Xantrex Technology HW 1000 Battery Charger User Manual
Contents
1. 1 2 Safety Instructions 1 3 Installation Codes 1 3 Installation Tools and Materials 1 4 High Level Overview of Installation Steps 1 4 Basic Installation Procedures 1 5 Step 1 Designing the Installation 1 6 Step 2 Choosing a Location for the Freedom HW 1 12 Step 3 Mounting the Freedom HW 1 13 Connecting the Equipment Ground 1 14 Grounding Locations 1 14 Step 4 Connecting the AC Input Wires 1 15 General AC Wiring Considerations 1 15 AC Input Connections 1 16 Step 5 Connecting AC Output to an Existing AC Circuit 1 18 Step 6 Connecting the DC Cables 1 23 DC Grounding EE EE EER EE EE EE EE EE EE 1 26 Step 7 Mounting the Display Panel 1 27 Step 8 Testing Your Installation 1 28 Testing in Invert Mode 1 28 Testing in Shore Power Mode2. 1 29 975 0468 01 01 This guide for use by qualified installers only ix 2 Specifications Electrical Specifications Inverter Mode 2 2 Electrical Specifications Charge Mode 2 3 Environmental Specifications 24 System Specifications 24 Physical Specifications 24 Regulatory Approvals 2 5 Inverter Overload Operation 2 5 Invert Power Derating vs Ambient Temperature 2 6 Charger Output Current vs AC Input Voltage 2 7 This guide for use by qualified installers only Installation Chapter 1 provides information to help in installing a Freedom HW Inverter Charger Installation It covers the following Materials list Safety instructions and various installation codes that may be applicable to your installation Sample installation tools and materials High level overview of installation steps Installation procedures starting on page 1 5 including mounting and connecting the equipment ground AC cabling DC cabling and grounding steps 1 1 This guide for use by qualified installers only Materials List Your
3. Freedom HW 1000 Inverter Charger Installation Guide Smart choice for power xantrex Freedom HW 1000 Inverter Charger Installation Guide This guide for use by qualified installers only About Xantrex Xantrex Technology Inc www xantrex com a subsidiary of Schneider Electric is a world leader in the development manufacturing and marketing of advanced power electronic products and systems for the renewable and mobile power markets The company s products convert and control raw electrical power from any central distributed renewable or backup power source into high quality power required by electronic equipment and the electricity grid Xantrex is headquartered in Vancouver Canada with facilities in the United States Germany Spain and a joint venture in China About Schneider Electric As a global specialist in energy management with operations in more than 100 countries Schneider Electric offers integrated solutions across multiple market segments including leadership positions in energy and infrastructure industrial processes building automation and data centres networks as well as a broad presence in residential applications Focused on making energy safe reliable and efficient the company s 120 000 employees achieved sales of more than 17 3 billion euros in 2007 through an active commitment to help individuals and organizations Make the most of their energy Trademarks Xantrex Free
4. Shock and Energy hazards Make sure wiring is disconnected from all electrical sources before handling All wiring must be done in accordance with local and national electrical wiring codes Do not connect the output terminals of the Freedom HW to any incoming AC source General AC Wiring Considerations AC cable size AC Wiring Connectors AC and DC Wiring Separation AC Wiring Compartment AC Wiring 975 0468 01 01 The AC input cable may be either solid or stranded as required but must have three conductors and be sized as in Table 1 4 on page 1 16 Connect AC wires with crimp on splice connectors The amount of insulation you strip off individual wires will be specified by the connector manufacturer and is different for different types of connectors Do not mix AC and DC wiring in the same conduit or panel Where DC and AC wires must cross make sure they do so at 90 to one another Consult applicable codes for details about DC and AC wiring in close proximity to each other For your reference the AC Wiring Compartment is shown in Figure 1 5 To hard wire the Freedom HW AC input and output to an existing AC installation read this section AC wiring includes all the wires and connectors between the AC source and the Freedom HW and all wiring between the inverter the AC panels circuit breakers and the GFCIs The type and size of the wiring varies with the installation and load For some RV applications fl
5. one of which serves the Freedom HW The AC load panel can incorporate an AC output circuit breaker and breakers for individual load circuits CAUTION Equipment damage Do not connect the output of the Freedom HW to what is known as a multi wire branch circuit These are four wire circuits consisting of a ground neutral and two lines that are 180 degrees out of phase with each other from a standard 120 240V split phase circuit These circuits are commonly used in kitchens to power split receptacles where the top and bottom halves of a duplex receptacle are connected to different lines AC Cabling 1 8 AC cabling includes all the wires and connectors between the AC source and the Freedom HW as well as all cabling between the Freedom HW and the AC output panels circuit breakers and loads The type and size of the wiring varies with the installation and load For example in high vibration environments such as RV applications wire nuts may not be acceptable so crimp splices would be required In other applications flexible multiple strand wire may be required Installation codes usually specify solid or stranded overall size of the conductors and type and temperature rating of the insulation around the wire 975 0468 01 01 This guide for use by qualified installers only AC Output Neutral Bonding DC Cabling 975 0468 01 01 Basic Installation Procedures AC breakers and fuses must be sized to ad
6. and will void your warranty Internal capacitors remain charged after all power is disconnected 7 To reduce the risk of electrical shock disconnect both AC and DC power from the Freedom HW before attempting any maintenance or cleaning or working on any circuits connected to the Freedom HW Turning off controls will not reduce this risk 8 The Freedom HW must be provided with an equipment grounding conductor connected to the AC input ground A WARNING Explosion hazard 1 Working in the vicinity of batteries is dangerous Batteries generate explosive gases during normal operation Therefore it is of utmost importance that each time before servicing the unit in the vicinity of the battery that you read this manual and follow the instructions exactly 2 This equipment contains components which tend to produce arcs or sparks To prevent fire or explosion do not install the Freedom HW in compartments containing batteries or flammable materials or in locations that require 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 3 To reduce the risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of any unit you intend to use in the vicinity of the battery 975 0468 01 01 This guide for use by qualified installers only Pe
