Freedom HF Inverter/Chargers Installation Guide Model Product Numbers 806-1020

Freedom HF Inverter/Chargers Installation Guide Model Product Numbers 806-1020
Freedom HF Install Guide.book Page 1 Tuesday, April 29, 2014 12:22 PM
TM
TM
Product image shown may vary from actual product. See features for comparisons.
Freedom HF Inverter/Chargers
Installation Guide
Model Product Numbers
806-1020
806-1054, 806-1054-01
806-1055, 806-1055-02
806-1544
806-1840, 806-1840-01,
806-1840-02
Freedom HF Install Guide.book Page 2 Tuesday, April 29, 2014 12:22 PM
Freedom HF Install Guide.book Page i Tuesday, April 29, 2014 12:22 PM
Copyright © 2014 Schneider Electric. All Rights Reserved. All trademarks are
owned by Schneider Electric Industries SAS or its affiliated companies.
Exclusion for Documentation
Contact Information
UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
Telephone:
+1 800 670 0707
+1 408 987 6030
Web:
www.xantrex.com
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, 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; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH,
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT IS CONTAINED WITH THE ENGLISH
LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Information About Your System
As soon as you open your product, record the following information and be sure to
keep your proof of purchase.
Serial Number
_________________________________
975-0395-01-01
Product Number
_________________________________
Date and Revision
Purchased From
_________________________________
Purchase Date
_________________________________
Document Part Number
April 2014 Rev D
Product Numbers
1000-watt Models:
806-1020 (Freedom HF 1000)
806-1055, 806-1054, 806-1054-01 (Freedom HF 1055)
806-1055-02 (Freedom HF 1055 EMS)
To view, download, or print the latest revision, visit the website shown under Contact
Information.
1500-watt Model:
806-1544 (Freedom HF 1500)
1800-watt Models:
806-1840 (Freedom HF 1800)
806-1840-01 (Freedom HF 1800 T)
806-1840-02 (Freedom HF 1800 EMS)
975-0395-01-01
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Freedom HF Install Guide.book Page ii Tuesday, April 29, 2014 12:22 PM
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for installing and configuring a Freedom HF Inverter/Charger
for Recreational, Fleet Vehicle, or Marine installations.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
Scope
The Guide provides safety guidelines, as well as information about
operating and troubleshooting the installation. It does not provide details
about particular brands of batteries. You need to consult individual battery
manufacturers for this information.
Audience
The information in this Guide is intended for qualified personnel. Qualified
personnel have training, knowledge, and experience in:
•
Installing electrical equipment and PV power systems (up to 1000
volts).
•
Applying all applicable installation codes.
•
Analyzing and reducing the hazards involved in performing electrical
work.
•
Selecting and using Personal Protective Equipment (PPE).
Conventions Used
The following conventions are used in this guide.
ii
WARNING indicates a potentially hazardous situation, which, if not
avoided, can result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided, can result in moderate or minor injury.
NOTICE indicates a potentially hazardous situation, which, if not
avoided, can result in equipment damage.
IMPORTANT: These notes describe things which are important for you
to know, however, they are not as serious as a caution or warning.
Related Information
You can find more information about Xantrex products and services at
www.xantrex.com.
Freedom HF Installation Guide
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Important Safety Instructions
IMPORTANT: READ AND SAVE THIS INSTALLATION
GUIDE FOR FUTURE REFERENCE.
ELECTRICAL SHOCK HAZARD
•
This chapter contains important safety instructions for the Freedom HF
Inverter/Charger (Freedom HF). Each time, before using the Freedom HF,
READ ALL instructions and cautionary markings on or provided with the
inverter/charger, the batteries, and all appropriate sections of this guide.
NOTE: The Freedom HF contains no user-serviceable parts.
•
•
•
•
Do not expose the Freedom HF to rain, snow, spray, or bilge water.
This inverter/charger is designed for marine applications only when
additional drip protection is installed in certain orientations. See the
installation guide for information.
Do not operate the inverter/charger if it has received a sharp blow,
been dropped, has cracks or openings in the enclosure including if the
fuse cover has been lost, damaged, or will not close, or otherwise
damaged in any other way.
Do not disassemble the inverter/charger. Internal capacitors remain
charged after all power is disconnected.
Disconnect both AC and DC power from the inverter/charger before
attempting any maintenance or cleaning or working on any circuits
connected to the inverter/charger. See note below.
Do not operate the inverter/charger with damaged or substandard
wiring. Make sure that all wiring is in good condition and is not
undersized.
Failure to follow these instructions will result in death or serious
injury.
NOTE: Turning off the inverter/charger using the on/off switch on the front
panel will not reduce an electrical shock hazard.
975-0395-01-01
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FIRE AND BURN HAZARD
•
•
Do not cover or obstruct the air intake vent openings and/or install in
a zero-clearance compartment.
Do not use transformerless battery chargers in conjunction with the
inverter/charger due to overheating.
Failure to follow these instructions will result in death or serious
injury.
NOTES:
1. Follow these instructions and those published by the battery
manufacturer and the manufacturer of any equipment you intend to use
in the vicinity of the battery. Review cautionary markings on these
products and on the engine.
2. This inverter/charger contains components which tend to produce arcs
or sparks.
3. Locations include any space containing gasoline-powered machinery,
fuel tanks, as well as joints, fittings, or other connections between
components of the fuel system.
EXPLOSION HAZARD
•
•
•
Charge only properly rated (such as 12 volts) lead-acid (GEL, AGM,
Flooded, or lead-calcium) rechargeable batteries because other
battery types may explode.
Do not work in the vicinity of lead-acid batteries. Batteries generate
explosive gases during normal operation. See note #1.
Do not install and/or operate in compartments containing flammable
materials or in locations that require ignition-protected equipment.
See notes #2 and #3.
Failure to follow these instructions will result in death or serious
injury.
iv
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Precautions When Working With Batteries
5.
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE
AND EXPLOSION FROM VENTED GASES HAZARDS
•
•
•
•
Always wear proper, non-absorbent gloves, complete eye protection,
and clothing protection. Avoid touching your eyes and wiping your
forehead while working near batteries. See note #4.
Remove all personal metal items, like rings, bracelets, and watches
when working with batteries. See notes #5 and #6 below.
Never smoke or allow a spark or flame near the engine or batteries.
Never charge a frozen battery.
6.
7.
Use extra 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.
Batteries can produce a short circuit current high enough to weld a ring
or metal bracelet or the like to the battery terminal, causing a severe
burn.
When removing a battery, always remove the negative terminal from
the battery first for systems with grounded negative. If it is grounded
positive, remove the positive terminal first. Make sure all loads
connected to the battery and all accessories are off so you don’t cause
an arc.
Failure to follow these instructions can result in death or serious
injury.
NOTES:
1. Mount and place the Freedom HF Inverter/Charger unit away from
batteries in a well ventilated compartment.
2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
4. 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.
975-0395-01-01
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Precautions When Preparing to Charge
Precautions When Placing the Inverter/Charger
EXPOSURE TO CHEMICALS AND GASES HAZARD
FIRE HAZARD
•
•
Do not install the inverter/charger or any part of its supplied wiring in
engine compartments.
•
Make sure the area around the battery is well ventilated.
Make sure the voltage of the batteries matches the output voltage of
the inverter/charger.
Be careful to keep corrosion from coming into contact with your eyes
and skin when cleaning battery terminals.
Failure to follow these instructions can result in death or serious
injury.
Failure to follow these instructions can result in death or serious
injury.
NOTES:
•
Study and follow all of the battery manufacturer's specific precautions,
such as removing or not removing cell caps while charging, whether
equalization is acceptable for your battery, and recommended rates of
charge.
•
For flooded non-sealed batteries, add distilled water in each cell until
battery acid reaches the level specified by the battery manufacturer.
This helps to purge excessive gas from cells. Do not overfill. For a
battery without removable cell caps, carefully follow manufacturer's
instructions.
vi
RISK OF DAMAGE TO THE INVERTER/CHARGER
•
•
•
Never allow battery acid to drip on the inverter/charger when reading
gravity, or filling battery.
Never place the Freedom HF Inverter/Charger unit directly above
batteries; gases from a battery will corrode and damage the inverter/
charger.
