Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15

Battery Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15

Battery Cable Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–16

DC Disconnect and Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17

Battery Cable Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18

Connecting the Battery Bank to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–19

Installing a Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–21

AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22

AC Distribution Panel (Sub-panel) Mounting and Conduit Installation - - - - - - - - - - - - - - -2–22

Accessing the AC Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22

AC Output Wiring to the AC Distribution Panel (Sub-panel) - - - - - - - - - - - - - - - - - - - - - -2–25

AC Input Wiring - On-Grid Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–26

AC Input Wiring using a Generator in an On-Grid Application - - - - - - - - - - - - - - - - - - - - -2–27

AC Input Wiring - Off-Grid Applications using a 120 Vac Generator - - - - - - - - - - - - - - - -2–28

AC Input Wiring - Off-Grid Applications using a 240 Vac Generator for 120 Vac Loads - - -2–29

Series Stacking (120 Vac/60 Hz Models only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–30

3 Operation

Front Panel Controls and Indicators- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

POWER ON/OFF Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

BATTERY SENSE Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

COM Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Remote Controls (RC8/RC4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Stacking Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Battery Type Selector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

SEARCH MODE WATTS Potentiometer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6

Battery Charger Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7

Over Discharge Protection/AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8

Over Discharge Protection (ODP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9

AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10

Battery Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Inverter Mode LED - Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Over Temp / Overload LED - Red / Green (error condition) - - - - - - - - - - - - - - - - - - - -3–13

Battery High/Battery Low LED - Red/Green (error condition) - - - - - - - - - - - - - - - - - -3–13

Charger LED - Orange / Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

Audible Indicator (internal) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15

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Contents

Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16

Charger Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17

3-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17

Equalize Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18

4 Troubleshooting

Troubleshooting the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Ceiling Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Cell Phones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Computers and Sensitive Electronics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Consumer Electronics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Clocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Decreasing Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Dimmer Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Fluorescent Lights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Heavy Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Microwave Ovens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

Rechargeable Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

Undersized Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

A Specifications

Specifications of the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2

B Battery Information

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2

Deep-cycle Flooded Lead Acid (FLA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2

Sealed Batteries (Gel and AGM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3

NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3

Understanding Battery Capacity Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4

Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4

Understanding Amp-hour Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5

Calculating Amp Hours - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5

Amp Hour Example Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6

Battery bank size worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7

Battery Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8

Wiring Batteries in Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8

Wiring Batteries in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–9

Wiring Batteries in Series-Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–10

Battery Connections for Stacked Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12

975-0012-01-02 Rev A xi

Contents

Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13

Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13

Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–15

General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–16

C Multi-wire Branch Circuit Wiring

Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2

Identifying Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Correcting Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5

Warranty and Return Information

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

Index

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1 xii 975-0012-01-02 Rev A

Figures

Figure 1-1 Front Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Figure 1-2 AC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Figure 1-3 DC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Figure 1-4 Product Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

Figure 1-5 Model/Serial Number Sticker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

Figure 2-1 On-Grid Basic Configuration (Utility Backup)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Figure 2-2 Off-Grid Configuration (Generator only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Figure 2-3 On-Grid Configuration - with Renewable Energy Sources - - - - - - - - - - - - - - - - - - - - - 2–8

Figure 2-4 Off-Grid Configuration - with Renewable Energy Sources- - - - - - - - - - - - - - - - - - - - - 2–9

Figure 2-5 Charge Rate versus Peak AC Voltage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

Figure 2-6 Dimensions (not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

Figure 2-7 Suggested Mounting Method - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

Figure 2-8 Mounting on Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

Figure 2-9 DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

Figure 2-10 Battery Cable Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18

Figure 2-11 DC Terminals on the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19

Figure 2-12 Connecting the Battery Bank to the DR Inverter/Charger- - - - - - - - - - - - - - - - - - - - - 2–20

Figure 2-13 Battery Temperature Sensor (BTS) RJ11 Jack Location - - - - - - - - - - - - - - - - - - - - - 2–21

Figure 2-14 Connecting the BTS to the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21

Figure 2-15 AC Side Cover Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23

Figure 2-16 AC Terminals for AC Input to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24

Figure 2-17 AC Terminals for AC output to the Sub-panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25

Figure 2-18 AC Wiring- On-Grid Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26

Figure 2-19 AC Wiring using a Generator - On-Grid Application - - - - - - - - - - - - - - - - - - - - - - - 2–27

Figure 2-20 AC Wiring using a 120 Vac Generator - Off-Grid Application - - - - - - - - - - - - - - - - - 2–28

Figure 2-21 AC Wiring using a 240 Vac Generator with 120 Vac Loads only- Off-Grid Application 2–29

Figure 2-22 AC Wiring for dual-inverters - On-Grid Application (120 Vac models only) - - - - - - - 2–31

Figure 2-23 Wiring for dual-inverters - On-Grid Application (120 Vac models only) - - - - - - - - - - 2–32

Figure 3-1 Front Panel Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Figure 3-2 Battery Type Selector Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Figure 3-3 Battery Type Selector Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7

Figure 3-4 Battery Charger Rate Potentiometer (DR1512 values used) - - - - - - - - - - - - - - - - - - - - 3–8

Figure 3-5 ODP Enabled/Disabled Positions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9

Figure 3-6 Automatically Calculated Discharge Cutoff Voltage per Cell - - - - - - - - - - - - - - - - - - - 3–9

Figure 3-7 ODP Enabled/Disabled Positions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11

Figure 3-8 Typical Setting for Most Utility Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11

975-0012-01-02 Rev A xiii

Figures

Figure 3-9 Battery Capacity Potentiometer (new) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Figure 3-10 Battery Capacity Potentiometer (old)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Figure 3-11 LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Figure 3-12 AC Pass-through and Charger AC Input Circuit Breakers - - - - - - - - - - - - - - - - - - - - -3–15

Figure 3-13 Startup Items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–16

Figure 3-14 Charger Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–18

Figure 3-15 Equalize Positions on Battery Type Selector Switch - - - - - - - - - - - - - - - - - - - - - - - -3–19

Figure 3-16 Equalize 1 Battery Charger Rate Potentiometer (Position “1”)- - - - - - - - - - - - - - - - - -3–20

Figure 3-17 Equalize 2 Battery Capacity Rate Potentiometer (Position “0”) - - - - - - - - - - - - - - - - -3–20

Figure B-1 6-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8

Figure B-2 12-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - B–9

Figure B-3 Battery Wiring in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–9

Figure B-4 Battery Wiring 24-volt - Parallel Configuration - Step 1 - - - - - - - - - - - - - - - - - - - - - B–10

Figure B-5 Battery Wiring 24-volt - Parallel Configuration - Step 2 - - - - - - - - - - - - - - - - - - - - - B–10

Figure B-6 Battery Wiring 24-volt - Parallel Configuration - Step 3 - - - - - - - - - - - - - - - - - - - - - B–11

Figure B-7 Example of Battery Connections for Stacked Inverters (24 Vdc shown) - - - - - - - - - - B–12

Figure C-1 Conventional Home-type Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2

Figure C-2 Multi-wire Branch Circuit Wiring and Current Flow - - - - - - - - - - - - - - - - - - - - - - - - C–3

Figure C-3 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit - - - - - - - - - - - - - - C–3

Figure C-4 Multi-wire Branch Circuit Wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Figure C-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring - - - - - - - - C–6S xiv 975-0012-01-02 Rev A

Tables

Table 1-1 Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

Table 1-2 Letter Suffix Code Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

Table 2-1 Peak Input Filtrate versus Charging Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

Table 2-2 Safety Ground Conductor Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

Table 2-3 Minimum Recommended Battery Cable Size versus Length - - - - - - - - - - - - - - - - - - 2–16

Table 2-4 Battery Cable to Maximum Breaker/Fuse Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17

Table 2-5 Minimum Recommended Wire Size, Torque Values (Input and Output), and Maximum Output Breaker Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23

Table 3-1 Battery Type Selector Switch Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5

Table 3-2 Approximate Charge rate Setting/Amperage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8

Table 3-3 ODP/AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10

Table 3-4 AC Pass-through Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15

Table 3-5 Battery Charger Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15

Table 4-1 Troubleshooting the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Table A-1 Electrical Specifications for the DR Inverter/Charger - 120 Vac/60 Hz Models - - - - - - -A–2

Table A-2 Electrical Specifications for the DR Inverter/Chargers - 220 Vac/60 Hz Models - - - - - -A–4

Table A-3 Electrical Specifications for the DR Inverter/Charger - 230 Vac/50 Hz Models - - - - - - -A–5

Table A-4 Environmental Specifications for the DR Inverter/Charger - - - - - - - - - - - - - - - - - - - -A–7

Table B-1 Determining Average Daily Load in Amp-hours (Example - - - - - - - - - - - - - - - - - - - -B–6

Table B-2 Determining Battery Bank Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7

Table B-3 Typical Appliance Wattage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7

Table B-4 Variances in Charging Voltage based on Battery Temperature - - - - - - - - - - - - - - - - - B–14

Table B-5 Temperature Compensation Calculation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–14

Table B-6 Battery State-of-Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–17

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xvi

1

Introduction

Chapter 1, “Introduction” contains information about the features and functions of the DR Inverter/Charger.

Introduction

Introduction

Modified Sine

Wave Power

Battery Charger/AC

Transfer Relay

Simplicity

High Efficiency

Low Power

Consumption

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. Internal protection circuits prevent over-discharge of the batteries by shutting down the inverter when a low battery condition occurs. When utility or generator power is restored, the inverter transfers to the AC source and recharges the batteries.

The front panel features LEDs for reading system status, and controls to customize the inverter settings for your battery bank.

The DR Inverter is an economical product designed to provide a reliable supply of electricity to all the essential circuits in the home or business during a power outage. The critical loads can be powered for hours or days, depending on the size of the system battery bank. When utility grid power returns, the batteries are quickly recharged to ensure they will be ready to supply backup power during the next outage.

Accessories allow the DR Series to also serve as a central hub of a renewable energy system.

The DR Inverter provide a modified sine wave output which operates most AC appliances and equipment.

The inverter/charger includes a 3-stage battery charger designed to recharge any type of battery in the shortest possible time. The built-in, fully automatic AC transfer relay automatically transfers power from the utility to the inverter and handles a full 60 amps of current at 120 Vac (30 amps for pass-through plus

20 to 30 amps for charging - depending on the model).

The DR Inverter is simple to operate. All inverter and battery charger controls are located on the front panel.

The inverter/charger operates at over 90% efficiency through most of its power range in Invert-mode.

DR Inverter use extremely low current while in the search mode, consuming less than 1 watt of power. In the O N mode, the inverter/charger uses less than 12 watts of power.

Features

The following sections illustrate the features of the DR Inverter. Figure 1-1 shows the features of the front side of the DR Inverter and identifies the AC side from the

DC side.

1–2 975-0012-01-02 Rev A

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.

Figure 1-2 AC Side of the DR Inverter

975-0012-01-02 Rev A 1–3

Introduction

DC Side

Battery Positive

(+) Terminal

The DC side of the DR Inverter has the equipment ground lug, the positive (+) battery terminal, and the negative (–) battery 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.

Remote Control (RC8)

The RC8 allows the inverter to be switched ON or OFF remotely and includes an

LED status indicator. This unit is also compatible with the RC4 (the predecessor to the RC8); although the RC4 is no longer available for purchase from Xantrex.

Stacking Interface (DRI)

The DRI stacking interface provides 3-wire 120/240 Vac at twice the power using dual DR Inverters (120 Vac/60 Hz units only).

Conduit Box (DRCB)

The DRCB conduit box connects to the DC side of the inverter and accepts a DC conduit run.

Unpacking and Inspection

Carefully unpack the inverter/charger from its shipping carton.

1–4 975-0012-01-02 Rev A

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.

❐ Save the original shipping carton and packing materials! If the inverter ever needs to be returned for service, it should be shipped in the original carton.

This is also a good way to protect the inverter if it ever needs to be moved.

❐ Record the unit’s model, serial number and date of purchase in the appropriate fields in section “Information About Your System” on page WA–4.

Important: Due to continual improvement through product updates, photographs and/ or illustrations used in this manual may not exactly match your unit. Xantrex Technology

Inc. reserves the right to update this product without notice or releasing an updated manual when fit, form or function are not affected.

Model Identification and Numbering Conventions

The DR Inverter is identified by the model/serial number labels. The Serial

Number can be located on the mounting rail or inside the top cover. Model

Number labels may be located on the bottom side of the front cover or possibly inside the front cover. All the necessary information is provided on the label such as AC output voltage, power and frequency (punch holes).

The inverter also has a letter designator followed by 4 or 5 digits (depending on revision). The model number describes the type of inverter, the output specifications, the required battery voltage and the output voltage and frequency

Table 1-1 Model Identification and Numbering Conventions

DR indicates the type of inverter/charger - DR Series.

15

12

E the first two digits of the numerical designator indicate the inverter’s output power - 1500 Watts.

the second two digits indicate the required nominal battery bank voltage -

12 Vdc.

the letter suffix code indicates the output voltage and frequency of the inverter -

230 Vac/50 Hz.

Product Family Country Code

(Letter Suffix)

Example: DR 1512 E

Output Power Battery Voltage

975-0012-01-02 Rev A

Figure 1-4 Product Identification

1–5

Introduction

Table 1-2 Letter Suffix Code Definitions

Letter Suffix

(no letter)

E

J

K

W

Output Voltage

120 Vac

230 Vac

105 Vac

105 Vac

220 Vac

Output frequency

60 Hz

50 Hz

50 Hz

60 Hz

60 Hz

Regulatory

Figure 1-5 Model Number Sticker

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.

