User Manual - Alternative Energy, Inc.
Contents
1. 19 21 VDC 33 VDC 53 9 A 61 6 A XP 1100 48VDC 55 2 VDC 41 5 42 5 VDC 62 VDC 27 A 30 5 A XP 1100 66VDC 75 9 VDC 57 5 58 5 VDC 91 VDC 19 6 A 22 1 A XP 1100 108VDC 124 0 VDC 94 95 VDC 149 VDC 12 A 13 6 A XP 1100 12VDC 0 AWG 00 AWG 0000 AWG 0000 AWG XP 1100 24VDC 6 AWG 4 AWG 2 AWG 0 AWG XP 1100 48VDC 12 AWG 10 AWG 8 AWG 6 AWG XP 1100 66VDC 16 AWG 12 AWG 10 AWG 10 AWG XP 1100 108VDC 18 AWG 16 AWG 14 AWG 14 AWG Page 12 See page 13 for Mechanical dimensions and mounting hole locations XP600 1100 INSTALLATION AND OPERATION MANUAL APPENDIX B Page 13 0 7 690 0 3 565 0 780 1 280 8 897 9 342 12 100 0 375 7 315 7 690 281 0 125 DIA 4 PLCS 0 12 100 0 3 565 0 7 690 0 3 565 0 375 7 315 7 690 0 780 1 280 11 842 12 345 15 050 281 0 125 DIA 4 PLCS 0 15 050 0 3 565 XP600 XP1100 TOP FRONT SIDE FRONT SIDE TOP XP600 1100 INSTALLATION AND OPERATION MANUAL APPENDIX C Page 14 Note Use Rated Current and voltage in Appendix A to select an appropriate Toggle Switch or Relay for your specific model inverter XP 600 and XP 1100 with DC Toggle Switch XP 600 and XP 1100 with DC Relay INSTALLATION CAUTION Be sure to disconnect all DC power to installation wiring Be sure to disconnect batteries and chargers Make all connections to the2. XP600 1100 INSTALLATION AND OPERATION MANUAL Page 4 specify these products is in Watts W which is power the inverter can actually deliver If Exeltech inverters were specified in VA Our 1100 Watt inverter could be rated at 1375 VA at 8 power factor 1570 VA 7 pf or an incredible 2200 VA 5 pf It is confusing to specify a product in VA because the power factor must also be specified Exeltech s XP Series inverters can output their full rated o o power continuously at 30 C 86 F The inverter can maintain a spectrally pure output with any load due to a specially designed non linear control loop in the primary DC to DC converter This circuitry is one of three circuits which protect the inverter from any overload condition XP 600 and XP 1100 These inverters can supply twice their rated output power for 3 seconds in order to start motors or supply in rush currents to electronic loads If output power is exceeded for greater than 3 seconds output voltage is reduced to a level which will provide the inverter s rated power to the load by clipping tops of the waveform The inverter can operate safely in this mode indefinitely Should the overload condition clear the inverter will again provide the cleanest Sine Wave in the industry This over current circuitry insures maximum peak current does not exceed 300 of rated RMS current Should this number be exceeded it will again reduce output voltage as required to ma
3. inverter BEFORE connecting DC leads to the battery Inverter Battery DC Toggle Switch See Appendix A Inverter Battery Relay Coil Relay Normally Open Contacts DC Toggle Switch Low Current XP 600 and XP 1100 Rear View with access cover removed AC DC Connections BAT BAT GROUND NEUTRAL LINE REMOTE DO NOT REMOVE THE BONDING STRIP Ground to Neutral unless grounding of neutral is accomplished elsewhere such as at a service entrance box Maintain ground connection in any case Bonding strip XP600 1100 INSTALLATION AND OPERATION MANUAL Document subject to change without notice 931 X61M 0C 7317 Jack Newell Blvd North Fort Worth Texas 76118 7100 817 595 4969 voice 817 595 1290 fax 800 886 4683 toll free website www exeltech com TECH Made in the USA
4. 7317 Jack Newell Blvd North Fort Worth Texas 76118 7100 817 595 4969 voice 817 595 1290 fax 800 886 4683 toll free website www exeltech com TECH XP600 1100 INSTALLATION AND OPERATION MANUAL R Manufacturer of UL Listed Products XP600 1100 INSTALLATION AND OPERATION MANUAL Page 1 Copyright 2001 Exeltech Inc All rights reserved This Document may not be copied photocopied reproduced translated or converted to any electronic or machine readable form in whole or in part without prior written approval of Exeltech Inc Acknowledgments Project Management Ben Baker and John Goetz Writing Gary Chemelewski Copy Editing Ben Baker Art Photography and Layout John Goetz July 2002 Exeltech 7317 Jack Newell Blvd North Fort Worth Texas 76118 7100 XP600 1100 INSTALLATION AND OPERATION MANUAL Page 2 Introduction 1 0 Standard Features 2 0 Installation 3 0 Operation 4 0 Appendix A Appendix B Appendix C page 3 page 5 page 8 page 11 page 12 page 13 page 14 Table of Contents XP600 1100 INSTALLATION AND OPERATION MANUAL Page 3 Thank you for purchasing the finest sine wave inverter in the power conversion industry Exeltech s journey to excellence includes the first affordable sine wave inverter first modular inverter system first N 1 redundant inverter system and the cleanest sine wave output in the industry Exeltech strives to manufacture products of the highest possible qualit