Do not place a battery on top of the inverter/charger.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
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Precautions for Using Rechargeable Appliances
RISK OF DAMAGE TO RECHARGEABLE APPLIANCES
Avoid using the following with the Freedom HF:
• Small battery-operated appliances like flashlights, razors, and night
lights that can be plugged directly into an AC receptacle to recharge.
• Some chargers for battery packs used in power hand tools. These
affected chargers display a warning label stating that dangerous
voltages are present at the battery terminals.
Regulatory
The Freedom HF Inverter/Charger is certified to appropriate US and
Canadian standards. For more information see .
The Freedom HF Inverter/Charger is intended to be used for mobile or
commercial applications. This inverter/charger is designed for marine
applications only when additional drip protection is installed in certain
orientations. See the installation guide for information.
It is not intended for other applications as it may not comply with the
additional safety code requirements needed for those other applications. See
“Limitations On Use” below.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
Most rechargeable battery-operated equipment uses a separate charger or
transformer that is plugged into an AC receptacle and produces a low
voltage charging output.
Some chargers for small rechargeable batteries can be damaged if
connected to the Freedom HF.
If you are unsure about using your rechargeable appliance with the Freedom
HF, contact the equipment manufacturer to find out if the appliance is
acceptable for use with an inverter that has a modified sine wave output
voltage.
975-0395-01-01
LIMITATIONS ON USE
Do not use in connection with life support systems.
Failure to follow these instructions can result in death or serious
injury.
NOTE: The Freedom HF Inverter/Charger is a modified sine wave inverter/
charger. Please ensure your equipment or devices are compatible with
modified sine wave prior to usage.
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FCC Information to the User
KKK Information to the User
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to
radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
•
Reorient or relocate the receiving antenna.
•
Increase the separation between the equipment and receiver.
•
Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
•
Consult the dealer or an experienced radio/TV technician for help.
The Freedom HF 1055 EMS and 1800 EMS models are marked “KKK-A1822D Ready”. These models are marketed for use in ambulances and
emergency vehicle applications. For information of compliance of the
ambulance as a whole, please refer to specifications as laid out in Federal
Specification for the Star-of-Life Ambulance also known as KKK-A-1822.
Unauthorized changes or modifications to the equipment could void the
user’s authority to operate the equipment.
viii
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Contents
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Materials List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
High Level Overview of Installation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Basic Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drip Shield Installation (For Marine Installations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Marine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Freedom HF Install Guide.book Page 1 Tuesday, April 29, 2014 12:22 PM
The Freedom HF (PNs: 806-1840, 806-1020) base package includes
the minimum following items:
• one Freedom HF unit
• one set of owner’s and installation guides and a mounting
template
• one display panel with 7-inch (0.17 m) cable
• one communications cable (25 feet) (7.5 m)
• two DC terminal covers
• one strain-relief clamp
• one GFCI cover plate with knockout
• one display panel blanking plate (not shown)
• one display panel mounting bezel (not shown)
• one set of lock washers and nuts (not shown)
Freedom HF unit
PN 806-1840 shown
Ow
Other Freedom HF OEM models may include other DC and/or AC
connectors.
sG
ner’
uid
ati
tall
Ins
Product image shown
may vary from actual
product. See Features
for comparisons.
GFCI cover plate
mo
e
id
Gu
on
e
un
tin
g te
mp
late
Owner’s and Installation
Guides and mounting
template
strain-relief clamp
NOTE: If any of the items are missing, contact Xantrex or any
authorized Xantrex dealer for replacement. See “Contact
Information” on page i.
Display panel is attached on
some models.
communications cable
DC terminal covers
This guide for use by qualified personnel only.
Materials List
Figure 1 What’s In The Box
975-0395-01-01
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Safety Instructions
Before You Begin the Installation
Installation Codes
Before beginning your installation:
Governing installation codes vary depending on the specific
location and application of the installation. Some examples include
the following:
•
•
•
•
Read the entire Installation Guide so you can plan the
installation from beginning to end.
Assemble all the tools and materials you require for the
installation.
Review the Important Safety Instructions on page iii.
Be aware of all safety and electrical codes which must be met.
•
•
•
•
•
ELECTRICAL SHOCK AND FIRE HAZARD
•
•
•
All wiring should be done by qualified personnel to ensure
compliance with all applicable installation codes and regulations.
Disconnect all AC and DC power sources.
Disable and secure all AC and DC disconnect devices and automatic
generator starting devices.
The U.S. National Electrical Code (NEC)
The Canadian Electrical Code (CEC)
The U.S. Code of Federal Regulations (CFRs)
Canadian Standards Association (CSA) and the RV Industry
Association (RVIA) for installations in RVs
The American Boating & Yachting Committee (ABYC) for
Marine installations in the U.S.
It is the installer’s responsibility to ensure that all applicable
installation requirements are met.
Failure to follow these instructions can result in death or serious
injury.
2
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Installation Tools and Materials
You will need the following to install the Freedom HF:
❐ Mounting screws or bolts
❐ #2 Phillips screwdriver
❐ 3.5mm slot long neck screwdriver for WAGO1 terminals that
are available in Freedom HF 1000, 1055, and 1800 models.
❐ Wrench for DC terminals (1/2” or 13mm or adjustable)
❐ AC cable (i.e. two-conductor-plus-ground cable), sized
appropriately for load and application
❐ Wire nuts or crimp connectors for AC wire and appropriate
tools
❐ Two 1/2” strain-relief clamps (supplied) for AC cables
❐ DC cable, sized appropriately for load and application
❐ Lugs for DC cables to fit 8 mm (5/16”) DC stud terminals) as
well as appropriate tools (e.g. crimping tool)
❐ AC and DC disconnects and over-current protective devices
This guide for use by qualified personnel only.
❐ Wire stripper
1. WAGO® manufactures connection devices such as terminal blocks and related accessories.
Many Freedom HF models use WAGO terminal blocks as AC input and output connections.
975-0395-01-01
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High Level Overview of Installation Steps
Installing the Freedom HF includes the following steps.
1.
Ensure that AC and DC power are both OFF.
2.
Mount the inverter securely and permanently in one of the
acceptable orientations.
3.
Connect the Equipment Grounding Terminal to the equipment
ground bus.
4.
Connect the AC input wiring to the AC source panel.
5.
Connect the AC output wiring to the AC load panel.
6.
Connect one end of the DC negative cable to the negative of the
battery, and the other to the negative terminal of the unit.
7.
Install an appropriately sized fuse and DC disconnect in the
positive cable.
8.
Connect the DC positive cable to the positive of the battery, and
to the positive terminal of the unit.
9.
Close the DC disconnect switch.
Do not proceed with installation until you have read “Safety
Instructions” on page 2.
4
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Basic Installation Procedures
❐ Step 1: Designing an installation. (Start on page 6.)
❐ Step 2: Choosing a location for the Freedom HF.
(Start on page 12.)
❐ Step 3: Mounting the Freedom HF. (Start on page 13.)
❐ Step 4: Connecting the AC input wires. (Start on page 15.)
❐ Step 5: Connecting the AC output wires. (Start on page 19.)
❐ Step 6: Connecting the DC cables. (Start on page 22.)
❐ Step 7: Mounting the display panel. (Start on page 31.)
❐ Step 8: Testing your installation. (Start on page 32.)
975-0395-01-01
This guide for use by qualified personnel only.
This section provides sample installation information as a guide for
your installation. For your convenience, the overall procedure is
divided into ten main steps:
5
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Basic Installation Procedures
Step 1: Designing the Installation
Most Freedom HF installations share common components, and
some of these are briefly described below. Figure 2 shows some
components and their relationship to each other in a typical
recreational vehicle or fleet vehicle installation. (Also, see “Marine
Installation” on page 37.)
HF| 1000
FR EE D O M
Equipment Ground
DC Fuse /
Disconnect or
Circuit Breaker
12V Deep Cycle
Bat tery
AC Load Panel
l
+
–
to engine
AC Source Panel
Equipment Ground
Vehicle Starting
Bat tery
Automatic or Manual AC
Source Select or Switch
Shorepower
Generator
Figure 2 Typical Recreational Vehicle and Fleet Vehicle Installation
6
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Generator
A source of 120 volts, 60Hz sine wave alternating current is needed
to provide energy to charge batteries and pass power through to AC
loads. This source is usually the utility grid (power company) or an
AC generator. An automatic or manual AC source selector switch
can be used to switch between the multiple sources of shore power
to the Freedom HF system.
