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Xantrex DR1512 User's Manual

1. 2 5 DC Disconnect 2 5 Battery Considerations 2 5 Battery Location 2 6 Battery Temperature 2 6 Basic Configurations 2 6 Generators 2 10 Inverter Mounting 2 11 DC Wiring 2 13 DC Circuit Grounding 2 13 General DC Grounding Requirements 2 13 975 0012 01 02 RevA ix Contents Batteries 2 15 Battery Types 2 15 Battery Bank Sizing 2 15 Battery Configuration 2 15 Battery Cable Sizing 2 16 DC Disconnect and Over current Protection 2 17 Battery Cable Connections 2 18 Connecting the Battery Bank to the Inverter 2 19 Installing a Batt
2. 3 16 Charger Controls and Indicators 3 18 Equalize Positions on Battery Type Selector Switch 3 19 Equalize 1 Battery Charger Rate Potentiometer Position 1 3 20 Equalize 2 Battery Capacity Rate Potentiometer Position 0 3 20 6 volt Battery Wiring Series Configuration B 8 12 volt Battery Wiring Series Configuration B 9 Battery Wiring in Parallel B 9 Battery Wiring 24 volt Parallel Configuration Step 1 B 10 Battery Wiring 24 volt Parallel Configuration Step 2 B 10 Battery Wiring 24 volt Parallel Configuration Step 3 B 11 Example of Battery Connections for Stacked Inverters 24 Vdc shown B 12 Conventional Home type Wiring C 2 Multi wire Branch Circuit Wiring and Current Flow C 3 120 Vac Inverter Incorrectly Wired in a Multi wire Branch Circuit C 3 Multi wire Branch Circuit Wiring C 4 Using a Step down Autotransformer in Multi wire Branch Circuit Wiring C 6S 975 0012 01 02 RevA Tables Table 1 1 Table 1 2
3. B 2 Sealed Batteries Gel and AGM B 3 NiCad and NiFe Batteries B 3 Understanding Battery Capacity Ratings B 4 Battery Bank Sizing B 4 Understanding Amp hour Requirements B 5 Calculating Amp Hours B 5 Amp Hour Example Worksheet B 6 Battery bank size worksheet B 7 Battery Configurations B 8 Wiring Batteries in Series B 8 Wiring Batteries in Parallel B 9 Wiring Batteries in Series Parallel B 10 Battery Connections for Stacked Inverters B 12 975 0012 01 02 RevA xi Contents Battery Maintenance B 13 Battery Charging B 13 Equalization Charging B 15 General Maintenance B 16 C Multi wire Branch Circuit Wiring Multi wir
4. 4 2 Problem Loads 4 3 Ceiling Fans 4 3 Cell Phones 4 3 Computers and Sensitive Electronics 4 3 Consumer Electronics 4 3 Clocks 4 4 Decreasing Loads 4 4 Dimmer Switches 4 4 Fluorescent Lights 4 4 Heavy Loads 4 4 Microwave Ovens 7 4 4 Printers 4 5 Rechargeable Devices 4 5 Undersized Loads 4 5 Specifications Specifications of the DR Inverter A 2 Battery Information Introduction B 2 Battery Types B 2 Deep cycle Flooded Lead Acid FLA
5. 1 4 Remote Control RC8 1 4 Stacking Interface DRI 1 4 Conduit Box DRCB 1 4 Unpacking and Inspection 1 4 Model Identification and Numbering Conventions 1 5 2 Installation Pre installation Planning 2 2 Location 2 2 Mounting 2 3 Ventilation 2 3 Tools Required 2 3 Hardware Materials Required 2 4 Wiring Considerations 2 4 DC Terminal Connections 2 4 Grounding Considerations 2 4 AC Grounding 2 4 DC Grounding 2 4 Wire Routing 2 4 Electrical Panels and Circuit Breaker Requirements 2 5 AC Distribution Panel Sub Panel
6. 2 8 Off Grid Configuration with Renewable Energy Sources 2 9 Charge Rate versus Peak AC Voltage 2 10 Dimensions not to scale 2 11 Suggested Mounting Method 2 12 Mounting on Plywood 2 12 DC Grounding 2 14 Battery Cable Connections 2 18 DC Terminals on the DR Inverter 2 19 Connecting the Battery Bank to the DR Inverter Charger 2 20 Battery Temperature Sensor BTS RJ11 Jack Location 2 21 Connecting the BTS to the DR Inverter 2 21 AC Side Cover Panels 2 23 AC Terminals for AC Input to the Inverter 2 24 AC Terminals for AC output to the Sub panel 2 25 AC Wiring On Grid Application 2 26 AC Wiring using a Generator On Grid Application 2 27 AC Wiring using a 120 Vac Generator Off Grid Application 2 28 AC Wiring using a 240 Vac Generator with 120 Vac Loads only Off Grid Application 2 29 AC Wiring for du
7. DC Disconnect t DR Inverter Charger s OE ahs AC Input J AC Output 7 To Primary System Ground AC Distribution Panel Sub Panel Battery Temperature Sensor BTS Remote Control Optional Battery Bank Figure 2 1 On Grid Basic Configuration Utility Backup AC Generator Conduit if used DC Conduit Box DRCB DC Disconnect t Optional m DR Inverter Charger l 2 i Generator Disconnect acinput J J AC Distribution Panel AC Loads Q Remote Control ARC Optional w F a awe To Primary System Ground p j Battery Temperature Sensor BTS Battery Bank Figure 2 2 Off Grid Configuration Generator only 975 0012 01 02 RevA 2 7 Installation Renewable Energy RE Sources Photovoltaic DC Diversion Load for Hydro Generator DC Diversion Load for Wind Generator Disconnect and PVGFP Controller Load Controller Main Electrical Panel DC Conduit Box DRCB Optional To Primary System Ground AC Distribution Panel Sub Panel AC Loads cs ls 6 Battery Temperature Sensor BTS Remote Control Optional Battery Bank Figure 2 3 On Grid Configuration with Renewable Energy Sources 2 8 975 0012 01 02 RevA Pre installation Planning Renewable Energy RE Sources Photovoltaic Hydro Wind Ve S ZA S 7 O N DC Com
8. Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT Exclusions If this product is a consumer product federal law does not allow an exclusion of implied warranties To the extent you are entitled to implied warranties under federal law
9. AC input wiring from the generator to the inverter charger if used DC input wiring from the RE to the inverter charger if used DC input wiring from the batteries to the inverter charger e AC output wiring from the inverter charger to the sub panel e Battery Temperature Sensor cable from the batteries to the inverter charger if used e Remote control cable to the inverter charger if used e DC ground from the batteries to an external ground rod e Load circuit wiring rerouted from the main service panel to the sub panel Check for existing electrical or plumbing prior to making cuts in the walls Cut holes in the walls at appropriate locations for routing wiring cables Electrical Panels and Circuit Breaker Requirements The following electrical panels and circuit breakers may be required for this installation AC Distribution Panel Sub Panel DC Disconnect Loads backed up by the inverter will need to be rerouted from the main electrical panel to a sub panel This can be done several different ways depending upon the installation Always refer to electrical codes for safe wiring practices Install a DC disconnect breaker or fuse in the positive battery line This breaker protects the DC wiring in the event of an accidental short Size the breaker in accordance with the battery cables Switch this breaker OFF whenever servicing the batteries Battery Considerations 975 0012 01 02 RevA The DR Inverter can support
10. Operation contains information about how to operate the DR Inverter Charger Operation Front Panel Controls and Indicators All operating controls indicators and sense connectors are located on the front panel of the unit The controls are easily accessible and the LEDs provide inverter charger status at a glance Battery Type Selector DEEP CYCLE LEAD ACID 7 8 LEAD CALCIUM MAINTENANCE FREE 6 9 AGM GEL CELL 5 0 EQUALIZE 1 4 1 EQUALIZE 2 BATTERY CHARGER BULK ORANGE SOLID ABSORPTION ORANGE BLINKING FLOAT GREEN SOLID BATTERY CHARGER RATE BATTERY HIGH RED BATTERY LOW GREEN OVER DISCHARGE PROTECTION OVER TEMP RED OVERLOAD GREEN AC TRANSFER VOLTAGE SPARC MODE WATTS BATTERY CAPACITY POWER ON OFF f COM PORT BATTERY SENSE Z LED Status Battery Charge Control Indicators Battery Type Selector Inverter Mode Controls Search Watts Inverter Mode Indicator Battery Sense Port L POWER ON OFF COMPort Figure 3 1 Front Panel Controls and Indicators POWER ON OFF Switch The POWER ON OFF control is a momentary contact switch that turns the inverter charger ON or OFF by pressing it once When the inverter is first connected to the batteries it will run through a self test consisting of flashing the LEDs in sequence operating the cooling fan momentarily and switching the transfer relay three times Once the self test has successfully completed the POWER ON OFF switch
11. Place a layer of baking soda on the shelves to neutralize any acid that may be spilled in the future lead acid batteries only Enclosures located outside must be rainproof and screened to prevent access by rodents or insects The battery enclosure should provide a fairly stable temperature for the batteries If it is installed in a cold environment insulation should be used to protect the batteries from the cold The insulation also provides a more consistent temperature and better system performance The battery enclosure should not be installed in direct sunlight where the summer sun can overheat the batteries Locate the enclosure where it will be protected from the afternoon sun and provide vents in the top and bottom of the enclosure to provide air flow High battery temperatures greatly shortens the life of the batteries Basic Configurations 2 6 The following illustrations show basic applications for the DR Inverter Charger They include the following configurations e On Grid Configuration Utility Backup e Off Grid Configuration Generator only e On Grid Configuration with Renewable Energy Sources e Off Grid Configuration with Renewable Energy Sources and a Generator Consult with your system design for other possible configurations depending on site and code requirements 975 0012 01 02 RevA Pre installation Planning Main Electrical Panel Conduit if used A DC Conduit Box DRCB Optional
12. The temperature compensation calculations are derived from Table B 5 Table B 5 Temperature Compensation Calculation Battery Type 24 volt Systems 48 volt Systems Lead Acid 0 060 volts 60 mV per 0 120 Volts 120 mV per degree degree Celsius Celsius NiCad 0 040 volts 40 mV per 0 080 volts 80 mV per degree degree Celsius Celsius Important Ifthe battery temperature is allowed to fall to extremely cold temperatures the inverter with a BTS may not be able to properly recharge cold batteries due to maximum voltage limits of the inverter Ensure the batteries are protected from extreme temperatures B 14 975 0012 01 02 Rev A Battery Maintenance Equalization Charging Purpose Effect Non equalized batteries Frequency An equalize charge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells Equalize charging also produces gassing which stirs up the electrolyte mixture and helps distribute the acid more evenly Batteries that are not equalize charged can be damaged by sulfate accumulation thus sealing off a percentage of the plates and reducing battery capacity They may also have sulfuric acid accumulate at the bottom of the battery potentially damaging the plates At the same time the electrolyte at the top of the battery gets watery This effect is called stratification Every month or two the batteries should be equalize charged CAUTION Damage
13. Measure 7 5 8 from the center of the first 2 x 4 and draw another level line Place the center of the second 2 x 4 over this line and secure to the wall as described in Step 5 5 Using the dimensions illustrated in Figure 2 6 drill mounting holes into the center of the 2 x 4 s for the inverter 6 Secure the inverter to the 2 x 4 s using 4 x 1 inch lag bolts and washers Wall studs 16 inches on center behind wallboard 7 5 8 c c 2 x 4 mounting supports a 2 x 4 s must span 3 studs from floor to provide adequate Wallboard T support BE Approximately 4 5ft Figure 2 7 Suggested Mounting Method Wall studs 16 inches on center behind wallboard Ensure the plywood spans across a minimum of three wall studs for adequate support Approximately 4 5 ft from floor Figure 2 8 Mounting on Plywood 2 12 975 0012 01 02 RevA DC Wiring DC Wiring This section describes the DC wiring requirements and how to make the connections It provides the required cable and wire sizes recommended lengths for cables and disconnect circuit breaker requirements DC Circuit Grounding Grounding is an important part of the system installation and must be performed correctly to ensure safe operation of the equipment Grounding requirements vary by country and application Consult the NEC for specific requirements The ground conductor should be sized appropriately for the over current protection device being
14. T e RETE EEA AC Distribution Kici DRI Panel Sub panel DE Pe Stacking 240 Vac Panel li I l oe Cable nae Ee 120 Vac on on 240 Vac Loads aa F ae Loads raia iR AE E GROUND i Figure 2 22 AC Wiring for dual inverters On Grid Application 120 Vac models only 975 0012 01 02 RevA Installation AC Generator 120 240 Vac LEGEND GROUND Be sure to check the Generator for a Neutral to Ground Bond and remove it There can only be one Neutral to Ground bond in the system NEUTRAL D Generator Disconnect 7 Pe eonen Optional 1 DR Inverter Charger Primary 1 i i 1 H i 4 Vy H i i li i i fi ly i i DR Inverter Charger il li i A Secondary H H o gt e6 I I i i 1 I I H i l i i LE g e Jaj l i i EE sa l i i aoe A j ee l l i cuaccacnennccnccnonnenennea os a I l l l Cee I I I i I li i Pa i AC Distribution 1 l i DRI Panel Sub panel 1 i Stacking ri I ij Cable i 240 Vac Panel J j i i i mane 240Vac it ae Loads i si w 10 H H H e amp 3 i a an o ii 120 Vac ba i ti Loads H it E R4 if a i i jt H of ee eer Ei S S 8 it Hin Neutral to Ground Piney Syston et Bed Ground a U L Seeeeeoe2ee222 AARAAAEAAASOLSS Figure 2 23 Wiring for dual inverters On Grid Application 120 Vac models only 2 32 975 0012 01 02 Rev A Operation Chapter 3
15. Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 4 1 Table A 1 Table A 2 Table A 3 Table A 4 Table B 1 Table B 2 Table B 3 Table B 4 Table B 5 Table B 6 Model Identification and Numbering Conventions 1 5 Letter Suffix Code Definitions 1 6 Peak Input Filtrate versus Charging Current 2 10 Safety Ground Conductor Size 2 13 Minimum Recommended Battery Cable Size versus Length 2 16 Battery Cable to Maximum Breaker Fuse Size 2 17 Minimum Recommended Wire Size Torque Values Input and Output and Maximum Output Breaker Size 2 23 Battery Type Selector Switch Settings 3 5 Approximate Charge rate Setting Amperage 3 8 ODP AC Transfer Voltage 3 10 AC Pass through Circuit Breakers 3 15 Battery Charger Circuit Breakers 3 15 Troubleshooting the DR Inverter 4 2 Electrical Specifications for the DR Inverter Charger 120 Vac 60 Hz Models A 2 Electrical Specifications for the DR Inverter C
16. apart If not then 2x4 s or plywood can be used A WARNING Personal Injury Use appropriate lifting techniques Have extra people on hand to assist in lifting the inverter into position while it is being secured To secure the DR Inverter to the wall studs 1 Locate the studs and mark their location on the wall 2 Measure the desired height from the floor for the inverter to be mounted 3 Using a level run a horizontal line The length of the line must span at least three studs 4 Using the dimensions illustrated in Figure 2 6 drill mounting holes into the center of the studs for the inverter 5 Secure the inverter to the studs using 4 x 1 inch lag bolts and washers DC 20 1 8 51 cm AC Side 16 41 cm Side a 14 36 cm EEE Positive re Battery Terminal ov 7 5 8 a 19 cm Ground Lug gt Q 8 3 8 ntrex 21 cm xa Negative KJ ee g Batte Terka 1 2 5 cm 7 18 cm 1 7 8 5 cm 8 20 cm Figure 2 6 Dimensions not to scale To secure the DR Inverter to the mounting location using 2 x 4 s or plywood 1 Repeat steps 1 through 3 above 2 Place a pre cut 2 x 4 flat side against the wall on the marked location and drill pilot holes through the 2 x 4 s and studs 975 0012 01 02 RevA 2 11 Installation 3 Secure the 2 x 4 with 10 wood screws length to penetrate 11 2 inches into the studs as shown in Figure 2 7 4
17. s main breaker box before proceeding 1 Determine the location of the sub panel and install it according to the manufacturer s directions Install the AC conduit between the sub panel output and inverter Install conduit between the inverter input and the main breaker box Determine which circuits require backup Install the appropriate circuit breakers into the sub panel Install an appropriately sized circuit breaker 30 amp maximum in the sub panel This will later be wired to the inverter s output If two inverters are being used in a stacked configuration install a double pole circuit breaker for 240 Vac service Accessing the AC Terminals AN CAUTION Equipment Damage The inverter s AC output must never be wired to the utility or generator output This will cause severe damage to the inverter which is not covered under warranty All AC wiring connects to the terminal block located on the right hand side of the inverter To make the AC connections to the inverter 1 To access the terminal block remove the side cover panels if installed by removing the two or three Phillips screws Units are shipped without the covers installed packed in a small plastic bag with additional hardware Locate the AC input and output terminals on the block Refer to Figure 2 15 on page 2 23 975 0012 01 02 RevA AC Wiring Important The lower AC cover varies depending on the model DR24XX and DR36X
18. to the extent permitted by applicable law they are limited to the duration of this Limited Warranty Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages so the above limitation s or exclusion s may not apply to you This Limited Warranty gives you specific legal rights You may have other rights which may vary from state to state or province to province Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFICALLY PLEASE NOTE THAT THE DR INVERTER CHARGER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES WITHOUT LIMITING THE GENERALITY OF THE FOREGOING XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX DR INVERTER CHARGER IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES Please note that the DR Inverter Charger is not intended for use as an uninterruptible power supply and Xantrex makes no warranty or representation in connection with any use of the product for such purposes WA 2 975 0012 01 02 RevA Warranty and Return Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization RMA number and the correct factory Ship To address Products must also be shippe
19. BA i IVE rom Battery Negative Terminal Ventilation Holes lt F e l a amp al Figure 1 3 DC Side of the DR Inverter Optional Equipment The following options are available for the DR Inverter Chargers Remote Control RC8 The RC8 allows the inverter to be switched ON or OFF remotely and includes an LED status indicator This unit is also compatible with the RC4 the predecessor to the RC8 although the RC4 is no longer available for purchase from Xantrex Stacking Interface DRI The DRI stacking interface provides 3 wire 120 240 Vac at twice the power using dual DR Inverters 120 Vac 60 Hz units only Conduit Box DRCB The DRCB conduit box connects to the DC side of the inverter and accepts a DC conduit run Unpacking and Inspection Carefully unpack the inverter charger from its shipping carton 975 0012 01 02 RevA Features Important The unit weighs 35 45 Ib 15 9 20 4 kg depending on model Have additional help available if necessary to assist in lifting the unit during installation O Verify all of the items listed on the packing material sheet are present Please call Xantrex Customer Service at 800 670 0707 if any items are missing O Save your proof of purchase This is required if the unit should require warranty service O Save the original shipping carton and packing materials If the inverter ever needs to be returned for service it should be