These standards guarantee that the DR Inverter/Charger has been tested to nationally recognized safety standards (UL for the US) and have been found to be free from reasonably foreseeable risk of fire, electric shock and related hazards.

The DR Inverter/Charger is intended to be used for residential or commercial applications. Do NOT use this unit for applications for which it is not listed

(i.e., land vehicles or marine craft). It may not comply with the safety code requirements or could possibly present other operational or safety hazards.

1–6 975-0012-01-02 Rev A

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.

CAUTION: Personal Injury

The inverter/charger can weigh up to 45 lbs (20.4 kg) depending upon configuration.

Always use proper lifting techniques during installation to prevent personal injury.

Location

Inverters contain sophisticated electronic components and should be located in a well protected, dry environment away from sources of fluctuating or extreme temperatures and moisture. Exposure to saltwater is particularly destructive and potentially hazardous.

Locate the inverter as close to the batteries as possible in order to keep the battery cable length short. However, do not locate the inverter above the batteries or in the same compartment as vented batteries. Batteries generate hydrogen sulfide gas which is corrosive to electronic equipment. They also generate hydrogen and oxygen. If accumulated, an arc caused by connecting the battery cables or switching a relay could ignite this mixture. Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable.

CAUTION: Corrosion Damage

If the inverter is installed in a location where it is exposed to a corrosive or condensing environment and fails due to corrosion, it will not be covered under warranty.

Important: Inverters can generate RFI (Radio Frequency Interference). Locate any sensitive electronic equipment susceptible to RFI as far away from the inverter as possible. This includes radios and TVs.

2–2 975-0012-01-02 Rev A

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. The mounting surface must be capable of supporting twice the weight of the inverter to comply with UL 1741.

Ventilation

Install the inverter in a well ventilated area/enclosure for proper operation. The inverter’s thermal shutdown point will be reached sooner than normal in a poorly ventilated environment, resulting in reduced peak power output and surge capability, as well as shorter inverter life.

The inverter contains an internal fan. Ensure the air vents and intakes are not obstructed in any way. Provide a minimum clearance of 6 inches around the top and sides of the inverter for ventilation.

Tools Required

The following tools may be required to complete this installation.

❐ #2 Phillips screw driver

❐ Slotted screw driver

❐ Assorted open-end wrenches

❐ Socket wrench and fittings

❐ Multimeter (True rms)

❐ Hole saw

❐ Level

❐ Wire strippers

❐ Torque wrench

❐ Electrical tape

❐ Pencil

❐ Utility knife

975-0012-01-02 Rev A 2–3

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.

• The DC terminals accept cable sizes up to #4/0 AWG that use ring terminals with 5/16" holes.

For maximum safety, run both AC and DC cables in conduit.

DC Terminal Connections

Battery-to-inverter cabling should be only as long as required.

For Example: If #4/0 AWG cables are used, do not exceed 5 feet (one way) in

12 Vdc systems; do not exceed 10 feet (one way) in 24 Vdc systems.

For optimum performance, use pre-assembled battery cables designed specifically for this application (available from Xantrex).

Grounding Considerations

AC Grounding

The inverter/charger should be connected to a grounded, permanent wiring system. Neutral and ground conductors should only be bonded at the main electrical service panel.

DC Grounding

The negative battery conductor should be bonded to the grounding system at only one point in the system. The size for the conductor is usually based on the size of the largest conductor in the DC system.

2–4 975-0012-01-02 Rev A

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. Possible routing scenarios include:

• AC input wiring from the main electrical service panel to the inverter/charger

(if used)

• AC input wiring from the generator to the inverter/charger (if used)

• DC input wiring from the RE to the inverter/charger (if used)

• DC input wiring from the batteries to the inverter/charger

• AC output wiring from the inverter/charger to the sub-panel

• Battery Temperature Sensor cable from the batteries to the inverter/charger (if used)

• Remote control cable to the inverter/charger (if used)

• DC ground from the batteries to an external ground rod

• Load circuit wiring rerouted from the main service panel to the sub-panel

Check for existing electrical or plumbing prior to making cuts in the walls. Cut holes in the walls at appropriate locations for routing wiring/cables.

Electrical Panels and Circuit Breaker Requirements

The following electrical panels and circuit breakers may be required for this installation.

AC Distribution Panel (Sub-Panel)

Loads backed up by the inverter will need to be rerouted from the main electrical panel to a sub-panel. This can be done several different ways, depending upon the installation. Always refer to electrical codes for safe wiring practices.

DC Disconnect

Install a DC disconnect breaker or fuse in the positive battery line. This breaker protects the DC wiring in the event of an accidental short. Size the breaker in accordance with the battery cables. Switch this breaker OFF whenever servicing the batteries.

Battery Considerations

The DR Inverter can support either 12-volt battery banks or 24-volt battery banks.

The battery voltage MUST match the voltage requirements of the inverter. To determine the correct voltage for the system, check the last two digits on the inverter’s model number. For example, the DR1512 is a 12-volt inverter and requires a 12 Vdc battery system. The DR2424 is a 24-volt inverter and requires a

24 Vdc battery system.

975-0012-01-02 Rev A 2–5

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.

For safety and to limit access to the batteries, a lockable, ventilated, battery enclosure or dedicated room should be used. If an enclosure is used, it should be vented to the outside via a one inch vent pipe located at the top of the enclosure.

Install an intake vent at the bottom of the enclosure to promote air circulation.

These vents exhaust explosive hydrogen gases and must not be overlooked when designing an enclosure.

The enclosure should be made of an acid resistant material or have a finish that resists acid to prevent corrosion. It should be capable of holding the electrolyte from at least one battery should a leak occur.

Place a layer of baking soda on the shelves to neutralize any acid that may be spilled in the future (lead-acid batteries only).

Enclosures located outside must be rainproof and screened to prevent access by rodents or insects.

Battery Temperature

The battery enclosure should provide a fairly stable temperature for the batteries.

If it is installed in a cold environment, insulation should be used to protect the batteries from the cold. The insulation also provides a more consistent temperature and better system performance.

The battery enclosure should not be installed in direct sunlight where the summer sun can overheat the batteries. Locate the enclosure where it will be protected from the afternoon sun and provide vents in the top and bottom of the enclosure to provide air flow. High battery temperatures greatly shortens the life of the batteries.

Basic Configurations

The following illustrations show basic applications for the DR Inverter/Charger.

They include the following configurations.

• On-Grid Configuration - Utility Backup

• Off-Grid Configuration - Generator only

• On-Grid Configuration with Renewable Energy Sources

• Off-Grid Configuration with Renewable Energy Sources and a Generator

Consult with your system design for other possible configurations depending on site and code requirements.

2–6 975-0012-01-02 Rev A

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. Small emergency type (lower power) generators may not have a stable enough voltage for the inverter to synchronize to or provide enough current to fully charge the batteries.

The maximum charge rate the battery charger can deliver is dependant upon the peak AC voltage available. Since the battery charger uses only the top portion of the input sine wave, small variations in peak voltage result in large variations in the amount of energy to the charger. The charger’s rated output is based on a utility voltage of 120 Vac RMS (the usual measured value). This should have a peak voltage of 169 Vac p p

(230 Vac has a peak voltage of 325 Vac). For every 10 volts of peak lost, the charge rate is reduced by approximately half.

Size the generator appropriately for the system, including battery charge and load current (typically twice the wattage output of the inverter).

Table 2-1 and Figure 2-5 demonstrates how the peak voltage available affects the charging current.

Table 2-1 Peak Input Filtrate versus Charging Current

Peak Voltage

Available

170 Vac p

160 Vac p

145 Vac p

DR1512

70 amps

35 amps

15 amps

DR2412

120 amps

60 amps

25 amps

DR1524

35 amps

17.5 amps

7 amps

DR242

70 amps

35 amps

15 amps

DR3624

70 amps

35 amps

15 amps

Figure 2-5 Charge Rate versus Peak AC Voltage

2–10 975-0012-01-02 Rev A

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.

To secure the DR Inverter to the wall studs:

1. Locate the studs and mark their location on the wall.

2. Measure the desired height from the floor for the inverter to be mounted.

3. Using a level, run a horizontal line. The length of the line must span at least three studs.

4. Using the dimensions illustrated in Figure 2-6, drill mounting holes into the center of the studs for the inverter.

5. Secure the inverter to the studs using ¼ x 1½ inch lag bolts and washers.

Figure 2-6 Dimensions (not to scale)

To secure the DR Inverter to the mounting location using 2 x 4’s or plywood:

1. Repeat steps 1 through 3 above.

2. Place a pre-cut 2 x 4 (flat side against the wall) on the marked location and drill pilot holes through the 2 x 4’s and studs.

975-0012-01-02 Rev A 2–11

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.

Figure 2-7 Suggested Mounting Method

Figure 2-8 Mounting on Plywood

2–12

Ensure the plywood spans across a minimum of three wall studs for adequate support.

975-0012-01-02 Rev A

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.

The ground conductor should be sized appropriately for the over-current protection device being used and according to NEC 250-95 (Ninth Edition)

(see Table 2-2 below for a portion of the NEC code).

Table 2-2 Safety Ground Conductor Size

Size of Over-current Device

Protecting the Conductor

Minimum Size of the Copper

Ground Wire

30 or 60 amp

100 amp

200 amp

300 amp

400 amp

#10 AWG

#8 AWG

#6 AWG

#4 AWG

#3 AWG

General DC Grounding Requirements

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).

This is the single point earth ground for the inverter system.

To ground the DC circuits:

1. Connect the negative (-) terminal of the battery bank to an appropriately sized conductor and connect it to the ground bus in the DC Disconnect.

2. Connect an appropriately sized conductor to the Ground bus in the DC

Disconnect and connect it to the primary system ground.

The system ground is the same ground used by the AC side of the system.

975-0012-01-02 Rev A 2–13

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. Only the deep discharge types are recommended for inverter applications. Choose the batteries best suited for the inverter installation and cost.

Use only the same battery type for all batteries in the bank. For best performance, all batteries should be from the same lot and date. This information is usually printed on a label located on the battery.

Additional information regarding batteries can be found in the Appendix B,

“Battery Information”.

Battery Bank Sizing

The size of the battery bank determines how long the AC loads will operate in a backup mode without utility power. The larger the battery bank, the longer the run time. Size the battery bank to the AC load requirements and length of time required to run from the batteries. In general, the battery bank should not be discharged more than 50%. Additional DC charging devices such as solar, wind, hydro, etc., can provide longer run times by recharging the batteries in the absence of AC utility or generator power.

Additional details on estimating battery bank size and capacity can be found in

“Battery Bank Sizing” on page B–4.

Battery Configuration

The battery bank must be wired to match the inverter’s DC input voltage specifications (12 Vdc, 24 Vdc, or 48 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 (to match the inverter’s DC requirements).

• PARALLEL - Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads.

• SERIES-PARALLEL - Series-parallel configurations increase both the battery voltage (to match the inverter’s DC requirements) and run-time for operating the AC loads.

For additional information on how to wire these battery-bank configurations, see

“Battery Configurations” on page B–8.

975-0012-01-02 Rev A 2–15

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.

Longer cable runs increase resistance, thus lowering the overall efficiency of the system. This is especially true in lower voltage systems (i.e., 12 Vdc) where, depending upon the length of the cable run, it may be necessary to oversize the diameter of the wire, or parallel (double) the cables.

Important: Only use copper cables. Always use a properly sized cable and length rated for the amperage of the inverter and batteries.

WARNING: Fire Hazard

Undersized cables can overheat and melt, creating a fire hazard when subjected to heavy

(peak) loads.

Table 2-3 provides recommended minimum cable sizes for various cable lengths and inverter amperages. These recommendations may not meet all local or NEC requirements.

Important: Run the positive and negative battery cables as close to each other as possible by taping them together. This reduces the effects of inductance and produces a better waveform thus increasing efficiency. See Xantrex Technical Note 008 on the

Xantrex website for additional information on Battery Cable Inductance.

Table 2-3 Minimum Recommended Battery Cable Size versus Length

Inverter

Model

DR1512

DR2412

DR1524

DR2424

DR3624

Typical

Amperage 1 to 3 feet (one-way) 3 to 5 feet (one-way) 5 to 10 feet (one-way)

150 A

240 A

75 A

120 A

180 A

#2/0 AWG (67.4 mm

2

)

#4/0 AWG (107 mm

2

)

#2/0 AWG (67.4 mm

2

)

#2/0 AWG (67.4 mm

2

)

#4/0 AWG (107 mm

2

)

#2/0 AWG (67.4 mm

2

)

#2/0 AWG (67.4 mm

2

)

#2/0 AWG (67.4 mm

2

)

#4/0 AWG (107 mm

2

)

#4/0 AWG (107 mm

2

)

#4/0 AWG (107 mm

2

)

#2/0 AWG (67.4 mm

2

)

#2/0 AWG (67.4 mm

2

)

#4/0 AWG (107 mm

2

)

#4/0 AWG (107 mm

2

)

2–16

Important: If the system includes a large battery bank or large DC source (such as a micro-hydroelectric plant or wind generator), increasing the size of the cables and disconnects will greatly reduce the number of nuisance outages associated with breaker tripping and open fuses.