The Freedom HF is compatible with most generators which produce
nominal 120 volts AC 60Hz sine wave AC power.
The AC source feeding the Freedom HF must have the neutral
conductor bonded to ground. When the inverter passes shore power
through, it will lift the bonding relay on the output and will rely on
the input being bonded in order to ensure that the power delivered to
a sub panel is properly bonded. See “AC Output Neutral Bonding”
on page 9 for more information on bonding relay operation.
IMPORTANT: Throughout this manual, the term “shore power” refers to
AC input power from a utility grid, generator, or other AC source.
AC Input: The circuit breaker or fuse (connected through hard
wiring) that is used to supply the Freedom HF must be rated at no
more than 30A and must be approved for use on 120 volts AC
branch circuits. The wire used between the breaker and the Freedom
HF input must be sized adequately to carry current up to the rating
of the input breaker and in accordance with the electrical codes or
regulations applicable to your installation.
975-0395-01-01
Since the DC charging current limit of the Freedom HF may be
configured to provide as little as two amps it is possible to use very
small generators with the Freedom HF to charge batteries. The
Freedom HF has been tested with generators of various sizes,
including some as small as 700 watts.
AC Disconnect and Over-Current Protection Device
Most safety requirements and electrical codes require the Freedom
HF’s AC and DC inputs and outputs to be provided with overcurrent protection (such as circuit breakers or fuses) and disconnect
devices.
AC Output: The circuit breaker or fuse must be rated at no more
than the rating of the input breaker in the installation and must be
approved for use on 120 volts AC branch circuits. The wire used
between the Freedom HF and the AC output breaker must be of
adequate size to match the AC input circuit breaker’s rating. The
wiring from each AC output breaker to each of the loads must be
adequately sized to carry the current rating of the individual AC
output breaker.
This guide for use by qualified personnel only.
Basic Installation Procedures
AC Shore Power
7
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Basic Installation Procedures
Disconnect Devices: Each system requires a method of
disconnecting the AC circuits. If the over-current protection devices
are circuit breakers, they will also serve as the disconnects. If fuses
are used, separate AC disconnect switches will be needed ahead of
the fuses. These will have to be a branch circuit rated for 120 volts
AC and have an appropriate current rating.
AC Distribution Panels
Most systems incorporate distribution centers both ahead of the
Freedom HF (the AC source panel) and between the Freedom HF
and the loads (the AC load panel). An AC source panel includes a
main circuit breaker, which serves as over-current protection and as
a disconnect for the AC shore power supply line. Additional circuit
breakers serve individual circuits, one of which serves the Freedom
HF. The AC load panel can incorporate an AC output circuit
breaker and breakers for individual load circuits.
EQUIPMENT DAMAGE
Do not connect the output of the Freedom HF to what is known as a
“multi-wire branch circuit”. These are four-wire circuits consisting of a
ground, neutral, and two lines that are 180 degrees out of phase with each
other (from a standard 120/240V “split phase” circuit). These circuits are
commonly used in kitchens to power “split receptacles” where the top
and bottom halves of a duplex receptacle are connected to different lines.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
8
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AC Cabling
AC Output Neutral Bonding
AC cabling includes all the wires and connectors between the AC
source and the Freedom HF, as well as all cabling between the
Freedom HF and the AC output panels, circuit breakers, and loads.
The type and size of the wiring varies with the installation and load.
For example, in high vibration environments, such as marine or RV
applications, wire nuts may not be acceptable, so crimp splices
would be required. In other applications, flexible multiple-strand
wire may be required. Installation codes usually specify solid or
stranded, overall size of the conductors, and type and temperature
rating of the insulation around the wire.
The neutral conductor of the Freedom HF’s AC output circuit (i.e.,
AC Output Neutral) is automatically connected to the safety ground
during inverter operation. When AC utility power is present and the
Freedom HF is charging, this connection is not present, so that the
utility neutral (i.e., AC Input Neutral) is only connected to utility
ground at your source. This conforms to National Electrical Code,
which requires that separately derived AC sources (such as inverters
and generators) to have their neutral conductors tied to ground in the
same way that the neutral conductor from the utility is tied to
ground in only one place. Check the regulations for your specific
application to ensure that the installation will comply with the
necessary requirements. In other words, the AC Input Neutral and
Output Neutral must be isolated from each other.
AC breakers and fuses must be sized to adequately protect the
wiring that is installed on the input and output AC circuits of the
Freedom HF. All breakers and wiring must be sized and connected
in accordance with the electrical codes or regulations applicable to
your installation. Table 1 gives some examples of wiring sizes based
on the U.S. National Electrical Code and the Canadian Electrical
Code. These examples are based on using a two-conductor-plusground cable rated at 75 °C, and assuming an ambient temperature
of up to 30 °C. Ensure that your breakers, and fuses have suitable
temperature ratings for your wiring. Other codes and regulations
may also be applicable to your installation.
This guide for use by qualified personnel only.
Basic Installation Procedures
Table 1 Required AC Wire Size vs Breaker Rating
Breaker Size (amps)
10A
15A
20A
30A
Minimum Wire Size
14AWG
14AWG
12AWG
10AWG
975-0395-01-01
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Freedom HF Install Guide.book Page 10 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
AC Grounding
As per UL458 SA29.5, for all grounded AC cord-connected marine
inverter/chargers: The Freedom HF 1055 EMS and the Freedom HF
1800 EMS should be grounded to reduce risk of electric shock.
Make sure that the three-prong plug is plugged into properly
installed and grounded AC wall outlet in accordance with all local
codes and ordinances.
As per UL458 SA29.5, for all permanently connected marine
inverter/chargers: The rest of the Freedom HF models should be
connected to a grounded, metal, permanent wiring system. Also,
make sure that an AC ground wire is connected to the AC ground
terminal on the unit. Do not just connect the line and neutral wires.
All connections to a unit should comply with all local codes and
ordinances.
DC Cabling
This includes all the cables and connectors between the batteries,
the DC disconnect and over-current protection device, and the
Freedom HF. Most mobile installations require multi-strand
insulated cables for flexibility and durability in high vibration
environments and require disconnects and over-current devices.
Electrical wiring sizes are indicated by AWG notation. Under the
AWG standard, a larger gauge number indicates a smaller wire
diameter. Wire size is usually marked on the larger sized cables.
Table 2 specifies the minimum recommended DC cable size and
10
maximum fuse size for the Freedom HF. The DC cables must be
copper and must be rated 75 °C minimum. The cables should be
terminated with lugs that fit the DC stud terminals snugly (8 mm or
5/16” hole size).
Table 2 Recommended Cable and Fuse Sizes
Inverter/Charger
Cable Length:
Battery to Inverter Minimum
(one way)
Cable Size
Maximum
battery Fuse
Size
Freedom HF 1000/1055
Less than 5 feet
No. 2 AWG
150 Adc
(1.5 meters)
Freedom HF 1500/1800
Less than 5 feet
No. 2/0 AWG
250 Adc
(1.5 meters)
Note: It is not recommended using a cable longer than 5 feet (1.5 meters) in each
direction. Cable sizes above are based on the US National Electrical Code Table 310.17
- 75C cables, assuming an ambient temperature of 30 °C cables.
IMPORTANT: Using the correct cable size is critical to achieving the
rated performance of the Freedom HF unit. When starting a heavy load the
Freedom HF can draw current surges from the battery of up to 400A. If the
DC wiring is too small the voltage drop from this surge will result in a
voltage at the Freedom HF terminals that is too low for the Freedom HF to
operate correctly. The Freedom HF may appear to operate correctly with
smaller cables until a heavy load such as a microwave or refrigerator
attempts to start - then the unit may work correctly sometimes and not work
correctly other times.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 11 Tuesday, April 29, 2014 12:22 PM
DC Disconnects and Over-Current Devices
Ground Fault Circuit Interrupters (GFCIs)
The DC circuit from the battery to the Freedom HF must be
equipped with a disconnect and over-current device. This usually
consists of a circuit breaker, a “fused-disconnect,” or a separate fuse
and DC disconnect. Do not confuse AC circuit breakers with DC
circuit breakers. They are not interchangeable. The rating of the fuse
or breaker must be matched to the size of cables used in accordance
with the applicable installation codes. The breaker or disconnect
and fuse should be located as close as possible to the battery, in the
positive cable. Applicable codes may limit how far the protection
can be from the battery.