20. Battery Bank Sizing Calculation To calculate the battery bank size use the average amp hours per day that you calculated using Table B 1 then make the other calculation shown in Table B 2 to calculate the battery bank size you need to support your loads Table B 2 Determining Battery Bank Size Average amp hours per day 95 Divided by inverter efficiency 90 for DR Inverter 0 9 Divided by battery efficiency usually 0 75 0 75 Adjusted hours per day 140 Divided by Depth of Discharge usually 60 0 6 Multiplied by days of autonomy 5 Battery bank size required 1173 Ah Worksheets Table B 1 and Table B 2 are examples only Use the specifications noted on the label of each AC appliance and fill in the values specific for the appliances used in this installation on the a work sheet Table B 3 provides a typical wattage for selected appliances However you should try to find the exact wattage on the appliance label Table B 3 Typical Appliance Wattage Appliance Watts Appliance Watts Fluorescent Type Light 10 Blender 400 Computer 200 300 Toaster 1000 Microwave compact 600 800 Hot Plate 1800 Microwave full size 1500 Washer Dryer 375 1000 Stereo or VCR 50 3 8 Drill 500 Color Television 19 150 Hair Dryer or Iron 1000 Refrigerator 3 cu ft 180 Vacuum Cleaner 1200 Refrigerator 12 cu ft 480 Coffee Maker 1200 975 0012 01 02 RevA Battery Information Battery Configuration
21. Figure 2 10 illustrates the proper method to connect the battery cables to the DR Inverter s DC terminals Do not place anything between battery cable lug and terminal surface Assemble exactly as shown 2 0 Copper Compression Lug 2 0 Aluminum Mechanical Lug Figure 2 10 Battery Cable Connections A CAUTION Equipment Damage The inverter is not reverse polarity protected Reversing the battery polarity on the DC input connections will cause permanent damage to the inverter which is not covered under warranty Always check polarity before making connections to the inverter WARNING Shock Hazard Ensure the inverter is off before disconnecting the battery cables and that AC power is disconnected from the inverter input 2 18 975 0012 01 02 RevA Positive WARNING DC Wiring Battery Terminal 36 eens j 4 Negative Torque the oa e Battery Terminal Positive m aie Battery terminal to w 10 15 ft lbs a Torque the 13 6 to 20 3 nm fg Negative Be i Battery terminal to E 10 15 ft lbs E y a 13 6 to 20 3 nm LS m Torque value for y y the Ground Lug Ground Lug 4 is 10 15 in lbs 1 1 to 1 7 nm Figure 2 11 DC Terminals on the DR Inverter Connecting the Battery Bank to the Inverter Follow the procedure below to connect the battery bank to the inverter WARNING Shock Hazard Ensure the inverter is off before connecting
22. Hot Cra oR 15 A Black Hot Current Flow 15 A Black Hot e a Current Flow 15 A Current Flow 5 A Single White Neutral 120 Vac 120 Vac Single White Neutral 120 Vac 120 Vac Current Flow 0 A Current Flow 10 A D Bare Ground J Bare Ground Bare Ground Splice p When unbalanced White Neutral Splice current flows through White Neutral Splice Out of Phase current Current Flow 15 A each leg only the Current Flow 15 A subtract at this point difference current Current Flow 0 A flows through the neutral return wire Figure C 2 Multi wire Branch Circuit Wiring and Current Flow Load Center sis 120 Vac Inverter or Generator Et T L2 amp 4 cass 15A 15A Breaker Breaker Ganged Ganged e a ee ee Red Hot Current Flow 15 A Black Hot Current Flow 15 A Single White Neutral Current Flow 30 A 120 Vac 120 Vac White Neutral Splice Current Flow 15 A WARNING FIRE HAZARD The in phase currents ADDS at this point exceeding wire capacity Figure C 3 120 Vac Inverter Incorrectly Wired in a Multi wire Branch Circuit 975 0012 01 02 RevA C 3 Multi wire Branch Circuit Wiring Identifying Multi wire Branch Circuits Identifying characteristic WARNING Shock Hazard The next step involves opening the load center exposing live circuits This procedure should only be performed by qualified persons or
23. end to the BATTERY SENSE port located on the front of the inverter 2 Secure the sensor to one of the batteries located in the center of the battery pack Battery Type Selector f CLE LEADACID 7 ee 5 RE Za SE 9 MAINTENANCE FREE 6 9 Muo s E a o eouuze Battery Sense 4 Bo EQUALIZE 2 RJ1 1 port OE EAD CALCIUM BATTERY CHARGER BULK ORANGE SOLID ABSORPTIONSORANGE BLINKING FLOAT GREEN SOLID BATTERY CHARGER RATE BATTERY HIGH RED BATTERY LOW GREEN OVER DISCHARGE PROTECTION OVER TEMP RED OVERLOAD GREEN AG TRANSFER VOLTAGE SEARCH ATTS c NVEMTER MODE BATTERY CAPACITY POWER ON OFF fi BATTERY SENS7 COM PORT a 97O 90D rje me a Shy Ano Hours Figure 2 13 Battery Temperature Sensor BTS RJ11 Jack Location DR Inverter Charger Vent outlet Battery Temperature Sensor BTS Battery Bank Figure 2 14 Connecting the BTS to the DR Inverter 2 21 Installation AC Wiring This section describes the AC wiring requirements and how to make the connections It provides the required wire sizes recommended lengths for conductors and disconnect circuit breaker requirements Important The installation of sub panels and wiring should be performed by a qualified person or a licensed electrician following all local and NEC codes AC Distribution Panel Sub panel Mounting and Conduit Installation WARNING Shock Hazard Disconnect the power from the utility
24. mSec Rating 38 amps AC 77 amps AC 412 amps AC 80 amps AC 100 amps AC 100 mSec Rating 27 amps AC 55 amps AC 29 amps AC 58 amps AC 72 Amps AC DC Input Current Search Mode 0 045 amps 0 055 amps 0 030 amps 0 030 amps 0 030 amps Full Voltage 0 700 amps 0 900 amps 0 350 amps 0 450 amps 0 500 amps DC Current at 165 amps 280 amps 80 amps 140 amps 210 amps Rated Power Short Circuit 400 amps 800 amps 280 amps 560 amps 720 amps Current 975 0012 01 02 RevA Specifications of the DR Inverter Table A 1 Electrical Specifications for the DR Inverter Charger 120 Vac 60 Hz Models Model DR1512 DR2412 DR1524 DR2424 DR3624 DC Input Voltage nominal 12 6 Vdc 12 6 Vde 25 2 Vde 25 2 Vdc 25 2 Vde DC Input Voltage Range 10 8 to 15 5 Vdc 10 8 to 15 5 Vdc 21 6 to 31 0 Vdc 21 6 to 31 0 Vdc 21 6 to 31 0 Vdc Auto Low Battery Protection enabled 11V 11 V 22 V 22 V 22 V DC Charger Rate 0 to 70 amps 0 to 120 amps 0 to 35 amps 0 to 70 amps 0 to 70 amps Adjustable Common Specifications Voltage Regulation 5 maximum Voltage Regulation 2 5 Typical Waveform modified sine wave Load Power Factor allowed 0 5 to 1 0 leading or lagging Adjustable Load Sensing Range 5 watts minimum to 100 watts maximum Series Operation Yes Force Air Cooling Variable speed fan Automatic Transfer 30 amps Relay N
25. panel Important The ground and neutral must be bonded at one place and only one place in the system If the generator is the main source of power 1 e no utility grid power then the neutral and ground connections are bonded at the generator If the generator is acting as a backup for the utility grid then the bond should be at the main utility service entrance box In this case ensure that no bond exists at the generator output To connect the AC output wiring to the sub panel 1 Connect the GROUND wire to the inverter s AC GROUND chassis terminal Connect the other end of this wire to the GROUND bus in the sub panel 2 Connect the NEUTRAL white wire to the inverter s NEUTRAL OUTPUT terminal Connect the other end of this wire to the NEUTRAL bus in the sub panel 3 Connect the HOT black wire to the inverter s terminal labeled AC HOT OUTPUT Connect the other end of this wire to the sub panel s input circuit breaker 4 Torque all inverter terminal block connections to 16 in Ibs 1 8 nm Refer to the sub panel manufacturer s specifications for wire torque requirements to sub panel terminals Torque the terminal connections to 16 in Ibs 1 8 nm GROUND NEUTRAL HOT OUT OUT Figure 2 17 AC Terminals for AC output to the Sub panel Important The two neutral connections input and output are common to one another and may be used in any combination 975 0012 01 02 RevA 2 25 Installation
26. the following reasons e Alkaline batteries such as NiCad and NiFe types have a nominal cell voltage of 1 2 volts per cell Xantrex inverters and battery chargers are optimized for use with lead acid batteries having a nominal 2 0 volts per cell that is 12 cells for a 24 volt system and 24 cells for a 48 volt system The number of cells required in a battery bank for alkaline batteries must therefore be adjusted for a 24 and 48 volt system i e 20 cells for a 24 volt system and 40 cells for a 48 volt system e Alkaline batteries require a higher charge voltage to fully recharge and drop to a lower voltage during discharge compared to a similarly sized lead acid type battery Another option for 24 volt only alkaline battery banks is to use only 19 cells instead of 20 Fewer cells allow the battery charger to operate more closely to the settings used for lead acid batteries However the battery voltage will drop to as low as 18 volts when discharging the batteries Consult the battery manufacturer or supplier regarding system requirements and battery charger settings for alkaline type batteries B 3 Battery Information Understanding Battery Capacity Ratings Discharge rate Calculation CCA rating Deep cycle batteries have their amp hour rating expressed as at the x hour rate The hour rating refers to the time it takes to discharge the batteries A faster hour rate 6 hour rate means more current is withdr
27. the generator voltage to momentarily drop Typical Setting Range for Utility Application ODP OFF Typical Setting Range for Utility Application ODP ON A 3 Q Figure 3 8 Typical Setting for Most Utility Application 975 0012 01 02 RevA 3 11 Operation Battery Capacity The Battery Capacity potentiometer is used to set the correct charge profile for the battery capacity amp hours used with the inverter see illustration below The setting allows the inverter to calculate over discharge protection values and also the end of the Bulk Absorption charge mode at which point the inverter switches to the Float mode of battery charging The potentiometer should be adjusted as close as possible to the actual capacity of the battery bank for optimum charging If the system s battery bank is larger than 1000 amp hours set the potentiometer for 1K Important If using dual inverters configurations set each charger for half the value Important Most battery manufacturers list the amp hour rating on the battery label 1000 amp hours 1000 amp hour or larger battery banks 50 amp hours small battery bank Figure 3 9 Battery Capacity Potentiometer new Important The Battery Capacity Amp Hrs potentiometer values have changed between the minimum value of 50 Ah and 1 kAh Please use the photo that matches your unit 250 amp hours 1000 amp hours 1000 amp hour or larger bat
28. the switch to the appropriate position for the system s batteries when Equalize charging has completed NEVER EQUALIZE GEL BATTERIES Use together with BATTERY CHARGER RATE potentiometer position1 or BATTERY CAPACITY potentiometer position 0 2 Equalize voltages are displayed in the table with an asterisk Switch positions 0 and 1 only 3 Switch position 7 is the default values as shipped from the factory 4 Always refer to the battery manufacturer s specifications for equalization SEARCH MODE WATTS Potentiometer 3 6 The Search Mode Watts potentiometer adjusts the current threshold required to bring the inverter out of search mode into full wave operation With search mode enabled the inverter pulses the AC output looking for an applied load With no load detected the inverter goes into the search mode to minimize energy consumption When a load is applied the load current is sensed bringing the inverter into full power operation Disabling the threshold setting the potentiometer fully CCW causes the inverter to remain ON in full power operation regardless of an applied load To set the Search Mode Watts 1 Remove the AC input source from the inverter The inverter switches to battery operation Ensure all inverter supported appliances are switched OFF 2 Turn the potentiometer completely CW to MAX Switch on the load which will trigger the inverter to full power This could be a lamp
29. to DC Loads The high voltages reached during an equalize charge may damage DC loads that are connected to the inverter Disconnect any DC loads from the inverter before running an equalize charge CAUTION Damage to Batteries Equalization should be done for standard electrolyte vented batteries only Sealed or GEL cell batteries should not be equalize charged Consult your battery supplier for details on equalize charging for the battery type in your system 975 0012 01 02 RevA Battery Information General Maintenance Water Levels Battery Cables and Posts Torque Battery Connections Flooded lead acid batteries require periodic water refills in each battery cell Only distilled water should be used in a battery as tap or mineral water may contain contaminants which will upset the battery chemistry and may damage the battery When filling the battery clean the surface first to prevent dirt from entering the cell Fill the cell to just above the plates or to the bottom of the internal collar inside the battery Never fill the cells to the top or acid will leak out during charging Check the water level in the batteries frequently when performing an equalize charge and add water if necessary Always follow the safety steps covered in the front of the manual Battery posts must be clean to reduce the resistance between the battery post and cable connection A buildup of dirt or oxidation may eventually lead to the cabl
30. to be deep discharged before being recharged making it suitable for inverter applications Flooded batteries require periodic maintenance consisting mainly of adding distilled water to the cells Types of FLA Batteries Attributes Golf Cart Popular for smaller off grid home systems e Many medium sized inverter systems use L16 batteries e Rugged long lasting e Typically rated at 6 volts 220 to 350 amp hours Industrial electric forklift e Popular in large inverter systems Extremely rugged lasts up to 10 years or more in an inverter system e Typically 2 volt cells 1 000 amp hours or more 975 0012 01 02 RevA Battery Types Sealed Batteries Gel and AGM Description Attributes Gel Cell and absorbed glass mat AGM batteries are sealed and do not require the addition of distilled water Since these batteries are valve regulated over charging can cause irreversible damage Attributes of sealed batteries are Types of Sealed Batteries Attributes Gel Cell e Gelled electrolyte instead of liquid e Long life up to 1500 cycles typical e Low self discharge Absorbed Glass Mat e Electrolyte is contained in glass fibre mats between battery plates e Similar to gel cells in characteristics e Good low temperature performance NiCad and NiFe Batteries Disadvantages Other options 975 0012 01 02 RevA These types of batteries can be used but are not optimized for the DR Inverter for
31. to oversize the diameter of the wire or parallel double the cables Important Only use copper cables Always use a properly sized cable and length rated for the amperage of the inverter and batteries A WARNING Fire Hazard Undersized cables can overheat and melt creating a fire hazard when subjected to heavy peak loads Table 2 3 provides recommended minimum cable sizes for various cable lengths and inverter amperages These recommendations may not meet all local or NEC requirements Important Run the positive and negative battery cables as close to each other as possible by taping them together This reduces the effects of inductance and produces a better waveform thus increasing efficiency See Xantrex Technical Note 008 on the Xantrex website for additional information on Battery Cable Inductance Table 2 3 Minimum Recommended Battery Cable Size versus Length Inverter Typical Model Amperage 1 to 3 feet one way 3 to 5 feet one way 5 to 10 feet one way DR1512 150 A 2 0 AWG 67 4mm 2 0 AWG 67 4 mm 4 0 AWG 107 mm DR2412 240 A 4 0 AWG 107 mm 2 0 AWG 67 4 mm 2 0 AWG 67 4 mm DR1524 75 A 2 0 AWG 67 4mm 2 0 AWG 67 4 mm _ 2 0 AWG 67 4 mm DR2424 120A 2 0 AWG 67 4mm 4 0 AWG 107 mm 4 0 AWG 107 mm DR3624 180 A 4 0 AWG 107 mm 4 0 AWG 107 mm _ 4 0 AWG 107 mm Important Ifthe system includes a large battery ba
32. 10 Profiles Three stage Charging Yes float absorption bulk Temperature Comp optional Probe BTS Remote Control RC8 4 optional a Specifications subject to change without notice b This is the minimum AC current required to obtain full pass through and maximum battery charging c Product may not meet voltage regulation specifications at other than Input Nominal at full rated load d Also compatible with the RC4 975 0012 01 02 RevA Table A 4 Environmental Specifications for the DR Inverter Charger Specifications of the DR Inverter Model DR1512 DR2412 DR1524 DR2424 DR3624 Dimensions 8 5 wx 7 25 Hx 21 D 21 6 cm W x 18 4 cm H x 54 6 cm D Unit Weight 35 Ibs 16 kg 45 lbs 21 kg 35 lbs 16 kg 40 lbs 16 kg 45 lbs 21 kg E Models 38 Ibs 18 kg N A 39 Ibs 18 kg 45 lbs 21 kg N A Ambient Temp Range rated 0 to 25 C Operating 0 C to 50 C Storage 55 C to 75 C Altitude Operating 15 000 feet Non operating 50 000 feet Mounting Wall mount with 16 mounting centers Shelf Mount a Specifications subject to change without notice b Allows for hardware extensions such as mounting rails DC terminals and front panel controls 975 0012 01 02 RevA Battery Information Appendix B Battery Information supplies general information about batteries such as battery types battery bank sizing b
33. 5 4 6 Specifications Appendix A Specifications contains information about the electrical specifications and environmental specifications of the DR Inverter Charger Specifications Specifications of the DR Inverter Table A 1 provides the electrical specifications for the DR Inverter Charger 120 Vac 60 Hz models Table A 2 provides the electrical specifications for the DR Inverter Charger 220 Vac 60 Hz models Table A 3 provides the electrical specifications for the DR Inverter Charger 230 Vac 50 Hz models Table A 4 provides the environmental specifications for all models of the DR Inverter Charger Table A 1 Electrical Specifications for the DR Inverter Charger 120 Vac 60 Hz Models Model DR1512 DR2412 DR1524 DR2424 DR3624 AC Input Voltage 120 Vac 120 Vac 120 Vac 120 Vac 120 Vac AC Input Low 40 105 Vac 40 105 Vac 40 105 Vac 40 105 Vac 40 105 Vac Transfer Voltage AC Input Current 45 amps 55 amps 45 amps 55 amps 55 amps Continuous Power 1500 VA 2400 VA 1500 VA 2400 VA 3600 VA 25 C Continuous Output 12 5 amps AC 20 amps AC 12 5 amps AC 20 amps AC 30 amps AC 25 C Efficiency 94 max 94 max 94 max 95 max 95 max AC Output Voltage 120 Vac 120 Vac 120 Vac 120 Vac 120 Vac rms Frequency 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 0 04 Crystal controlled Surge Capability 5 sec Rating 2400 watts 4200 watts 3500 watts 6200 watts 7500 watts 1