5. FF SWITCH OVER VOLTAGE PROTECTION UNDER VOLTAGE PROTECTION OVER TEMPERATURE PROTECTION OVERPOWER SHORT CIRCUIT PROTECTION The inverter has three levels of overpower protection The first limits peak instantaneous current The second system limits absolute power coming from the module Both of these circuits act to reduce output XP600 1100 INSTALLATION AND OPERATION MANUAL Page 7 voltage as required to limit current to a safe level The overpower protection circuit will recover instantly when the overpower condition clears The third is short circuit protection If the over current condition is so severe that it causes output voltage to collapse to 1 Vp for more than 1 second the inverter will shut down and not auto matically restart This requires the user to clear the short circuit safely and guarantee that hazardous voltage will not come back on line until desired To reset the inverter from this condition cycle power switch OFF then ON again XP600 1100 INSTALLATION AND OPERATION MANUAL CAUTION WARNING WARNING CAUTION It is essential to read and understand all Warnings Cautions and Notes before any connections are made to the Unit or System If further assistance is needed call 817 595 4969 and ask for Customer Service The inverter is designed to operate from a Battery Performance cannot be guaranteed and damage can result when a charger or power supply is used w
6. connected from the system and the battery charger continues to supply current When battery voltage falls to within 2 to 4 of low line voltage the LOW BATT THERM buzzer will sound If the condition continues without reducing load to the inverter or adding charge to the battery the inverter will shut off When voltage rises to approximately 95 of nominal battery voltage the inverter will turn back on and the alarm condition will clear The inverter can be manually reset by cycling the on off switch This will reset the protection circuit and turn the inverter on at any voltage above minimum voltage The inverter is also protected against overheating It will provide its full rated output up to the temperature listed in the specification sheet If it is subjected to higher ambient temperatures or air circulation is blocked the inverter may overheat If the LOWBATT THERM buzzer sounds immediate action is required or the inverter will shut down Either reduce load or provide more cooling in the immediate environment If no action is taken the inverter will likely shut down within 2 minutes When the inverter shuts down the alarm condition will persist and the cooling fan will continue to run Since the inverter has eliminated its load it will cool fairly quickly It will automatically restart when it has cooled sufficiently and the LOW BATT THERM alarm will clear 105 C internal temperature Warning buzz 5 C before shut off ON O
7. ction from the Rear Panel terminal labeled REMOTE to one pole of a small toggle switch Then from the other pole of toggle switch make a connection to battery negative Make sure the toggle switch is off Note in order for the Remote On Off switch to operate inverter On Off switch on the Front Panel must be off Appliances Loads may be hard wired to the rear terminal strip shown in Appendix C in addition to the loads plugged into the front outlets The sum of the loads must not exceed the inverter output capability 2 3 4 5 Page 10 XP600 1100 INSTALLATION AND OPERATION MANUAL TURN ON INVERTER XP 600 and XP 1100 Note TURN ON APPLIANCE LOAD 1 2 3 Note Turn inverter on using Toggle Switch on Front Panel or the REMOTE switch if installed LED next to the switch will illuminate indicating the inverter is operational If using REMOTE switch the Front Panel Switch must be off If either switch is on the inverter will turn on Both switches must be off for the inverter to turn off Check Input Power Requirements of the appliance Make sure that it is less than Rated Output Power of the inverter If more than one appliance will be run simultaneously the sum of their Input Power Requirements must be less than Rated Output Power of the inverter If Appliance Load has been hard wired to the barrier terminal strip as illustrated in Appendi