975-0012-01-02 Rev A

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. However, Xantrex offers a DC rated, ETL

Listed, circuit breaker disconnect module specifically designed for use with

Xantrex™ inverters to meet NEC compliance. Two amperage ratings are available: a DC250 (250 amps) and a DC175 (175 amps) in either single or dual breaker configurations for single- or dual-inverter installations.

Important: Xantrex™ DC disconnects are not designed to accept doubled

(paralleled) cables which may be required for long cable runs. Also, the plastic red and black covers on the DC inverter inputs are not designed to accommodate dual cables. If dual cables are used, the optional conduit box (DRCB) must be used.

Some installations may not require conduit or a disconnect device, although over-current protection is still required. Xantrex offers a fuse block (TFB) providing the code required inverter over-current protection for these applications.

Refer to the table below for the proper size disconnect device for specific cable diameters.

Table 2-4 Battery Cable to Maximum Breaker/Fuse Size

Cable Size

Required

#2 AWG

#2/0 AWG

#4/0 AWG

Rating in Conduit

115 amps max

175 amps max

250 amps max

Maximum Breaker

Size

Rating in “Free

Air”

N/A

DC175

DC250

170 amps max

265 amps max

360 amps max

Maximum Fuse

Size

TFB200

TFB300

TFB400

Important: The NEC allows rounding to the next standard fuse size from the cable rating (i.e., 150 amp cable size rounds up to a standard 175 amp size). The term “free air” is defined by the NEC as cabling that is not enclosed in a conduit or a raceway. Cables enclosed in conduit or raceways have substantially lower continuous current carrying ability due to heating factors.

975-0012-01-02 Rev A 2–17

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.

Figure 2-10 illustrates the proper method to connect the battery cables to the DR

Inverter’s DC terminals.

Do not place anything between battery cable lug and terminal surface.

Assemble exactly as shown.

2/0 Copper Compression Lug 2/0 Aluminum Mechanical Lug

Figure 2-10 Battery Cable Connections

CAUTION: Equipment Damage

The inverter is not reverse polarity protected. Reversing the battery polarity on the DC input connections will cause permanent damage to the inverter which is not covered under warranty. Always check polarity before making connections to the inverter.

WARNING: Shock Hazard

Ensure the inverter is off before disconnecting the battery cables, and that AC power is disconnected from the inverter input.

2–18 975-0012-01-02 Rev A

DC Wiring

Positive (+)

Battery Terminal

Torque the

Positive (+)

Battery terminal to

10-15 ft-lbs

(13.6 to 20.3 nm)

Negative (–)

Battery Terminal

Torque the

Negative (–)

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)

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.

:

975-0012-01-02 Rev A

WARNING: Shock Hazard

Ensure the inverter is off before connecting or disconnecting the battery cables and that all

AC power is disconnected from the inverter’s inputs.

To connect the battery bank to the inverter:

1. Determine the correct size battery cable to use for installation from Table 2-3 on page 2–16.

2. Determine the correct size disconnect/fuse for installation from Table 2-4 on page 2–17.

3. Color code the cables with tape or heat shrink tubing. The standard colors are red for positive (+) and black for negative (–). (NEC requires white for the negative conductors.)

4. Connect the negative (–) cable to the battery’s negative terminal (torque to manufacturer’s recommendations).

5. Install the over-current device (fuse or circuit breaker) between the battery’s positive terminal and the inverter’s positive terminal (as close to the batteries as possible).

6. Connect the (short) positive cable to the battery’s positive terminal (torque to manufacturer’s recommendations).

7. Ensure the correct polarity of the cables with a DC voltmeter (DVM).

2–19

Installation

: Equip

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. Use an insulated ½ inch wrench or socket to tighten the 5/16 SAE nuts to

10-15 ft-lb (13.6 to 20.3 nm) for each inverter input terminal.

CAUTION: Equipment Damage

Do not put anything between the cable ring terminal and the flat metal part of the terminal. overheating of the terminal may occur. Do not apply any type of antioxidant paste until after the battery cable wiring is tightened.

11. Apply antioxidant paste to the battery and inverter terminals.

12. Install the battery terminal connection covers (red for positive, black for negative) over the inverter’s DC terminals and secure with the screws and washers provided.

2–20

Figure 2-12 Connecting the Battery Bank to the DR Inverter/Charger

975-0012-01-02 Rev A

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. Run the battery temperature sensor wire in the DC conduit (if used) and route the RJ11 connector end to the BATTERY SENSE port located on the front of the inverter.

2. Secure the sensor to one of the batteries located in the center of the battery pack.

Battery Sense

(RJ11) port

Figure 2-13 Battery Temperature Sensor (BTS) RJ11 Jack Location

975-0012-01-02 Rev A

Figure 2-14 Connecting the BTS to the DR Inverter

2–21

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 Distribution Panel (Sub-panel) Mounting and Conduit Installation

WARNING: Shock Hazard

Disconnect the power from the utility’s main breaker box before proceeding.

1. Determine the location of the sub-panel and install it according to the manufacturer’s directions.

2. Install the AC conduit between the sub-panel (output) and inverter.

3. Install conduit between the inverter (input) and the main breaker box.

4. Determine which circuits require backup. Install the appropriate circuit breakers into the sub-panel.

5. Install an appropriately sized circuit breaker (30 amp maximum) in the sub-panel. This will later be wired to the inverter’s output. If two inverters are being used in a stacked configuration, install a double-pole circuit breaker for

240 Vac service.

Accessing the AC Terminals

CAUTION: Equipment Damage

The inverter’s AC output must never be wired to the utility or generator output. This will cause severe damage to the inverter which is not covered under warranty.

All AC wiring connects to the terminal block located on the right-hand side of the inverter.

To make the AC connections to the inverter:

1. To access the terminal block, remove the side cover panels (if installed) by removing the two (or three) Phillips screws. Units are shipped without the covers installed (packed in a small plastic bag with additional hardware).

2. Locate the AC input and output terminals on the block. Refer to Figure 2-15 on page 2–23.

2–22 975-0012-01-02 Rev A

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

DR15XX

High Power Conduit Box

DR24XX and DR36XX models

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.

Important: Refer to the NEC for actual wire sizes for specific installations.

Table 2-5 Minimum Recommended Wire Size, Torque Values (Input and Output), and Maximum Output

Breaker Size

AC Input

Inverter

Model 120 Vac 220-240 Vac 120 Vac

DR1512 #8 or 6 AWG #10 AWG #10 AWG

AC Output

220-240 Vac

DR2412

DR1524

DR2424

DR3624

#6 AWG

#8 or 6 AWG

#6 AWG

#6 AWG

#10 AWG

#10 AWG

#10 AWG

Not Available

#10 AWG

#10 AWG

#10 AWG

#8 AWG

Torque Value for Terminal

Connections

#16 AWG

#14 AWG

#16 AWG

#14 AWG

16 in-lbs

(1.8 nm)

16 in-lbs

(1.8 nm)

16 in-lbs

(1.8 nm)

16 in-lbs

(1.8 nm)

Not Available 16 in-lbs

(1.8 nm)

Maximum

Output

Breaker Size

30 amps AC

30 amps AC

30 amps AC

30 amps AC

30 amps AC

WARNING: Fire Hazard

To reduce the risk of fire, connect only to a circuit provided with the maximum branch-circuit overcurrent protection noted above in accordance with the National

Electrical Code, ANSI/FFPA70.

975-0012-01-02 Rev A 2–23

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. Install an appropriately sized circuit breaker in the electrical service panel.

This will serve as both an AC disconnect and over-current protection. If using a generator only, use the circuit breaker in the generator.

3. Feed the HOT, NEUTRAL, and GROUND wires (using conduit) from the inverter to the AC source. Leave several inches of extra wire at each end.

4. Make the connections to the inverter first. Wiring to the AC source is performed after all connections have been made in the inverter.

a) Connect the GROUND (green) wire to the inverter’s AC GROUND terminal. b) Connect the NEUTRAL (white) wire from the AC source to the inverter’s

NEUTRAL INPUT terminal. c) Connect the HOT (black) wire from the AC source to the inverter’s AC

HOT INPUT terminal.

5. Torque all connections to 16 in-lbs (1.8 nm).

2–24

Torque the terminal connections to

16 in-lbs (1.8 nm)

GROUND NEUTRAL IN

HOT IN

Figure 2-16 AC Terminals for AC Input to the Inverter

975-0012-01-02 Rev A

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.

To connect the AC output wiring to the sub-panel:

1. Connect the GROUND wire to the inverter’s AC GROUND chassis terminal.

Connect the other end of this wire to the GROUND bus in the sub-panel.

2. Connect the NEUTRAL (white) wire to the inverter’s NEUTRAL OUTPUT terminal. Connect the other end of this wire to the NEUTRAL bus in the sub-panel.

3. Connect the HOT (black) wire to the inverter’s terminal labeled AC HOT

OUTPUT. Connect the other end of this wire to the sub-panel’s input circuit breaker.

4. Torque all inverter terminal block connections to 16 in-lbs (1.8 nm).

5. Refer to the sub-panel manufacturer’s specifications for wire torque requirements to sub-panel terminals.

Torque the terminal connections to

16 in-lbs (1.8 nm)

GROUND NEUTRAL

OUT

HOT

OUT

975-0012-01-02 Rev A

Figure 2-17 AC Terminals for AC output to the Sub-panel

Important: The two neutral connections (input and output) are common to one another and may be used in any combination.

2–25

Installation

The following diagrams illustrate the AC wiring for the following basic

120/240 Vac scenarios. Consult your system design for other possible configurations.

• On-Grid Application (See Figure 2-18)

• On-Grid using with a generator Backup (See Figure 2-19)

• On-Grid Dual-Inverter Application (See Figure 2-20)

• Off Grid Application using a 120 Vac Generator (See Figure 2-21)

• Off-Grid Application using a 240 Vac Generator (See Figure 2-22)

• Off-Grid Dual-Inverter Application (see Figure 2-23)

AC Input Wiring - On-Grid Applications

Follow the example below to complete the wiring for an on-grid application.

Figure 2-18 AC Wiring- On-Grid Application

2–26 975-0012-01-02 Rev A

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.

Figure 2-19 AC Wiring using a Generator - On-Grid Application

975-0012-01-02 Rev A 2–27

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.

Figure 2-20 AC Wiring using a 120 Vac Generator - Off-Grid Application

2–28 975-0012-01-02 Rev A

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.

Figure 2-21 AC Wiring using a 240 Vac Generator with 120 Vac Loads only- Off-Grid Application

975-0012-01-02 Rev A 2–29

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.

In this mode, one of the inverters will function as the “primary” and the other inverter becomes the “secondary.” The first unit switched ON becomes the

primary and ensures the secondary’s output is 180 degrees out of phase for

240 Vac operation. Both units can charge the batteries or provide battery backup power during a utility outage.

The following illustrations provide a general overview of AC configurations using stacked inverters. Detailed wiring and operating instructions are provided with the

DRI interface kit available from Xantrex Technology Inc.

The following diagrams illustrate the AC Wiring for a basic On-Grid and Off-Grid application.

2–30 975-0012-01-02 Rev A

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.

LED Status

Indicators

Battery Charge Control

Battery Type Selector

Inverter Mode Controls

(Search Watts)

Inverter Mode Indicator

COM Port

POWER ON/OFF

Battery Sense Port

Figure 3-1 Front Panel Controls and Indicators

POWER ON/OFF Switch

The POWER ON/OFF control is a momentary contact switch that turns the inverter/charger ON or OFF by pressing it once. When the inverter is first connected to the batteries, it will run through a self test consisting of flashing the

LEDs in sequence, operating the cooling fan momentarily and switching the transfer relay three times. Once the self test has successfully completed, the

POWER ON/OFF switch is activated. Pressing the switch once turns the inverter

ON. Another press turns the inverter OFF.

3–2 975-0012-01-02 Rev A

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. The sensor should be taped onto the side of one of the batteries. The information received in this port adjusts the charger’s output higher in cold temperatures, assuring the batteries receive a full charge, and lowers it during warm temperatures, reducing battery gassing and providing overcharge protection.

Important: The Battery Sense only adjusts charging voltage. It does not disable the charger.

Refer to the Installation section for the BTS location on the battery.

COM Port

COM PORT (J1) is a dual function RJ11 (6-pin) connector. Its primary function is to provide serial communications to an optional Xantrex™ remote control unit

(RC4 or RC8). The port also acts as a stacking interface control when two DR

Inverters are used in a series configuration. When two inverters are stacked, a remote control cannot be used with either unit.

Remote Controls (RC8/RC4)

DR Inverter are designed to operate with either an RC8 or RC4 remote control units. Both remotes incorporate a membrane switch with a single red LED display combination to start and stop the inverter, as well as provide overall system operating status.

• Solid - With AC line power present, the unit is charging the batteries while directing AC to the load. With no AC line power present, the inverter is running on the batteries and supplying AC to the load.

• Blinking Slow (1 to 3 flashes @ 1 second intervals) - The inverter is in search mode (no load connected).

• Blinking Fast (3 to 5 flashes @ 1 second intervals) - The inverter is charging the batteries.

• Flickering (3 to 5 flashes @ 1 second intervals) - The inverter has detected an over-current error. The LED (and inverter) will turn OFF whenever an overcurrent condition exceeds eight seconds.