34. D IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Date and Revision March 2005 Revision Part Number 975 0012 01 02 Rev A Contact Information Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Web www xantrex com About This Manual Purpose Scope Audience Organization 975 0012 01 02 RevA The purpose of this Installation and Operation Manual is to provide explanations and procedures for installing operating maintaining and troubleshooting the DR Inverter Charger The Manual provides safety guidelines detailed planning and setup information procedures for installing the inverter as well as information about operating and troubleshooting the unit It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information The Manual is intended for anyone who needs to install and operate the DR Inverter Charger Installers should be certified technicians or electricians This Manual is organized into four chapters and three appendices Chapter 1 Introduction contains information ab
35. Number Purchased From O Purchase Date If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service Type of installation e g On Grid Off grid Length of time inverter has been installed Battery battery bank size Battery type e g flooded sealed gel cell AGM DC wiring size and length Alarm sounding Description of indicators on front panel Appliances operating when problem occurred OOd OO lald Description of problem WA 4 975 0012 01 02 RevA Index A AM radios 4 3 AWG 2 4 Batteries Battery Care and Maintenance Equalization Charging B 15 Temperature Compensation B 13 Battery Types Absorbed Glass Mat B 3 Flooded Lead Acid FLA B 2 Gel Cell B 3 Golf Cart B 2 Industrial electric forklift B 2 NiCad and NiFe B 3 Charging Bulk Voltage B 13 Charge Rates B 13 Float Voltage B 13 batteries first aid when working with vii precautions when working with vii Battery B 13 C computers 4 3 computers use with inverter 4 3 Customer Service preparing to call WA 4 F first aid vii Fluorescent lights 4 4 I Information about Your System form WA 4 inverter purchase date WA 4 serial number W A 4 P peak output voltage 4 4 Problem Loads 4 3 proof of purchase WA 4 purchase date WA 4 R Rever
36. Smart choice for power DR1512 DR2412 DR1524 DR2424 DR3624 DR1512W DR1524W DR1512E DR1524E DR1548E DR2424E e Installation and Operations Manual DR Inverter Charger www xantrex com Smart choice for power Xa ntrex DR Inverter Charger Installation and Operation Manual About Xantrex Xantrex Technology Inc is a world leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility scale systems for wind solar batteries fuel cells microturbines and backup power applications in both grid connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks DR Inverter Charger is a trademark of Xantrex International Xantrex is a registered trademark of Xantrex International Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright DR Inverter Charger Installation and Operations Manual March 2005 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDE
37. The following diagrams illustrate the AC wiring for the following basic 120 240 Vac scenarios Consult your system design for other possible configurations e On Grid Application See Figure 2 18 e On Grid using with a generator Backup See Figure 2 19 e On Grid Dual Inverter Application See Figure 2 20 e Off Grid Application using a 120 Vac Generator See Figure 2 21 e Off Grid Application using a 240 Vac Generator See Figure 2 22 e Off Grid Dual Inverter Application see Figure 2 23 AC Input Wiring On Grid Applications Follow the example below to complete the wiring for an on grid application LEGEND s o am o o ames Main I SEAE EN GROUND NIN Electrical NEUTRAL Service Panel Neutral to Ground Bond 1 LJ J i e o o o H 4 I ee Gocis Primary System sPtaer eee ee ye Ha ae Ground ne seth T 5 et n OO l g s GROUND 8et 7 i e pP 120 Vac AC Distribution Loads Panel Sub panel 120 Vac Panel Figure 2 18 AC Wiring On Grid Application 2 26 975 0012 01 02 Rev A AC Wiring AC Input Wiring using a Generator in an On Grid Application If a generator is used as a backup for the utility then a manual transfer switch must be added to provide a means to switch the generator power to the inverter s inputs The generator can be used during extended outages to recharge the batteries and provide pass through power for the loads Start an
38. X models are equipped with a conduit box and not a plate The conduit box is required for the larger diameter wire providing ample bending radius Screws Standard Cover Plate High Power Conduit Box DR15XX DR24XX and DR36XX models Figure 2 15 AC Side Cover Panels Before wiring the input of the inverter refer to Table 2 5 below for the minimum recommended wire size Important Refer to the NEC for actual wire sizes for specific installations Table 2 5 Minimum Recommended Wire Size Torque Values Input and Output and Maximum Output Breaker Size AC Input AC Output Torque Value Maximum Inverter for Terminal Output Model 120 Vac 220 240 Vac 120 Vac 220 240 Vac Connections Breaker Size DR1512 8or6AWG 10 AWG 10 AWG 16 AWG 16 in Ibs 30 amps AC 1 8 nm DR2412 6 AWG 10 AWG 10 AWG 14 AWG 16 in lbs 30 amps AC 1 8 nm DR1524 8or6 AWG 10 AWG 10 AWG 16 AWG 16 in Ibs 30 amps AC 1 8 nm DR2424 6 AWG 10 AWG 10 AWG 14 AWG 16 in lbs 30 amps AC 1 8 nm DR3624 6 AWG Not Available 8 AWG Not Available 16 in lbs 30 amps AC 1 8 nm WARNING Fire Hazard To reduce the risk of fire connect only to a circuit provided with the maximum branch circuit overcurrent protection noted above in accordance with the National Electrical Code ANSI FFPA70 975 0012 01 02 RevA 2 23 Installation Important The U S requires conduit be used in this typ
39. a disconnect device although over current protection is still required Xantrex offers a fuse block TFB providing the code required inverter over current protection for these applications Refer to the table below for the proper size disconnect device for specific cable diameters Table 2 4 Battery Cable to Maximum Breaker Fuse Size Cable Size Maximum Breaker Rating in Free Maximum Fuse Required Rating in Conduit Size Air Size 2 AWG 115 amps max N A 170 amps max TFB200 2 0 AWG 175 amps max DC175 265 amps max TFB300 4 0 AWG 250 amps max DC250 360 amps max TFB400 Important The NEC allows rounding to the next standard fuse size from the cable rating i e 150 amp cable size rounds up to a standard 175 amp size The term free air is defined by the NEC as cabling that is not enclosed in a conduit or a raceway Cables enclosed in conduit or raceways have substantially lower continuous current carrying ability due to heating factors 975 0012 01 02 RevA Installation Battery Cable Connections Battery cables must have crimped or preferably soldered and crimped copper compression lugs unless aluminum mechanical lugs are used Soldered connections alone are not acceptable High quality UL listed battery cables are available from Xantrex in an assortment of lengths 14 to 10 feet and in 2 0 AWG or 4 0 AWG sizes These cables are color coded with pressure crimped sealed ring terminals
40. acking interface cable DRI is required to connect the series stacking port of the inverters In this mode one of the inverters will function as the primary and the other inverter becomes the secondary The first unit switched ON becomes the primary and ensures the secondary s output is 180 degrees out of phase for 240 Vac operation Both units can charge the batteries or provide battery backup power during a utility outage The following illustrations provide a general overview of AC configurations using stacked inverters Detailed wiring and operating instructions are provided with the DRI interface kit available from Xantrex Technology Inc The following diagrams illustrate the AC Wiring for a basic On Grid and Off Grid application 975 0012 01 02 RevA LEGEND GROUND NEUTRAL AC Wiring Main Electrical Service Panel Neutral to Ground l Bond l I l Primary System I l Ground j is l Fel el ll lee eal eel lea ee eral eel le elle eit t DR Inverter Charger sia I l P 4 I eA l D Primary E E ce owe o oe i e i i l eens l I ae d i tis pos Jea gimen E o L NEUTRAL IN Oi o io ko es eee oe oe _ eee es ee iy B o r E l PE 1 l iy it I i E nE ee i DR Inverter Charger ae ry ty Secondary ie i i i e owe 1 i I i i a I Liu ae ane a en e Pee Hise i l Tea SOLTE i n es l I TO
41. al inverters On Grid Application 120 Vac models only 2 31 Wiring for dual inverters On Grid Application 120 Vac models only 2 32 Front Panel Controls and Indicators 3 2 Battery Type Selector Adjustment 3 4 Battery Type Selector Adjustment 3 7 Battery Charger Rate Potentiometer DR1512 values used 3 8 ODP Enabled Disabled Positions 3 9 Automatically Calculated Discharge Cutoff Voltage per Cell 3 9 ODP Enabled Disabled Positions 3 11 Typical Setting for Most Utility Application 3 11 xiii Figures Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure B 1 Figure B 2 Figure B 3 Figure B 4 Figure B 5 Figure B 6 Figure B 7 Figure C 1 Figure C 2 Figure C 3 Figure C 4 Figure C 5 xiv Battery Capacity Potentiometer new 3 12 Battery Capacity Potentiometer old 3 12 LED Indicators 3 13 AC Pass through and Charger AC Input Circuit Breakers 3 15 Startup Items
42. alculates the lowest safe DC voltage leaving approximately 20 battery capacity based on the position the Battery Type Selector switch and the amount of current drawn by the load Under no load conditions this level is typically between 11 8 and 12 0 Vdc for a 12 volt battery bank Important The range of set points between 2 and 5 o clock also determine the low AC Transfer Voltage This must be considered when adjusting this potentiometer with ODP enabled see Table 3 3 Important When ODP is disabled set points between 9 and 1 o0 clock the inverter is programmed to shut OFF when the batteries reach approximately 8 5 Vdc 1 4166 V cell for 12 Vdc systems 17 Vdc for 24 volt systems ODP Disabled Range ODP Enabled Range Figure 3 5 ODP Enabled Disabled Positions 12 Vdc 24 Vdc P 120 240 1 95 1 9 4 11 4 22 8 a 1854 HHT 2 185 10 8 21 6 S 1754 3 a 10 2 20 4 1 65 1 6 9 6 19 2 1 55 1 5 4 9 0 18 0 1 0 1 0 01 0 001 Discharge Rate Battery Capacity Figure 3 6 Automatically Calculated Discharge Cutoff Voltage per Cell 975 0012 01 02 Rev A 3 9 Operation AC Transfer Voltage During normal operation the inverter supplies AC power to the applied loads through the pass through circuit and simultaneously charges the system batteries Whenever the external AC source drops be
43. attery configurations and battery care For detailed information see your battery manufacturer or your system designer Battery Information Introduction Batteries Recommendations Battery Types Deep discharge Starting Batteries are available in different sizes amp hour ratings voltage liquid or gel vented or non vented chemistries etc They are also available for starting applications such as an automobile starting battery and deep discharge applications Consider the following recommendations for battery use e Use only the deep discharge types for inverter applications e Use the same battery type for all batteries in the bank e Use only batteries from the same lot and date in your battery bank This information is usually printed on a label located on the battery There are two principal types of batteries starting and deep discharge with several different types of chemistries Batteries can be either sealed or non sealed vented The battery types recommended for use in an inverter system are Flooded Lead Acid FLA Sealed Gel Cells GEL Sealed Absorbed Glass Mat AGM and alkaline types Nickel iron NiFe and Nickel Cadmium NiCad Automotive starting batteries are designed to provide high starting current for short periods of time and are not appropriate for inverter applications Deep cycle Flooded Lead Acid FLA Description Attributes B 2 A flooded lead acid battery is designed
44. attery string to the negative terminal of the second battery string Each battery s amp hour rating is 100 Ah amp s 2 Series String 1 6V 6V 6V 6V Parallel Parallel Connection Connection Series String 2 6V 6V 6V 6V Figure B 5 Battery Wiring 24 volt Parallel Configuration Step 2 975 0012 01 02 RevA Battery Configurations Connect to inverter To connect to the inverter 1 Connect a cable from the positive terminal of the first battery string to the inverter s positive DC terminal via a fused device 2 Connect the negative terminal of the last battery string to the negative terminal of inverter s DC terminal Connection from Series String 1 to inverter s positive terminal Series String 1 6v 6v 6v 6v Each battery s amp hour rating is 100 Ah Series String 2 6v 6v 6v 6v NV SHUNT DC Disconnect can be L L Connection from Series String 2 to either a circuit breaker or a inverter s negative terminal fuse with a disconnect 24 V INVERTER Total battery capacity 200 Ahi Figure B 6 Battery Wiring 24 volt Parallel Configuration Step 3 Important Connecting the positive and negative wires to the inverter from different strings ensures a balanced charge discharge through the batteries resulting in longer run times and improved battery life 975 0012 01 02 Rev A Battery Information Battery Connections for Stacked In
45. atts the second two digits indicate the required nominal battery bank voltage 12 12 Vde the letter suffix code indicates the output voltage and frequency of the inverter E 230 Vac 50 Hz Product Family m Country Code Letter Suffix Example DR 1512 E Output Power Battery Voltage Figure 1 4 Product Identification Introduction Regulatory Table 1 2 Letter Suffix Code Definitions Letter Suffix Output Voltage Output frequency no letter 120 Vac 60 Hz E 230 Vac 50 Hz J 105 Vac 50 Hz K 105 Vac 60 Hz W 220 Vac 60 Hz MODEL DR1512 C DR1524 C DR2412 C DR2424 C DR3624 G POWER INVERTER CHARGER Ws conFoRMs To 3049940 UL 1741 FIRST EDITION CAUTION RISK OF ELECTRICAL SHOCK Both AC amp DC sources are terminated inside this equipment Disconnect both sources before servicing AC FIELD WIRING TERMINALS 16 0 Ib in Max 2 0 Nm Max Provided with integral protection against overloads Xantrex Technology Inc www xantrex com Made in the Dominican Republic f Month 1 Year q o1 02 o3 04 os o6 05 06 07 o 07 es fos o E e DATE OF MFR Figure 1 5 Model Number Sticker The 120 Vac 60 Hz models of the DR Series inverter charger models DR1512 DR1524 DR2412 DR2424 and DR3624 are ETL Listed to UL Standard 1741 First Edition Power Conditioning Units for use in Residential and Commercial Photovolta
46. awn from the batteries during their discharge period There is an inevitable amount of heat associated with the flow of current through a battery and the higher amount of current the greater the amount of heat will be generated The heat is energy which is no longer available to the battery to power loads a relatively long discharge rate 72 hour rate will result in a larger number of amp hours being available for electrical loads This calculation shows how to determine the level of current drawn from a battery at any given hour rate battery capacity divided by the hour rate equals the current drawn from the battery For example a battery rated 220 Ah at a 6 hour rate would be discharged at 36 amps 220 6 For most residential applications of the DR Inverter the 72 hour rate is appropriate because on average a household uses low amounts of current lights TV radio for example with occasional bursts or higher consumption appliances like toasters or washing machines For those installations where high continuous electrical consumption rates are anticipated it is more appropriate to use the 20 hour rate The CCA rating cold cranking amps shown on starting batteries expresses battery capacity in terms of its ability to provide large amounts of current for intervals measured in minutes not hours This is why starting batteries are not appropriate for inverter systems Battery Bank Sizing Running time and size Depth of discharge Day
47. bbreviations and Acronyms AC Alternating Current ASC Authorized Service Center AHJ Authority Having Jurisdiction COM COMnmunications Port CW Clockwise rotates to the right CCW Counter clockwise rotates to the left DC Direct Current DR Inverter DR Inverter Charger DRI DR Interface for stacking LED Light Emitting Diode PV Photovoltaic PVGFP PV Ground Fault Protection RE Renewable Energy RMA Return Material Authorization Related Information You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com 975 0012 01 02 RevA Important Safety Instructions General 975 0012 01 02 RevA SAVE THESE INSTRUCTIONS This manual contains important instructions for all DR Inverter Charger models that shall be followed during installation and maintenance of the inverter 1 Before installing and using the DR Inverter Charger read all instructions and cautionary markings on the DR Inverter Charger and all appropriate sections of this guide Be sure to read all instructions and cautionary markings for any equipment attached to this unit 2 This unit is designed for indoor use only Do not expose the DR Inverter Charger to rain snow or spray 3 To reduce risk of fire hazard do not cover or obstruct the ventilation openings Do not install the DR Inverter Charger in a zero clearance compartment Overheating may result 4 Use
48. biner Box DC Diversion Load for Hydro Generator ET DC Disconnect and PVGFP come a DC Diversion Load for Wind Generator arn Commuter Disconnect le ssm a _ DC Charge z Controller _ AC Generator Conduit if used DR Inverter Charger l EA l 7 E i I cones Disconnect Disconnect Input aI i C J DC Conduit Box DRCB Optional Optional AC Distribution Panel Battery Temperature Sensor BTS Remote Control Optional BATTERY ENCLOSURE hoes To Primary System Ground D triat Battery Bank Figure 2 4 Off Grid Configuration with Renewable Energy Sources 975 0012 01 02 RevA 2 9 Installation Generators An AC generator can be used as an input source instead of the utility power or can be connected using additional hardware to power the loads when utility is not present utility outage and to charge the batteries The generator must be of the permanently installed type and not a portable type unit used for emergency power Small emergency type lower power generators may not have a stable enough voltage for the inverter to synchronize to or provide enough current to fully charge the batteries The maximum charge rate the battery charger can deliver is dependant upon the peak AC voltage available Since the battery charger uses only the top portion of the input sine wave small variations in p