A GFCI is a device that de-energizes a circuit when a current to
ground exceeds a specified value that is less than that required to
blow the circuit breaker. GFCIs are intended to protect people from
electric shocks and are usually required in wet or damp locations.
Batteries
The Freedom HF uses 12-volt battery banks. Every Freedom HF
system requires a deep-cycle battery or group of batteries that
provide the DC current that the Freedom HF converts to AC.
975-0395-01-01
Installations in marine and recreational vehicles require GFCI
protection of branch circuits connected to the AC output of the
Freedom HF.
The modified sine wave output of the Freedom HF is not equivalent
to the waveform provided by electric utilities, and compliance with
UL and CSA standards requires that the manufacturer test and
recommend specific GFCIs that will work correctly with the
Freedom HF. Here are the recommendations:
Make
Hubbell
Leviton
Pass & Seymour
Model
GF15WLA
N7599
1595
This guide for use by qualified personnel only.
Basic Installation Procedures
11
Freedom HF Install Guide.book Page 12 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
Step 2: Choosing a Location for the Unit
❐ Ventilated. Allow at least 5 inches (13cm) of clearance at the
FIRE AND EXPLOSION HAZARDS
•
•
Do not install the Freedom HF 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, or joints, fittings, or other connections between
components of the fuel system. This equipment contains components
that tend to produce arcs or sparks.
Do not cover or obstruct the ventilation openings. Do not install the
Freedom HF in a zero-clearance compartment. Overheating may
result.
Failure to follow these instructions can result in death or serious
injury.
The Freedom HF should only be installed in locations that meet the
following requirements:
❐ Dry. Do not allow water or other fluids to drip or splash on the
Freedom HF. Do not mount the Freedom HF in an area
subject to splashing water or bilge water.
❐ Cool. Normal air temperature should be between 32 °F and
DC end of the Freedom HF for air flow, 1 inch (2.5cm) on each
side, and 2 inches (5cm) at the AC end. The more clearance for
ventilation around the unit, the better the performance. Do not
allow the ventilation openings on the ends of the unit to become
obstructed.
❐ Safe. Do not install the Freedom HF in the same compartment
as batteries or in any compartment capable of storing
flammable liquids like gasoline.
❐ Close to the battery compartment and the AC source and
load panels. Avoid excessive cable lengths (which reduce input
and output power due to wire resistance). Use the
recommended cable lengths and sizes, especially between the
battery banks and the Freedom HF.
❐ Protected from battery acid and gases. Never allow battery
acid to drip on the Freedom HF or its wiring when reading
specific gravity or filling the battery. Also do not mount the unit
where it will be exposed to gases produced by the batteries.
These gases are very corrosive, and prolonged exposure will
damage the Freedom HF.
104 °F (0 °C and 40 °C)—the cooler the better.
12
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 13 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
To mount the Freedom HF:
1. Remove the Freedom HF from its shipping container, verify
that all components are present, and record relevant product
information on “Information About Your System” in the
Owner’s Guide.
2.
1
Select an appropriate mounting location and orientation. (See
Figure 3 below.) To meet regulatory requirements, for use in
on-land applications, the Freedom HF must be mounted in one
of the following orientations:
•
•
2
3
Under a horizontal surface (see 1)
In a horizontal position on a vertical surface (see 2)
NOTE: For marine installations, only this orientation is allowed, due to
the probability of moisture finding access into the enclosure.
•
See page 34 for drip
shield installation on
Marine applications.
On a horizontal surface (see 3)
975-0395-01-01
Figure 3 Approved Mounting Orientations
3.
Look for the mounting template and unfold. Tape it to the
mounting surface and pilot-drill the desired number of
mounting holes. Remove the template.
4.
Fasten the Freedom HF to the mounting surface. If you are
mounting the unit on a wall or bulkhead, use #12 or #14 panhead wood or sheet metal screws to secure it to the framing
behind the wall or bulkhead. Alternatively, use nut inserts and
1/4”-20 machine screws.
This guide for use by qualified personnel only.
Step 3: Mounting the Unit
13
Freedom HF Install Guide.book Page 14 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
Connecting the Equipment Ground
Grounding Locations
FIRE HAZARD
Never operate the Freedom HF without properly connecting the
equipment ground. A fire hazard could result from improper grounding.
Failure to follow these instructions can result in death or serious
injury.
The Freedom HF has a ground stud on the side of the unit as shown
in Figure 4. Follow the guidelines in “Grounding Locations” to
connect the inverter’s chassis to the ground.
Equipment
ground stud
Figure 4 DC Panel Connections
14
You must connect the equipment ground stud to a grounding
point—usually the vehicle’s chassis or DC negative bus ground—
using recommended copper wire (if insulated then green insulation
with or without one or more yellow stripes) or larger.
For recommended equipment ground cable size, see below.
Table 3 Recommended Equipment Ground Cable size
Minimum equipment ground cable size
(Stranded cable is recommended)
a
Recreational Vehicle No. 8 AWG
No. 3 AWG (Freedom HF 1000)
Marineb
No. 1/0 AWG (Freedom HF 1500/1800)
NOTE:There are no restrictions on length for the equipment ground cable.
Application
a. Based on US National Electrical Code NFPA70, Article 551, par. 551-20c 2005 version.
b. Based on ABYC E-11 11.18 dated 07/03
In general, the equipment ground cable size must not be smaller
than one AWG size than the supply cable.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 15 Tuesday, April 29, 2014 12:22 PM
Step 4: Connecting the AC Input Wires
Basic Installation Procedures
FIRE, SHOCK, AND ENERGY HAZARDS
Make sure wiring is disconnected from all electrical sources before
handling. All wiring must be done in accordance with local and national
electrical wiring codes. Do not connect the output terminals of the
Freedom HF to any incoming AC source.
Failure to follow these instructions can result in death or serious
injury.
AC Wiring Connectors Where applicable, connect AC wires
with crimp-on splice connectors. The amount of insulation you strip
off individual wires will be specified by the connector manufacturer
and is different for different types of connectors.
AC and DC Wiring Separation Do not mix AC and DC wiring
in the same conduit or panel. Where DC and AC wires must cross,
make sure they do so at 90 to one another. Consult applicable codes
for details about DC and AC wiring in close proximity to each other.
AC Wiring and GFCIs You can plug loads (12 amps continuous,
15 amps maximum) directly into the GFCI receptacle on the front
panel of the Freedom HF. You can also connect the inverter to an
existing AC installation and then plug loads into GFCI receptacles
connected to that circuit.
If you plan to use the Freedom HF with the GFCI installed on the
unit, proceed to “Step 6: Connecting the DC Cables” on page 22.
AC wiring includes all the wires and connectors between the AC
source and the Freedom HF and all wiring between the inverter, the
AC panels, circuit breakers, and the GFCIs. The type and size of the
wiring varies with the installation and load. For some RV
applications, flexible multiple-strand wire is required.
975-0395-01-01
This guide for use by qualified personnel only.
General AC Wiring Considerations
AC wiring must be sized appropriately to carry full load current on
the input and output AC circuits in accordance with the electrical
codes or regulations applicable to your installation. Table 4 is based
15
Freedom HF Install Guide.book Page 16 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
on the U.S. National Electrical Code and the Canadian Electrical
Code, assuming two-conductor-plus-ground cable, using 75 °C
wiring, at an ambient temperature of 30 °C. Other codes and
regulations may be applicable to your installation.