975-0012-01-02 Rev A 3–3

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.

Stacking Interface

Whenever two DR Series inverters are used in a series (stacked) configuration, one unit (primary) controls the other unit (secondary). Communication between the two inverters is done via the COM port (J1). The first unit switched ON, using its front panel POWER ON/OFF switch, becomes the controlling (primary) inverter.

Controls

There are several controls on the inverter’s front panel that provide adjustments for the battery charger, and AC output energy saving mode.

Battery Type Selector

The Battery Type Selector is a 10 position rotary switch used to set the inverter’s charger for the proper Float and Bulk voltage levels. These levels are selected depending on the type of batteries used.

There are also 2 positions (0 and 1) which allow the batteries to be equalized.

Equalizing batteries should only be done on liquid lead acid batteries and never on gel batteries. Refer to the table below for the charge voltages in the various switch positions. Consult the battery manufacturer for optimum battery voltage charging settings.

Battery Type Selector Enlargement

(pointing to Setting 7)

Figure 3-2 Battery Type Selector Adjustment

3–4 975-0012-01-02 Rev A

Front Panel Controls and Indicators

Table 3-1 Battery Type Selector Switch Settings

12-volt Models 24-volt Models Charge Function

3

4

5

6

7

8

9

Switch

Position

0

1

2

Description

Equalize 1 - equalizes at a rate equal to the battery bank capacity (in amphours) divided by

40.

Equalize 2 - charges at a rate set by the

BATTERY

CHARGER

RATE control.

Deep Cell Lead

Acid 2

Float

Voltage

13.2

13.2

13.3

Bulk/

Equalize*

Voltage

Float

Voltage

*15.0

*15.5

15.0

26.4

26.4

26.6

Bulk/

Equalize*

Voltage

Equalize Charge

Rate

*30.0

Battery Capacity

Setting (C/40)

*31.0

30.0

Battery Charger

Rate Setting

(manual)

Not Specified

Gel Cel 2

Gel Cell 1

PcCa-lead

Calcium

Deep Cycle

Lead Acid 1

(Default Setting)

NiCad 1

NiCad 2

13.6

13.7

13.5

13.2

13.4

14.0

14.5

14.3

14.4

14.1

14.3

14.6

16.0

16.0

27.2

27.4

27.0

26.4

26.6

28.0

29.0

28.6

28.8

28.2

28.6

29.2

32.0

32.0

Use for NiCad battery systems.

Recommended for use with nickel iron batteries.

Equalize Time

6 hrs. minimum

12 hrs. maximum

6 hrs. minimum

12 hrs. maximum

Provides an additional Float and Bulk settings for deep cycle, lead acid batteries.

Refer to the battery manufacturer’s recommendation for Float and Bulk settings.

Provides an additional setting of Bulk and

Float voltages.

Recommended for gel cell batteries that specify high float voltages. Check with the battery’s manufacturer.

Typical gel cell setting.

Use this setting for sealed type car batteries.

Factory setting for typical deep cycle lead acid batteries.

See Important notes that follow.

975-0012-01-02 Rev A 3–5

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. Switch position “7” is the default values as shipped from the factory.

4. Always refer to the battery manufacturer’s specifications for equalization.

SEARCH MODE WATTS Potentiometer

The Search Mode Watts potentiometer adjusts the current threshold required to bring the inverter out of search mode into full wave operation. With search mode enabled, the inverter pulses the AC output looking for an applied load. With no load detected, the inverter goes into the search mode to minimize energy consumption. When a load is applied, the load current is sensed, bringing the inverter into full power operation. Disabling the threshold (setting the potentiometer fully CCW) causes the inverter to remain ON (in full power operation) regardless of an applied load.

To set the Search Mode Watts:

1. Remove the AC input source from the inverter. The inverter switches to battery operation. Ensure all inverter supported appliances are switched OFF.

2. Turn the potentiometer completely CW (to MAX).

3. Switch on the load which will trigger the inverter to full power. This could be a lamp located in a convenient location if the power goes out. The light may flicker as the inverter searches the line for a load. The green INVERTER

MODE LED blinks 2-3 times a second, indicating the inverter is in the

SEARCH MODE.

4. Slowly turn the potentiometer CCW (toward MIN) when the proper setting is found, the lamp and INVERTER MODE LED will light steady.

5. Turn the lamp OFF for a moment. The inverter should switch back to the

SEARCH MODE. Turn the lamp ON. Ensure the inverter comes out of the

Search Mode. Adjust the potentiometer up or down as necessary.

Important: The Search Mode only activates when the unit is operating in the inverter mode (from batteries) to prevent unnecessary battery discharge when electrical power is not required. If the inverter is supporting loads that must constantly be powered, turn the search mode OFF by setting the potentiometer fully CCW to the DEFEAT position.

3–6 975-0012-01-02 Rev A

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. See “AC Transfer Voltage” on page 3–10.

Lower wattage device turns ON inverter

Search Mode

Potentiometer

DEFEAT Switches

Search Mode OFF

Higher wattage device turns ON inverter

Figure 3-3 Battery Type Selector Adjustment

Battery Charger Rate

The Battery Charger Rate potentiometer sets the maximum charge current supplied to the battery bank and is also used to regulate constant current in the

Bulk Charge Mode. The level should be adjusted to provide a charge rate less than or equal to the amp-hour capacity of the battery bank divided by a factor of five.

Example:

1. Inverter DR1512 has a maximum charge rate of 70 amps.

a) Battery bank amp-hour capacity = 500 amp-hours using gel cell batteries.

b) Divide the amp-hour capacity by 5 (500/5 = 100).

c) Set the potentiometer to MAX (70 amps) as it is less than 100.

2. Inverter DR1512 has maximum charge rate of 70 amps.

a) Battery bank amp/hour capacity is 250 amp-hours using gel cell batteries. b) Divide the amp-hour capacity by 5 (250/5 = 50).

c) Set the potentiometer to approximately 71% (50 amps).

975-0012-01-02 Rev A 3–7

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).

Table 3-2 Approximate Charge rate Setting/Amperage

Model

DR1512

DR2424

DR3624

DR2412

DR1524

Percent of Potentiometer Rotation (between stops)

0% Min.

0 amps

25%

17.5 amps

50%

35 amps

75%

100%

Max

52.5 amps 70 amps

0 amps

0 amps

30 amps 60 amps

8.75 amps 17.5 amps

90 amps 120 amps

26.25 amps 35 amps

25%

(17.5 amps 50%

(35 amps

75%

(50 amps)

Example 2

0%

(0 amps

100%

(70 amps)

Example 1

Figure 3-4 Battery Charger Rate Potentiometer (DR1512 values used)

Over Discharge Protection/AC Transfer Voltage

The Over Discharge Protection/AC Transfer Voltage potentiometer performs two related functions. When set between the 2 and 5 o’clock position (right), both

ODP and the AC Transfer Voltage function simultaneously (see table on next page). When the potentiometer is set between the 9 and 1 o’clock position (left), only the AC Transfer Voltage is functional (ODP is disabled).

Important: The ODP is not scaled. It is either on or off. The min/max settings only refer the AC transfer function.

3–8 975-0012-01-02 Rev A

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 12.0 Vdc (for a 12-volt battery bank).

Important: The range of set points between 2 and 5 o’clock also determine the low AC

Transfer Voltage. This must be considered when adjusting this potentiometer with ODP enabled (see Table 3-3).

Important: When ODP is disabled (set points between 9 and 1 o’clock), the inverter is programmed to shut OFF when the batteries reach approximately 8.5 Vdc (1.4166 V/cell) for 12-Vdc systems (17 Vdc for 24-volt systems).

ODP Disabled

Range

ODP Enabled

Range

Figure 3-5 ODP Enabled/Disabled Positions

2

1.95

1.9

1.85

1.8

1.75

1.7

1.65

1.6

1.55

1.5

1 0.1

0.01

Discharge Rate/Battery Capacity

Figure 3-6 Automatically Calculated Discharge Cutoff Voltage per Cell

975-0012-01-02 Rev A

12 Vdc 24 Vdc

12.0

24.0

11.4

10.8

22.8

21.6

10.2

20.4

9.6

19.2

9.0

0.001

18.0

3–9

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. Whenever the incoming AC voltage drops to 40 volts or below, the inverter will switch to battery power.

2. The AC Transfer Voltage potentiometer is set to 2:00 o’clock with ODP enabled. Whenever the incoming AC voltage drops to 105 volts or below, the inverter will switch to battery power.

Important: ODP does not affect the operation of the AC Transfer Voltage. ODP is either ON or OFF, depending upon the position of the potentiometer.

Important: To achieve the fastest transfer time (typically less than 16 ms), set the AC

Transfer Voltage potentiometer near the 2:00 o’clock position (with the ODP enabled); or, near the 1:00 o’clock position (with the ODP disabled). If a high number of “nuisance transfers” caused by transients on the AC line occur, adjust the potentiometer from the maximum position toward the minimum position (i.e., 2 o’clock toward 5 o’clock with

ODP enabled; or 1 o’clock toward 9 o’clock with ODP disabled).

Table 3-3 ODP/AC Transfer Voltage

ODP Adjustment

ODP Disabled ODP Enabled

AC Transfer Voltage

100 to 105 Vac

(-J/-K Models) 120 Vac Models

30 Vac 45 Vac

220 to 230 Vac

(-W /-E Models)

90 Vac

9:00

5:00

Approximate Approximate

77 Vac 85 Vac 170 Vac

Approximate

Important: There are 6 settings available for the AC Transfer Voltage for both ODP

OFF and ON as shown in the Table 3-3 below.

Approximate

81 Vac 90 Vac 180 Vac

Approximate Approximate

86 Vac 95 Vac 190 Vac

Approximate Approximate

90 Vac 100 Vac 200 Vac

Approximate Approximate

95 Vac 105 Vac 210 Vac

3–10 975-0012-01-02 Rev A

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. Setting the AC Transfer Voltage potentiometer between these values will allow the incoming source voltage to drop to this level and still operate the connected appliances (load). If the appliances do not operate properly at the lower AC utility pass-through voltage, increasing the setting of the potentiometer (toward MAX) allows the inverter to transfer to battery power (providing full AC output) during these periods.

Important: When setting the AC Transfer Voltage potentiometer for generator applications, the setting may need to be lowered if high powered loads cause the generator voltage to momentarily drop.

Typical Setting Range for Utility

Application (ODP OFF)

Typical Setting Range for Utility

Application (ODP ON)

Figure 3-8 Typical Setting for Most Utility Application

975-0012-01-02 Rev A 3–11

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.

The potentiometer should be adjusted as close as possible to the actual capacity of the battery bank for optimum charging. If the system’s battery bank is larger than

1000 amp-hours, set the potentiometer for 1K.

Important: If using dual inverters configurations, set each charger for half the value.

Important: Most battery manufacturers list the amp/hour rating on the battery label.

3–12

50 amp-hours

(small battery bank)

1000 amp-hours

(1000 amp-hour or larger battery banks)

Figure 3-9 Battery Capacity Potentiometer (new)

Important: The Battery Capacity (Amp/Hrs) potentiometer values have changed between the minimum value of 50 Ah and 1 kAh. Please use the photo that matches your unit.

250 amp-hours

125 amp-hours

50 amp-hours

(small battery bank)

370 amp-hours

500 amp-hours

1000 amp-hours

(1000 amp-hour or larger battery banks)

Figure 3-10 Battery Capacity Potentiometer (old)

975-0012-01-02 Rev A

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.

INVERTER

MODE

OVER TEMP/OVERLOAD

BATTERY HIGH/LOW

BATTERY CHARGER

Figure 3-11 LED Indicators

Inverter Mode LED - Green

The green Inverter Mode LED lights (solid) to indicate the inverter is running on batteries (full wave operation). When the inverter is in search mode (no load applied) the LED flashes 2 to 3 times per second. During AC line operation, with

AC passing directly through to the connected load, the LED remains OFF.

Over Temp / Overload LED - Red / Green (error condition)

The Over Temp / Overload LED is a dual color, dual function indicator. When the inverter’s temperature is too high for safe operation, the LED lights (red) to indicate the Over Temp condition. When the temperature returns to a safe level, the LED turns OFF. If the condition persists, the inverter will shut down, cool and then restart.

Whenever the current draw exceeds a value programmed into the microcontroller, the LED lights (green) to indicate the Overload condition. The LED can remain ON for up to one hour (before inverter shutdown) if the condition is caused by a fault in the charger circuit. When the fault condition clears, the LED turns OFF. If the condition is caused by backfeed (connecting the AC line to the inverter’s output) the LED will remain ON for approximately 10 seconds before the inverter shuts down.

Battery High/Battery Low LED - Red/Green (error condition)

The Battery Hi / Battery Low LED is a dual-color, dual-function indicator.

Whenever battery voltage exceeds a safe value, the LED lights red to indicate the condition. This value is typically 15.5 volts DC for a 12 volt system (31 volts DC for a 24 volt system). If the condition persists, the inverter will shut down until the battery voltage returns to a safe level and then restart.

975-0012-01-02 Rev A 3–13

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.

Important: The inverter automatically restarts when the following error conditions are detected: LOW/HIGH BATTERY, OVER TEMPERATURE, or a quick duration

SHORTED OUTPUT or OVER-CURRENT. The inverter shuts OFF and requires a

MANUAL restart if the following conditions are detected: a prolonged overload condition

(approximately 10 seconds) or the inverter’s output is connected directly to an AC power source (utility grid or generator).