49. c 220 to 230 Vac ODP Disabled ODP Enabled J K Models 120 Vac Models W E Models 9 00 5 00 O 30 Vac 45 Vac 90 Vac Approximate Approximate 77 Vac 85 Vac 170 Vac Approximate Approximate 81 Vac 90 Vac 180 Vac Approximate Approximate 86 Vac 95 Vac 190 Vac Approximate Approximate 90 Vac 100 Vac 200 Vac Approximate Approximate 95 Vac 105 Vac 210 Vac 3 10 975 0012 01 02 RevA Front Panel Controls and Indicators Maximum 105 Vac for 120 Vac models AC Transfer Voltage Adjustable with ODP Disabled Maximum 105 Vac for 120 Vac models Minimum 45 Vac for 120 Vac models AC Transfer Voltage Adjustable with ODP Enabled Minimum 45 Vac for 120 Vac models Figure 3 7 ODP Enabled Disabled Positions Important Most AC appliances will operate properly with an AC pass through voltage between 95 and 105 volts Setting the AC Transfer Voltage potentiometer between these values will allow the incoming source voltage to drop to this level and still operate the connected appliances load If the appliances do not operate properly at the lower AC utility pass through voltage increasing the setting of the potentiometer toward MAX allows the inverter to transfer to battery power providing full AC output during these periods Important When setting the AC Transfer Voltage potentiometer for generator applications the setting may need to be lowered if high powered loads cause
50. completely CCW to find the start position Rotate the potentiometer CW to the desired position i e halfway between the stops for a 50 setting Table 3 2 Approximate Charge rate Setting Amperage Percent of Potentiometer Rotation between stops 100 Model 0 Min 25 50 75 Max DR1512 0 amps 17 5 amps 35 amps 52 5 amps 70 amps DR2424 DR3624 DR2412 0 amps 30 amps 60 amps 90 amps 120 amps DR1524 0 amps 8 75 amps 17 5 amps 26 25 amps 35 amps 25 17 5 amps 50 35 amps 75 50 amps 0 Example 2 0 amps 100 70 amps Example 1 Figure 3 4 Battery Charger Rate Potentiometer DR1512 values used Over Discharge Protection AC Transfer Voltage 3 8 The Over Discharge Protection AC Transfer Voltage potentiometer performs two related functions When set between the 2 and 5 o clock position right both ODP and the AC Transfer Voltage function simultaneously see table on next page When the potentiometer is set between the 9 and 1 o clock position left only the AC Transfer Voltage is functional ODP is disabled Important The ODP is not scaled It is either on or off The min max settings only refer the AC transfer function 975 0012 01 02 RevA Front Panel Controls and Indicators Over Discharge Protection ODP When enabled ODP shuts down the inverter at a specified voltage low battery cutoff to protect the batteries from over discharge damage The inverter circuitry c
51. d prepaid Product shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared to supply e The serial number of your product Information about the installation and use of the unit Information about the failure and or reason for the return e A copy of your dated proof of purchase Record these details in on page WA 4 Return Procedure 1 Package the unit safely preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging 2 Include the following e The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of the USA or Canada In addition to the above you MUST include return freight funds and are ful
52. d products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and Hawaii are excluded Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada How do you get service If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual For some products Xantrex maintains a network of regional Authorized Service Centers Call Xantrex or check our website to see if your product can be repaired at one of these facilities What proof of purchase is required In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex Proof of purchase may be in any one of the following forms e The dated purchase receipt from the original p
53. d stop the generator manually using the generator s pull cord ON OFF switch etc LEGEND GROUND SS NEUTRAL Main A Electrical ope l i Utility 24 Service i TAR Panel Grid AC Generator A 120 240 Vac Neutral to Ground Be sure to check the Generator Bond l for a Neutral to Ground Bond D and remove it There can only be one Neutral to Ground bond in the system euesecesse Generator Manual Transfer Disconnect Switch Optional Optional Primary System Ground pim ee ee a ee ee ee ee _ cme meas q A a nnslv AC Distribution Panel Sub panel 120 Vac Panel Figure 2 19 AC Wiring using a Generator On Grid Application 975 0012 01 02 RevA 2 27 Installation AC Input Wiring Off Grid Applications using a 120 Vac Generator Follow the example below to complete the wiring for an off grid application LEGEND sseeeessees GROUND Be sure to check the Generator for a Neutral to Ground Bond and remove it There can only be one Neutral to Ground bond in the system AC Generator 120 Vac Hot Neutral OUT Ground es Generator Disconnect Optional DR Inverter Charger o gt I aeea l aon gph de mee k ppd out sor i TA i iie a ea a a AC Distribution o o nana x Panel Sub panel 120 Vac Panel Neutral to Ground Bond dana Se ee ee ee eB ee SB ee eee ee eee I ommmmmmmmm es
54. ding ensure you have the appropriate sized batteries for this inverter Batteries are available in different sizes amp hour ratings voltage liquid or gel vented or non vented chemistries etc They are also available for starting applications such as an automobile starting battery and deep discharge applications Only the deep discharge types are recommended for inverter applications Choose the batteries best suited for the inverter installation and cost Use only the same battery type for all batteries in the bank For best performance all batteries should be from the same lot and date This information is usually printed on a label located on the battery Additional information regarding batteries can be found in the Appendix B Battery Information The size of the battery bank determines how long the AC loads will operate in a backup mode without utility power The larger the battery bank the longer the run time Size the battery bank to the AC load requirements and length of time required to run from the batteries In general the battery bank should not be discharged more than 50 Additional DC charging devices such as solar wind hydro etc can provide longer run times by recharging the batteries in the absence of AC utility or generator power Additional details on estimating battery bank size and capacity can be found in Battery Bank Sizing on page B 4 Battery Configuration 975 0012 01 02 RevA The batt
55. e terminal overheating during periods of high current draw Use a stiff wire brush and remove all dirt and corrosion from the battery terminals and cables Use an alkaline solution of baking soda and water to clean the terminals and neutralize any battery acid on the terminals or cable lugs AN WARNING Shock Hazard Before attempting to clean the battery posts turn off the DC circuit breaker Use only insulated tools and remove all jewellery AN CAUTION Damage to Batteries Never let a baking soda solution get into the battery as it will neutralize the acid resulting in permanent damage After the terminals are clean reassemble the cable to the battery terminal and torque the connections to the battery manufacturer s recommendations Coat the battery terminals with an antioxidant compound 975 0012 01 02 RevA State of Charge 975 0012 01 02 RevA Battery Maintenance The battery s state of charge should be checked often and only when the battery at a state of rest when the battery is not powering loads or actively being charged First thing in the morning is usually the best time to check the state of charge If the batteries are readily accessible measure the voltage across the individual battery terminals There should be less than a 0 2 volt difference between each battery To determine the individual cell voltage divide the voltage by the number of cells in the battery 25 2 volts divided by 12 ce
56. e BATTERY TYPE SELECTOR switch to position 0 or 1 To start the equalization charging process cycle the AC power i e disconnect and then reconnect the AC source A solid orange BATTERY CHARGER LED indicates equalize charge a Position 0 equalizes the batteries at the rate of the battery bank capacity divided by 40 C 40 at a voltage of 15 volts for 12 volt systems or 30 volts for 24 volt systems This is set with the BATTERY CAPACITY potentiometer b Position 1 equalizes the batteries at the rate set with the BATTERY CHARGER RATE CONTROL at a voltage of 15 5 volts for 12 volt systems or 31 volts for 24 volt systems When the voltage condition is met and 6 hours have elapsed the charger will switch to the float mode If the condition is not met i e the current draw is above the rate set with the BATTERY CAPACITY potentiometer position 0 or BATTERY CHARGER RATE potentiometer position 1 the charger will continue until the condition is met or for a maximum of 12 hours At this point the charger switches to float at the equalize I or 2 voltage setting see Figure 3 1 Battery Type Selector Switch Settings on page 3 5 5 Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system s batteries when the Equalize charge has completed Important Refer to Battery Maintenance on page B 13 for additional information Equalize 1 Equalize 2 Figu
57. e Branch Circuits C 2 Identifying Multi wire Branch Circuits C4 Correcting Multi wire Branch Circuit Wiring C 5 Warranty and Return Information WA 1 Indek ciee eee en a E a ene E AEA Se IX 1 xii 975 0012 01 02 Rev A Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 2 20 Figure 2 21 Figure 2 22 Figure 2 23 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 975 0012 01 02 RevA Front Panel Features 1 3 AC Side of the DR Inverter 1 3 DC Side of the DR Inverter 14 Product Identification 1 5 Model Serial Number Sticker 1 6 On Grid Basic Configuration Utility Backup 2 7 Off Grid Configuration Generator only 2 7 On Grid Configuration with Renewable Energy Sources
58. e National Electrical Code ANSI NFPA 70 Current Edition When sizing conductors and conduits interfacing to the DR Inverter both shall be in accordance with the National Electric Code ANSI NFPA 70 as well as all state and local code requirements This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI NFPA 70 current edition This is the single point earth ground for the inverter system Use copper conductors only with insulation rated for 75 C The grounds on the DR Inverter are marked with this symbol The AC voltage and current on the DR Inverter is marked with this symbol A The DC voltage and current on the DR Inverter is marked with this symbol Z Phase on the DR Inverter is marked with this symbol Z AN WARNING Fire Hazard Do not install 120 volt AC stand alone inverters onto 120 240 volt AC multi branch circuit wiring This could pose a fire hazard due to an overloaded neutral return wire in this configuration See Multi wire Branch Circuit Wiring on page C 1 for details Explosive gas precautions vi A WARNING Explosion Hazard Working in the vicinity of lead acid batteries is dangerous Batteries generate explosive gases during normal operation Therefore you must read this guide and follow the instructions exactly before installing or using your DR Inverter Charger 1 This equipment contains componen
59. e Worksheet Complete the following steps to calculate the amp hour requirements per day for your system Use and Table B 2 as examples to complete your own To calculate amp hour requirements 1 Determine the loads the inverter will power and enter their wattage in the watts column 2 Determine the number of hours or decimal portion of hours the appliance is used each day Enter this figure in the Hours column 3 Determine the number of days the appliance will be used during the week Enter this figure in the Days column 4 Multiply Hours x Days for each load identified to determine the watt hours per week 5 Add the total watt hours per week for all loads then divide by 7 to obtain the average total watt hours per day 6 Divide the total average per day by the DC nominal voltage This figure represents the average amp hours per day that you will use Table B 1 Determining Average Daily Load in Amp hours Example Days per Weekly Load Watts Hours per Day week used watt hours 5 lights 15 W CFL 75 W 5 7 2625 Breadmaker 1200 0 75 2 1800 Energy efficient 200 x 0 3 24 10080 refrigerator Laptop computer 50 6 5 1500 Total weekly watt hours of AC load 16005 Wh Divided by days per week 7 Average total watt hours per day 2286 Divided by DC nominal voltage 24 Average amp hours per day Ah d 95 B 6 975 0012 01 02 Rev A Battery bank size worksheet
60. e inverter so that its bottom cover which has no holes will not allow burning material to be ejected in the event of an internal fire Use 0 25 inch diameter bolts for mounting The mounting surface must be capable of supporting twice the weight of the inverter to comply with UL 1741 Ventilation Install the inverter in a well ventilated area enclosure for proper operation The inverter s thermal shutdown point will be reached sooner than normal in a poorly ventilated environment resulting in reduced peak power output and surge capability as well as shorter inverter life The inverter contains an internal fan Ensure the air vents and intakes are not obstructed in any way Provide a minimum clearance of 6 inches around the top and sides of the inverter for ventilation Tools Required The following tools may be required to complete this installation 2 Phillips screw driver Slotted screw driver Assorted open end wrenches Socket wrench and fittings Multimeter True rms Hole saw Level Wire strippers Torque wrench Electrical tape Pencil Utility knife NMOadaAaaAAaAaAaAaA a Oa 975 0012 01 02 RevA 2 3 Installation Hardware Materials Required The following hardware or materials may be required to complete this installation O 4 ft x 4 ft sheet of 3 4 plywood or 2 x 4 s studding material O 12 wood screws or 1 2 x 1 1 4 lag bolts O Conduit and appropriate fittings o Wire nuts Wiring Consideration
61. e of installation Refer to the NEC and local codes Conduit fittings can be replaced with strain reliefs where code permits A WARNING Shock Hazard Disconnect the battery cables from the inverter if they are already connected To connect the AC Input to the Inverter 1 Disconnect the main breaker at the main electrical service panel if used or disconnect the AC generator 2 Install an appropriately sized circuit breaker in the electrical service panel This will serve as both an AC disconnect and over current protection If using a generator only use the circuit breaker in the generator 3 Feed the HOT NEUTRAL and GROUND wires using conduit from the inverter to the AC source Leave several inches of extra wire at each end 4 Make the connections to the inverter first Wiring to the AC source is performed after all connections have been made in the inverter a Connect the GROUND green wire to the inverter AC GROUND terminal b Connect the NEUTRAL white wire from the AC source to the inverter s NEUTRAL INPUT terminal c Connect the HOT black wire from the AC source to the inverter s AC HOT INPUT terminal 5 Torque all connections to 16 in lbs 1 8 nm Torque the terminal connections to 16 in lbs 1 8 nm GROUND NEUTRAL IN HOT IN Figure 2 16 AC Terminals for AC Input to the Inverter 2 24 975 0012 01 02 RevA AC Wiring AC Output Wiring to the AC Distribution Panel Sub
62. e your batteries Check the water level monthly to maintain it at the appropriate level 975 0012 01 02 RevA B 13 Battery Information Table B 4 Variances in Charging Voltage based on Battery Temperature Temperature around the BTS 12 volt units 24 volt units 48 volt units Lead Acid NiCad Lead Acid NiCad Lead Acid NiCad Celsius Fahrenheit 6 cells 10 cells 12 cells 20 cells 24 cells 40 cells 60 140 1 05 0 70 2 10 1 40 4 20 2 80 55 131 0 90 0 60 1 80 1 20 3 60 2 40 50 122 0 75 0 50 1 50 1 00 3 00 2 00 45 113 0 60 0 40 1 20 0 80 2 40 1 60 40 104 0 45 0 30 0 90 0 60 1 80 1 20 35 95 0 30 0 20 0 60 0 40 1 20 0 80 30 86 0 15 0 10 0 30 0 20 0 60 0 40 25 77 0 00 0 00 0 00 0 00 0 00 0 00 20 68 0 15 0 10 0 30 0 20 0 60 0 40 15 59 0 30 0 20 0 60 0 40 1 20 0 80 10 50 0 45 0 30 0 90 0 60 1 80 1 20 5 41 0 90 0 60 1 20 0 80 2 40 1 60 0 32 0 75 0 50 1 50 1 00 3 00 2 00 5 23 0 90 0 60 1 80 1 20 3 60 2 40 10 14 1 05 1 20 2 10 1 40 4 20 2 80 15 5 1 20 0 80 2 40 1 60 4 80 3 20 20 4 1 35 1 40 2 70 1 80 5 40 3 60 25 13 1 50 1 00 3 00 2 00 6 00 4 00 30 22 1 65 1 10 3 30 2 20 6 60 4 40 35 31 1 80 1 20 3 60 2 40 7 20 4 80 40 40 1 95 1 30 3 90 2 60 7 80 5 20 Temperature compensation is based on battery type 5 mv cell for lead acid type batteries and 2 mv cell for alkaline type batteries NiCad or NiFe
63. eak voltage result in large variations in the amount of energy to the charger The charger s rated output is based on a utility voltage of 120 Vac RMS the usual measured value This should have a peak voltage of 169 Vac 230 Vac has a peak voltage of 325 Vac For every 10 volts of peak lost the charge rate is reduced by approximately half Size the generator appropriately for the system including battery charge and load current typically twice the wattage output of the inverter Table 2 1 and Figure 2 5 demonstrates how the peak voltage available affects the charging current Table 2 1 Peak Input Filtrate versus Charging Current Peak Voltage Available DR1512 DR2412 DR1524 DR242 DR3624 170 Vac 70 amps 120 amps 35 amps 70 amps 70 amps 160 Vac 35 amps 60 amps 17 5 amps 35 amps 35 amps 145 Vac 15 amps 25 amps 7 amps 15 amps 15 amps 100 170 V Peak 83 4 66 7 Charge Rate any model 50 33 4 16 7 0 150 V Peak 160 V Peak 2 00 2 17 2 33 Battery Voltage Per Cell Figure 2 5 Charge Rate versus Peak AC Voltage 2 10 2 62 975 0012 01 02 Rev A Pre installation Planning Inverter Mounting The DR Series inverter can weigh as much as 45 Ib 20 4 kg Wallboard is not strong enough to support its weight so additional support must be used or added The inverter can be mounted directly to the wall studs if the wall studs are 16
64. eck for open AC output breakers or uses and AC wiring connections Charger turns OFF while charging from a generator Problem Loads High peak AC input voltages from the generator Load the generator down with a heavy load Turn the generator output voltage down The inverter can drive most loads however there are special conditions that can cause a load to behave differently than expected The following describes some of the common problems encountered when using an inverter Ceiling Fans Most large diameter slow turning fans run correctly but generate more noise than when connected to utility power High speed fans tend to operate normally Cell Phones Some cellular telephones experience interference in the form of a clicking sound Computers and Sensitive Electronics Some computers and sophisticated electronics have power supplies that do not present a load until correct line voltage is available When this occurs each unit waits for the other to begin This can usually be solved by plugging in an additional load such as a lamp to bring the inverter out of its search mode Also when using a computer avoid starting large loads Consumer Electronics AM radios tend to pick up inverter noise especially on the lower half of their band Inexpensive tape recorders are likely to experience noise as well When using sensitive electronic devices avoid starting large loads 975 0012 01 02 RevA Troubleshoot