Table 4 Required AC wire size vs. required breaker rating
Required Breaker Size (amps)
Required Wire Size
Freedom HF 1000
30 A maximum
10 AWG
Freedom HF 1055
30 A maximum
10 AWG
Freedom HF 1500
15 A maximum
custom cable with connector
Freedom HF 1800
30 A maximum
10 AWG
Freedom HF 1800 T
15 A maximum
custom cable with connector
Freedom HF
1800 EMS
15 A maximum
standard AC cable with threeprong grounded AC plug
Freedom HF
1055 EMS
15 A maximum
standard AC cable with threeprong grounded AC plug
The AC input terminal is located on the front panel and is labeled
properly as AC IN or AC INPUT. Depending on the model, you can
have three types of wire terminals.
•
The Freedom HF 1000, Freedom HF 1055, Freedom HF 1800
and Freedom HF 1500 models come with WAGO-type
terminals where individual wires can be attached securely.
•
•
The Freedom HF 1800 T comes with a PTI1 connector that
attaches to an AC cable terminated with a corresponding PTI
connector.
The Freedom HF 1055 EMS and Freedom HF 1800 EMS come
with a standard AC cable with three-prong grounded AC plug.
EQUIPMENT DAMAGE
Make sure the wires are connected properly. The AC wiring terminal
blocks are split into input and output sections.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
When making the AC input and AC output connections, observe the
correct color code for the appropriate AC wire, as described in
Table 5.
Table 5 Color codes for typical AC wiring
Color
AC Wire
Black or Brown
White or Blue
Green, Green/Yellow, or bare copper
Line
Neutral
Ground
1. Phillips & Temro Industries manufactures accessories for heating, cooling, silencing, emission and hybrid/electric vehicle technologies. The electrical cables with PTI connectors referred to in this manual are custom cables that are available for the trucking industry.
16
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 17 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
10mm
clamp slot
AC
IN
to circuit
breaker
terminal
opening
L
G
N
1.
2.
Ensure AC and DC power sources are turned off.
Install the required circuit breaker in the AC distribution panel
supplying AC power to the unit.
3.
4.
Strip a single strand (e.g. Romex®)1 AC input wire, as appropriate.
Locate the Line, Ground and Neutral terminals on the AC input
terminal labeled as L, G, and N respectively.
Using a 3.5mm slot long neck screwdriver, open the WAGO cage
clamp by inserting the tool in the clamp slot for Ground terminal.
Insert Ground AC wire into Ground terminal slot on the unit.
Repeat steps 5 and 6 for Line and Neutral connections.
Connect the other end of the wires to the circuit breaker in the AC
distribution panel supplying AC power to the unit.
5.
6.
7.
8.
TEST
Failure to follow these instructions can damage the unit and/or
damage other equipment.
This guide for use by qualified personnel only.
Make sure the wires are connected properly. Improper connections
(connecting a line conductor to a neutral conductor, for example) will
cause the Freedom HF to malfunction and may permanently damage the
inverter. Damage caused by a reverse polarity connection is not covered
by your warranty.
TEST
REVERSE POLARITY DAMAGE
AC Input Connections for the Freedom HF
1000, Freedom HF 1055, Freedom HF 1500,
and Freedom HF 1800 Models
1.Romex is a brand name owned by Southwire and used here as an example but not as
an endorsement of a particular brand.
975-0395-01-01
17
Freedom HF Install Guide.book Page 18 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
AC Input Connections for the Freedom HF 1800 T Model
AC Input Connections for the Freedom HF 1055 EMS and
Freedom HF 1800 EMS Models
to circuit
breaker
TEST
TEST
Failure to follow these instructions will result in death or serious
injury.
RESET
TEST
Do not alter the AC cord and its three-prong plug. The AC cord is preinstalled and pre-wired to the AC Input terminals of the unit.
Do not connect the plug to other than a properly grounded electrical wall
outlet.
RESET
4.
TEST
3.
Ensure AC and DC power sources are turned off.
Install the required circuit breaker in the AC distribution panel
supplying AC power to the unit.
Connect the female PTI cable connector to the AC IN male receptacle
on the unit.
Connect the other end of the wires to the circuit breaker in the AC
distribution panel supplying AC power to the unit.
RESET
1.
2.
RESET
ELECTRIC SHOCK HAZARD
to wall
outlet
1.
2.
18
Ensure AC and DC power sources are turned off.
Connect the three-prong plug to an AC wall outlet.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 19 Tuesday, April 29, 2014 12:22 PM
FIRE, SHOCK, AND ENERGY HAZARDS
Make sure wiring is disconnected from all electrical sources before
handling. All wiring must be done in accordance with local and national
electrical wiring codes.
Failure to follow these instructions can result in death or serious
injury.
EQUIPMENT DAMAGE
Do not connect any AC source (such as a generator or utility power) to
the AC wiring output of the Freedom HF.
The Freedom HF will not operate if its output is connected to AC voltage
from another source, and potentially hazardous or damaging conditions
may occur. These conditions can occur even if the inverter is off.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
Do not connect the Freedom HF to an AC branch circuit that has
high-power consumption loads.
Basic Installation Procedures
A manufacturer-tested and approved GFCI must be connected to the
Freedom HF AC output, and on every receptacle connected to the
AC hard wired installation. Other types may fail to operate properly
when connected to the Freedom HF. Although you can reuse the
factory-installed GFCI, the manufacturer has also tested and
approved the following GFCIs for use with the Freedom HF
inverter/charger. See “Ground Fault Circuit Interrupters (GFCIs)”
on page 11.
FIRE, SHOCK, AND ENERGY HAZARDS
Make sure wiring is disconnected from all electrical sources before
handling. All wiring must be done in accordance with local and national
electrical wiring codes.
Failure to follow these instructions can result in death or serious
injury.
This guide for use by qualified personnel only.
Step 5: Connecting AC Output to an Existing AC Circuit
The Freedom HF will not operate electric heaters, air conditioners,
stoves, and other electrical appliances that consume more than 1000
watts (Freedom HF 1000) or 1800 watts (Freedom HF 1800).
975-0395-01-01
19
Freedom HF Install Guide.book Page 20 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
AC Output Connections for the Freedom HF 1000,
Freedom HF 1055, and Freedom HF 1800 models
AC Output Connections for the Freedom HF 1800 T
Model
To make a permanent connection to existing AC wiring:
10mm
FREEDOM HF 1000
1800 T
clamp slot
FREEDOM HF 1800 T
RESET
AC
OUT
to circuit
breaker
terminal opening
L
1.
2.
3.
4.
5.
6.
7.
8.
20
G
N
to circuit
breaker
Ensure AC and DC power sources are turned off.
Install the required circuit breaker in the inverter distribution panel
receiving AC power from the inverter.
Strip a single strand (e.g. Romex) AC output wire, as appropriate.
Locate the Line, Ground and Neutral terminals on the AC OUT
terminal labeled as L, G, and N respectively.
Using a 3.5mm slot long neck screwdriver, open the WAGO cage
clamp by inserting the tool in the clamp slot for Ground terminal.
Insert Ground AC wire into Ground terminal slot on the unit.
Repeat steps 5 and 6 for Line and Neutral connections.
Connect the other end of the wires to a circuit breaker in the inverter
distribution panel.
1.
2.
3.
4.
Ensure AC and DC power sources are turned off.
Install the required circuit breaker in the inverter distribution panel
receiving AC power from the inverter.
Connect the male PTI cable connector to the AC OUT female PTI
receptacle on the unit.
Connect the other end of the wires to a circuit breaker in the inverter
distribution panel.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 21 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
AC Output Connections for the Freedom HF
1055 EMS and Freedom HF 1800 EMS Models
7.
8.
GND
4.
5.
6.
AC OUTPUT
3.
N L
Do not connect the ACOUT to any
other source of power . Damage to unit may occur
.
CAUTION!
1.
2.
Make sure the wires are connected properly. Improper connections
(connecting a line conductor to a neutral conductor, for example) will
cause the Freedom HF to malfunction and may permanently damage the
inverter. Damage caused by a reverse polarity connection is not covered
by your warranty.
10mm
ground terminal
to circuit
breaker
Ensure AC and DC power sources are turned off.
Install the required circuit breaker in the inverter distribution panel
receiving AC power from the inverter.
Remove the GFCI unit to expose the AC output terminals inside the
wiring compartment behind the AC OUT knockout.