Charger LED - Orange / Green

The Charger LED is a dual color (red/green), triple function indicator.

• When the charger is in Bulk mode, the LED lights orange.

• When the charger is in Absorption mode, the LED blinks orange.

• When the charger is in Float mode, the LED lights green.

Important: Orange is a flickering mix of red and green. It can look different depending on the angle at which the LED is viewed. It should never be a solid red.

Important: The battery charger control circuit operates from the battery voltage. If the battery voltage falls below 7 volts, the inverter/charger will not operate. The batteries must first be recharged using a stand-alone charger to bring the voltage up to a level where the inverter/charger can operate.

Audible Indicator (internal)

A buzzer is located on the control board as an audible alert to fault conditions such as Battery High/Battery Low, or Overload. Steady buzzing indicates an impending inverter shut down. A pulsing chirp indicates the inverter is temporarily off-line due to a fault condition (either within the inverter or related to the system).

3–14 975-0012-01-02 Rev A

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.

Table 3-4 AC Pass-through Circuit Breakers

Models

120 Vac

210-230 Vac

DR15XX

30 amps

15 amps

DR24XX

30 amps

15 amps

DR36XX

30 amps

N/A

Table 3-5 Battery Charger Circuit Breakers

Models

120 Vac

210-230 Vac

DR15XX

20 amps

8 amps

DR24XX

30 amps

15 amps

DR36XX

30 amps

N/A

AC Pass-through

Circuit Breaker

Charger AC Input

Circuit Breaker

Figure 3-12 AC Pass-through and Charger AC Input Circuit Breakers

975-0012-01-02 Rev A 3–15

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. Apply AC power to the inverter.

4. The inverter starts charging the batteries in the Bulk mode, indicated by the

CHARGER LED illuminating a solid orange.

5. Using a true RMS AC voltmeter, check the output voltage of the inverter. This voltage can be checked at either the AC terminal block or in the sub-panel

(between the HOT and NEUTRAL lines). The voltage should be 120 Vac

(230 Vac for “E” models, 220 Vac for “W” models, or 105 Vac for “J” and

“K” models). (Non-true RMS meters register from 90 to 110 Vac.)

6. Switch the AC disconnect circuit breaker to OFF. The inverter will go into the inverter mode (if a sufficient load is applied to the AC output while in the search mode). The green INVERTER MODE LED will light solid indicating the inverter is active. The voltage on the AC output of the inverter will remain the same as above (± 5% maximum).

Important: If the inverter is in the SEARCH MODE (INVERTER MODE LED flashing) and a sufficient load is not available to bring the inverter up to full voltage, turn the SEARCH MODE WATTS potentiometer fully CCW to defeat the search function.

7. Reapply the AC power by switching the AC disconnect to ON. Allow the batteries to fully recharge.

3–16

POWER ON/OFF Switch

INVERTER MODE LED

Charger LED

SEARCH MODE WATTS Potentiometer

Figure 3-13 Startup Items

Important: The unit will not use renewable energy for AC output as long as AC input

(utility or generator) is available to the inverter.

975-0012-01-02 Rev A

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. The bulk charge level is adjustable using the BATTERY

CHARGER RATE potentiometer. Once the battery voltage rises to the bulk voltage threshold, the charger then switches to the absorption mode.

Absorption Charge

Absorption charge is the second stage of battery charging and provides the batteries a controlled, constant voltage for a set period of time. A blinking orange

BATTERY CHARGER LED indicates absorption charge.

During this stage the current supplied to the batteries slowly decreases. When the current equals the programmed return amps value (battery bank capacity/40) set with the BATTERY BANK CAPACITY potentiometer, the charger switches to the third stage–float.

Important: If there are DC loads connected to the battery, the current may never decrease to the level to initiate the float stage. The inverter/charger incorporates a timer circuit which starts counting when AC voltage is applied. To ensure that the charger does not stay indefinitely in the absorption charge mode, the timer automatically switches to the float charge mode when 12 hours have elapsed.

Float Charge

Float charge, the final stage of battery charging, maintains a charge to the batteries whenever AC is present on the inverter’s input. A solid green BATTERY

CHARGER LED indicates float charging which reduces battery gassing, minimizes watering requirements (for flooded batteries) and ensures the batteries are in a constant state of readiness.

A new 3-stage charging cycle is initiated after an AC source is reapplied to the inverter’s AC input terminals such as after a utility outage.

Important: The Float Charge is a very low-current charge, also called a “tricklecharge”. Some batteries may require higher current. Consult the battery manufacturer to determine if the batteries being used can handle a float charge. The inverter will adjust its charge rate to meet the battery requirement.

975-0012-01-02 Rev A 3–17

Operation

Battery Charger LED

Solid Orange = Bulk

Blinking Orange = Absorption

Solid Green = Float

Battery Capacity

Equalize Charging

Figure 3-14 Charger Controls and Indicators

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. If the sulfate is left on the plates, it will harden, and permanently reduce the battery’s capacity.

Stratification separates the heaver acid from the water, and the concentrated acid remains at the lower portion of the plates, eventually corroding them.

Equalize charging holds the battery at the Equalize voltage for a minimum of

6 hours. This stirs up the electrolyte, distributing the acid, and removing the sulfate from the plates. Equalizing the batteries every month or two (depending on usage) prolongs the life of the batteries and provides better battery performance.

CAUTION: Explosion Hazard

Only unsealed or vented batteries should be equalize charged. Since Hydrogen and oxygen gases are produced when equalized, provide adequate ventilation and remove all sources of ignition to prevent explosion. Remove DC loads while equalizing as they can be damaged by the higher battery voltage. Consult the battery manufacturer’s recommendation for equalize charging settings.

To Set the Equalize Charge:

1. Remove all DC loads connected to the batteries.

2. Remove all battery vent caps.

3. Check the battery water level, it should be just over the top of the plates (do not overfill). Use only distilled water for filling batteries.

3–18 975-0012-01-02 Rev A

975-0012-01-02 Rev A

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.

a) Position “0” equalizes the batteries at the rate of the battery bank capacity divided by 40 (C/40) at a voltage of 15 volts for 12-volt systems or

30 volts for 24-volt systems. This is set with the BATTERY CAPACITY potentiometer.

b) Position “1” equalizes the batteries at the rate set with the BATTERY

CHARGER RATE CONTROL at a voltage of 15.5 volts for 12-volt systems or 31 volts for 24-volt systems.

When the voltage condition is met and 6 hours have elapsed, the charger will switch to the float mode. If the condition is not met (i.e., the current draw is above the rate set with the BATTERY CAPACITY potentiometer (position

“0”) or BATTERY CHARGER RATE potentiometer (position “1”)), the charger will continue until the condition is met, or for a maximum of

12 hours. At this point the charger switches to float at the equalize 1 or 2 voltage setting (see Figure 3-1, “Battery Type Selector Switch Settings” on page 3–5).

5. Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system’s batteries when the Equalize charge has completed.

Important: Refer to “Battery Maintenance” on page B–13 for additional information.

Equalize 1

Equalize 2

Figure 3-15 Equalize Positions on Battery Type Selector Switch

3–19

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”.

Figure 3-17 Equalize 2 Battery Capacity Rate Potentiometer (Position “0”)

3–20 975-0012-01-02 Rev A

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

No AC output voltage and no warning LEDs on ON.

AC output voltage is low and the inverter turns loads ON and OFF.

Possible Cause

Battery voltage at the inverter terminals is too high or low.

Low Battery.

Solution

Check the battery voltage, fuses or breakers, and cable connections.

Check the condition of the batteries and recharge if possible.

Replace the batteries.

Check and clean all DC connections.

AC output is low.

Loose or corroded battery connections.

Loose AC output connections.

Charger is inoperative.

Wrong voltmeter is being used.

AC voltage has dropped out-of-tolerance

Loose AC input connections.

Check all AC output connections.

Use a True RMS voltmeter.

Check the AC voltage for proper voltage and frequency (depending on model).

Check all AC output wiring connections

Refer to the section on adjusting the

“Charger Rate”.

Charger is supplying a lower charge rate.

Charger controls are improperly set.

AC LEDs flicker while charging.

Low peak AC input voltage (169 Vac p required for full charger output)

Use larger generator (increasing AC voltage/RPM’s may help).

Loose or corroded battery connections.

Check and clean all DC connections.

Loose AC input connections.

Check all AC output wiring connections.

Generator is unstable - charger is losing synchronization.

Generator is unstable and charger is losing synchronization.

Turn BATTERY CHARGER RATE potentiometer down to less than halfway until problem is gone.

Turn BATTERY CHARGER RATE potentiometer down to less than halfway until problem is gone.

4–2 975-0012-01-02 Rev A

Problem Loads

Table 4-1 Troubleshooting the DR Inverter

Error Condition

CHARGER LED:

Possible Cause Solution

- indicates charging, but no charge is going to the batteries.

- is ON, but there is no output power.

Charger turns OFF while charging from a generator

Circuit Breaker on the side of the inverter is open.

No AC voltage on inverter’s AC terminal block.

Reset the AC CHARGER circuit breaker on the side of the unit.

Check “AC PASS-THRU” Circuit

Breaker on the side of the inverter.

Good AC voltage on inverter’s AC terminal block.

High peak AC input voltages from the generator

Check for open AC output breakers or uses and AC wiring connections.

Load the generator down with a heavy load.

Turn the generator output voltage down.

Problem Loads

The inverter can drive most loads, however, there are special conditions that can cause a load to behave differently than expected. The following describes some of the common problems encountered when using an inverter.

Ceiling Fans

Most large diameter, slow turning fans run correctly, but generate more noise than when connected to utility power. High speed fans tend to operate normally.

Cell Phones

Some cellular telephones experience interference in the form of a clicking sound.

Computers and Sensitive Electronics

Some computers and sophisticated electronics have power supplies that do not present a load until correct line voltage is available. When this occurs, each unit waits for the other to begin. This can usually be solved by plugging in an additional load (such as a lamp) to bring the inverter out of its search mode. Also, when using a computer, avoid starting large loads.

Consumer Electronics

AM radios tend to pick up inverter noise, especially on the lower half of their band. Inexpensive tape recorders are likely to experience noise as well. When using sensitive electronic devices, avoid starting large loads.

975-0012-01-02 Rev A 4–3

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. In order to operate, especially with no other loads present, the inverter’s load sensing circuit will have to be defeated. Refer to the Operation/Search Mode Watts.

Decreasing Loads

If the amount of power a load draws decreases after it has been switched on (such as with a small motor) and its current draw becomes less than the load sensing threshold, it will be turned alternately ON and OFF by the inverter. This can usually be solved by plugging in an additional load (such as a lamp).

Dimmer Switches

Most dimmer switches lose their ability to dim the lights when used with an inverter and operate only in the fully ON or OFF position. Newer, microprocessor controlled dimmers tend to work better in inverter applications.

Fluorescent Lights

Some devices cannot be detected by the inverter’s load sensor and will not operate. Small fluorescent lights are the most common example. This can usually be solved by plugging in an additional load. Also, try turning the lamps AC plug over.

Heavy Loads

If the battery bank cannot deliver the necessary amperage to drive a heavy load, the inverter will shut OFF. The battery voltage will then slowly rise back above the low voltage threshold causing the inverter to resume operation. As soon as the heavy load draws the batteries down, the cycle will continue unless the load is reduced or an additional source of power is added.

Microwave Ovens

Microwave ovens are sensitive to peak output voltages. The higher the voltage, the faster they cook. Since the inverter’s peak output voltage is dependent upon battery voltage and load size, the microwave’s cook time may need to be increased.

4–4 975-0012-01-02 Rev A

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.

Undersized Loads

If the power consumed by a device is less than the inverter’s search mode circuitry threshold, it will not run. This can usually be solved by plugging in an additional load such as a 100 watt light bulb.

CAUTION: Equipment Damage

Some products can be damaged when used with modified sine-wave power. If in doubt, check with the product’s manufacturer.

975-0012-01-02 Rev A 4–5

4–6

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.