65. either 12 volt battery banks or 24 volt battery banks The battery voltage MUST match the voltage requirements of the inverter To determine the correct voltage for the system check the last two digits on the inverter s model number For example the DR1512 is a 12 volt inverter and requires a 12 Vdc battery system The DR2424 is a 24 volt inverter and requires a 24 Vdc battery system Installation Battery Location Battery Temperature Locate the batteries in an accessible location Two feet clearance above the batteries is recommended for access to the battery caps They should be located as close to the inverter as possible without limiting access to the inverter s disconnects Install the batteries to the left of a wall mounted inverter for easy access to the DC side of the inverter and shorter cable runs For safety and to limit access to the batteries a lockable ventilated battery enclosure or dedicated room should be used If an enclosure is used it should be vented to the outside via a one inch vent pipe located at the top of the enclosure Install an intake vent at the bottom of the enclosure to promote air circulation These vents exhaust explosive hydrogen gases and must not be overlooked when designing an enclosure The enclosure should be made of an acid resistant material or have a finish that resists acid to prevent corrosion It should be capable of holding the electrolyte from at least one battery should a leak occur
66. electricians Multi wire branch circuits can be identified by removing the cover on the load center and inspecting the wiring Conventional 120 Vac circuits are identified by a 2 wire plus ground black white and copper romex for each circuit Multi wire branch circuits use a 3 wire plus ground arrangement black red white and copper for each circuit run If this arrangement exists in the panel and it is being powered by a stand alone 120 Vac inverter a potential fire hazard exists For safety these circuits must be rewired to meet code Red From L1 Breaker Red From L2 Breaker To Branch Circuits f Single Neutral White Ground Bare Copper Figure C 4 Multi wire Branch Circuit Wiring 975 0012 01 02 RevA Correcting Multi wire Branch Circuit Wiring Correcting Multi wire Branch Circuit Wiring Acceptable options Recommended option Correcting multi wire branch circuit wiring is not easy Two options which will correct multi wiring branch circuit wiring are e Rewire existing multi wire branch circuits to conventional home run wiring This requires a qualified electrician knowledgeable about multi wire branch circuit wiring and is expensive There may be multiple multi wire branch circuits located throughout the structure requiring complete rewiring e Add a second inverter in a series stacked arrangement This is an expensive solution but would restore the original 240 Vac sp
67. er a circuit breaker or a fuse with a disconnect 12 V INVERTER Total battery capacity 200 Ah Figure B 3 Battery Wiring in Parallel 975 0012 01 02 RevA B 9 Battery Information Wiring Batteries in Series Parallel Effect Steps Series wiring Parallel wiring Wiring the batteries in a series parallel configuration increases the current and voltage of the battery bank Series parallel wiring is more complicated and care should be taken when wiring these banks It is done in three steps wiring the batteries in series wiring them in parallel then wiring the string to the inverter To wire in series 1 First wire the batteries in series voltage adds with the positive terminal of one battery connected to the negative terminal of the next battery to meet the inverter s DC input requirements 24 volts shown in Figure B 4 and Figure B 5 2 Repeat this step for the next battery string Two identical strings of batteries are now wired in series SO et t bt 6 6V 6V 6V 6V Series String 1 Each battery s amp hour rating is 100 Ah gt oe 62 62 6V 6V 6V 6V Series String 2 Figure B 4 Battery Wiring 24 volt Parallel Configuration Step 1 To wire the batteries in parallel 1 Connect the positive terminal of the first battery string to the positive terminal of the second battery string 2 Connect the negative terminal of the first b
68. erter s negative terminal 10 Use an insulated 2 inch wrench or socket to tighten the 5 16 SAE nuts to 10 15 ft lb 13 6 to 20 3 nm for each inverter input terminal CAUTION Equipment Damage Do not put anything between the cable ring terminal and the flat metal part of the terminal overheating of the terminal may occur Do not apply any type of antioxidant paste until after the battery cable wiring is tightened 11 Apply antioxidant paste to the battery and inverter terminals 12 Install the battery terminal connection covers red for positive black for negative over the inverter s DC terminals and secure with the screws and washers provided DC250 LEGEND DISCONNECT GROUND a a gie Positive DR Inverter Charger on Ean Seccsceccccsoccccse To Primary System Ground Battery Bank d ie ie a Figure 2 12 Connecting the Battery Bank to the DR Inverter Charger 975 0012 01 02 Rev A DC Wiring Installing a Battery Temperature Sensor 975 0012 01 02 RevA A battery temperature sensor BTS option can easily be installed in the system to ensure proper charging of the batteries based on temperature Installing a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures To install the Battery Temperature Sensor 1 Run the battery temperature sensor wire in the DC conduit if used and route the RJ11 connector
69. erters are used in a series stacked configuration one unit primary controls the other unit secondary Communication between the two inverters is done via the COM port J1 The first unit switched ON using its front panel POWER ON OFF switch becomes the controlling primary inverter Controls There are several controls on the inverter s front panel that provide adjustments for the battery charger and AC output energy saving mode Battery Type Selector The Battery Type Selector is a 10 position rotary switch used to set the inverter s charger for the proper Float and Bulk voltage levels These levels are selected depending on the type of batteries used There are also 2 positions 0 and 1 which allow the batteries to be equalized Equalizing batteries should only be done on liquid lead acid batteries and never on gel batteries Refer to the table below for the charge voltages in the various switch positions Consult the battery manufacturer for optimum battery voltage charging settings i Sanon T Battery Type Selector Enlargement pointing to Setting 7 Figure 3 2 Battery Type Selector Adjustment 3 4 975 0012 01 02 Rev A Table 3 1 Battery Type Selector Switch Settings 12 volt Models 24 volt Models Front Panel Controls and Indicators Charge Function Bulk Bulk i Switch Float Equalize Float Equalize Equalize Charge Position Description Voltage Vo
70. ery Temperature Sensor 2 21 AC Wiring 2 22 AC Distribution Panel Sub panel Mounting and Conduit Installation 2 22 Accessing the AC Terminals 2 22 AC Output Wiring to the AC Distribution Panel Sub panel 2 25 AC Input Wiring On Grid Applications 2 26 AC Input Wiring using a Generator in an On Grid Application 2 27 AC Input Wiring Off Grid Applications using a 120 Vac Generator 2 28 AC Input Wiring Off Grid Applications using a 240 Vac Generator for 120 Vac Loads 2 29 Series Stacking 120 Vac 60 Hz Models only 2 30 3 Operation Front Panel Controls and Indicators 3 2 POWER ON OFF Switch 3 2 Ports 3 3 BATTERY SENSE Port 3 3 COM Port 3 3 Remote Controls RC8 RC4 3 3 Stacking Interface 3 4 Controls 3 4 Battery Type Select
71. ery bank must be wired to match the inverter s DC input voltage specifications 12 Vdc 24 Vdc or 48 Vdc In addition the batteries can be wired to provide additional run time The various wiring configurations are SERIES Wiring batteries in series increases the total bank output voltage to match the inverter s DC requirements e PARALLEL Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads e SERIES PARALLEL Series parallel configurations increase both the battery voltage to match the inverter s DC requirements and run time for operating the AC loads For additional information on how to wire these battery bank configurations see Battery Configurations on page B 8 Installation Battery Cable Sizing Proper cable sizing diameter and length is critical to the safe and efficient operation of an inverter system Larger diameter cables smaller AWG number have less voltage drop and are therefore more efficient when transferring power to and from the batteries If a cable is undersized diameter too small it could potentially overheat creating a fire hazard Cable length is another important factor Runs should be kept as short as practical Longer cable runs increase resistance thus lowering the overall efficiency of the system This is especially true in lower voltage systems i e 12 Vdc where depending upon the length of the cable run it may be necessary
72. fate prevents the cells from receiving or delivering full power If the sulfate is left on the plates it will harden and permanently reduce the battery s capacity Stratification separates the heaver acid from the water and the concentrated acid remains at the lower portion of the plates eventually corroding them Equalize charging holds the battery at the Equalize voltage for a minimum of 6 hours This stirs up the electrolyte distributing the acid and removing the sulfate from the plates Equalizing the batteries every month or two depending on usage prolongs the life of the batteries and provides better battery performance A CAUTION Explosion Hazard Only unsealed or vented batteries should be equalize charged Since Hydrogen and oxygen gases are produced when equalized provide adequate ventilation and remove all sources of ignition to prevent explosion Remove DC loads while equalizing as they can be damaged by the higher battery voltage Consult the battery manufacturer s recommendation for equalize charging settings To Set the Equalize Charge 1 Remove all DC loads connected to the batteries 2 Remove all battery vent caps 3 Check the battery water level it should be just over the top of the plates do not overfill Use only distilled water for filling batteries 3 18 975 0012 01 02 RevA Charger Mode Important Recheck the water the level after equalize charging and refill if necessary 4 Set th
73. h battery s amp hour Each battery s amp hour rating is 100 Ah rating is 100 Ah i 6V 6V 6V 6V 6V 6V SHUNT DC Disconnect either a circuit DC Disconnect breaker or a either a circuit fuse with a breaker or a disconnect 12 V INVERTER fuse with a 24 V INVERTER Total battery capacity 100 Ah disconnect Total battery capacity 100 Ah Figure B 1 6 volt Battery Wiring Series Configuration B 8 975 0012 01 02 RevA Battery Configurations A Each battery s amp hour rating 12 V 12V is 100 Ah DC Disconnect either a circuit breaker or a fuse with a disconnect 24 V INVERTER Total battery capacity 100 Ah Figure B 2 12 volt Battery Wiring Series Configuration Wiring Batteries in Parallel Effect Wiring the batteries in a parallel configuration increases the current of the battery string The voltage of the battery bank remains the same as an individual battery Parallel configurations extend the run times of the AC loads by providing increased current for the inverter to draw from In a parallel configuration all the negative battery terminals are connected together and all the positive battery terminals are connected together Wiring example Figure B 3 is an example of how to wire batteries in a parallel configuration Each battery s amp hour rating is 100 Ah DC Disconnect eith
74. harger does not stay indefinitely in the absorption charge mode the timer automatically switches to the float charge mode when 12 hours have elapsed Float Charge Float charge the final stage of battery charging maintains a charge to the batteries whenever AC is present on the inverter s input A solid green BATTERY CHARGER LED indicates float charging which reduces battery gassing minimizes watering requirements for flooded batteries and ensures the batteries are in a constant state of readiness A new 3 stage charging cycle is initiated after an AC source is reapplied to the inverter s AC input terminals such as after a utility outage Important The Float Charge is a very low current charge also called a trickle charge Some batteries may require higher current Consult the battery manufacturer to determine if the batteries being used can handle a float charge The inverter will adjust its charge rate to meet the battery requirement Operation Battery Type Selector ry O oe 99 Cos Battery Charger LED Solid Orange Bulk Blinking Orange Absorption Solid Green Float Battery Capacity Figure 3 14 Charger Controls and Indicators Equalize Charging Equalize charging is a special mode of battery charging During use the battery s cells can become unequal in the voltage and current they can deliver This is due to a buildup of sulfate on the plates as well as stratified electrolyte Sul
75. hargers 220 Vac 60 Hz Models A 4 Electrical Specifications for the DR Inverter Charger 230 Vac 50 Hz Models A 5 Environmental Specifications for the DR Inverter Charger A 7 Determining Average Daily Load in Amp hours Example B 6 Determining Battery Bank Size B 7 Typical Appliance Wattage B 7 Variances in Charging Voltage based on Battery Temperature B 14 Temperature Compensation Calculation B 14 Battery State of Charge B 17 975 0012 01 02 Rev A XV xvi Introduction Chapter 1 Introduction contains information about the features and functions of the DR Inverter Charger Introduction Introduction Modified Sine Wave Power Battery Charger AC Transfer Relay Simplicity High Efficiency Low Power Consumption Features 1 2 Thank you for purchasing the DR Inverter Charger from Xantrex Technology Inc The DR Inverter is one of the finest inverter chargers on the market today incorporating state of the art technology and high reliability The inverter features an AC pass through circuit powering your home appliances from utility or generator power while charging the batteries When utility power fails the battery backup system keeps your appliance
76. he search mode See AC Transfer Voltage on page 3 10 m Lower wattage device turns ON inverter Search Mode Potentiometer Higher wattage device DEFEAT Switches turns ON inverter Search Mode OFF Figure 3 3 Battery Type Selector Adjustment Battery Charger Rate 975 0012 01 02 RevA The Battery Charger Rate potentiometer sets the maximum charge current supplied to the battery bank and is also used to regulate constant current in the Bulk Charge Mode The level should be adjusted to provide a charge rate less than or equal to the amp hour capacity of the battery bank divided by a factor of five Example 1 Inverter DR1512 has a maximum charge rate of 70 amps a Battery bank amp hour capacity 500 amp hours using gel cell batteries b Divide the amp hour capacity by 5 500 5 100 c Set the potentiometer to MAX 70 amps as it is less than 100 2 Inverter DR1512 has maximum charge rate of 70 amps a Battery bank amp hour capacity is 250 amp hours using gel cell batteries b Divide the amp hour capacity by 5 250 5 50 c Set the potentiometer to approximately 71 50 amps Operation Use Table 3 2 to find the approximate setting of the Battery Charge Rate potentiometer The settings do not need to be exact but should be as close as possible to the actual value required Important The potentiometer does not have an arrow to indicate its position Use a small blade screwdriver and rotate the control
77. ic Power Systems These standards guarantee that the DR Inverter Charger has been tested to nationally recognized safety standards UL for the US and have been found to be free from reasonably foreseeable risk of fire electric shock and related hazards The DR Inverter Charger is intended to be used for residential or commercial applications Do NOT use this unit for applications for which it is not listed i e land vehicles or marine craft It may not comply with the safety code requirements or could possibly present other operational or safety hazards 975 0012 01 02 RevA Installation Chapter 2 Installation contains information about how to plan for and install the DR Inverter Charger Installation Pre installation Planning Location Important Before installing and using the DR Inverter Charger read all instructions and cautionary markings on the DR Inverter Charger and all appropriate sections of this guide Be sure to read all instructions and cautionary markings for any equipment attached to this unit Take some time prior to installing the equipment to pre plan the installation Location mounting and ventilation should be taking into consideration before any cabling can be done AN CAUTION Personal Injury The inverter charger can weigh up to 45 lbs 20 4 kg depending upon configuration Always use proper lifting techniques during installation to prevent personal injury Inverters contain
78. icity because it ran for a short period of time Calculating Amp Hours Calculations Amps to watts 975 0012 01 02 RevA To determine the amp hours you will consume you need to list your anticipated loads and the length of time you will operate each one Determine the number of hours per day and the number of days during the week you will use the appliance For example you use the microwave every day but a breadmaker only once a week If you use an appliance for less than an hour express the time as a decimal portion of an hour All electrical appliances have labels which state their energy consumption Look for an amps rating on motors and a watts rating on other appliances If the label plate has expressed power consumption in amps multiply by volts for the watts required watts volts x amps Battery Information Considerations When calculating battery bank size consider the following e Motors typically require 3 to 6 times their running current when starting Check the manufacturer s data sheets for their starting current requirements If you will be starting large motors from the inverter increase the battery bank size to allow for the higher start up current e Refrigerators and ice makers typically run only about 1 3 of the time therefore the running wattage is 1 3 of the total wattage of the appliance Divide the total wattage of the appliance by 3 when determining the battery requirements Amp Hour Exampl