7. as follows e ACOutput L e AC Output N A separate screw is provided to connect the AC output ground Strip about 2 inches 50 mm from the jacket of the AC output cable The AC output cable may be either solid or stranded as required but must have three conductors and sized as in Table 1 4 on page 1 16 The AC terminal block accepts wire sizes up to No 10 AWG Strip approximately 3 8 inch 10 mm off the insulation of each conductor Remove the AC wiring compartment cover Run the AC cable through the left hand side knockout and into the wiring compartment Fasten the Ground wire to the grounding screw Using the 1 8 inch slot screwdriver loosen the wire attachment screws on the terminals This guide for use by qualified installers only A CAUTION Reverse polarity Improper connections connecting a line conductor to a neutral conductor for example will cause the Freedom HW to malfunction and may permanently damage the inverter Damage caused by a reverse polarity connection is not covered by your warranty 11 Insert the Line and Neutral wires into the corresponding terminals 12 Tighten the wire attachment screws to a torque of 15 6 21 6 in lbf 1 76 2 44 N m Leave some wiring slack inside the wiring compartment Ensure you have maintained correct polarity and that there are no loose strands of wire 13 Reinstall the AC wiring compartment cover 14 Connect the outgoing AC wires to the A
8. the Freedom HW input must be sized adequately to carry current up to the rating of the input breaker and in accordance with the electrical codes or regulations applicable to your installation 1 7 This guide for use by qualified installers only AC Distribution Panels AC Output The circuit breaker or fuse must be rated at no more than the rating of the input breaker in the installation and must be approved for use on 120 Vac branch circuits The wire used between the Freedom HW and the AC output breaker must be of adequate size to match the AC input circuit breaker s rating The wiring from each AC output breaker to each of the loads must be adequately sized to carry the current rating of the individual AC output breaker Disconnect Devices Each system requires a method of disconnecting the AC circuits If the over current protection devices are circuit breakers they will also serve as the disconnects If fuses are used separate AC disconnect switches will be needed ahead of the fuses These will have to be a branch circuit rated for 120 Vac and have an appropriate current rating Most systems incorporate distribution centers both ahead of the Freedom HW the AC source panel and between the Freedom HW and the loads the AC load panel An AC source panel includes a main circuit breaker which serves as over current protection and as a disconnect for the AC shore power supply line Additional circuit breakers serve individual circuits
9. the terminal manufacturer Make sure no stray wires protrude from the connector or terminal You may find it more convenient to have the crimp connectors attached by the company that sells you the cable and or connectors For each cable end that will be connected to the inverter strip 1 2 inch 13 mm to 3 4 inch 19 mm of insulation from the cable The amount stripped off will depend on the terminals chosen Attach the connector that will join the cable to the inverter DC terminal Install a fuse and fuse holder in the cable that will be used for the positive side of the DC circuit The fuse must e be as close to the battery positive terminal as possible e berated for DC circuits e have an Ampere Interrupting Capacity AIC that exceeds the short circuit current available from the battery i e Class T fuse To prevent sparking when making the connection ensure the disconnect battery selector switch is off Attach the connector on the positive cable to the positive DC terminal on the inverter 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures 10 Install the lock washer and nut that are supplied with the inverter Tighten the nut to a torque of 108 120 in lbf 12 2 13 6 N m Make the connection snug enough so the ring terminal does not move around on the DC terminal but do not overtighten See Figure 1 9 DC Cable Connections on page 1 26 CAUTION Loose co
10. two screws one for each side Important Do not route the communications cable in parallel and in conduit with the AC and DC wires In situations where the cable must cross with the AC and DC wires make sure they cross at a 90 angle to each other This guide for use by qualified installers only Step 8 Testing Your Installation WARNING Shock hazard Pressing the Inverter button to turn OFF the Freedom HW inverter function on display panel does not disconnect DC or AC input power to the Freedom HW If shore power is present at AC input terminals it will pass through to the AC output There are two tests to be performed The first test verifies that the Freedom HW is inverting DC battery power and delivering AC power to its output The second test is intended for installations where AC input and output is hard wired to the Freedom HW This test verifies that the Freedom HW transfers from inverter power to shore power when shore power is present Note Shore power pass through refers to the AC input power from a utility grid generator or external AC source When you are ready to test your installation and operate the Freedom HW close the DC fuse and Disconnect or the DC circuit breaker to supply DC power to the Freedom HW Testing in Invert Mode To test the Freedom HW in invert mode 1 For hard wired installations ensure shore power is not present 2 Press the Inverter button to turn the inverter o
11. 14 2 13 8 AGM 14 3 13 4 Fixed 13 5 13 5 975 0468 01 01 2 7 2 8 Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free NA customerservice xantrex com Www Xantrex com 975 0468 01 01 Printed in China