8. d under the Rear Cover Use Appendix A to choose the appropriate gauge wire for your specific model provides the User with a remote method to turn the inverter on and off REMOTE connection is on the barrier terminal strip located under the Rear Cover All models except 230 VAC output have two NEMA 5 15R outlets standard wall receptacle located on the Front Panel Additionally they may be hard wired to appliance load using connections on the barrier terminal strip under Rear Cover is provided by a thermostatically controlled brushless fan located on the Front Panel located on the front panel will be ON when inverter is powered up and DC power is available produces an audible alarm if DC input voltage falls to a level within 2 to 4 of the low limit of inverter or if there is an over temperature condition inverters have an IEC 320 receptacle located on the Front Plate Standard Features 2 0 XP600 1100 INSTALLATION AND OPERATION MANUAL Page 6 located on front panel turns the inverter on and off If input voltage to the inverter exceeds set limits the inverter will immediately and without warning shut off When input voltage returns to normal range the inverter will immediately restart Since high over voltages tend to have very fast edges the inverter must shut down quickly to protect itself This kind of fault usually occurs if the battery is suddenly dis
9. ing a mounting location consider the following requirements listed in order of importance Inverter must be sheltered from the elements Select a clean dry location Inverter requires adequate ventilation for cooling With proper cooling the inverter will operate efficiently and meet its published ratings All models can be mounted in several positions Best position with fan down Second best horizontal Third vertical with fan up Least preferred upside down Inverter should be mounted as close to the battery as possible Shorter wire has less resistance which translates to increased efficiencies An in line fuse is recommended to protect the battery and wiring to the inverter This fuse should be located very close to the battery positive terminal To select appropriate size fuse consult the Rated and Peak Current table in appendix A charger and inverter are off XP 600 and XP 1100 Positive and Negative input terminals are 5 16 studs with brass hardware They are provided under the Rear Cover Use Appendix A to choose the appropriate gauge wire for your specific model and distance from the battery 1 Disconnect the grounded terminal of battery and make sure the Page 9 XP600 1100 INSTALLATION AND OPERATION MANUAL Make DC input connections to the inverter as illustrated in Appendix C Optional Using 12 18 AWG wire make Remote On Off conne
10. intain that limit Again the inverter can operate in this mode indefinitely so that when the overload clears output voltage is automatically restored The third protection mechanism is short circuit If the inverter exceeds it s peak current Ip capacity for a prolonged period it will shut off automatically The period of time required to shut off changes with the degree of overload A high overload shuts off in one second A slight overload may require several seconds This typically requires a 5 ohm load per 1000 Watts for several seconds This guarantees the inverter is disabled in the event that the user attempts to clear the short without first shutting off the inverter The inverter in fact acts as an extremely high performance circuit breaker The short circuit and overload circuitry responds much faster than any normal fuse or breaker so no external current limiting devices are necessary Exeltech s XP Series inverters can output their full rated power continuously at 30C 86F The inverter is derated 20 of its XP600 1100 INSTALLATION AND OPERATION MANUAL Page 5 full power for every 10 degrees C over 30 degress C IE 80 of normal capacity at 40 degrees C 60 at 50 degrees C etc DC INPUTS REMOTE ON OFF AC OUTPUTS COOLING DC POWER ON LED LOW BATT THERM BUZZER XP 1100 XP 600 230 VAC Positive and Negative input terminals are 5 16 studs with brass hardware They are accesse