79. illuminating a solid orange 5 Using a true RMS AC voltmeter check the output voltage of the inverter This voltage can be checked at either the AC terminal block or in the sub panel between the HOT and NEUTRAL lines The voltage should be 120 Vac 230 Vac for E models 220 Vac for W models or 105 Vac for J and K models Non true RMS meters register from 90 to 110 Vac 6 Switch the AC disconnect circuit breaker to OFF The inverter will go into the inverter mode if a sufficient load is applied to the AC output while in the search mode The green INVERTER MODE LED will light solid indicating the inverter is active The voltage on the AC output of the inverter will remain the same as above 5 maximum Important If the inverter is in the SEARCH MODE INVERTER MODE LED flashing and a sufficient load is not available to bring the inverter up to full voltage turn the SEARCH MODE WATTS potentiometer fully CCW to defeat the search function 7 Reapply the AC power by switching the AC disconnect to ON Allow the batteries to fully recharge Battery Type Selector e ee a gt Charger LED O OFO GIE Oe POWER ON OFF Switch INVERTER MODE LED SEARCH MODE WATTS Potentiometer Figure 3 13 Startup Items Important The unit will not use renewable energy for AC output as long as AC input utility or generator is available to the inverter 975 0012 01 02 Rev A Cha
80. ing Clocks Decreasing Loads Dimmer Switches The inverter s crystal controlled oscillator keeps the frequency accurate to within a few seconds a day however external loads in the system may alter the inverter s output waveform causing clocks to run at different speeds There may be periods where clocks keep time and then mysteriously do not This is because most clocks do not draw enough power to trigger the load sensing circuit In order to operate especially with no other loads present the inverter s load sensing circuit will have to be defeated Refer to the Operation Search Mode Watts If the amount of power a load draws decreases after it has been switched on such as with a small motor and its current draw becomes less than the load sensing threshold it will be turned alternately ON and OFF by the inverter This can usually be solved by plugging in an additional load such as a lamp Most dimmer switches lose their ability to dim the lights when used with an inverter and operate only in the fully ON or OFF position Newer microprocessor controlled dimmers tend to work better in inverter applications Fluorescent Lights Heavy Loads Some devices cannot be detected by the inverter s load sensor and will not operate Small fluorescent lights are the most common example This can usually be solved by plugging in an additional load Also try turning the lamps AC plug over If the battery bank cannot deliver the neces
81. ions are detected a prolonged overload condition approximately 10 seconds or the inverter s output is connected directly to an AC power source utility grid or generator Charger LED Orange Green The Charger LED is a dual color red green triple function indicator e When the charger is in Bulk mode the LED lights orange e When the charger is in Absorption mode the LED blinks orange e When the charger is in Float mode the LED lights green Important Orange is a flickering mix of red and green It can look different depending on the angle at which the LED is viewed It should never be a solid red Important The battery charger control circuit operates from the battery voltage If the battery voltage falls below 7 volts the inverter charger will not operate The batteries must first be recharged using a stand alone charger to bring the voltage up to a level where the inverter charger can operate Audible Indicator internal A buzzer is located on the control board as an audible alert to fault conditions such as Battery High Battery Low or Overload Steady buzzing indicates an impending inverter shut down A pulsing chirp indicates the inverter is temporarily off line due to a fault condition either within the inverter or related to the system 3 14 975 0012 01 02 RevA Circuit Breakers 975 0012 01 02 RevA Front Panel Controls and Indicators The DR Inverter contains two circuit breakers located o
82. is activated Pressing the switch once turns the inverter ON Another press turns the inverter OFF 3 2 975 0012 01 02 RevA Ports BATTERY SENSE Port COM Port Front Panel Controls and Indicators There are two ports on the inverter charger Both ports are RJ11 type telephone style connectors One is used for connecting a remote control to the inverter The other is used for regulating the charger voltage based on the temperature of the battery bank The BATTERY SENSE Port is used for connecting a battery temperature sensor BTS to control the charging rate based on battery temperature The sensor should be taped onto the side of one of the batteries The information received in this port adjusts the charger s output higher in cold temperatures assuring the batteries receive a full charge and lowers it during warm temperatures reducing battery gassing and providing overcharge protection Important The Battery Sense only adjusts charging voltage It does not disable the charger Refer to the Installation section for the BTS location on the battery COM PORT J1 is a dual function RJ11 6 pin connector Its primary function is to provide serial communications to an optional Xantrex remote control unit RC4 or RC8 The port also acts as a stacking interface control when two DR Inverters are used in a series configuration When two inverters are stacked a remote control cannot be used with either unit Remote Control
83. lit phase configuration This solution may actually be less expensive than having an electrician re wire the multi wire branch circuits It also provides increased power backup protection and can power 240 Vac loads Add a step down autotransformer to the output of the inverter to restore the split phase configuration This is the least expensive and easiest method to correct for multi wire branch circuit wiring Refer to Figure C 5 Using this method half of the current is supplied to one leg of the circuit and half to the other in a split phase arrangement 180 out of phase This will restore the original functionality and safety to the multi wire branch circuit WARNING Fire Hazard Until one of the solutions above is implemented a stand alone 120 Vac inverter or generator must not be installed where multi wire branch circuits exist 975 0012 01 02 RevA Multi wire Branch Circuit Wiring 120 Vac Inverter or Generator NEUTRAL T240 AutoTransformer White Neutral E e ae Oe E re ee a a ee I ae a M Load Center Ay a BA SA Breaker Breaker Ganged Ganged ee _ Red Hot Current Flow 15A Black Hot Current Flow 15 A Single White Neutral 120 Vac Current Flow 0 A 120 Vac White Neutral Splice Current Flow 15 A The out of phase H current SUBTRACTS at this point Figure C 5 Using a Step down Autotransformer in Mul
84. lls 2 1 volts per cell If a greater difference is measured the batteries may need to be equalized liquid lead acid types only or replaced All batteries in the bank should measure the same voltage this is not an accurate measurement for cross tied batteries as each battery is in parallel with another battery making individual battery measurements impossible The voltage should match the following table for the entire battery bank output These values indicate the overall battery s state of charge for the entire bank Individual cell voltages if available are also shown as a percentage of charge The values given are for a temperature of 77 F 25 C Cooler temperatures produce lower voltage measurements Table B 6 Battery State of Charge System Voltage Individual Percent of Full Cell Charge 12 Volt 24 Volt 48 Volt Voltage 100 12 7 25 4 50 8 2 12 90 12 6 25 2 50 4 2 10 80 12 5 25 0 50 0 2 08 70 12 3 24 6 49 2 2 05 60 12 2 24 4 48 8 2 03 50 12 1 24 2 48 4 2 02 40 12 0 24 0 48 0 2 00 30 11 8 23 6 47 2 1 97 20 11 7 23 4 46 8 1 95 10 11 6 23 2 46 4 1 93 0 lt 11 6 lt 23 2 lt 46 4 lt 1 93 Important Table B 6 only applies for batteries that have been at rest for a minimum of 3 hours i e no inverting no charging Multi wire Branch Circuit Wiring Appendix C Multi wire Branch Circuit Wiring supplies information about Multi
85. located in a convenient location if the power goes out The light may flicker as the inverter searches the line for a load The green INVERTER MODE LED blinks 2 3 times a second indicating the inverter is in the SEARCH MODE 4 Slowly turn the potentiometer CCW toward MIN when the proper setting is found the lamp and INVERTER MODE LED will light steady 5 Turn the lamp OFF for a moment The inverter should switch back to the SEARCH MODE Turn the lamp ON Ensure the inverter comes out of the Search Mode Adjust the potentiometer up or down as necessary Important The Search Mode only activates when the unit is operating in the inverter mode from batteries to prevent unnecessary battery discharge when electrical power is not required If the inverter is supporting loads that must constantly be powered turn the search mode OFF by setting the potentiometer fully CCW to the DEFEAT position 975 0012 01 02 RevA Sanoiy bil Selector Front Panel Controls and Indicators Important Some loads constantly draw power even though they are switched OFF These include TVs with instant ON circuits microwaves with digital displays VCRs etc It is best to operate these devices from another circuit or install a switch to turn these OFF completely or don t use the Search Mode Important When the SEARCH MODE is used with series stacked inverters only 120 Vac loads connected to the master inverter will bring the unit out of t
86. low the AC Transfer Voltage set by the potentiometer the inverter switches to battery power in order to maintain the connected load Examples 120 Vac inverter system 1 The AC Transfer Voltage potentiometer is set to 9 00 o clock with ODP disabled Whenever the incoming AC voltage drops to 40 volts or below the inverter will switch to battery power 2 The AC Transfer Voltage potentiometer is set to 2 00 o clock with ODP enabled Whenever the incoming AC voltage drops to 105 volts or below the inverter will switch to battery power Important ODP does not affect the operation of the AC Transfer Voltage ODP is either ON or OFF depending upon the position of the potentiometer Important There are 6 settings available for the AC Transfer Voltage for both ODP OFF and ON as shown in the Table 3 3 below Important To achieve the fastest transfer time typically less than 16 ms set the AC Transfer Voltage potentiometer near the 2 00 o clock position with the ODP enabled or near the 1 00 o clock position with the ODP disabled If a high number of nuisance transfers caused by transients on the AC line occur adjust the potentiometer from the maximum position toward the minimum position 1 e 2 o clock toward 5 o clock with ODP enabled or 1 0 clock toward 9 o clock with ODP disabled Table 3 3 ODP AC Transfer Voltage ODP Adjustment AC Transfer Voltage 100 to 105 Va
87. ls out leaving only the difference current between the two circuits Refer to Figure C 2 A safety problem occurs when a stand alone 120 Vac inverter is installed to power these circuits causing the one neutral wire to now carry the in phase currents for both circuits Since the current is in phase the two circuits add instead of subtract potentially doubling the current flow in the neutral return wire Refer to Figure C 3 The branch circuit breakers do not protect the neutral wire from overload under this condition This excess current will overheat the neutral wire potentially creating a fire hazard Load Center 240 Vac L1 PTS from Grid an N Neutral U U 15A 15A Breaker Breaker Ground Black Hot Black Hot Current Flow 15A Current Flow 15A White Neutral 120 Vac 120 Vac Current Flow 15 A White Neutral Ue Current Flow 15 A Bare Ground Bare Ground Figure C 1 Conventional Home type Wiring 975 0012 01 02 RevA Multi wire Branch Circuits S Load Center Load Center 240 Vac a0 E 240 Vac L1 rom Grid 7 N N from Grid B a Neutral Neutral AISA cesses ee TEA ay 15A aa sa Breaker Breaker Breaker Breaker Ground Ganged Ganged Ground Ganged Ganged L P CEEE EE Red
88. ltage Voltage Voltage Rate Equalize Time 0 Equalize 1 13 2 15 0 26 4 30 0 Battery Capacity 6 hrs minimum equalizes at a rate Setting C 40 12 hrs maximum equal to the battery bank capacity in amp hours divided by 40 1 Equalize 2 13 2 15 5 26 4 31 0 Battery Charger 6 hrs minimum charges at a rate Rate Setting 12 hrs maximum set by the manual BATTERY CHARGER RATE control 2 Deep Cell Lead 13 3 15 0 26 6 30 0 Provides an additional Float and Bulk Acid 2 settings for deep cycle lead acid batteries Refer to the battery manufacturer s recommendation for Float and Bulk settings 3 Not Specified 13 6 14 3 27 2 28 6 Provides an additional setting of Bulk and Float voltages 4 Gel Cel 2 13 7 14 4 27 4 28 8 Recommended for gel cell batteries that specify high float voltages Check with the battery s manufacturer 5 Gel Cell 1 13 5 14 1 27 0 28 2 Typical gel cell setting 6 PcCa lead 13 2 14 3 26 4 28 6 Use this setting for sealed type car Calcium batteries 7 Deep Cycle 13 4 14 6 26 6 29 2 Factory setting for typical deep cycle Lead Acid 1 lead acid batteries Default Setting 8 NiCad 1 14 0 16 0 28 0 32 0 Use for NiCad battery systems 9 NiCad 2 14 5 16 0 29 0 32 0 Recommended for use with nickel iron batteries See Important notes that follow 975 0012 01 02 RevA Operation Important 1 Switch positions 0 and 1 are for monthly battery maintenance only Return
89. ly responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility Out of Warranty Service If the warranty period for your DR Inverter Charger has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your inverter may be serviced or replaced for a flat fee To return your DR Inverter Charger for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page WA 3 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received 975 0012 01 02 RevA WA 3 Warranty and Return Information About Your System As soon as you open your DR Inverter Charger package record the following information and be sure to keep your proof of purchase Serial
90. mmon Specifications Voltage Regulation maximum 5 Voltage Regulation Typical 2 5 Waveform modified sine wave Load Power Factor allowed 0 5 to 1 0 leading or lagging Adjustable Load Sensing Range 5 watts minimum to 100 watts maximum Series Operation NO Force Air Cooling Variable speed fan Automatic Transfer Relay 20 amps Number of Charging Profiles 10 Three stage Charging Yes float absorption bulk 975 0012 01 02 Rev A Specifications of the DR Inverter Table A 2 Electrical Specifications for the DR Inverter Chargers 220 Vac 60 Hz Models Model DR1512W DR2412W Temperature Comp Probe BTS optional Remote Control RC8 4 optional a Specifications subject to change without notice b This is the minimum AC current required to obtain full pass through and maximum battery charging c Product may not meet voltage regulation specifications at other than Input Nominal at full rated load d Also compatible with the RC4 Table A 3 Electrical Specifications for the DR Inverter Charger 230 Vac 50 Hz Models Model DR1512E DR1524E DR1548E DR2424E AC Input Voltage 230 Vac 230 Vac 230 Vac 230 Vac AC Input Low Transfer 80 to 210 Vac 80 to 210 Vac 80 to 210 Vac 80 to 210 Vac Voltage AC Input Current 55 amps 55 amps 55 amps 55 amps Continuous Power 1500 VA 1500 VA 1500 VA 2400 VA 25 C Continuous Out
91. n the right hand side of the chassis directly above the AC input terminal block The pass through AC input circuit breaker protects the AC wiring and connected load The charger AC input circuit breaker protects the charger circuit The breakers are rated for the maximum charge rate and pass through current allowed according to the rating of the internal relay Table 3 4 AC Pass through Circuit Breakers Models DR15XX DR24XX DR36XX 120 Vac 30 amps 30 amps 30 amps 210 230 Vac 15 amps 15 amps N A Table 3 5 Battery Charger Circuit Breakers Models DR15XX DR24XX DR36XX 120 Vac 20 amps 30 amps 30 amps 210 230 Vac 8 amps 15 amps N A AC Pass through Circuit Breaker Charger AC Input Circuit Breaker Figure 3 12 AC Pass through and Charger AC Input Circuit Breakers Operation Start up Once the inverter is properly connected to the batteries AC source and loads using a sub panel the inverter is ready for operation Recheck the controls and ensure they are in the proper position Recheck all wiring and ensure it is correct Starting the inverter 1 Apply DC power to the inverter by switching on the DC disconnect circuit breaker The inverter will go through a self test and then shut OFF 2 Press the ON OFF button once The inverter will sound an audible chirp Apply AC power to the inverter The inverter starts charging the batteries in the Bulk mode indicated by the CHARGER LED
92. near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching your eyes while working near batteries 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 If you need to remove a battery always remove the grounded terminal from the battery first Make sure all accessories are off so you don t cause a spark Always use identical types of batteries Never install old or untested batteries Check each battery s date code or label to ensure age and type Batteries are temperature sensitive For optimum performance the should be installed in a stable temperature environment Always recycle old batteries Contact your local recycling center for proper disposal information vii viii Contents Important Safety Instructions v 1 Introduction Introduction 1 2 Features 1 2 AC Side 1 3 DC Side 14 Optional Equipment
93. nk or large DC source such as a micro hydroelectric plant or wind generator increasing the size of the cables and disconnects will greatly reduce the number of nuisance outages associated with breaker tripping and open fuses 2 16 975 0012 01 02 Rev A DC Wiring DC Disconnect and Over current Protection For safety and to comply with regulations battery over current protection is required Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability The National Electrical Code NEC requires both over current protection and a disconnect switch for residential and commercial electrical systems These items are not supplied as part of the inverter However Xantrex offers a DC rated ETL Listed circuit breaker disconnect module specifically designed for use with Xantrex inverters to meet NEC compliance Two amperage ratings are available a DC250 250 amps and a DC175 175 amps in either single or dual breaker configurations for single or dual inverter installations Important Xantrex DC disconnects are not designed to accept doubled paralleled cables which may be required for long cable runs Also the plastic red and black covers on the DC inverter inputs are not designed to accommodate dual cables If dual cables are used the optional conduit box DRCB must be used Some installations may not require conduit or