12. 70 foot cable p n 31 6275 00 Flush mounting the panel on a wall or bulkhead requires an opening specified in the display panel mounting template About 1 5 inches 3 8 cm of free space is required within the wall to accommodate the depth of the panel Be sure there is no wiring or other obstructions within the wall before you make an opening To mount the display panel 1 Choose a location that is dry out of direct sunlight free from corrosive or explosive fumes and otherwise appropriate for mounting an electronic device Remove the display panel from Freedom HW 3 Pilot drill the corner holes using the display panel mounting template and cut out the hole in which the display panel will be inserted 4 Position the display panel mounting plate over the hole and fasten it to the wall using all four screws in all the corners of the mounting plate 5 Route the communications cable s inside the wall and through the mounting plate opening 6 Insert the cable s connector the one through the opening in the jack on the backside of the display panel 7 Place the display panel through the opening of the mounting plate and secure it with two screws one for each side 8 Route the communications cable to the Freedom HW s display panel compartment and insert the other connector in the jack located near the battery select dip switch 9 Install the display panel compartment cover over the compartment and secure it with
13. C load panel 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures CAUTION Equipment damage E x Do NOT connect the AC OUT Neutral and Line to the AC IN Neutral and Line See Important note below See Important note below GENERATOR INVERTER SUBPANEL See Important note below TRANSFER SWITCH AC OUTLETS with GFCI SHORE POWER gt MAIN AC PANEL INVERTER LOADS Figure 1 6 AC Wiring Diagram with an Inverter Subpanel In this wiring diagram the AC input to the Freedom HW comes from the main AC panel which contains the input circuit breaker The AC output wiring is routed to a separate inverter subpanel with a dedicated circuit breaker Important The generator must have its neutral bonded to ground If it is not bonded a bonding jumper must be installed between the neutral and ground at the generator s output or at the generator side of the transfer switch Also both the main AC panel and the inverter subpanel must not have a permanent neutral to ground bonds installed 975 0468 01 01 1 21 This guide for use by qualified installers only CAUTION Equipment damage Do NOT connect the AC OUT Neutral and Line 7 to the AC IN Neutral and Line 7 See Important note below GENERATOR See Important note below TRANSFER SWITCH MAIN AC PANEL SHORE P
14. Freedom HW Inverter Charger package includes the items listed below e Freedom HW Inverter Charger unit e display panel p n 808 9557 with 7 inch 0 17 m display panel cable p n 053 0049 02 e display panel mounting plate p n 808 9555 e display panel mounting template p n 531 0081 01 01 e display panel compartment cover p n 808 9556 e AC wiring compartment cover p n 210 0738 01 01 e two reference materials an Owner s Guide and an Installation Guide p n 975 0468 01 01 and 975 0467 01 01 e one set of lock washers and nuts already connected to the bolts p n 061 2002 and 062 0030 Freedom HW unit Display panel is already mounted on the unit and connected to the remote panel port using the 7 inch display panel cable Underneath is the display panel compartment that houses the remote panel port and the remote dip switch Wiring compartment cover 3 Display panel Display panel mounting plate compartment cover Figure 1 1 What s In The Box 1 2 975 0468 01 01 This guide for use by qualified installers only Safety Instructions Safety Instructions WARNING Shock hazard Xantrex Technology recommends that all wiring be done by a certified technician or electrician to ensure adherence to the applicable electrical safety wiring regulations e Before you begin the installation review the Important Safety Instructions on page v and read this entire Installation section so you
15. OWER gt Input breakers must be provided by installers INVERTER LOADS Figure 1 7 AC Wiring Diagram without an Inverter Subpanel In this wiring diagram the AC input to the Freedom HW comes directly from an AC source The AC source input wiring must be protected by an AC breaker of 30 A max The output wiring is routed to the main AC panel which is also protected by AC breakers or circuit breakers Important The generator must have its neutral bonded to ground If it is not bonded a bonding jumper must be installed between the neutral and ground at the generator s output or at the generator side of the transfer switch Also the main AC panel must not have a permanent neutral to ground bond installed 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Step 6 Connecting the DC Cables CAUTION Before making the final DC connection check cable polarity at both the battery and the Freedom HW Positive must be connected to positive negative must be connected to negative Reversing the positive and negative battery cables will damage the Freedom HW and void your warranty This type of damage is easily detected WARNING Fire hazard Use only copper wire rated 75 C minimum Make sure all DC connections are tight to a torque of 108 120 in Ibf 12 2 13 6 N m Loose connections will overheat 975 0468 01 01 Follow the procedur
16. S IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW XANTREX COM Date and Revision Document Part Number Product Number December 2008 Rev A 975 0468 01 01 806 1055 Contact Information Telephone 1 800 670 0707 toll free North America 1 408 987 6030 direct Fax 1 800 994 7828 toll free North America Email customerservice xantrex com Web www xantrex com This guide for use by qualified installers only About This Guide Purpose Scope Audience The purpose of this Installation Guide is to provide explanations and procedures for setting up and installing a Freedom HW Installation For complete information on how to operate maintain and troubleshoot the Freedom HW unit see the Freedom HF Inverter Charger Owner s Guide Doc Part Number 975 0467 01 01 Recreational or Fleet Vehicle The Guide provides safety guidelines detailed planning and setup information as well as procedures for installing the inverter charger unit It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information The Guide is intended for qualified installers who need to install and configure the Freedom HW Inverter Charger The installer should be a qualified technician or e
17. al Vehicle 13 Install the lock washer and nut that are supplied Tighten the nut to a torque of 108 120 in Ibf 12 2 13 6 N m Make the connection snug enough so the ring terminal does not move around on the DC terminal but do not overtighten Figure 1 9 DC Cable Connections To connect the DC ground The equipment grounding lug on the DC end of the Freedom HW is used to connect the chassis of the Freedom HW to your system s DC negative connection or grounding bus point as required by electrical regulations Use copper wire that is either bare or provided with green insulation Do not use the DC Ground Lug for your AC grounding See the AC wiring instructions in this section Follow the guidelines below that correspond to the specific type of installation These guidelines assume you are using the DC supply cable and fuse sizes recommended in this manual If you are using different sizes refer to the applicable installation code for DC grounding details Use 8AWG copper wire and connect it between the Chassis Ground lug and the vehicle s DC grounding point usually the vehicle chassis or a dedicated DC ground bus 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Step 7 Mounting the Display Panel 975 0468 01 01 Xantrex has three communications cables of different lengths available for purchase Choose a 25 foot cable p n 31 6257 00 50 foot cable p n 31 6262 00 or a