Install a strain-relief clamp on the AC OUT knockout.
Strip a single strand (e.g. Romex) AC output wire, as appropriate.
Locate the Line, Ground and Neutral terminals on the AC output
terminal labeled as L, GND, and N respectively.
Passing the wire through the knockout, insert the Ground AC output
wire into the Ground terminal slot on the unit.
Repeat steps 5 to 7 for Line and Neutral connections.
Tighten the wire attachment screws to a torque of 1.3–1.8 lbf-ft (1.76–
2.44 Nm). Leave some wiring slack inside the wiring compartment.
Ensure you have maintained correct polarity and that there are no
loose strands of wire.
975-0395-01-01
Failure to follow these instructions can damage the unit and/or
damage other equipment.
9. Secure the wires by adjusting the strain-relief clamp.
10. Install the GFCI back into the front panel of the unit.
11. Alternatively, if you do not reinstall the GFCI, make sure that you cap
the exposed wires and install a blanking plate to cover the space
vacated by the GFCI.
12. Connect the other end of the wires to a circuit breaker in the inverter
distribution panel.
This guide for use by qualified personnel only.
REVERSE POLARITY DAMAGE
FREEDOM HF 1800 EMS
21
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Basic Installation Procedures
Step 6: Connecting the DC Cables
The following instructions only apply to the following models:
Freedom HF 1000, Freedom HF 1055, Freedom HF 1800, and
Freedom HF 1800 T.
REVERSE POLARITY DAMAGE
Check cable polarity at both the battery and the Freedom HF before
making the final DC connection. Positive must be connected to positive;
negative must be connected to negative.
Reversing the positive and negative battery cables will damage the
Freedom HF and void your warranty.
Follow the procedure given below to connect the battery leads to the
terminals on the DC end. The cables should be as short as possible
and large enough to handle the required current, in accordance with
the electrical codes or regulations applicable to your installation.
Table 2 on page 10 specifies the minimum DC cable size and
maximum fuse size for the Freedom HF.
Do not route your DC cables through an electrical distribution
panel, battery isolator, or other device that will cause additional
voltage drops.
Figure 5 shows the DC end for your reference.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
FIRE HAZARD
Use only copper wire rated 75 °C minimum. Make sure all DC
connections are tight to a torque of 108–120 inch-pounds (12.2–13.6Nm).
Loose connections will overheat.
Failure to follow these instructions can result in death or serious
injury.
Figure 5 DC End for Freedom HF 1000, 1055, 1800, and 1800 T
22
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 23 Tuesday, April 29, 2014 12:22 PM
6.
Refer to Figure 6.
Basic Installation Procedures
Thread a supplied DC terminal cover over the positive and
negative cables. The red cover goes on the positive cable; the
black cover on the negative cable.
1.
Make sure the inverter is off and no AC or DC is connected to
the unit.
7.
2.
Remove the nuts and washers from the Freedom HF positive
and negative DC terminals.
Attach the connector that will join the cable to the inverter DC
terminal.
8.
3.
Strip 1/2 inch (13 mm) to 3/4 inch (19 mm) insulation from one
end of each cable. The amount stripped off will depend on the
terminals chosen.
Install a fuse and fuse holder in the cable that will be used for
the positive side of the DC circuit.
The fuse must:
4.
5.
Attach the connectors that will secure the cables to the battery,
to the disconnect/battery selector switch, and the fuse block.
The connectors you use must create a permanent, lowresistance connection.
If crimp connectors are required, it is recommended to use
approved and certified connectors, and to use the tool
recommended by the terminal manufacturer. Make sure no
stray wires protrude from the connector or terminal.
(You may find it more convenient to have the crimp connectors
attached by the company that sells you the cable and/or
connectors.)
For each cable end that will be connected to the inverter, strip
1/2 inch (13 mm) to 3/4 inch (19 mm) of insulation from the
cable. The amount stripped off will depend on the terminals
chosen.
975-0395-01-01
•
•
•
9.
be as close to the battery positive terminal as possible
be rated for DC circuits
have an Ampere Interrupting Capacity (AIC) that exceeds
the short-circuit current available from the battery (i.e.,
Class T fuse)
To prevent sparking when making the connection, ensure the
disconnect/battery selector switch is off.
10. Attach the connector on the positive cable to the positive DC
terminal on the inverter.
This guide for use by qualified personnel only.
To make the DC connections
11. Install the lock washer and nut that are supplied with the
inverter. Tighten the nut to a torque of 108–120 in-lbf (12.2–
13.6 N-m). Make the connection snug enough so the ring
terminal does not move around on the DC terminal, but do not
overtighten. See Figure 6, “DC Cable Connections” on page 25.
23
Freedom HF Install Guide.book Page 24 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
EQUIPMENT DAMAGE
Tighten the nuts on terminals properly. Loose connections cause
excessive voltage drop and may cause overheated wires and melted
insulation.
Do not over-tighten the nut on the DC input terminals. Damage to the DC
input terminals may result. The maximum torque setting is 120 in-lbf
(13.6 N-m).
Failure to follow these instructions can damage the unit and/or
damage other equipment.
REVERSE POLARITY DAMAGE
Check cable polarity at both the battery and the Freedom HF before
making the final DC connection. Positive must be connected to positive;
negative must be connected to negative.
Reversing the positive and negative battery cables will blow a fuse in the
Freedom HF and void your warranty.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
12. Before proceeding, double check that the cable you have just
installed connects the positive DC terminal of the inverter to
the disconnect/battery selector switch, fuse holder, and that the
other end of the fuse holder is connected to the positive
terminal of the battery.
FIRE HAZARD
Do not complete the next step if flammable fumes are present. Explosion
or fire may result if the disconnect/battery selector switch is not in the off
position. Thoroughly ventilate the battery compartment before making
this connection.
Failure to follow these instructions can result in death or serious
injury.
13. Connect the cable from the negative post of the battery to the
negative DC terminal of the inverter.
14. Install the lock washer and nut that are supplied. Tighten the
nut to a torque of 108–120 in-lbf (12.2–13.6 N-m). Make the
connection snug enough so the ring terminal does not move
around on the DC terminal, but do not overtighten.
15. Slip the DC terminal covers over the Freedom HF DC
terminals.
24
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 25 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
Anderson Connectors
Figure 6 DC Cable Connections
Anderson connector
Figure 7 DC End for Freedom HF 1055 EMS and 1800 EMS
This guide for use by qualified personnel only.
The Freedom HF 1055 EMS and 1800 EMS models are pre-wired
with an Anderson1 connector that attaches to matching terminal
connectors in certain trucks and vehicles.
1. Anderson Power Products® manufactures power interconnects and accessories. An Anderson connector is a term used in this manual to mean a connector manufactured by Anderson
Power Products and refers to either SB175 or SB350.
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Freedom HF Install Guide.book Page 26 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
DC Grounding
To connect the DC ground:
Inverter Ignition Control (For Freedom HF 1000,
1055, 1500, 1800, and 1800 T)
The equipment grounding lug on the DC end of the Freedom HF is
used to connect the chassis of the Freedom HF to your system’s DC
negative connection or grounding bus point as required by electrical
regulations. Use copper wire that is either bare or provided with
green insulation. Do not use the DC Ground Lug for your AC
grounding. (See the AC wiring instructions in this section.)
The Freedom HF can be wired to inhibit inverter operation in the
absence of a vehicle’s (or vessel's) ignition control signal. This
feature can avoid unnecessary battery drain that would otherwise
occur if the inverter was operated without a charging source such as
the vehicle alternator. The feature is standard on the Freedom HF
platform.
Follow the guidelines below that correspond to the specific type of
installation. These guidelines assume you are using the DC supply
cable and fuse sizes recommended in this manual. If you are using
different sizes, refer to the applicable installation code for DC
grounding details.
To enable ignition control:
1. Ensure that AC and DC power are both OFF.
Recreational Vehicle Use 8AWG copper wire and connect it
between the Chassis Ground lug and the vehicle’s DC grounding
point (usually the vehicle chassis or a dedicated DC ground bus).