94. oltage for proper voltage and frequency depending on model Check all AC output wiring connections Charger is supplying a lower charge rate Charger controls are improperly set Low peak AC input voltage 169 Vac required for full charger output P Loose or corroded battery connections Loose AC input connections Generator is unstable charger is losing synchronization Refer to the section on adjusting the Charger Rate Use larger generator increasing AC voltage RPM s may help Check and clean all DC connections Check all AC output wiring connections Turn BATTERY CHARGER RATE potentiometer down to less than halfway until problem is gone AC LEDs flicker while charging 4 2 Generator is unstable and charger is losing synchronization Turn BATTERY CHARGER RATE potentiometer down to less than halfway until problem is gone 975 0012 01 02 RevA Table 4 1 Troubleshooting the DR Inverter Error Condition Possible Cause Problem Loads Solution CHARGER LED indicates charging but no charge is going to the batteries is ON but there is no output power Circuit Breaker on the side of the inverter is open No AC voltage on inverter s AC terminal block Good AC voltage on inverter s AC terminal block Reset the AC CHARGER circuit breaker on the side of the unit Check AC PASS THRU Circuit Breaker on the side of the inverter Ch
95. only attachments recommended or sold by the manufacturer Doing otherwise may result in a risk of fire electric shock or injury to persons 5 To avoid a risk of fire and electric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the DR Inverter Charger with damaged or substandard wiring 6 Do not operate the DR Inverter Charger if it has received a sharp blow been dropped or otherwise damaged in any way If the DR Inverter Charger is damaged see the Warranty section 7 Do not disassemble the DR Inverter Charger It contains no user serviceable parts See Warranty for instructions on obtaining service Attempting to service the DR Inverter Charger yourself may result in a risk of electrical shock or fire Internal capacitors remain charged after all power is disconnected 8 The DR Inverter contains more than one live circuit batteries and AC line Power may be present at more than one source To reduce the risk of electrical shock disconnect both AC and DC power from the DR Inverter Charger before attempting any maintenance or cleaning or working on any circuits connected to the DR Inverter Charger Turning off controls will not reduce this risk 9 Use insulated tools to reduce the chance of short circuits when installing or working with the inverter the batteries or a PV array Safety Wiring Requirements All wiring methods and materials shall be in accordance with th
96. or 3 4 SEARCH MODE WATTS Potentiometer 3 6 Battery Charger Rate 3 7 Over Discharge Protection AC Transfer Voltage 3 8 Over Discharge Protection ODP 3 9 AC Transfer Voltage 3 10 Battery Capacity 3 12 LED Indicators 3 13 Inverter Mode LED Green 3 13 Over Temp Overload LED Red Green error condition 3 13 Battery High Battery Low LED Red Green error condition 3 13 Charger LED Orange Green 3 14 Audible Indicator internal 3 14 Circuit Breakers 3 15 x 975 0012 01 02 RevA 4 Contents Start up 3 16 Charger Mode 3 17 3 Stage Charging Process 3 17 Equalize Charging 3 18 Troubleshooting Troubleshooting the DR Inverter
97. or disconnecting the battery cables and that all AC power is disconnected from the inverter s inputs 975 0012 01 02 RevA To connect the battery bank to the inverter 1 Determine the correct size battery cable to use for installation from Table 2 3 on page 2 16 2 Determine the correct size disconnect fuse for installation from Table 2 4 on page 2 17 3 Color code the cables with tape or heat shrink tubing The standard colors are red for positive and black for negative NEC requires white for the negative conductors 4 Connect the negative cable to the battery s negative terminal torque to manufacturer s recommendations 5 Install the over current device fuse or circuit breaker between the battery s positive terminal and the inverter s positive terminal as close to the batteries as possible 6 Connect the short positive cable to the battery s positive terminal torque to manufacturer s recommendations 7 Ensure the correct polarity of the cables with a DC voltmeter DVM Installation 8 Observing battery polarity connect the positive battery cable from the over current device to the inverter s positive terminal Important The next step may cause a small spark and snapping sound when connecting the cable to the inverter This is normal and is caused by the inverter s capacitors charging up 9 Observing battery polarity connect the negative battery cable to the inv
98. out the features and functions of the DR Inverter Charger Chapter 2 Installation contains information about how to plan for and install the DR Inverter Charger Chapter 3 Operation contains information about how to operate the DR Inverter Charger Chapter 4 Troubleshooting contains information about how to troubleshoot possible error conditions while using the DR Inverter Charger Appendix A Specifications contains information about the electrical specifications and environmental specifications of the DR Inverter Charger Appendix B Appendix B Battery Information supplies general information about batteries such as battery types battery bank sizing battery configurations and battery care For detailed information see your battery manufacturer or your system designer Appendix C Multi wire Branch Circuit Wiring supplies information about Multi wire Branch Circuit Wiring Precautions when using stand alone 120 Vac inverters or generators About This Manual Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warning A
99. put 12 5 amps AC 20 amps AC 12 5 amps AC 20 amps AC 25 C Efficiency 94 max 94 max 94 max 95 max AC Output Voltage 230 Vac 230 Vac 230 Vac 230 Vac rms Surge Capability 1 mSec Rating 20 amps AC 20 amps AC 20 amps AC 40 amps AC DC Input Current Search Mode 0 045 amps 0 055 amps 0 030 amps 0 030 amps Full Voltage 0 700 amps 0 900 amps 0 350 amps 0 450 amps DC Current at Rated 165 amps 280 amps 80 amps 140 amps Power Short Circuit Current 400 amps 800 amps 280 amps 560 amps DC Input Voltage 12 6 Vdc 25 2 Vde 50 4 Vdc 25 2 Vdc nominal DC Input Voltage Range 975 0012 01 02 Rev A 10 9 to 15 5 Vdc 21 8 to 31 Vde 43 6 to 62 Vdc 21 8 to 31 Vde Specifications Table A 3 Electrical Specifications for the DR Inverter Charger 230 Vac 50 Hz Models Model DR1512E DR1524E DR1548E DR2424E Auto Low Battery Protection enabled 11 V 11 V 22 V 22 V DC Charger Rate Adjustable 0 to 70 amps 0 to 35 amps 0 to 17 5 amps 0 to 70 amps Common Specifications Voltage Regulation maximum 5 Voltage Regulation Typical 2 5 Waveform modified sine wave Load Power Factor allowed 0 5 to 1 0 leading or lagging Adjustable Load Sensing Range 5 watts minimum to 100 watts maximum Series Operation NO Force Air Cooling Variable speed fan Automatic Transfer 20 amps Relay Number of Charging
100. re 3 15 Equalize Positions on Battery Type Selector Switch 975 0012 01 02 RevA 3 19 Operation See Table 3 1 Switch Position 1 See Table 3 1 Switch Position 0 Figure 3 17 Equalize 2 Battery Capacity Rate Potentiometer Position 0 3 20 975 0012 01 02 RevA Troubleshooting Chapter 4 Troubleshooting contains information about how to troubleshoot possible error conditions while using the DR Inverter Charger Troubleshooting Troubleshooting the DR Inverter Table 4 1 provides a list of possible error conditions that may occur their possible causes and possible solutions to resolve the error condition Table 4 1 Troubleshooting the DR Inverter Error Condition Possible Cause Solution No AC output voltage and no warning LEDs on ON Battery voltage at the inverter terminals is too high or low Check the battery voltage fuses or breakers and cable connections AC output voltage is low and the inverter turns loads ON and OFF Low Battery Check the condition of the batteries and recharge if possible Replace the batteries AC output is low Loose or corroded battery connections Loose AC output connections Wrong voltmeter is being used Check and clean all DC connections Check all AC output connections Use a True RMS voltmeter Charger is inoperative AC voltage has dropped out of tolerance Loose AC input connections Check the AC v
101. rger Mode Charger Mode 3 Stage Charging Process 975 0012 01 02 RevA The charging cycle uses a 3 stage charging process to maintain the batteries Whenever nominal AC is present at the inverter s input it passes power through to the connected load and begins charging the batteries indicated by the dual color BATTERY CHARGER LED Bulk Charge Bulk charge is the first stage in the charging process and provides the batteries with a controlled constant current A solid orange BATTERY CHARGER LED indicates bulk charge The bulk charge level is adjustable using the BATTERY CHARGER RATE potentiometer Once the battery voltage rises to the bulk voltage threshold the charger then switches to the absorption mode Absorption Charge Absorption charge is the second stage of battery charging and provides the batteries a controlled constant voltage for a set period of time A blinking orange BATTERY CHARGER LED indicates absorption charge During this stage the current supplied to the batteries slowly decreases When the current equals the programmed return amps value battery bank capacity 40 set with the BATTERY BANK CAPACITY potentiometer the charger switches to the third stage float Important If there are DC loads connected to the battery the current may never decrease to the level to initiate the float stage The inverter charger incorporates a timer circuit which starts counting when AC voltage is applied To ensure that the c
102. ry Bank Sizing Back up power systems which use utility power for recharging should use the estimated number of days of maximum power outage for determining days of autonomy Understanding Amp hour Requirements Amp hours Watts to amps Time and power To estimate the battery bank requirements you must first calculate the amount of power you will draw from the batteries during your period of autonomy This power draw is then translated into amp hours Ah the unit of measure to express deep cycle battery capacity Amp hours are calculated multiplying the current drawn by the load by the length of time it will operate To calculate amps when the power consumption is expressed in watts use the following equation A W V where W watts and V volts DC For example A 100 watt light bulb will draw approximately 8 33 amps 8 33 100 12 If the light runs for three hours it will consume 8 33 x 3 or 25 Ah of power The length of time a load is operated will affect the power draw In some cases an appliance which draws a large wattage may not consume as many amp hours as a load drawing fewer watts but running for a longer period of time For Example A circular saw draws 1500 watts or 125 amps It takes 5 seconds to complete across cut Twelve such cuts would take a minute and you would consume 125 A x 0 016 hour 2 Ah 1 60 0 016 Observation The circular saw while it draws more power consumed fewer amp hours of electr
103. s All wiring and installation methods should conform to applicable electrical and building codes Pre plan the wire and conduit runs e The AC terminals accept cable sizes up to 6 AWG e The DC terminals accept cable sizes up to 4 0 AWG that use ring terminals with 5 16 holes For maximum safety run both AC and DC cables in conduit DC Terminal Connections Battery to inverter cabling should be only as long as required For Example If 4 0 AWG cables are used do not exceed 5 feet one way in 12 Vdc systems do not exceed 10 feet one way in 24 Vdc systems For optimum performance use pre assembled battery cables designed specifically for this application available from Xantrex Grounding Considerations AC Grounding DC Grounding The inverter charger should be connected to a grounded permanent wiring system Neutral and ground conductors should only be bonded at the main electrical service panel The negative battery conductor should be bonded to the grounding system at only one point in the system The size for the conductor is usually based on the size of the largest conductor in the DC system 975 0012 01 02 RevA Wire Routing Pre installation Planning Determine all wire routes both to and from the inverter and which knockouts are best suited for connecting the AC conduits Possible routing scenarios include e AC input wiring from the main electrical service panel to the inverter charger if used
104. s The battery bank must be wired to match the inverter s DC input voltage specifications 12 or 24 Vdc In addition the batteries can be wired to provide additional run time The various wiring configurations are Series Wiring batteries in series increases the total bank output voltage This voltage MUST match the DC requirements of the inverter or inverter and or battery damage may occur Parallel Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads The more batteries connected in parallel the longer the loads can be powered from the inverter Series Parallel Series parallel configurations increase both the battery voltage to match the inverter s DC requirements and run time for operating the AC loads This voltage must match the DC requirements of the inverter Batteries with more than two or three series strings in parallel often exhibit poor performance characteristics and shortened life Wiring Batteries in Series Effect Wiring the batteries in a series configuration increases the voltage of the battery string Six volt batteries can be combined to form 12 volt 24 volt or 48 volt battery banks In the same way 12 volt batteries connected in series form 24 volt battery banks The total current capacity of the bank does not increase and remains the same amp hour rating as it does for a single battery Important The voltage must match the DC requirements of the inverter Eac
105. s RC8 RC4 975 0012 01 02 RevA DR Inverter are designed to operate with either an RC8 or RC4 remote control units Both remotes incorporate a membrane switch with a single red LED display combination to start and stop the inverter as well as provide overall system operating status Solid With AC line power present the unit is charging the batteries while directing AC to the load With no AC line power present the inverter is running on the batteries and supplying AC to the load Blinking Slow 1 to 3 flashes 1 second intervals The inverter is in search mode no load connected Blinking Fast 3 to 5 flashes 1 second intervals The inverter is charging the batteries Flickering 3 to 5 flashes 1 second intervals The inverter has detected an over current error The LED and inverter will turn OFF whenever an over current condition exceeds eight seconds 3 3 Operation Erratic Blinking 0 to 3 and 2 to 5 flashes 2 second intervals The inverter has detected an error condition caused by overheating low battery voltage or high battery voltage e OFF The inverter is OFF The remote control must be connected prior to switching the inverter ON otherwise the micro controller will not recognize or respond to the remote If the remote is not recognized switch the inverter OFF and then ON using the inverter s front panel POWER ON OFF switch Stacking Interface Whenever two DR Series inv
106. s of autonomy The battery bank s size determines the length of time the inverter can supply AC output power The larger the bank the longer the inverter can run In general the battery bank should be designed so the batteries do not discharge more than 60 of their capacity on a regular basis Discharging up to 80 is acceptable on a limited basis such as a prolonged utility outage Totally discharging a battery can reduce its effective life or permanently damage it For off grid stand alone applications design a battery bank that can power the loads for three to five days without requiring recharging This design calculation assumes a worst case scenario where there is no recharging taking place during these days of autonomy Days of autonomy may vary depending upon the availability of other charging sources the critical nature of the load and other factors If the system is to be powered by renewable energy sources such as solar wind and micro hydro determine the appropriate number of days of autonomy by allowing for cloudy or calm weather as well as other seasonal variations in available energy If an engine generator is part of the system design the days of autonomy can be determined by simply deciding how often you are prepared to run the generator Significant battery cost reductions can be achieved by shortening the days of autonomy and allowing a generator to run for a schedule time period daily 975 0012 01 02 RevA Batte
107. s powered until utility power is restored Internal protection circuits prevent over discharge of the batteries by shutting down the inverter when a low battery condition occurs When utility or generator power is restored the inverter transfers to the AC source and recharges the batteries The front panel features LEDs for reading system status and controls to customize the inverter settings for your battery bank The DR Inverter is an economical product designed to provide a reliable supply of electricity to all the essential circuits in the home or business during a power outage The critical loads can be powered for hours or days depending on the size of the system battery bank When utility grid power returns the batteries are quickly recharged to ensure they will be ready to supply backup power during the next outage Accessories allow the DR Series to also serve as a central hub of a renewable energy system The DR Inverter provide a modified sine wave output which operates most AC appliances and equipment The inverter charger includes a 3 stage battery charger designed to recharge any type of battery in the shortest possible time The built in fully automatic AC transfer relay automatically transfers power from the utility to the inverter and handles a full 60 amps of current at 120 Vac 30 amps for pass through plus 20 to 30 amps for charging depending on the model The DR Inverter is simple to operate All inverter and bat