18. can plan your installation from beginning to end e Disconnect all AC and DC power sources to prevent accidental shock Disable and secure all AC and DC disconnect devices and automatic generator starting devices Installation Codes Governing installation codes vary depending on the specific location and application of the installation Some examples include the following e The U S National Electrical Code NEC e The Canadian Electrical Code CEC e The U S Code of Federal Regulations CFRs e Canadian Standards Association CSA and the RV Industry Association RVIA for installations in RVs It is the installer s responsibility to ensure that all applicable installation requirements are met 975 0468 01 01 1 3 This guide for use by qualified installers only Installation Tools and Materials You will need the following to install the Freedom HW A OOO O m A Wire stripper Mounting screws or bolts 2 Phillips screwdriver Wrench for DC terminals 1 2 inch or 13mm or adjustable AC cable i e 2 conductor plus ground cable sized appropriately for load and application Wire nuts or crimp connectors for AC wire and appropriate tools DC cable sized appropriately for load and application Lugs for DC cables to fit 8 mm 5 16 in DC stud terminals as well as appropriate tools e g crimping tool AC and DC disconnects and over current protective devices High Level Overview of Installation Steps In
19. ch can be used to switch between the multiple sources of shore power to the Freedom HW system The AC source feeding the Freedom HW must have the neutral conductor bonded to ground When the inverter passes shore power through it will lift the bonding relay on the output and will rely on the input being bonded in order to ensure that the power delivered to a sub panel is properly bonded See AC Output Neutral Bonding on page 1 9 for more information on bonding relay operation Important Throughout this manual the term shore power refers to AC input power from a utility grid generator or other AC source The Freedom HW is compatible with most generators which produce nominal 120 Vac 60Hz sine wave AC power Since the DC charging current limit of the Freedom HW may be configured to provide as little as 7 A it is possible to use very small generators with the Freedom HW to charge batteries The Freedom HW has been tested with generators of various sizes including some as small as 700W Most safety requirements and electrical codes require the Freedom HW s AC and DC inputs and outputs to be provided with over current protection such as circuit breakers or fuses and disconnect devices AC Input The circuit breaker or fuse connected through hard wiring that is used to supply the Freedom HW must be rated at no more than 30A and must be approved for use on 120 Vac branch circuits The wire used between the breaker and
20. cy 60 Hz DC Output Nominal voltage 12 0 Vdc Min battery voltage for charging 0 0 Vde Max output voltage 14 4 Vdc Nominal output current User selectable 5 A 15 A 35 A 55 A Charger current derating Automatically reduce charger current as internal temperature exceeds 80 C and input Vac approaches low transfer Efficiency at nominal output 278 Other Battery type settings Flooded default Gel AGM or Fixed 13 5V Charge algorithms Three stages Bulk Absorption and Float Independent battery banks 1 975 0468 01 01 2 3 Environmental Specifications Operating Temperature Range 32 104 F 0 40 C with output derated above 77 F 25 C Storage Temperature Range 40 158 F 40 70 C Humidity Operation Storage 5 95 RH non condensing System Specifications Pass through 120 Vac 60 Hz 30 A 3 hr Max 24 A continuous Transfer relay rating 30A 2 0hp Transfer time lt 30ms milliseconds Transfer on bad voltage 90 100V for low AC and 130 140 for high AC Cooling Fan activated by any of the following e High internal temperature e High AC output power Physical Specifications Unit Dimensions and Weight Length 15 5 39 3cm Width 9 5 24 1cm Height 4 2 10 6cm Weight 10 3 Ibs 4 7 kg 2 4 975 0468 01 01 Regulatory Approvals Regulatory Ap
21. dom Smart Choice for Power and Make the most of their energy are trademarks of Schneider Electric Services International sprl registered in the U S and other countries 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 Xantrex Freedom HW Inverter Charger Installation Guide December 2008 Xantrex Technology Inc All rights reserved No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of Xantrex Technology Inc 5917 195th St NE Arlington WA 98223 Xantrex Technology Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX A MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION B ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK AND REMINDS YOU THAT IF THIS MANUAL I
22. e given below to connect the battery leads to the terminals on the DC end The cables should be as short as possible and large enough to handle the required current in accordance with the electrical codes or regulations applicable to your installation Table 1 2 on page 1 10 specifies the minimum DC cable size and maximum fuse size for the Freedom HW Do not route your DC cables through an electrical distribution panel battery isolator or other device that will cause additional voltage drops Figure 1 8 shows the DC end for your reference T DC Input 12VDC 100A AC Output 120VAC 60Hz 3A rms Pas 120VAG 60Hz 15A Max Serial No Figure 1 8 DC End This guide for use by qualified installers only To make the DC connections Refer to Figure 1 9 1 Make sure the inverter is off and no AC or DC is connected to the unit Remove the nuts and washers from the Freedom HW positive and negative DC terminals Strip 1 2 inch 13 mm to 3 4 inch 19 mm insulation from one end of each cable The amount stripped off will depend on the terminals chosen Attach the connectors that will secure the cables to the battery to the disconnect battery selector switch and the fuse block The connectors you use must create a permanent low resistance connection If crimp connectors are required Xantrex recommends using approved and certified connectors and to use the tool recommended by