Marine Use copper wire that is bare or has insulation rated
minimum 105 °C, and connect it between the Chassis Ground lug
and the boat’s DC grounding bus or engine negative bus. For the
Freedom HF 1000, use a wire of gauge 4AWG minimum. For the
Freedom HF 1500, use a wire of gauge 2AWG minimum. For the
Freedom HF 1800, use a wire of gauge 1/0AWG minimum.
26
2.
Ensure the vehicle’s ignition is turned to OFF position. It is
highly recommended to remove battery power by
disconnecting the vehicle's battery cables. Refer to the vehicle’s
Owner’s Guide for proper instructions on how to disconnect the
battery cables.
3.
Locate the vehicle's ignition control wire from the vehicle’s
ignition circuit. This wire must be fused appropriately at no
more than five amps. Refer to the vehicle’s Owner’s Guide for
guidance.
4.
Using a #1 Phillips screw driver, remove the screw securing the
DC wiring cover on the left hand side of the unit.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 27 Tuesday, April 29, 2014 12:22 PM
6.
Unscrew and remove the red jumper wire, using a flat screw
driver, in between terminal A and terminal Ignition
Control. The jumper wire acts to disable ignition control and
removing it will enable it.
7.
Strip the vehicle’s ignition control wire and connect it to
terminal Ignition Control.
NOTE: Do not make any external connections to terminal A.
This can result in non-warranty damage to the unit.
JUMPER WIRE
Ignition Control
terminals
Basic Installation Procedures
Remove the DC wiring cover to expose the ignition control
terminals of the DC wiring compartment.
FRE
This guide for use by qualified personnel only.
5.
8.
Route the ignition control wire to the left side of the display
panel.
9.
Replace the DC wiring cover onto the DC wiring compartment.
The ignition control wire should pass-through the hole on the
side of the DC wiring cover.
Figure 8 Exposed Ignition Control Terminals
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Freedom HF Install Guide.book Page 28 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
Power Module (For Freedom HF 1055 EMS
and 1800 EMS)
Ignition control
wire coming out
through hole.
1800 T
RESET
RESET
TEST
TEST
DC wiring cover
In addition to having the ability to inhibit inverter operation in the
absence of a vehicle’s (or vessel's) ignition control signal, the
Freedom HF 1055 EMS and 1800 EMS models also have the ability
to provide auxiliary DC power from the battery for small loads not
exceeding 20 amps DC in total. Auxiliary DC power is provided
when the same ignition control signal is present. This means that the
vehicle’s ignition is turned to ON position. The unit internally
connects the DC OUT terminal to the battery’s positive terminal.
To enable ignition control and to connect auxiliary DC power:
1. Ensure that AC and DC power are both OFF.
28
2.
Ensure the vehicle’s ignition is turned to OFF position. It is
highly recommended to remove battery power by
disconnecting the vehicle's battery cables. Refer to the vehicle’s
Owner’s Guide for proper instructions on how to disconnect the
battery cables.
3.
Locate the vehicle's ignition control wire from the vehicle’s
ignition circuit. This must be fused appropriately at no more
than five amps. Refer to the vehicle’s Owner’s Guide for
guidance.
4.
Choose an auxiliary DC appliance that will be ignition
controlled. The appliance must be rated at 12 volts.
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 29 Tuesday, April 29, 2014 12:22 PM
Unscrew and remove the red jumper wire, using a small flat
screw driver, in between the terminals Ignition Control and
Disabled. The jumper wire acts to disable ignition control and
removing it will enable it.
6.
Basic Installation Procedures
Strip the vehicle’s ignition control wire and connect it to the
middle terminal Ignition Control.
NOTE: Do not make any external connections to terminal
Disabled. This can result in non-warranty damage to the unit.
7.
Locate wiring for the auxiliary DC appliance that will be
ignition controlled. Use a minimum of 10 AWG wire.
8.
Strip the auxiliary DC wire and connect it to the left-most
terminal DC OUT 12V, 20A.
JUMPER WIRE
DC OUT 20-amp
fuse.
FREEDOM HF 1800 EMS
RESET
RESET
TEST
TEST
This wire
connects to a
12-volt DC
appliance.
Ignition Control Wire
9.
Figure 9 Power Module for EMS Models
975-0395-01-01
Auxiliary DC Wire
DO NOT USE
Ignition control
wire connects to
the vehicle’s
ignition circuit.
This guide for use by qualified personnel only.
5.
Connect the other end of the auxiliary DC wire to the DC
appliance.
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Freedom HF Install Guide.book Page 30 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
10. Reconnect the battery cables of the vehicle. Refer to the
vehicle’s Owner’s Guide for proper instructions on how to
reconnect the battery cables.
11. Turn the vehicle’s ignition to the ON position.
12. Turn the DC appliance on. Otherwise, if the DC appliance does
not have a switch it should automatically turn on at this point.
30
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 31 Tuesday, April 29, 2014 12:22 PM
The communications cable supplied with the display panel is 25 feet
(7.62 meters) long. If you want to replace the cable with one that is
shorter, use a high quality, six-wire telephone extension cable.
Flush mounting the panel on a wall or bulkhead requires an opening
that is approximately 3.25 × 1.25 inches (8.25 × 3.18 cm). About
1.5 inches (3.81 cm) of free space is required within the wall to
accommodate the depth of the panel. Be sure there is no wiring or
other obstructions within the wall before you make an opening.
To mount the display panel:
1. Choose a location that is dry, out of direct sunlight, free from
corrosive or explosive fumes, and otherwise appropriate for
mounting an electronic device.
2.
Tape the mounting template (in the Freedom HF package) to
the mounting surface and mark the locations of the mounting
holes and the area to be cut away.
3.
Pilot-drill the mounting holes and cut out the hole in which the
panel will be inserted.
4.
Route the communications cable(s) inside the wall and through
the opening.
5.
Insert one of the cable’s connectors in either jack on the bottom
of the panel.
6.
Place the panel in the opening and secure it with appropriate
fasteners.
7.
Route the communications cable to the Freedom HF and insert
the connector in the jack located near the battery select dip
switch.
This guide for use by qualified personnel only.
Basic Installation Procedures
Step 7: Mounting the Display Panel
IMPORTANT: Do not route the communications cable in parallel and in
conduit with the AC and DC wires. In situations where the cable must cross
with the AC and DC wires, make sure they cross at a 90° angle to each
other.
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Freedom HF Install Guide.book Page 32 Tuesday, April 29, 2014 12:22 PM
Basic Installation Procedures
Step 8: Testing Your Installation
Testing in Invert Mode
ELECTRICAL SHOCK HAZARD
Pressing the Inverter button to turn OFF the Freedom HF inverter
function on display panel does not disconnect DC or AC input power to
the Freedom HF. If shore power is present at AC input terminals, it will
pass through to the AC output.
Failure to follow these instructions can result in death or serious
injury.
There are two tests to be performed. The first test verifies that the
Freedom HF is inverting DC battery power and delivering AC
power to its output.
The second test is intended for installations where AC input and
output is hard wired to the Freedom HF. This test verifies that the
Freedom HF transfers from inverter power to shore power when
shore power is present.
To test the Freedom HF in invert mode:
1. For hard wired installations, ensure shore power is not present.
2.
Press the Inverter button to turn the inverter on.
The status LED on the display panel glows yellow and the LED
display illuminates.
3.
Plug an appliance within the power rating of the inverter into
the Freedom HF GFCI or an AC outlet hard wired to the
Freedom HF.
4.
Turn the appliance on to verify that it operates.
If the appliance operates, your installation is successful. If your
installation has AC input and output hard wired to the Freedom HF,
proceed to “Testing in Shore Power Mode”.
If the status LED on the display panel glows red, see the
Troubleshooting chapter.
NOTE: Shore power (pass-through) refers to the AC input power
from a utility grid, generator or external AC source.
When you are ready to test your installation and operate the
Freedom HF, close the DC fuse and Disconnect or the DC circuit
breaker to supply DC power to the Freedom HF.
32
Freedom HF Installation Guide
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Basic Installation Procedures
Testing in Shore Power Mode
To test the Freedom HF in shore power mode:
◆ With the appliance from the previous test still connected and
The Freedom HF transfers the appliances to shore power. The
status LED on the display panel will change from yellow to a
ten-second flashing yellow and then green.
If the appliance operates, your installation is successful.