108. sary amperage to drive a heavy load the inverter will shut OFF The battery voltage will then slowly rise back above the low voltage threshold causing the inverter to resume operation As soon as the heavy load draws the batteries down the cycle will continue unless the load is reduced or an additional source of power is added Microwave Ovens 4 4 Microwave ovens are sensitive to peak output voltages The higher the voltage the faster they cook Since the inverter s peak output voltage is dependent upon battery voltage and load size the microwave s cook time may need to be increased 975 0012 01 02 RevA Problem Loads Printers Most inkjet type printers work well in inverter applications Laser printers however require high current for their fusing circuit and are not recommended for use with an inverter Rechargeable Devices When first using a rechargeable device monitor its temperature for 10 minutes to ensure it does not become abnormally hot Excessive heat will indicate that it is incompatible with the inverter Undersized Loads If the power consumed by a device is less than the inverter s search mode circuitry threshold it will not run This can usually be solved by plugging in an additional load such as a 100 watt light bulb A CAUTION Equipment Damage Some products can be damaged when used with modified sine wave power If in doubt check with the product s manufacturer 975 0012 01 02 Rev A 4
109. se Polarity 2 18 S safety instructions vii serial number W A 4 W warranty out of warranty service WA 3 terms and conditions WA 1 X Xantrex web site iv IX 2 Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 975 0012 01 02 Rev A PC Printed in the DR
110. sed by a fault in the charger circuit When the fault condition clears the LED turns OFF If the condition is caused by backfeed connecting the AC line to the inverter s output the LED will remain ON for approximately 10 seconds before the inverter shuts down Battery High Battery Low LED Red Green error condition 975 0012 01 02 RevA The Battery Hi Battery Low LED is a dual color dual function indicator Whenever battery voltage exceeds a safe value the LED lights red to indicate the condition This value is typically 15 5 volts DC for a 12 volt system 31 volts DC for a 24 volt system If the condition persists the inverter will shut down until the battery voltage returns to a safe level and then restart Operation Important In renewable energy applications solar wind hydro etc the DC charge controllers must be set to a level below the inverter s maximum input voltage or the inverter shuts OFF Whenever the battery voltage drops to its lowest safe level as calculated by the ODP the LED lights green to indicate the condition If the condition persists the inverter will shut down until the battery voltage returns to a safe level and then restart Important The inverter automatically restarts when the following error conditions are detected LOW HIGH BATTERY OVER TEMPERATURE or a quick duration SHORTED OUTPUT or OVER CURRENT The inverter shuts OFF and requires a MANUAL restart if the following condit
111. seseesees Seeeeeetae s ee E Primary System n S pon Figure 2 20 AC Wiring using a 120 Vac Generator Off Grid Application 2 28 975 0012 01 02 RevA AC Wiring AC Input Wiring Off Grid Applications using a 240 Vac Generator for 120 Vac Loads Follow the example below to complete the wiring for an off grid application LEGEND AC Generator w GROUND 120 240 Vac NEUTRAL Hot OUT Neutral Be sure to check the Generator for a Neutral to Ground Bond and remove it There can only be one Neutral to Ground bond Hot IN p in the system Step Down LIO Autotransformer mar optional Neutral Generator Disconnect a Optional DR Inverter Charger 1 ier AC Distribution Panel Sub panel Sees eee ete eee sees ese eee eee eee ee eee eee NEUTRALIN ou 120 Vac Panel ove o ene C OO H a l r r 120 Vac H Loads H ied os I H Neutral to Ground i cor Bond H J at 1 ot L as Primary System Ground Figure 2 21 AC Wiring using a 240 Vac Generator with 120 Vac Loads only Off Grid Application 975 0012 01 02 RevA 2 29 Installation Series Stacking 120 Vac 60 Hz Models only This COM port allows two DR Inverters 120 Vac 60 Hz models only to be used in the same system in a SERIES configuration to operate 240 Vac loads Series stacking can also be used to connect to 240 Vac only power systems providing both 120 and 240 Vac outputs A series st
112. shipped in the original carton This is also a good way to protect the inverter if it ever needs to be moved O Record the unit s model serial number and date of purchase in the appropriate fields in section Information About Your System on page WA 4 Important Due to continual improvement through product updates photographs and or illustrations used in this manual may not exactly match your unit Xantrex Technology Inc reserves the right to update this product without notice or releasing an updated manual when fit form or function are not affected Model Identification and Numbering Conventions 975 0012 01 02 RevA The DR Inverter is identified by the model serial number labels The Serial Number can be located on the mounting rail or inside the top cover Model Number labels may be located on the bottom side of the front cover or possibly inside the front cover All the necessary information is provided on the label such as AC output voltage power and frequency punch holes The inverter also has a letter designator followed by 4 or 5 digits depending on revision The model number describes the type of inverter the output specifications the required battery voltage and the output voltage and frequency Table 1 1 Model Identification and Numbering Conventions DR indicates the type of inverter charger DR Series the first two digits of the numerical designator indicate the inverter s output 15 power 1500 W
113. sophisticated electronic components and should be located in a well protected dry environment away from sources of fluctuating or extreme temperatures and moisture Exposure to saltwater is particularly destructive and potentially hazardous Locate the inverter as close to the batteries as possible in order to keep the battery cable length short However do not locate the inverter above the batteries or in the same compartment as vented batteries Batteries generate hydrogen sulfide gas which is corrosive to electronic equipment They also generate hydrogen and oxygen If accumulated an arc caused by connecting the battery cables or switching a relay could ignite this mixture Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable CAUTION Corrosion Damage If the inverter is installed in a location where it is exposed to a corrosive or condensing environment and fails due to corrosion it will not be covered under warranty Important Inverters can generate RFI Radio Frequency Interference Locate any sensitive electronic equipment susceptible to RFI as far away from the inverter as possible This includes radios and TVs 975 0012 01 02 RevA Pre installation Planning Mounting The National Building Code requires the inverter be mounted on a vertical surface or wall The keyhole slots must not be used as the only method of mounting The purpose of the wall mounting requirement is to orient th
114. t in poor inverter performance and greatly reduce battery life Battery Charging Charge Rate The maximum safe charge rate is related to the size and type of the batteries Flooded lead acid batteries with removable caps can be charged at a high rate Small batteries may require a lower charge rate Check with your battery vendor for the proper battery charging rate for the batteries used in the system Bulk Voltage This is the maximum voltage the batteries will be charged to during a normal charge cycle Gel cell batteries are set to a lower value and non sealed batteries are set to a higher voltage setting Float Voltage The Float voltage is set lower than the Bulk voltage and provides a maintenance charge on the batteries to keep them in a ready state Temperature For optimal battery charging the Bulk and Float charge rates should be adjusted Compensation according to the temperature of the battery This can be accomplished automatically by using a BTS The sensor attaches directly to the side of one of the batteries in the bank and provides precise battery temperature information When battery charging voltages are compensated based on temperature the charge voltage will vary depending on the temperature around the batteries The following table describes approximately how much the voltage may vary depending on the temperature of the batteries If you have liquid lead acid batteries non sealed you may need to periodically equaliz
115. tery banks Figure 3 10 Battery Capacity Potentiometer old 975 0012 01 02 RevA LED Indicators Front Panel Controls and Indicators There are four LEDs on the inverter s front panel indicating inverter status battery condition over temperature overload conditions and charger status These LEDs blink or change color depending on the condition or function they are displaying OVER TEMP OVERLOAD INVERTER BATTERY HIGH LOW MODE BATTERY CHARGER Figure 3 11 LED Indicators Inverter Mode LED Green The green Inverter Mode LED lights solid to indicate the inverter is running on batteries full wave operation When the inverter is in search mode no load applied the LED flashes 2 to 3 times per second During AC line operation with AC passing directly through to the connected load the LED remains OFF Over Temp Overload LED Red Green error condition The Over Temp Overload LED is a dual color dual function indicator When the inverter s temperature is too high for safe operation the LED lights red to indicate the Over Temp condition When the temperature returns to a safe level the LED turns OFF If the condition persists the inverter will shut down cool and then restart Whenever the current draw exceeds a value programmed into the micro controller the LED lights green to indicate the Overload condition The LED can remain ON for up to one hour before inverter shutdown if the condition is cau
116. tery charger controls are located on the front panel The inverter charger operates at over 90 efficiency through most of its power range in Invert mode DR Inverter use extremely low current while in the search mode consuming less than 1 watt of power In the ON mode the inverter charger uses less than 12 watts of power The following sections illustrate the features of the DR Inverter Figure 1 1 shows the features of the front side of the DR Inverter and identifies the AC side from the DC side 975 0012 01 02 RevA Features DC End AC End 3 o cm at gt Battery Type Selector ema t e i DR Series Po Inverter Charger ny s wer inverter 9 COM Port Front Panel Controls Battery Sense Port and Indicators Battery Caps Figure 1 1 Front Panel Features AC Side The AC side of the DR Inverter has one 30 amp breaker for pass thru AC Input and one 30 amp 20 amp in certain models breaker for charger AC input 30 Amp Breaker for Pass thru AC Input 20 or 30 Amp Breaker for Charger AC Input Ventilation Holes Cover plate is not shown in this photo Figure 1 2 AC Side of the DR Inverter 975 0012 01 02 Rev A 1 3 Introduction DC Side The DC side of the DR Inverter has the equipment ground lug the positive battery terminal and the negative battery terminal WARNING Battery Positive Terminal fet Ventilation Holes CLE BATTERIES DEEP CY
117. ti wire Branch Circuit Wiring 975 0012 01 02 Rev A Warranty and Return Information Warranty What does this warranty cover This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your DR Inverter Charger This warranty period lasts for Warranty period from the date of purchase at the point of sale to you the original end user customer You require proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require proof of purchase What will Xantrex do Xantrex will at its option repair or replace the defective product free of charge provided that you notify Xantrex of the product defect within the Warranty Period and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty Xantrex will at its option use new and or reconditioned parts in performing warranty repair and building replacement products Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaire
118. ts which tend to produce arcs or sparks To prevent fire or explosion do not install the DR Inverter Charger in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing gasoline powered machinery fuel tanks as well as joints fittings or other connections between components of the fuel system To reduce the risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed 975 0012 01 02 RevA Safety Precautions When Working With Batteries UN WARNING Explosion or Fire Hazard Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed 1 2 975 0012 01 02 RevA Make sure the area around the battery is well ventilated Never smoke or allow a spark or flame near the engine or batteries Use caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Remove all metal items like rings bracelets and watches when working with lead acid batteries Lead acid batteries produce a short circuit current high enough to weld metal to skin causing a severe burn Have someone within range of your voice or close enough to come to your aid when you work
119. umber of 10 Charging Profiles Three stage Yes float absorption bulk Charging Temperature Comp optional Probe BTS Remote Control optional RC8 4 a Specifications subject to change without notice b This is the minimum AC current required to obtain full pass through and maximum battery charging c Product may not meet voltage regulation specifications at other than Input Nominal at full rated load d Also compatible with the RC4 975 0012 01 02 RevA A 3 Specifications Table A 2 Electrical Specifications for the DR Inverter Chargers 220 Vac 60 Hz Models Model DR1512W DR2412W AC Input Voltage 220 Vac 220 Vac AC Input Low Transfer Voltage 80 to 210 Vac 80 to 210 Vac AC Input Current 45 amps 55 amps Continuous Power 25 C 1500 VA 2400 VA Continuous Output 25 C 6 8 amps AC 6 8 amps AC Efficiency 94 max 94 max AC Output Voltage rms 220 Vac 220 Vac Frequency 0 04 Crystal controlled 60 Hz 60 Hz Surge Capability 1 mSec Rating 20 amps AC 20 amps AC DC Input Current Search Mode 0 045 amps 0 055 amps Full Voltage 0 700 amps 0 900 amps DC Current at Rated Power 150 amps 80 amps Short Circuit Current 400 amps 800 amps 12 6 Vdc 12 6 Vdc DC Input Voltage nominal DC Input Voltage Range 10 8 to 15 5 Vdc 10 8 to 15 5 Vdc Auto Low Battery Protection enabled 11 V 11V Charger Rate Adjustable 0 to 70 amps 0 to 120 amps Co
120. urchase of the product at point of sale to the end user or e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or e The dated invoice or purchase receipt showing the product exchanged under warranty 975 0012 01 02 RevA WA 1 Warranty and Return What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly installed physically damaged or altered either inter nally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifi cations including high input voltage from generators and lightning strikes c the product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter ASCs d the product if it is used as a component part of a product expressly warranted by another manufacturer e the product if its original identification trade mark serial number markings have been defaced altered or removed
121. used and according to NEC 250 95 Ninth Edition see Table 2 2 below for a portion of the NEC code Table 2 2 Safety Ground Conductor Size Size of Over current Device Minimum Size of the Copper Protecting the Conductor Ground Wire 30 or 60 amp 10 AWG 100 amp 8 AWG 200 amp 6 AWG 300 amp 4 AWG 400 amp 3 AWG General DC Grounding Requirements This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI NFPA 70 current edition This is the single point earth ground for the inverter system To ground the DC circuits 1 Connect the negative terminal of the battery bank to an appropriately sized conductor and connect it to the ground bus in the DC Disconnect 2 Connect an appropriately sized conductor to the Ground bus in the DC Disconnect and connect it to the primary system ground The system ground is the same ground used by the AC side of the system 975 0012 01 02 RevA 2 13 Installation DC250 DISCONNECT SHUNT amp Chassis NEGATIVE BUS Ground e o e o c o 0 p Lug A sas ae eae _ e ee J o o se eee eae 7 Sees sees sees ses esses sess esses ses To Primary System Ground Figure 2 9 DC Grounding 2 14 975 0012 01 02 RevA Batteries Battery Types Battery Bank Sizing DC Wiring The DR Inverter can support either 12 volt battery banks or 24 volt battery banks Before procee
122. verters When using inverters in a stacked configuration the same battery bank must be used for both inverters To ensure even charging of the batteries each inverter must be connected to both strings i e positive cable to string two and negative cable to string one for inverter 1 and positive cable to string one and negative cable to string two for inverter 2 as shown in the diagram below DC CONDUIT DC CONDUIT FOR FOR INVERTER 1 INVERTER 2 Primary Secondary DC Disconnect either a circuit breaker or a fuse with a disconnect DC Disconnect either a circuit breaker or a fuse with a disconnect ree Series String 1 12 Volt Battery 200 Ah 24 VDC 200 Ah 12 Volt Battery 200 Ah Batteries in Parallel 24 VDC 400 Ah Series String 2 24 VDC 200 Ah 12 Volt Battery 200 Ah 12 Volt Battery 200 Ah Figure B 7 Example of Battery Connections for Stacked Inverters 24 Vdc shown B 12 975 0012 01 02 Rev A Battery Maintenance Battery Maintenance Maintenance To get the best performance from an inverter system the batteries must be strategy properly setup and maintained This includes setting the proper voltages for Bulk and Float charging See the CAUTIONS in the section on Equalization Charging that follows In addition the battery terminals should be inspected cleaned and re torqued if necessary Neglecting any of these items may resul
123. wire Branch Circuit Wiring Precautions when using stand alone 120 Vac inverters or generators WARNING A possible fire hazard can exist if 120 Vac only sources such as inverters and generators are wired incorrectly into 120 240 Vac panels containing multi wire branch circuits This section describes how to check for multi wire branch circuits in the load center and presents some possible solutions to this wiring method Multi wire Branch Circuit Wiring Multi wire Branch Circuits Problem Legacy situation Normal condition Safety issue A potential safety problem exists when installing stand alone 120 Vac inverters into existing 120 240 Vac wired panels where multi wire branch circuit wiring methods were used Multi wire branch circuits are wired differently from home run type wiring Figure C 1 in that only one neutral wire is used to provide the neutral return path for each circuit connected to both phases of the AC grid This method has been employed by electricians in recent years to keep construction costs down by saving copper and labor costs involved in running a separate Romex for each circuit Under normal conditions this technique is quite safe and meets code requirements When used as originally installed the current for each circuit is 180 out of phase with each other so the neutral wire never receives more current than it was designed to handle as the current from each circuit subtracts or cance

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