23. equately protect the wiring that is installed on the input and output AC circuits of the Freedom HW All breakers and wiring must be sized and connected in accordance with the electrical codes or regulations applicable to your installation Table 1 1 gives some examples of wiring sizes based on the U S National Electrical Code and the Canadian Electrical Code These examples are based on using a 2 conductor plus ground cable rated at 75 C and assuming an ambient temperature of up to 30 C Ensure that your breakers and fuses have suitable temperature ratings for your wiring Other codes and regulations may also be applicable to your installation Table 1 1 Required AC Wire Size vs Breaker Rating Breaker Size 15A 20A 30A Minimum Wire Size 14AWG 12AWG 10AWG The neutral conductor of the Freedom HW s AC output circuit i e AC Output Neutral is automatically connected to the safety ground during inverter operation When the Freedom HW is using AC shore power this connection is not present so that the utility neutral i e AC Input Neutral is only connected to utility ground at your source This conforms to National Electrical Code which requires that separately derived AC sources such as inverters and generators to have their neutral conductors tied to ground in the same way that the neutral conductor from the utility is tied to ground in only one place Check the regulations for your specific application to ensure that the in
24. exible multiple strand wire is required AC wiring must be sized appropriately to carry full load current on the input and output AC circuits in accordance with the electrical codes or regulations applicable to your installation Table 1 4 is based on the U S National Electrical Code 2003 Ed and the Canadian Electrical Code assuming 2 conductor plus ground cable using 75 C wiring at an ambient temperature of 30 C Other codes and regulations may be applicable to your installation This guide for use by qualified installers only Table 1 4 Required AC wire size vs required breaker rating Required Breaker Size Required Wire Size Freedom HW 30 A maximum 10 AWG There are two knockouts on the front panel for AC input and output wiring AN CAUTION Equipment damage The AC wiring terminal block is split into input and output sections Damage to the inverter will occur if the unit is wired incorrectly When making the AC input and AC output connections observe the correct color code for the appropriate AC wire as described in Table 1 5 Table 1 5 Color codes for typical AC wiring Color AC Wire Black or Brown Line White or Blue Neutral Green Green Yellow or bare copper AC Input Connections Ground Ensure that AC and DC power are both OFF 2 Install the required circuit breaker in the AC output panel supplying the unit See Figure 1 6 on page 1 21 3 Remove the AC
25. for use by qualified installers only Ground Fault Circuit Interrupters GFCIs 975 0468 01 01 Basic Installation Procedures A GFCI is a device that de energizes a circuit when a current to ground exceeds a specified value that is less than that required to blow the circuit breaker GFCIs are intended to protect people from electric shocks and are usually required in wet or damp locations Installations in recreational vehicles require GFCI protection of branch circuits connected to the AC output of the Freedom HW The modified sine wave output of the Freedom HW is not equivalent to the waveform provided by electric utilities and compliance with UL and CSA standards requires that Xantrex test and recommend specific GFCIs that will work correctly with the Freedom HW For more information about GFCIs see the application note Using GFCI Receptacles on Xantrex Inverters and Inverter Chargers in the Document Library at www xantrex com support This guide for use by qualified installers only Step 2 Choosing a Location for the Freedom HW A WARNING Fire and explosion hazard This equipment contains components that tend to produce arcs or sparks To prevent fire or explosion do not install the Freedom HW in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing gasoline powered machinery fuel tanks or joints fittings or other co
26. ing the AC input wires Start on page 1 15 Step 5 Connecting the AC output wires Start on page 1 18 Step 6 Connecting the DC cables Start on page 1 23 Step 7 Mounting the display panel Start on page 1 27 Step 8 Testing your installation Start on page 1 28 1 5 This guide for use by qualified installers only Step 1 Designing the Installation Most Freedom HW installations share common components and some of these are briefly described below Figure 1 2 shows some components and their relationship to each other in a typical recreational vehicle or fleet vehicle installation Equipment Ground Bc Fuse t Disconnect or Circuit Breaker 12V Deep Cycle Battery Battery Isolator AC Load Panel DL l l to engine A AC Source Panel Vehicle Starting Equipment Ground Battery Automatic or Manual AC fx Source Select or Switch Shorepower Generator Figure 1 2 Typical Recreational Vehicle and Fleet Vehicle Installation 1 6 975 0468 01 01 This guide for use by qualified installers only AC shore power Generator AC Disconnect and Over Current Protection Device 975 0468 01 01 Basic Installation Procedures A source of 120 V 60Hz sine wave alternating current is needed to provide energy to charge batteries and pass power through to AC loads This source is usually the utility grid power company or an AC generator An automatic or manual AC source selector swit
27. inserts and 1 4 20 machine screws This guide for use by qualified installers only Connecting the Equipment Ground WARNING Fire hazard Never operate the Freedom HW without properly connecting the equipment ground A fire hazard could result from improper grounding The Freedom HW has a ground stud on the side of the unit as shown in Figure 1 4 Follow the guidelines in Grounding Locations to connect the inverter s chassis to the ground Equipment ground stud Figure 1 4 DC Panel Connections Grounding Locations You must connect the equipment ground stud to a grounding point usually the vehicle s chassis or DC negative bus ground using recommended copper wire if insulated then green insulation with or without one or more yellow stripes or larger For recommended equipment ground cable size see below Table 1 3 Recommended Equipment Ground Cable size Minimum equipment ground cable size Application Stranded cable is recommended Recreational Vehicle No 8 AWG Note There are no restrictions on length for the equipment ground cable a Based on US National Electrical Code NFPA70 Article 551 par 551 20c 2005 version In general the equipment ground cable size must not be smaller than one AWG size than the supply cable 1 14 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Step 4 Connecting the AC Input Wires WARNING Fire