Table A-1 Electrical Specifications for the DR Inverter/Charger a

- 120 Vac/60 Hz Models

Model DR1512

AC Input Voltage 120 Vac

AC Input Low

Transfer Voltage

40-105 Vac

45 amps

AC Input Current b

Continuous Power

(@ 25°C)

1500 VA

12.5 amps AC Continuous Output

(@25 °C)

Efficiency

AC Output Voltage

(rms)

Frequency:

(± 0.04% Crystal controlled)

94% max

120 Vac

60 Hz

Surge Capability:

5 sec Rating 2400 watts

1 mSec Rating 38 amps AC

100 mSec Rating 27 amps AC

DC Input Current:

Search Mode 0.045 amps

Full Voltage

DC Current at

Rated Power

0.700 amps

165 amps

Short Circuit

Current

400 amps

DR2412

120 Vac

40-105 Vac

55 amps

2400 VA

20 amps AC

94% max

120 Vac

60 Hz

4200 watts

77 amps AC

55 amps AC

0.055 amps

0.900 amps

280 amps

800 amps

DR1524

120 Vac

40-105 Vac

45 amps

1500 VA

12.5 amps AC

94% max

120 Vac

60 Hz

3500 watts

412 amps AC

29 amps AC

0.030 amps

0.350 amps

80 amps

280 amps

DR2424

120 Vac

40-105 Vac

55 amps

2400 VA

20 amps AC

95% max

120 Vac

60 Hz

6200 watts

80 amps AC

58 amps AC

0.030 amps

0.450 amps

140 amps

560 amps

DR3624

120 Vac

40-105 Vac

55 amps

3600 VA

30 amps AC

95% max

120 Vac

60 Hz

7500 watts

100 amps AC

72 Amps AC

0.030 amps

0.500 amps

210 amps

720 amps

A–2 975-0012-01-02 Rev A

Specifications of the DR Inverter

Table A-1 Electrical Specifications for the DR Inverter/Charger a

- 120 Vac/60 Hz Models

Model DR1512 DR2412 DR1524 DR2424 DR3624

DC Input Voltage

(nominal) c

DC Input Voltage

Range

Auto Low Battery

Protection enabled

12.6 Vdc

11 V

12.6 Vdc

11 V

25.2 Vdc

22 V

DC Charger Rate

(Adjustable)

0 to 70 amps

Common Specifications:

Voltage Regulation

(maximum)

± 5%

±2. 5% Voltage Regulation

(Typical)

Waveform modified sine wave

0 to 120 amps

0.5 to 1.0 (leading or lagging) Load Power Factor

(allowed)

Adjustable Load

Sensing Range

0 to 35 amps

5 watts minimum to 100 watts maximum

Series Operation Yes

Force Air Cooling Variable speed fan

30 amps Automatic Transfer

Relay

Number of

Charging Profiles

10

Yes (float, absorption, bulk) Three-stage

Charging

Temperature Comp

Probe (BTS)

Remote Control

(RC8) d optional optional

25.2 Vdc 25.2 Vdc

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 31.0 Vdc

22 V

0 to 70 amps

22 V

0 to 70 amps 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.

975-0012-01-02 Rev A A–3

Specifications

Table A-2 Electrical Specifications for the DR Inverter/Chargers a

- 220 Vac/60 Hz Models

Model DR1512W DR2412W

AC Input Voltage

AC Input Low Transfer Voltage

220 Vac

80 to 210 Vac

45 amps

AC Input Current b

Continuous Power (@ 25°C)

Continuous Output (@25 °C)

Efficiency

AC Output Voltage (rms)

1500 VA

6.8 amps AC

94% max

220 Vac

Frequency: (± 0.04% Crystal controlled) 60 Hz.

Surge Capability:

1 mSec Rating

DC Input Current:

20 amps AC

Search Mode

Full Voltage

DC Current at Rated Power

Short Circuit Current

0.045 amps

0.700 amps

150 amps

400 amps

12.6 Vdc

DC Input Voltage (nominal) c

DC Input Voltage Range

Auto Low Battery Protection enabled

10.8 to 15.5 Vdc

11 V

0 to 70 amps Charger Rate (Adjustable)

Common Specifications:

Voltage Regulation (maximum)

Voltage Regulation (Typical)

Waveform

Load Power Factor (allowed)

Adjustable Load Sensing Range

Series Operation

Force Air Cooling

Automatic Transfer Relay

Number of Charging Profiles

Three-stage Charging

± 5%

±2. 5% modified sine wave

0.5 to 1.0 (leading or lagging)

10

Yes (float, absorption, bulk)

220 Vac

80 to 210 Vac

55 amps

2400 VA

6.8 amps AC

94% max

220 Vac

60 Hz.

20 amps AC

0.055 amps

0.900 amps

80 amps

800 amps

12.6 Vdc

10.8 to 15.5 Vdc

11 V

0 to 120 amps

5 watts minimum to 100 watts maximum

NO

Variable speed fan

20 amps

A–4 975-0012-01-02 Rev A

Specifications of the DR Inverter

Table A-2 Electrical Specifications for the DR Inverter/Chargers a

- 220 Vac/60 Hz Models

Model

Temperature Comp Probe (BTS)

Remote Control (RC8) d

DR1512W optional 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.

Table A-3 Electrical Specifications for the DR Inverter/Charger a

- 230 Vac/50 Hz Models

Model DR1512E

AC Input Voltage

AC Input Low Transfer

Voltage

230 Vac

80 to 210 Vac

AC Input Current b

Continuous Power

(@ 25°C)

55 amps

1500 VA

Continuous Output

(@25 °C)

Efficiency

12.5 amps AC

AC Output Voltage

(rms)

94% max

230 Vac

Surge Capability:

1 mSec Rating 20 amps AC

DC Input Current:

Search Mode

Full Voltage

DC Current at Rated

Power

Short Circuit Current

DC Input Voltage

(nominal) c

DC Input Voltage

Range

0.045 amps

0.700 amps

165 amps

400 amps

12.6 Vdc

10.9 to 15.5 Vdc

DR1524E

230 Vac

80 to 210 Vac

55 amps

1500 VA

20 amps AC

94% max

230 Vac

20 amps AC

0.055 amps

0.900 amps

280 amps

800 amps

25.2 Vdc

21.8 to 31 Vdc

DR1548E

230 Vac

80 to 210 Vac

55 amps

1500 VA

12.5 amps AC

94% max

230 Vac

20 amps AC

0.030 amps

0.350 amps

80 amps

280 amps

50.4 Vdc

43.6 to 62 Vdc

DR2424E

230 Vac

80 to 210 Vac

55 amps

2400 VA

20 amps AC

95% max

230 Vac

40 amps AC

0.030 amps

0.450 amps

140 amps

560 amps

25.2 Vdc

21.8 to 31 Vdc

975-0012-01-02 Rev A A–5

Specifications

Table A-3 Electrical Specifications for the DR Inverter/Charger a

- 230 Vac/50 Hz Models

Model DR1512E DR1524E

Auto Low Battery

Protection enabled

DC Charger Rate

(Adjustable)

Common Specifications:

11 V

0 to 70 amps

± 5% Voltage Regulation

(maximum)

Voltage Regulation

(Typical)

Waveform

±2. 5% modified sine wave

11 V

0 to 35 amps

0.5 to 1.0 (leading or lagging) Load Power Factor

(allowed)

Adjustable Load

Sensing Range

5 watts minimum to 100 watts maximum

Series Operation

Force Air Cooling

Automatic Transfer

Relay

Number of Charging

Profiles

NO

Variable speed fan

20 amps

10

Three-stage Charging Yes (float, absorption, bulk)

Temperature Comp

Probe (BTS) optional

Remote Control (RC8) d optional

DR1548E

22 V

0 to 17.5 amps

DR2424E

22 V

0 to 70 amps 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.

A–6 975-0012-01-02 Rev A

Specifications of the DR Inverter

Table A-4 Environmental Specifications for the DR Inverter/Charger a

Model DR1512 DR2412 DR1524 DR2424 DR3624

Dimensions b

Unit Weight

“E” Models

8.5" w x 7.25" H x 21" D (21.6 cm W x 18.4 cm H x 54.6 cm D

35 lbs (16 kg)

38 lbs (18 kg)

Ambient Temp Range (rated 0 to 25 °C):

Operating 0 °C to +50 °C

Storage -55 °C to +75 °C

45 lbs (21 kg)

N/A

35 lbs (16 kg)

39 lbs (18 kg)

40 lbs (16 kg) 45 lbs (21 kg)

(45 lbs (21 kg) N/A

Altitude:

Operating

Non-operating

Mounting

15,000 feet

50,000 feet

Wall-mount (with 16" mounting centers)

Shelf Mount a.Specifications subject to change without notice.

b.Allows for hardware extensions such as mounting rails, DC terminals, and front panel controls.

975-0012-01-02 Rev A A–7

A–8

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

Recommendations

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.

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.

• Use only batteries from the same lot and date in your battery bank. This information is usually printed on a label located on the battery.

Battery Types

Deep discharge

Starting

There are two principal types of batteries: starting and deep-discharge (with several different types of chemistries). Batteries can be either sealed or non-sealed

(vented).

The battery types recommended for use in an inverter system are: Flooded Lead

Acid (FLA), Sealed Gel Cells (GEL), Sealed Absorbed Glass Mat (AGM); and alkaline types Nickel-iron (NiFe) and Nickel-Cadmium (NiCad).

Automotive (starting) batteries are designed to provide high starting current for short periods of time and are not appropriate for inverter applications.

Deep-cycle Flooded Lead Acid (FLA)

Description A flooded lead acid battery is designed to be deep-discharged before being recharged, making it suitable for inverter applications. Flooded batteries require periodic maintenance consisting mainly of adding distilled water to the cells.

Attributes

Types of FLA Batteries

Golf Cart

Industrial (electric forklift)

Attributes

• Popular for smaller off-grid home systems

• Many medium sized inverter systems use “L16” batteries

• Rugged, long lasting

• Typically rated at 6 volts

(220 to 350 amp hours)

• Popular in large inverter systems

• Extremely rugged - lasts up to 10 years or more in an inverter system

• Typically 2 volt cells

(1,000 amp hours or more)

B–2 975-0012-01-02 Rev A

Battery Types

Sealed Batteries (Gel and AGM)

Description

Attributes

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.

Attributes of sealed batteries are:

Types of Sealed Batteries

Gel Cell

Absorbed Glass Mat

Attributes

• Gelled electrolyte instead of liquid

• Long life (up to 1500 cycles, typical)

• Low self-discharge

• Electrolyte is contained in glass-fibre mats between battery plates

• Similar to gel cells in characteristics

• Good low temperature performance

NiCad and NiFe Batteries

Disadvantages

Other options

These types of batteries can be used but are not optimized for the DR Inverter for the following reasons:

• Alkaline batteries, such as NiCad and NiFe types, have a nominal cell voltage of 1.2 volts per cell.

Xantrex inverters and battery chargers are optimized for use with lead acid batteries having a nominal 2.0 volts per cell (that is, 12 cells for a 24-volt system and 24 cells for a 48-volt system).

The number of cells required in a battery bank for alkaline batteries must, therefore, be adjusted for a 24- and 48-volt system

(i.e, 20 cells for a 24-volt system and 40 cells for a 48-volt system).

• Alkaline batteries require a higher charge voltage to fully recharge, and drop to a lower voltage during discharge compared to a similarly sized lead-acid type battery.

Another option for 24 volt (only) alkaline battery banks is to use only 19 cells instead of 20. Fewer cells allow the battery charger to operate more closely to the settings used for lead-acid batteries. However, the battery voltage will drop to as low as 18 volts when discharging the batteries.

Consult the battery manufacturer or supplier regarding system requirements and battery charger settings for alkaline type batteries.

975-0012-01-02 Rev A B–3

Battery Information

Understanding Battery Capacity Ratings

Discharge rate

Calculation

CCA rating

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. There is an inevitable amount of heat associated with the flow of current through a battery and the higher amount of current the greater the amount of heat will be generated. The heat is energy which is no longer available to the battery to power loads. a relatively long discharge rate (72 hour rate) will result in a larger number of amp-hours being available for electrical loads.

This calculation shows how to determine the level of current drawn from a battery at any given hour rate—battery capacity divided by the hour rate equals the current drawn from the battery. For example, a battery rated 220 Ah at a 6 hour rate would be discharged at 36 amps (220/6).

For most residential applications of the DR Inverter the 72 hour rate is appropriate because on average a household uses low amounts of current (lights, TV, radio for example) with occasional bursts or higher consumption appliances like toasters or washing machines. For those installations where high continuous electrical consumption rates are anticipated it is more appropriate to use the 20 hour rate.

The CCA rating (cold cranking amps) shown on starting batteries expresses battery capacity in terms of its ability to provide large amounts of current for intervals measured in minutes, not hours. This is why starting batteries are not appropriate for inverter systems.

Battery Bank Sizing

Running time and size

Depth of discharge

Days of autonomy

The battery bank’s size determines the length of time the inverter can supply AC output power. The larger the bank, the longer the inverter can run.

In general, the battery bank should be designed so the batteries do not discharge more than 60% of their capacity on a regular basis. Discharging up to 80% is acceptable on a limited basis, such as a prolonged utility outage. Totally discharging a battery can reduce its effective life or permanently damage it.

For off-grid, stand-alone applications, design a battery bank that can power the loads for three to five days without requiring recharging. This design calculation assumes a worst case scenario where there is no recharging taking place during these days of autonomy.

Days of autonomy may vary depending upon the availability of other charging sources, the critical nature of the load and other factors. If the system is to be powered by renewable energy sources such as solar, wind, and micro-hydro, determine the appropriate number of days of autonomy by allowing for cloudy or calm weather as well as other seasonal variations in available energy.

If an engine generator is part of the system design, the days of autonomy can be determined by simply deciding how often you are prepared to run the generator.

Significant battery cost reductions can be achieved by shortening the days of autonomy and allowing a generator to run for a schedule time period daily.

B–4 975-0012-01-02 Rev A

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

Watts to amps

Time and power

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.

Amp hours are calculated multiplying the current drawn by the load by the length of time it will operate.

To calculate amps when the power consumption is expressed in watts, use the following equation:

A = W/V where W = watts and V = volts DC

For example:

A 100 watt light bulb will draw approximately 8.33 amps

8.33 = 100 /12

If the light runs for three hours it will consume (8.33 x 3) or 25 Ah of power.

The length of time a load is operated will affect the power draw. In some cases, an appliance which draws a large wattage may not consume as many amp hours as a load drawing fewer watts but running for a longer period of time.