11. ithout a battery in the circuit Before any connections are made to the Unit or System be sure to disconnect the battery terminals Always disconnect the grounded battery terminal first When re connecting connect ungrounded terminal first and grounded terminal last The AC neutral lead is bonded to chassis through the barrier terminal strip connector located on the back of unit Chassis must be bonded to earth ground through the external ground connector located on the rear of the unit See illustration on page 14 Installation 3 0 Page 8 Battery Inverter A A Positive earth ground B Negative Earth Ground Note Only A or B NOT BOTH The Negative or Positive terminal of the battery DC Source must be bonded to earth ground It s recommended that it be to the same earth ground used for AC ground Refer to the figure for wiring illustration XP600 1100 INSTALLATION AND OPERATION MANUAL CAUTION CAUTION INSTALLATION Location 1 2 3 INSTALLATION Wiring Polarity of leads is critical to avoid damage to the unit or system Check batteries and battery cables for correct polarity and voltage Observe all National and Local Electric Codes when connecting AC Power Connections Mounting location is critical to performance and life span of the inverter Heat and Moisture are the two worst enemies of any electronic device Therefore when choos
12. x C then turn appliance on Otherwise Plug the appliance into the provided receptacle on Front Panel then turn appliance on It is recommend that the inverter be turned ON before the appliance load Operation 4 0 Page 11 XP600 1100 INSTALLATION AND OPERATION MANUAL APPENDIX A XP 600 12VDC 13 8 VDC 10 4 10 6 VDC 16 5 VDC 58 8 A 66 6 A XP 600 24VDC 27 6 VDC 19 21 VDC 33 VDC 29 4 A 33 6 A XP 600 48VDC 55 2 VDC 41 5 42 5 VDC 62 VDC 14 7 A 16 6 A XP 600 66VDC 75 9 VDC 57 5 58 5 VDC 91 VDC 10 7 A 12 1 A XP 600 108VDC 124 0 VDC 94 95 VDC 149 VDC 6 5 A 7 4 A MODEL NORMAL VDC MINIMUM VDC CUT OFF ALARM MAXIMUM VDC RATED CURRENT PEAK CURRENT XP 600 12VDC MODEL Input Power Requirements Recommended Input Wire Sizes For Variable Distances from the Battery 4 AWG LESS THAN 5 0 AWG LESS THAN 10 0 AWG LESS THAN 15 00 AWG LESS THAN 20 XP 600 24VDC 10 AWG 6 AWG 4 AWG 4 AWG XP 600 48VDC 16 AWG 12 AWG 10 AWG 10 AWG XP 600 66VDC 18 AWG 16 AWG 14 AWG 12 AWG XP 600 108VDC 18 AWG 18 AWG 18 AWG 16 AWG Note The table specifies standard wire sizes not smaller than 18 AWG that will provide less than a 2 voltage drop at Low line Input voltage and Rated Output Power XP 1100 12VDC 13 8 VDC 10 4 10 6 VDC 16 5 VDC 107 8 A 122 1 A XP 1100 24VDC 27 6 VDC
13. y and is dedicated to 100 customer satisfaction Proudly built in the USA with American parts Exeltech is committed to TL 9000 standards and beyond adding people and procedures continually to further improve quality and customer service We welcome you as a customer to the Exeltech family Congratulations XP series inverters provide the cleanest best regulated sine wave output over the widest DC input of any inverter on the market today They are extremely low in Total Distortion specified to 2 and typically better than 1 5 Total Harmonic Distortion is typically 0 8 to 0 9 Remaining distortion is a result of residual switching noise which amounts to a very clean 25 KHZ sine wave superimposed on the fundamental output No significant harmonics of 25 KHZ exist This spectral purity will exist over the inverter s entire operating envelope including non linear and reactive loads As long as peak output current remains less than 300 of rated current total harmonic distortion will remain within the 2 spec Peak current capability of the inverter is key to understanding it s operational envelope As long as the inverter is supplying less than this amount it will function properly and operate virtually any load Many inverters are rated in Volt Amps VA as opposed to Watts This is in an attempt to make an inverter or UPS Uninterruptible Power Supply appear larger than it really is The only fair way to Introduction 1 0
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