28. lectrician with knowledge and experience in installing electrical equipment knowledge of the applicable installation codes and awareness of the hazards involved in performing electrical work and how to reduce those hazards Organization This Guide is organized into two chapters Chapter 1 provides information to help in installing a Freedom HW Inverter Charger Installation Chapter 2 contains electrical performance information and product specifications This guide for use by qualified installers only About This Guide Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warning Related Information You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com iv 975 0468 01 01 This guide for use by qualified installers only Important Safety Instructions READ AND SAVE THIS INSTALLATION GUIDE FOR FUTURE REFERENCE This chapter contains important safety and operating instructions for the Freedom HW Inverter Charger unit A WARNING Limitations on use The Freedom HW is not intended for use in connec
29. n The status LED on the display panel glows yellow and the LED display illuminates 3 Plug an appliance within the power rating of the inverter into the AC outlet hard wired to the Freedom HW 4 Turn the appliance on to verify that it operates If the appliance operates your installation is successful If your installation has AC input hard wired to the Freedom HW proceed to Testing in Shore Power Mode If the status LED on the display panel glows red see the Troubleshooting chapter 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Testing in Shore Power Mode To test the Freedom HW in shore power mode With the appliance from the previous test still connected and operating connect the shore power source The Freedom HW transfers the appliances to shore power The status LED on the display panel will change from yellow to a ten second flashing yellow and then green If the appliance operates your installation is successful Note If the Inverter button on the Freedom HW is set to Standby the Freedom HW will automatically supply the appliances with inverter power if the shore power source fails or becomes disconnected or the shore power voltage is too low less than 95 volts AC WARNING Shock hazard Whether or not the Inverter button is turned ON shore power will pass through the Freedom HW to the output when shore power is within normal operating ra
30. n reading specific gravity or filling the battery Also do not mount the unit where it will be exposed to gases produced by the batteries These gases are very corrosive and prolonged exposure will damage the Freedom HW 1 12 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Step 3 Mounting the Freedom HW 975 0468 01 01 To mount the Freedom HW 1 Remove the Freedom HW from its shipping container verify that all components are present and record relevant product information on Freedom HF Inverter Charger Owner s Guide Doc Part Number 975 0467 01 01 Warranty section Select an appropriate mounting location and orientation See Figure 1 3 below To meet regulatory requirements for use in on land applications the Freedom HW must be mounted in one of the following orientations e Under a horizontal surface see 1 e Ina horizontal position on a vertical surface see 2 e On a horizontal surface see 3 Figure 1 3 Approved Mounting Orientations Look for the mounting template and unfold Tape it to the mounting surface and pilot drill the desired number of mounting holes Remove the template Fasten the Freedom HW to the mounting surface If you are mounting the unit on a wall or bulkhead use 12 or 14 pan head wood or sheet metal screws to secure it to the framing behind the wall or bulkhead Alternatively use nut
31. nge 975 0468 01 01 This guide for use by qualified installers only 1 30 Specifications Chapter 2 contains electrical performance information and product specifications Note Specifications are subject to change without notice 2 1 Electrical Specifications Inverter Mode 2 2 DC Input Low operating voltage range 10 5 15 5 V SdL setting High operating voltage range 11 8 15 5 V SdH setting Under voltage alarm shutdown 10 5 11 0 V Under voltage recovery 12 0 V SdL setting Under voltage alarm shutdown 11 8 12 3 V Under voltage recovery 12 6 V SdH setting Safe non operating voltage range 0 16 Vdc Normal voltage 12 5V Nominal current at full load 100A AC Output Output voltage 120 Vac Continuous power 1 0kW 25 C Surge power 17A 2kW for 200 ms Max short circuit current 55A peak Frequency 60 Hz Wave shape Modified Sinewave Power derating above 40 C ambient temp See Invert Power Derating vs Ambient Temperature on page 2 6 Peak efficiency 288 Full load efficiency 285 Other No load input power producing lt 10W output voltage Off mode current draw lt 3mA 975 0468 01 01 Electrical Specifications Charge Mode Electrical Specifications Charge Mode AC Input Operating voltage range 95 135 Vac Nominal current 12Aac at 55A charge 120 Vac in Nominal frequen
32. nnections between components of the fuel system A WARNING Fire hazard To reduce the risk of fire do not cover or obstruct the ventilation openings Do not install the Freedom HW in a zero clearance compartment Overheating may result The Freedom HW should only be installed in locations that meet the following requirements O Dry Do not allow water or other fluids to drip or splash on the Freedom HW Do not mount the Freedom HW in an area subject to splashing water or bilge water O Cool Normal air temperature should be between 21 F and 165 F 20 C and 60 C the cooler the better O Ventilated Allow at least 5 in 13cm of clearance at the DC end of the Freedom HW for air flow 1 in 2 5cm on each side and 2 in 5cm at the AC end The more clearance for ventilation around the unit the better the performance Do not allow the ventilation openings on the ends of the unit to become obstructed O Safe Do not install the Freedom HW in the same compartment as batteries or in any compartment capable of storing flammable liquids like gasoline O Close to the battery compartment and the AC source and load panels Avoid excessive cable lengths which reduce input and output power due to wire resistance Use the recommended cable lengths and sizes especially between the battery banks and the Freedom HW M Protected from battery acid and gases Never allow battery acid to drip on the Freedom HW or its wiring whe