For Example:

A circular saw draws 1500 watts or 125 amps. It takes 5 seconds to complete a cross cut. Twelve such cuts would take a minute and you would consume 125

A x 0.016* hour = 2 Ah

*1/60 = 0.016

Observation The circular saw, while it draws more power, consumed fewer amp hours of electricity because it ran for a short period of time.

Calculating Amp Hours

Calculations

Amps to watts

To determine the amp hours you will consume, you need to list your anticipated loads and the length of time you will operate each one. Determine the number of hours per day and the number of days during the week you will use the appliance.

For example, you use the microwave every day, but a breadmaker only once a week. If you use an appliance for less than an hour, express the time as a decimal portion of an hour.

All electrical appliances have labels which state their energy consumption. Look for an amps rating on motors and a watts rating on other appliances.

If the label plate has expressed power consumption in amps, multiply by volts for the watts required. (watts = volts x amps).

975-0012-01-02 Rev A B–5

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.

• Refrigerators and ice-makers typically run only about 1/3 of the time, therefore, the running wattage is 1/3 of the total wattage of the appliance.

Divide the total wattage of the appliance by 3 when determining the battery requirements.

Amp Hour Example Worksheet

Complete the following steps to calculate the amp-hour requirements per day for your system. Use and Table B-2 as examples to complete your own.

To calculate amp-hour requirements:

1. Determine the loads the inverter will power and enter their wattage in the watts column.

2. Determine the number of hours (or decimal portion of hours) the appliance is used each day. Enter this figure in the Hours column.

3. Determine the number of days the appliance will be used during the week.

Enter this figure in the Days column.

4. Multiply Hours x Days for each load identified to determine the watt/hours per week.

5. Add the total watt/hours per week for all loads then divide by 7 to obtain the average total watt/hours per day.

6. Divide the total average per day by the DC nominal voltage.

This figure represents the average amp-hours per day that you will use.

Table B-1 Determining Average Daily Load in Amp-hours (Example

Load

5 lights: 15 W CFL

Breadmaker

Energy-efficient refrigerator

Laptop computer

Watts

75 W

1200

200 x 0.3

50

Hours per Day

5

0.75

24

Days per week used

7

2

6 5

Total weekly watt-hours of AC load

Divided by days per week

Average total watt-hours per day

Divided by DC nominal voltage

Average amp-hours per day (Ah/d)

Weekly watt-hours

2625

1800

10080

1500

16005 Wh

7

2286

24

95

B–6 975-0012-01-02 Rev A

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

Average amp hours per day

Divided by inverter efficiency (90%) for DR Inverter

Divided by battery efficiency (usually 0.75)

Adjusted hours per day

Divided by Depth of Discharge (usually 60%)

Multiplied by days of autonomy

Battery bank size required

95

0.9

0.75

140

0.6

5

1173 Ah

Worksheets Table B-1 and Table B-2 are examples only. Use the specifications noted on the label of each AC appliance and fill in the values specific for the appliances used in this installation on the a work sheet.

Table B-3 provides a typical wattage for selected appliances. However, you should try to find the exact wattage on the appliance label.

Table B-3 Typical Appliance Wattage

Appliance Watts

Fluorescent Type Light 10

Computer

Microwave (compact)

200-300

600-800

Microwave (full-size)

Stereo or VCR

1500

50

Color Television (19") 150

Refrigerator (3 cu ft) 180

Refrigerator (12 cu ft) 480

Appliance

Blender

Toaster

Hot Plate

Washer/Dryer

3/8" Drill

Hair Dryer or Iron

Vacuum Cleaner

Coffee Maker

Watts

400

1000

1800

375-1000

500

1000

1200

1200

975-0012-01-02 Rev A B–7

Battery Information

Battery Configurations

Series

Parallel

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:

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.

Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads. The more batteries connected in parallel the longer the loads can be powered from the inverter.

inverter’s DC requirements) and run-time for operating the AC loads. This voltage must match the DC requirements of the inverter.

Batteries with more than two or three series strings in parallel often exhibit poor performance characteristics and shortened life.

Wiring Batteries in Series

Effect

Important

Wiring the batteries in a series configuration increases the voltage of the battery string. Six-volt batteries can be combined to form 12-volt, 24-volt, or 48-volt battery banks. In the same way, 12-volt batteries connected in series form 24-volt battery banks. The total current capacity of the bank does not increase and remains the same amp-hour rating as it does for a single battery.

The voltage must match the DC requirements of the inverter.

Each battery's amp-hour rating is 100 Ah.

DC Disconnect

(either a circuit breaker or a fuse with a disconnect)

+

6 V

+

6 V

SHUNT

-

+ -

12 V INVERTER

(Total battery capacity = 100 Ah)

Each battery’s amp-hour rating is 100 Ah.

+

6 V

-

DC Disconnect

(either a circuit breaker or a fuse with a disconnect)

+ +

6 V

-

6 V

+ -

24 V INVERTER

(Total battery capacity = 100 Ah)

SHUNT

+

6 V

-

Figure B-1 6-volt Battery Wiring - “Series” Configuration

B–8 975-0012-01-02 Rev A

Battery Configurations

+

12 V

+

12 V

Each battery's amp-hour rating is 100 Ah.

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 example

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.

“Parallel” configurations extend the run times of the AC loads by providing increased current for the inverter to draw from. In a parallel configuration, all the negative battery terminals are connected together and all the positive battery terminals are connected together.

Figure B-3 is an example of how to wire batteries in a parallel configuration.

975-0012-01-02 Rev A

+

12 V

+

12 V

-

Each battery's amp-hour rating is 100 Ah.

SHUNT

DC Disconnect

(either a circuit breaker or a fuse with a disconnect)

+ -

12 V INVERTER

(Total battery capacity = 200 Ah)

Figure B-3 Battery Wiring in Parallel

B–9

Battery Information

Wiring Batteries in Series-Parallel

Effect

Steps

Series wiring

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.

It is done in three steps; wiring the batteries in series, wiring them in parallel, then wiring the string to the inverter.

To wire in series:

1. First wire the batteries in “series” (voltage adds) with the positive terminal of one battery connected to the negative terminal of the next battery to meet the inverter’s DC input requirements (24 volts shown in Figure B-4 and Figure

B-5.)

2. Repeat this step for the next battery string.

Two identical strings of batteries are now wired in series.

Parallel wiring

+ – + – + – + –

Series String 1

6 V 6 V 6 V 6 V

Each battery's amp-hour rating is 100 Ah.

+ – + – + – + –

Series String 2

6 V 6 V 6 V 6 V

Figure B-4 Battery Wiring 24-volt - Parallel Configuration - Step 1

To wire the batteries in parallel:

1. Connect the positive terminal of the first battery string to the positive terminal of the second battery string.

2. Connect the negative terminal of the first battery string to the negative terminal of the second battery string.

B–10

Each battery's amp-hour rating is 100 Ah.

+

6 V

Parallel

Connection

–

+

6 V

–

+

6 V

–

+

6 V

–

+

6 V

–

+

6 V

–

+

6 V

–

Series String 1

Parallel

Connection

+

6 V

–

Series String 2

Figure B-5 Battery Wiring 24-volt - Parallel Configuration - Step 2

975-0012-01-02 Rev A

Connect to inverter

Battery Configurations

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

+

+

6 V

6 V

–

–

DC Disconnect (can be either a circuit breaker or a fuse with a disconnect)

+ – +

6 V 6 V

Each battery's amp-hour rating is 100 Ah.

–

+

6 V

– +

6 V

–

+ –

24 V INVERTER

(Total battery capacity = 200 Ah)

SHUNT

+

6 V

–

+

6 V

–

Series String 1

Series String 2

Connection from Series String 2 to inverter's negative (–) terminal

Figure B-6 Battery Wiring 24-volt - Parallel Configuration - Step 3

Important: Connecting the positive and negative wires to the inverter from different strings ensures a balanced charge/discharge through the batteries, resulting in longer run times and improved battery life.

975-0012-01-02 Rev A B–11

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.

DC Disconnect

(either a circuit breaker or a fuse with a disconnect)

DC CONDUIT

FOR

INVERTER 1

(Primary)

DC Disconnect

(either a circuit breaker or a fuse with a disconnect)

DC CONDUIT

FOR

INVERTER 2

(Secondary)

Batteries in

Parallel

24 VDC 400 Ah

Shunt

–

12 Volt

Battery

200 Ah

+

–

12 Volt

Battery

200 Ah

+

–

12 Volt

Battery

200 Ah

+

–

12 Volt

Battery

200 Ah

+

Series String 1

24 VDC/200 Ah

Series String 2

24 VDC/200 Ah

Figure B-7 Example of Battery Connections for Stacked Inverters (24 Vdc shown)

B–12 975-0012-01-02 Rev A

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 Charging

Charge Rate

Bulk Voltage

Float Voltage

Temperature

Compensation

The maximum safe charge rate is related to the size and type of the batteries.

Flooded lead acid batteries (with removable caps) can be charged at a high rate.

Small batteries may require a lower charge rate. Check with your battery vendor for the proper battery charging rate for the batteries used in the system.

This is the maximum voltage the batteries will be charged to during a normal charge cycle. Gel cell batteries are set to a lower value and non-sealed batteries are set to a higher voltage setting.

The Float voltage is set lower than the Bulk voltage and provides a maintenance charge on the batteries to keep them in a ready state.

For optimal battery charging, the Bulk and Float charge rates should be adjusted according to the temperature of the battery. This can be accomplished automatically by using a BTS. The sensor attaches directly to the side of one of the batteries in the bank and provides precise battery temperature information.

When battery charging voltages are compensated based on temperature, the charge voltage will vary depending on the temperature around the batteries. The following table describes approximately how much the voltage may vary depending on the temperature of the batteries.

If you have liquid lead acid batteries (non-sealed), you may need to periodically equalize your batteries. Check the water level monthly to maintain it at the appropriate level.

975-0012-01-02 Rev A B–13

Battery Information

Table B-4 Variances in Charging Voltage based on Battery Temperature

Temperature

(around the BTS)

Celsius Fahrenheit

5

0

-5

-10

25

20

15

10

45

40

35

30

60

55

50

-15

-20

-25

-30

-35

-40

41

32

23

14

77

68

59

50

140

131

122

113

104

95

86

5

-4

-13

-22

-31

-40

12-volt units

Lead Acid

(6 cells)

0.00

0.15

0.30

0.45

0.90

0.75

0.90

1.05

-1.05

-0.90

-0.75

-0.60

-0.45

-0.30

-0.15

1.20

1.35

1.50

1.65

1.80

1.95

NiCad

(10 cells)

0.00

0.10

0.20

0.30

0.60

0.50

0.60

1.20

-0.70

-0.60

-0.50

-0.40

-0.30

-0.20

-0.10

0.80

1.40

1.00

1.10

1.20

1.30

24-volt units

Lead Acid

(12 cells)

0.00

0.30

0.60

0.90

1.20

1.50

1.80

2.10

-2.10

-1.80

-1.50

-1.20

-0.90

-0.60

-0.30

2.40

2.70

3.00

3.30

3.60

3.90

NiCad

(20 cells)

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

-1.40

-1.20

-1.00

-0.80

-0.60

-0.40

-0.20

1.60

1.80

2.00

2.20

2.40

2.60

48-volt units

Lead Acid

(24 cells)

0.00

0.60

1.20

1.80

2.40

3.00

3.60

4.20

-4.20

-3.60

-3.00

-2.40

-1.80

-1.20

-0.60

4.80

5.40

6.00

6.60

7.20

7.80

NiCad

(40 cells)

0.00

0.40

0.80

1.20

1.60

2.00

2.40

2.80

-2.80

-2.40

-2.00

-1.60

-1.20

-0.80

-0.40

3.20

3.60

4.00

4.40

4.80

5.20

Temperature compensation is based on battery type — 5 mv/cell for lead acid type batteries and 2 mv/cell for alkaline type batteries (NiCad or NiFe). The temperature compensation calculations are derived from Table B-5.

Table B-5 Temperature Compensation Calculation

Battery Type

Lead Acid

NiCad

24-volt Systems

0.060 volts (60 mV) per degree Celsius

0.040 volts (40 mV) per degree Celsius

48-volt Systems

0.120 Volts (120 mV) per degree

Celsius

0.080 volts (80 mV) per degree

Celsius

Important: If the battery temperature is allowed to fall to extremely cold temperatures, the inverter with a BTS may not be able to properly recharge cold batteries due to maximum voltage limits of the inverter. Ensure the batteries are protected from extreme temperatures.

B–14 975-0012-01-02 Rev A

Battery Maintenance

Equalization Charging

Purpose

Effect

Non-equalized batteries

Frequency

An equalize charge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells.

Equalize charging also produces gassing which stirs up the electrolyte mixture and helps distribute the acid more evenly.

Batteries that are not equalize charged can be damaged by sulfate accumulation, thus sealing off a percentage of the plates and reducing battery capacity. They may also have sulfuric acid accumulate at the bottom of the battery, potentially damaging the plates. At the same time, the electrolyte at the top of the battery gets watery. This effect is called stratification.

Every month or two the batteries should be equalize charged.

CAUTION: Damage to DC Loads

The high voltages reached during an equalize charge may damage DC loads that are connected to the inverter. Disconnect any DC loads from the inverter before running an equalize charge.