NOTE: If the Inverter button on the Freedom HF is turned ON, the
Freedom HF will automatically supply the appliances with
inverter power if the shore power source fails or becomes
disconnected.
If the Inverter button on the Freedom HF is turned ON and shore
power voltage is too low (less than 90 volts AC), the unit will
transfer to inverter power to continue running your appliances.
NOTE: Whether or not the Inverter button is turned ON, shore
power will pass through the Freedom HF to the output when shore
power is within normal operating range.
975-0395-01-01
This guide for use by qualified personnel only.
operating, connect the shore power source.
33
Freedom HF Install Guide.book Page 34 Tuesday, April 29, 2014 12:22 PM
Drip Shield Installation (For Marine Installations)
The drip shield helps to protect the unit from dripping or splashing
liquids, which will cause a shock hazard. Drip shields are especially
useful in marine installations where water from condensation, rain,
or sea may come into contact with the Freedom HF.
Different Views
ELECTRICAL SHOCK HAZARD
Use this product in dry areas only. Operating the unit under wet
conditions may expose you to a shock hazard. Installing drip shields may
not entirely protect you from this hazard. Do not operate the unit when it
is wet.
Failure to follow these instructions can result in death or serious
injury.
You may purchase the drip shield set by contacting customer
support. When ordering, mention part number 808-9531.
Drip Shield set part# 808-9531
Figure 10 Drip Shields
34
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 35 Tuesday, April 29, 2014 12:22 PM
Drip Shield Installation (For Marine Installations)
3.
Fasten the screws through the holes in the drip shield into the
wall. See Figure 10.
HF| 1000
Locate an appropriate setting for the drip shields above the
Freedom HF making sure you cover the entire width of the unit.
You can overlay the shields as shown in Figure 11 below.
FREEDOM
2.
This guide for use by qualified personnel only.
To install the drip shields:
1. Gather the four screws needed to fasten a single drip shield to a
wall.
Figure 11 Typical Drip Shield Placement on a Freedom HF 1800
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Freedom HF Install Guide.book Page 36 Tuesday, April 29, 2014 12:22 PM
Configuration
Refer the Owner’s Guide for instructions on configuring the battery
type accepted by the unit and on adjusting display, alarm, and
charging current settings.
36
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 37 Tuesday, April 29, 2014 12:22 PM
Marine Installation
2.
An AC source panel that includes a Max 30A circuit breaker
that supplies the Freedom HF
3.
An AC load panel with branch circuit breakers that supply only
loads that run off the Freedom HF
4.
Engine negative bus / DC ground bus
5.
DC power supplied by a battery bank and protected by a DC
fuse in the positive cable
6.
DC Fuse /
disconnect or
circuit breaker
12V Deep Cycle
Battery
Battery isolator
7.
DC alternator
8.
Starting battery
9.
Drip shield (not shown)
AC Load Panel
AC Source Panel
Starting Battery
This guide for use by qualified personnel only.
AC power supplied from a shore power connector
HF | 1000
1.
FR EE D O M
Figure 12 illustrates a typical marine installation with the following
components:
Shorepower
Figure 12 Typical Marine Installation
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Freedom HF Install Guide.book Page 38 Tuesday, April 29, 2014 12:22 PM
Specifications
NOTE: Specifications are subject to change without prior notice.
Physical Specifications
1000-watt models
1500 and 1800-watt models
L×W×H
15.5” (393mm) × 9.5” (241mm)× 4.2” (106mm)
Net Weight
10 lbs (4.5 kg)
18” (457mm) × 9.5” (241mm)× 4.2” (106mm)
12.8 lbs (5.8 kg)
NOTE: Excludes any external AC or DC wiring
harnesses included on some models.
Environmental Specifications
Ambient Temperature:
Operating Temperature Range
Storage Temperature Range
Humidity: Operation/Storage
Ambient Temperature:
Operating Temperature Range
Storage Temperature Range
System Specifications
Transfer relay rating
Transfer time
Transfer on bad voltage
Cooling
38
1000-watt models
1500 and 1800-watt models
0–40 ºC
-20–60 ºC, with output derated above 25 °C
-40–70 ºC
5–95% RH, non-condensing
0–40 ºC
-20–60 ºC, with output derated above 25 °C
-40–70 ºC
1000-watt models
1500 and 1800-watt models
30A, 2.0hp
<30ms (milliseconds)
90–100V for low AC and 130–140 for high AC
Fan, activated by any of the following:
•High internal temperature
•High AC output power
Freedom HF Installation Guide
Freedom HF Install Guide.book Page 39 Tuesday, April 29, 2014 12:22 PM
Specifications
NOTE: These specifications refer to inverter mode.
1000-watt models
1500 and 1800-watt models
Operating voltage range for all models
10.5–15.5 VDC (low limit)
11.8–15.5 VDC (high limit)
10.5–15.5 VDC (low limit)
11.8–15.5 VDC (high limit)
Operating voltage range for Freedom HF 1500
and Freedom HF 1800 T
n/a
10.5–15.5 VDC (low limit)
11.8–15.5 VDC (mid limit)
12.1–15.5 VDC (high limit)
Safe non-operating voltage range
0–16 VDC
0–16 VDC
Normal voltage for all models
12.5 VDC
12.5 VDC
Nominal current at full load
100 ADC
180 ADC
AC Output
1000-watt models
1500 and 1800-watt models
Output voltage
115 VAC
115 VAC
Continuous power
1.0kW @ 25 °C
1.8kW @ 25 °C
1.5kW @ 25 °C (Freedom HF 1500 only)
Surge power
17 A
(2kW for 200 ms)
30 A
(3.6kW for 300 ms)
Max short-circuit current
55 A peak
55 A peak
Frequency
60 Hz
60 Hz
Wave shape
Modified Sine Wave
Modified Sine Wave
Power derating above 40 °C ambient temp
See “Invert Power Derating vs. Ambient Temperature” on page 31.
Peak efficiency
87%
87%
Full load efficiency
80%
80%
Other
1000-watt models
1500 and 1800-watt models
No load input power (producing output voltage)
10W
10W
Off mode current draw
1mA
1mA
975-0395-01-01
This guide for use by qualified personnel only.
DC Input
39
Freedom HF Install Guide.book Page 40 Tuesday, April 29, 2014 12:22 PM
Specifications
NOTE: These specifications refer to charger mode.
AC Input
1000-watt models
1500 and 1800-watt models
Operating voltage range for all models
90–130 VAC
90–130 VAC
Operating voltage range for Freedom HF 1500
and Freedom HF 1800 T
5 A at 20 A charge, 120 VAC IN
10 A at 40 A charge, 120 VAC IN
Nominal current
5 A at 20 A charge, 120 VAC IN
10 A at 40 A charge, 120 VAC IN
Nominal frequency
60 Hz
60 Hz
DC Output
Nominal voltage
1000-watt models
12.0 VDC
1500 and 1800-watt models
12.0 VDC
Min battery voltage for charging
0.0 VDC
0.0 VDC
Max output voltage
14.4 VDC
14.4 VDC
Nominal output current
User selectable:
2A, 5A, 10A, 20A (Freedom HF 1000)
5A, 15A, 35A, 55A (Freedom HF 1055)
User selectable:
2A, 10A, 20A, 40A
Charger current derating
Charger current will automatically derate as
internal temperature exceeds 80 °C.
Charger current will automatically derate as
internal temperature exceeds 80 °C.
Efficiency at nominal output
75%
75%
Other
1000-watt models
1500 and 1800-watt models
No load input power (producing output voltage)
10W
10W
Off mode current draw
1mA
1mA
Regulatory Approvals
1000-watt models
1500 and 1800-watt models
ETL approved to CSA 107.1, UL458, and UL458 Marine Supplement (drip shield with product
number 808-9531 required).
40
Freedom HF Installation Guide
Freedom HF Install Guide.book Page i Tuesday, April 29, 2014 12:22 PM
Freedom HF Install Guide.book Page ii Tuesday, April 29, 2014 12:22 PM
Schneider Electric Solar
Inverters USA Inc.
+1 800 670 0707
+1 408 987 6030
www.xantrex.com
975-0395-01-01
Printed in China
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