33. nnections cause excessive voltage drop and may cause overheated wires and melted insulation gt CAUTION Do not over tighten the nut on the DC input terminals Damage to the DC input terminals may result The maximum torque setting is 120 in Ibf 13 6 N m gt CAUTION Reverse polarity DC power connections to the Freedom HW must be positive to positive and negative to negative A reverse polarity connection positive to negative will blow a fuse in the inverter and may permanently damage the inverter The fuse is not user replaceable and the inverter may need to be returned for servicing Damage caused by a reverse polarity connection is not covered by your warranty gt 11 Before proceeding double check that the cable you have just installed connects the positive DC terminal of the inverter to the disconnect battery selector switch fuse holder and that the other end of the fuse holder is connected to the positive terminal of the battery AN WARNING Explosion or fire Do not complete the next step if flammable fumes are present Explosion or fire may result if the disconnect battery selector switch is not in the off position Thoroughly ventilate the battery compartment before making this connection 12 Connect the cable from the negative post of the battery to the negative DC terminal of the inverter 975 0468 01 01 1 25 This guide for use by qualified installers only DC Grounding Recreation
34. nt Devices Batteries Important Using the correct cable size is critical to achieving the rated performance of the Freedom HW unit When starting a heavy load the Freedom HW can draw current surges from the battery of up to 400A If the DC wiring is too small the voltage drop from this surge will result in a voltage at the Freedom HW terminals that is too low for the Freedom HW to operate correctly The Freedom HW may appear to operate correctly with smaller cables until a heavy load such as a microwave or refrigerator attempts to start then the unit may work correctly sometimes and not work correctly other times The DC circuit from the battery to the Freedom HW must be equipped with a disconnect and over current device This usually consists of a circuit breaker a fused disconnect or a separate fuse and DC disconnect Do not confuse AC circuit breakers with DC circuit breakers They are not interchangeable The rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes The breaker or disconnect and fuse should be located as close as possible to the battery in the positive cable Applicable codes may limit how far the protection can be from the battery The Freedom HW uses 12 volt battery banks Every Freedom HW system requires a deep cycle battery or group of batteries that provide the DC current that the Freedom HW converts to AC 975 0468 01 01 This guide
35. provals ETL approved to CSA 107 1 UL458 Inverter Overload Operation This graph shows how long measured in seconds the Freedom HW will operate for a given output current measured in Amps The graph illustrates inverter operation at 25 C Time sec 4000 1600 1400 1200 eat 1000 800 600 400 200 0 10 12 14 16 18 20 30 40 50 Output Current Amps 975 0468 01 01 2 5 Invert Power Derating vs Ambient Temperature If the unit is in inverter mode and in elevated ambient temperature above 25 C you will have to reduce power draw according to the following chart to avoid over temperature shutdown Watts A 1000 12 5V Soe 900W 800W ao L 11 5V 33 C 750 W 750 850W mN I L AME ely ie 0 25 30 35 40 45 50 2 6 975 0468 01 01 Charger Output Current vs AC Input Voltage Charger Output Current vs AC Input Voltage When the Freedom HW is charging batteries from a weak shore power source the AC voltage may fall as the Freedom HW draws current To reduce the chance of the shore power voltage collapsing below the configured transfer level the Freedom HW will reduce the charging current at low shore power voltage according to the following graph 55A 35A 95V 105V 135V Table 2 1 Charging Voltage Battery Type Bulk Absorption Volts Float Volts Flooded 14 4 13 5 GEL
36. reverse polarity connection is not covered by your warranty 975 0468 01 01 11 12 13 Insert the Line and Neutral wires into the corresponding terminals Tighten the wire attachment screws to a torque of 15 6 21 6 in lbf 1 76 2 44 N m Leave some wiring slack inside the wiring compartment Reinstall the AC wiring compartment cover This guide for use by qualified installers only Step 5 Connecting AC Output to an Existing AC Circuit WARNING Shock fire and energy hazards Make sure wiring is disconnected from all electrical sources before handling All wiring must be done in accordance with applicable local and national electrical wiring codes AN WARNING Shock hazard and equipment damage Do not connect any AC source such as a generator or utility power to the AC wiring output of the Freedom HW The Freedom HW will not operate if its output is connected to AC voltage from another source and potentially hazardous or damaging conditions may occur These conditions can occur even if the inverter is off Do not connect the Freedom HW to an AC branch circuit that has high power consumption loads The Freedom HW will not operate electric heaters air conditioners stoves and other electrical appliances that consume more than 1000 watts A Xantrex tested and approved GFCI must be connected to the Freedom HW AC output and on every receptacle connected to the AC hard wired installation Other type
37. rsonal Precautions When Working With Batteries WARNING BATTERIES PRESENT RISK OF ELECTRICAL SHOCK BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE OR EXPLOSION FROM VENTED GASES OBSERVE PROPER PRECAUTIONS 975 0468 01 01 10 11 Study and follow all of the battery manufacturer s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer This helps to purge excessive gas from cells Do not overfill For a battery without cell caps carefully follow manufacturer s recharging instructions Make sure the area around the battery is well ventilated Never smoke or allow a spark or flame near the engine or batteries Use extra caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Remove all metal items like rings bracelets and watches when working with batteries Batteries can 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 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
38. s may fail to operate properly when connected to the Freedom HW Although you can reuse the factory installed GFCI Xantrex has also tested and approved the following GFCIs for use with the Freedom HW Make Model Hubbell GFR5252 Leviton 6598 8598 For more information about GFCIs see the application note Using GFCI Receptacles on Xantrex Inverters and Inverter Chargers in the Document Library at www xantrex com 1 18 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures WARNING Shock fire and energy hazards Make sure wiring is disconnected from all electrical sources before handling All wiring must be done in accordance with applicable local and national electrical wiring codes Do not connect the output leads of the inverter to any incoming AC source 975 0468 01 01 To make a permanent connection to existing AC wiring continuing from 13 of Step 4 Connecting the AC Input Wires on page 1 15 1 2 Ensure that AC and DC power are both OFF Install the required value of circuit breaker in the AC load panel see Figure 1 6 on page 1 21 and Figure 1 7 on page 1 22 Remove the left hand side AC wiring knockout from the front of the unit Important The applicable installation code may not allow you to run the AC IN and AC OUT wiring through the same AC knockout 4 10 Locate the terminal block The two output terminals are labeled