CAUTION: Damage to Batteries

Equalization should be done for standard electrolyte vented batteries only. Sealed or GEL cell batteries should not be equalize charged. Consult your battery supplier for details on equalize charging for the battery type in your system.

975-0012-01-02 Rev A B–15

Battery Information

General Maintenance

Water Levels

Battery Cables and

Posts

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. Never fill the cells to the top or acid will leak out during charging.

Check the water level in the batteries frequently when performing an equalize charge and add water if necessary. Always follow the safety steps covered in the front of the manual.

Battery posts must be clean to reduce the resistance between the battery post and cable connection. A buildup of dirt or oxidation may eventually lead to the cable terminal overheating during periods of high current draw.

Use a stiff wire brush and remove all dirt and corrosion from the battery terminals and cables. Use an alkaline solution of baking soda and water to clean the terminals and neutralize any battery acid on the terminals or cable lugs.

Torque Battery

Connections

WARNING: Shock Hazard

Before attempting to clean the battery posts, turn off the DC circuit breaker. Use only insulated tools and remove all jewellery.

CAUTION: Damage to Batteries

Never let a baking soda solution get into the battery as it will neutralize the acid resulting in permanent damage.

After the terminals are clean, reassemble the cable to the battery terminal and torque the connections to the battery manufacturer’s recommendations.

Coat the battery terminals with an antioxidant compound.

B–16 975-0012-01-02 Rev A

State of Charge

Battery Maintenance

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.

To determine the individual cell voltage, divide the voltage by the number of cells in the battery (25.2 volts divided by 12 cells = 2.1 volts per cell). If a greater difference is measured, the batteries may need to be equalized (liquid lead-acid types only) or replaced.

All batteries in the bank should measure the same voltage (this is not an accurate measurement for cross-tied batteries’ as each battery is in parallel with another battery making individual battery measurements impossible).

The voltage should match the following table for the entire battery bank output.

These values indicate the overall battery’s state of charge for the entire bank.

Individual cell voltages (if available) are also shown as a percentage of charge.

The values given are for a temperature of 77 °F (25 °C). Cooler temperatures produce lower voltage measurements.

Table B-6 Battery State-of-Charge

System Voltage

Percent of Full

Charge

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

12 Volt

12.7

12.6

12.5

12.3

12.2

12.1

12.0

11.8

11.7

11.6

< 11.6

24 Volt

25.4

25.2

25.0

24.6

24.4

24.2

24.0

23.6

23.4

23.2

< 23.2

48 Volt

50.8

50.4

50.0

49.2

48.8

48.4

48.0

47.2

46.8

46.4

< 46.4

Individual

Cell

Voltage

2.12

2.10

2.08

2.05

2.03

2.02

2.00

1.97

1.95

1.93

< 1.93

Important: Table B-6 only applies for batteries that have been at rest for a minimum of

3 hours (i.e., no inverting, no charging).

975-0012-01-02 Rev A B–17

B–18

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. This section describes how to check for multi-wire branch circuits in the load center and presents some possible solutions to this wiring method.

Multi-wire Branch Circuit Wiring

Multi-wire Branch Circuits

Problem

Legacy situation

Normal condition

Safety issue

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.

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. This method has been employed by electricians in recent years to keep construction costs down by saving copper and labor costs involved in running a separate Romex™ for each circuit.

Under normal conditions, this technique is quite safe and meets code requirements. When used as originally installed, the current for each circuit is

180° out-of-phase with each other, so the neutral wire never receives more current than it was designed to handle as the current from each circuit subtracts (or cancels out, leaving only the difference current between the two circuits). Refer to

Figure C-2.

A safety problem occurs when a stand-alone 120 Vac inverter is installed to power these circuits, causing the one neutral wire to now carry the in-phase currents for both circuits. Since the current is in-phase, the two circuits add instead of subtract, potentially doubling the current flow in the neutral return wire! Refer to Figure

C-3. The branch circuit breakers do not protect the neutral wire from overload under this condition. This excess current will overheat the neutral wire, potentially creating a fire hazard.

240 Vac from Grid

L1

L2

Neutral

Ground

Load Center

15 A

Breaker

15 A

Breaker

Black - Hot

(Current Flow 15A)

Black - Hot

(Current Flow 15A)

120 Vac

White - Neutral

(Current Flow 15 A)

White - Neutral

(Current Flow 15 A)

Bare - Ground

120 Vac

Bare - Ground

Figure C-1 Conventional Home-type Wiring

C–2 975-0012-01-02 Rev A

Multi-wire Branch Circuits

Load Center Load Center

240 Vac from Grid

L1

L2

Neutral

Ground

15 A

Breaker

(Ganged)

15 A

Breaker

(Ganged)

240 Vac from Grid

L1

L2

Neutral

Ground

15 A

Breaker

(Ganged)

15 A

Breaker

(Ganged)

Red - Hot

Black - Hot

(Current Flow 15 A)

(Current Flow 15 A)

Single White - Neutral

(Current Flow 0 A)

120 Vac 120 Vac

Black - Hot

(Current Flow 5 A)

Red - Hot

(Current Flow 15 A)

Single White - Neutral

(Current Flow 10 A)

120 Vac 120 Vac

Bare - Ground

Out-of-Phase current subtract at this point

(Current Flow 0 A)

Bare - Ground Splice

White - Neutral Splice

(Current Flow 15 A)

When unbalanced current flows through each leg, only the difference current flows through the neutral return wire.

Figure C-2 Multi-wire Branch Circuit Wiring and Current Flow

Bare - Ground

White - Neutral Splice

(Current Flow 15 A)

120 Vac

Inverter or Generator

L1

L2

Neutral

Ground

Load Center

15 A

Breaker

(Ganged)

15 A

Breaker

(Ganged)

Black - Hot

(Current Flow 15 A)

Red - Hot

(Current Flow 15 A

Single White - Neutral

(Current Flow 30 A)

120 Vac 120 Vac

Bare - Ground

WARNING: FIRE HAZARD

The in-phase currents ADDS at this point exceeding wire capacity!

White - Neutral Splice

(Current Flow 15 A)

Figure C-3 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit

975-0012-01-02 Rev A C–3

Multi-wire Branch Circuit Wiring

Identifying Multi-wire Branch Circuits

Identifying characteristic

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.

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.

Multi-wire branch circuits use a 3-wire-plus-ground arrangement (black, red, white and copper) for each circuit run.

If this arrangement exists in the panel and it is being powered by a stand-alone

120 Vac inverter, a potential fire hazard exists! For safety, these circuits must be rewired to meet code.

Red From L2

Breaker

Red From L1

Breaker

To Branch Circuits

Single Neutral

White

Ground Bare

Copper

Figure C-4 Multi-wire Branch Circuit Wiring

C–4 975-0012-01-02 Rev A

Correcting Multi-wire Branch Circuit Wiring

Correcting Multi-wire Branch Circuit Wiring

Acceptable options

Recommended option

Correcting multi-wire branch circuit wiring is not easy. Two options which will correct multi wiring branch circuit wiring are:

• 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. There may be multiple multi-wire branch circuits located throughout the structure, requiring complete rewiring.

• Add a second inverter in a “series stacked” arrangement. This is an expensive solution, but would restore the original 240 Vac split-phase configuration.

This solution may actually be less expensive than having an electrician re-wire the multi-wire branch circuits. It also provides increased power backup protection and can power 240 Vac loads.

Add a step-down autotransformer to the output of the inverter to restore the split-phase configuration. This is the least expensive and easiest method to correct for multi-wire branch circuit wiring. Refer to Figure C-5. Using this method, half of the current is supplied to one leg of the circuit and half to the other in a split-phase arrangement (180° out-of-phase). This will restore the original functionality and safety to the multi-wire branch circuit.

WARNING: Fire Hazard

Until one of the solutions above is implemented, a stand-alone 120 Vac inverter

(or generator) must not be installed where multi-wire branch circuits exist.

975-0012-01-02 Rev A C–5

Multi-wire Branch Circuit Wiring

120 Vac

Inverter or Generator

T240

AutoTransformer

Load Center

HOT - L1

HOT - L2

White - Neutral

L1

L2

Neutral

Ground

15 A

Breaker

(Ganged)

15 A

Breaker

(Ganged)

Black - Hot

(Current Flow 15 A)

Red - Hot

(Current Flow 15 A

Single White - Neutral

(Current Flow 0 A)

120 Vac 120 Vac

Bare - Ground

White - Neutral Splice

(Current Flow 15 A)

The out-of-phase current SUBTRACTS at this point.

Figure C-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring

C–6 975-0012-01-02 Rev A

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.

This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty

Period. Subsequent owners also require proof of purchase.

What will Xantrex do?

Xantrex will, at its option, repair or replace the defective product free of charge, provided that you notify Xantrex of the product defect within the Warranty Period, and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty.

Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building replacement products. Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement. If Xantrex repairs or replaces a product, its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer, whichever is greater. All replaced products and all parts removed from repaired products become the property of Xantrex.

Xantrex covers both parts and labor necessary to repair the product, and return shipment to the customer via a

Xantrex-selected non-expedited surface freight within the contiguous United States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada.

How do you get service?

If your product requires troubleshooting or warranty service, contact your merchant. If you are unable to contact your merchant, or the merchant is unable to provide service, contact Xantrex directly at:

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct)

Email: [email protected]

Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call

Xantrex or check our website to see if your product can be repaired at one of these facilities.

What proof of purchase is required?

In any warranty claim, dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex.

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

975-0012-01-02 Rev A WA–1

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. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to: a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either internally or externally, or damaged from improper use or use in an unsuitable environment; b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations, or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes; c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter

"ASCs"); d) the product if it is used as a component part of a product expressly warranted by another manufacturer; e) the product if its original identification (trade-mark, serial number) markings have been defaced, altered, or removed.

Disclaimer

Product

THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR

XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS,

GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN

CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF

MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT

RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT

REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD

STIPULATED UNDER THIS LIMITED WARRANTY.

IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL

DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT

RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY

DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION,

INTEGRATION OR OPERATION OF THE PRODUCT.

Exclusions

If this product is a consumer product, federal law does not allow an exclusion of implied warranties. To the extent you are entitled to implied warranties under federal law, to the extent permitted by applicable law they are limited to the duration of this Limited Warranty. Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you. This Limited Warranty gives you specific legal rights. You may have other rights which may vary from state to state or province to province.

Warning: Limitations On Use

Please refer to your product manual for limitations on uses of the product.

SPECIFICALLY, PLEASE NOTE THAT THE DR I NVERTER /C HARGER SHOULD NOT BE USED IN CONNECTION WITH LIFE

SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING THE GENERALITY OF THE

FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX DR

I NVERTER /C HARGER IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES.

Please note that the DR Inverter/Charger is not intended for use as an uninterruptible power supply and Xantrex makes no warranty or representation in connection with any use of the product for such purposes.

WA–2 975-0012-01-02 Rev A

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.

When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be prepared to supply:

• The serial number of your product

• Information about the installation and use of the unit

• Information about the failure and/or reason for the return

• A copy of your dated proof of purchase

Record these details in on page WA–4.

Return Procedure

1. Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging.

2. Include the following:

• The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the box.

• A return address where the unit can be shipped. Post office boxes are not acceptable.

• A contact telephone number where you can be reached during work hours.

• A brief description of the problem.

3. Ship the unit prepaid to the address provided by your Xantrex customer service representative.

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. However, you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility.

Out of Warranty Service

If the warranty period for your DR Inverter/Charger has expired, if the unit was damaged by misuse or incorrect installation, if other conditions of the warranty have not been met, or if no dated proof of purchase is available, your inverter may be serviced or replaced for a flat fee.

To return your DR Inverter/Charger for out of warranty service, contact Xantrex Customer Service for a Return

Material Authorization (RMA) number and follow the other steps outlined in “Return Procedure” on page WA–3.

Payment options such as credit card or money order will be explained by the Customer Service Representative. In cases where the minimum flat fee does not apply, as with incomplete units or units with excessive damage, an additional fee will be charged. If applicable, you will be contacted by Customer Service once your unit has been received.

975-0012-01-02 Rev A WA–3

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.

❐ Type of installation (e.g. On-Grid, Off-grid)

❐ Length of time inverter has been installed

❐ Battery/battery bank size

__________________________________

__________________________________

__________________________________

❐ Battery type (e.g. flooded, sealed gel cell, AGM) __________________________________

❐ DC wiring size and length __________________________________

❐ Alarm sounding?

❐

❐

Description of indicators on front panel

❐ Appliances operating when problem occurred

Description of problem

__________________________________

__________________________________

__________________________________

__________________________________

______________________________________________________________________________________

______________________________________________________________________________________

WA–4 975-0012-01-02 Rev A

Index

A

AM radios 4–3

AWG 2–4

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 precautions when working with

Battery B–13

vii

vii

C

computers 4–3 computers - use with inverter 4–3

Customer Service preparing to call WA–4

F

first aid vii

Fluorescent lights 4–4

I

Information about Your System form WA–4 inverter purchase date WA–4 serial number WA–4

P

peak output voltage 4–4

Problem Loads 4–3 proof of purchase WA–4 purchase date WA–4

R

Reverse Polarity 2–18

S

safety instructions serial number

vii

WA–4

W

warranty out of warranty service WA–3 terms and conditions WA–1

X

Xantrex web site iv

IX-2

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 [email protected]

www.xantrex.com

975-0012-01-02 Rev A PC Printed in the DR