39. stallation will comply with the necessary requirements In other words the AC Input Neutral and Output Neutral must be isolated from each other This includes all the cables and connectors between the batteries the DC disconnect and over current protection device and the Freedom HW Most mobile installations require multi strand insulated cables for flexibility and durability in high vibration environments and require disconnects and over current devices Electrical wiring sizes are indicated by AWG notation Under the AWG standard a larger gauge number indicates a smaller wire diameter Wire size is usually marked on the larger sized cables Table 1 2 specifies the minimum recommended DC cable size and maximum fuse size for the Freedom HW The DC cables must be copper and must be rated 75 C minimum The cables should be terminated with lugs that fit the DC stud terminals snugly 8 mm or 5 16 in hole size 1 9 This guide for use by qualified installers only Table 1 2 Recommended Cable Sizes Cable Length Battery Maximum battery Fuse Inverter Charger to Inverter one way Minimum Cable Size Size Freedom HW Less than 5 feet 1 5 No 2 AWG 150 Adc meters Note Xantrex recommends not using a cable longer than 5 feet 1 5 meters in each direction Cable sizes above are based on the US National Electrical Code Table 310 17 75C cables assuming an ambient temperature of 30 C cables DC Disconnects and Over Curre
40. stalling the Freedom HW includes the following steps 1 4 1 Zi 9 Ensure that AC and DC power are both OFF Mount the inverter securely and permanently in one of the acceptable orientations Connect the Equipment Grounding Terminal to the equipment ground bus Connect the AC input wiring to the AC source panel Connect the AC output wiring to the AC load panel Connect one end of the DC negative cable to the negative of the battery and the other to the negative terminal of the unit Install an appropriately sized fuse and DC disconnect in the positive cable Connect the DC positive cable to the positive of the battery and to the positive terminal of the unit Close the DC disconnect switch Do not proceed with installation until you have read Safety Instructions on page 1 3 975 0468 01 01 This guide for use by qualified installers only Basic Installation Procedures Basic Installation Procedures Xantrex recommends that you have your installation performed by a qualified technician or electrician 975 0468 01 01 This section provides sample installation information as a guide for your installation For your convenience the overall procedure is divided into ten main steps Oo Oo OOOO oO Oo Step 1 Designing an installation Start on page 1 6 Step 2 Choosing a location for the Freedom HW Start on page 1 12 Step 3 Mounting the Freedom HW Start on page 1 13 Step 4 Connect
41. tion with life support systems or other medical equipment or devices 1 Beforeinstalling and using the Freedom HW read all instructions and cautionary markings on the Freedom HW the batteries and all appropriate sections of this guide A CAUTION Risk of injury To reduce the risk of injury charge only 12 Vdc lead acid GEL AGM or Flooded rechargeable batteries Other battery types may burst causing personal injury and damage 2 Do not expose the Freedom HW to rain snow spray or bilge water To reduce risk of fire hazard do not cover or obstruct the ventilation openings Do not install the Freedom HW in a zero clearance compartment Overheating may result 3 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 Freedom HW with damaged or substandard wiring 4 The use of any attachments not recommended or sold by Xantrex may result in risk of fire electric shock or injury to persons 5 Do not operate the Freedom HW if it has received a sharp blow been dropped or otherwise damaged in any way If the Freedom HW is damaged see the Warranty section This guide for use by qualified installers only 6 Do not disassemble the Freedom HW It contains no user serviceable parts See Warranty for instructions on obtaining service Attempting to service the Freedom HW yourself may result in a risk of electrical shock or fire
42. 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 ground terminal from the battery first Make sure all accessories are off so you don t cause an arc vii This guide for use by qualified installers only 12 Never charge a frozen battery 13 Clean battery terminals Be careful to keep corrosion from coming into contact with your eyes 14 Locate the Freedom HW unit away from batteries in a separate well ventilated compartment 15 Never place the Freedom HW unit directly above batteries gases from a battery will corrode and damage the unit 16 Never allow battery acid to drip on the unit when reading gravity or filling battery 17 Do not operate the unit in a closed in area or restrict the ventilation in any way DC CONNECTION PRECAUTION 18 Connect and disconnect DC output connections only after setting any recreational vehicle unit switches to off position and opening AC disconnect 19 Proper disposal of batteries is required Refer to your local codes for disposal requirements viii 975 0468 01 01 This guide for use by qualified installers only Contents Important Safety Instructions v 1 Installation Materials List
43. wiring compartment cover Remove the left hand side AC wiring knockout from the front panel of the unit see Figure 1 5 on page 1 17 5 Locate the terminal block The two input terminals are labeled as follows e AC Input L e AC Input N A separate screw is provided to connect the AC input ground see Figure 1 5 on page 1 17 975 0468 01 01 This guide for use by qualified installers only AC input ground screw AC knockout Basic Installation Procedures FREEDOM AC output ground screw Hw 1000 AC knockout Pa Figure 1 5 Freedom HW AC Wiring Compartment 6 10 Strip about 2 inches 50 mm from the jacket of the AC input cable The AC input cable may be either solid or stranded as reguired but must have three conductors and be sized as in Table 1 4 on page 1 16 The AC terminal block accepts wire sizes up to No 10 AWG Strip approximately 3 8 inch 10 mm from the insulation of each conductor Run the AC cable through the right hand side knockout and into the wiring compartment Fasten the Ground wire to the grounding screw Using the 1 8 inch slot screwdriver loosen the wire attachment screws on the terminals CAUTION Reverse polarity Improper connections connecting a line conductor to a neutral conductor for example will cause the Freedom HW to malfunction and may permanently damage the inverter Damage caused by a
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