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Xantrex Technology 815-3524 Battery Charger User Manual

1. Generator y LI y v y Transfer Switch AC In Non Inverter Loads a Alternator Utility Power Figure 3 Typical Recreational Vehicle Electrical System 8 Engine Battery IMPORTANT Figure 3 does not show all required grounding or overcurrent protection See the next two pages as well as on page 14 for required DC grounding or overcurrent protection Always hire a qualified installer or you must be the one to ensure that all electrical safety requirements are met before during and after installation Legend Xanbus Network AC DC Low Voltage DC Freedom SW 230V Installation Guide Planning Preparations pl At IMPORTANT Read Owner s and Installation Guides prior to installation Always refer to local and 15A i f a national electrical codes for proper wire and breaker 205 E sizes prior to installation i Neutral See DC Cabling on 0 page 13 and DC GND j Disconnects and Over iq Current Devices on uy page 14 for cable sizes and fuse ratings MAIN ELECTRICAL PANEL HARDWIRE CONNECTIONS J FEI ETS ETENEE A 230V ACOUT 3 AMA in pass through MAIN 7 FROM SHORE oR IMPORTANT In Australia connection to 1 L GENERATOR POWER z ope 2524 and 3524 shore power that is supplied by
2. A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in moderate or minor injury NOTICE NOTICE indicates a potentially hazardous situation which if not avoided can result in equipment damage IMPORTANT These notes describe things which are important for you to know however they are not as serious as a caution or warning Related Information You can find more information about Xantrex branded products and services at www xantrex com Freedom SW 230V Installation Guide Important Safety Instructions IMPORTANT READ AND SAVE THIS INSTALLATION A DANGER GUIDE FOR FUTURE REFERENCE ELECTRICAL SHOCK HAZARD Do not expose the Freedom SW 230V to rain snow spray or bilge This chapter contains important safety and installation instructions for the water This inverter charger is designed for marine applications only Freedom SW 230V Inverter Charger Freedom SW 230V Each time when additional drip protection is installed in certain orientations before using the Freedom SW 230V READ ALL instructions and See Mounting Orientations on page 21 cautionary markings on or provided with the inverter charger the batteries Do not operate the inverter charger if it has received a sharp blow and all appropriate sections o
3. 975 0697 01 01 This orientation does not meet regulatory requirements 23 This guide for use by qualified personnel only Installing the Inverter Charger Step 3 Connecting the AC Input and AC Output Wires A DANGER FIRE ELECTRICAL SHOCK AND ENERGY HAZARDS Make sure wiring being connected to the inverter charger is de energized by a breaker or switch upstream Lockout Tagout is a recommended practice by many electrical contractors Always lockout and tag disconnect devices before making connections All wiring must be done in accordance with local and national electrical wiring codes Failure to follow these instructions will result in death or serious injury General AC Wiring Considerations AC and DC Wiring Separation Do not mix AC and DC wiring in the same conduit or panel Consult the applicable installation code for details about DC wiring and AC wiring in vicinity to each other AC Input and Output Isolation The AC input and output circuits of this inverter charger are isolated from each other when in invert mode to ensure safe operation This isolation must be maintained in the installation by being sure not to connect AC input and output wiring to a common point For example do not route the AC input and output neutrals to a common neutral bus It is highly 24 recommended to use a separate inverter load panel to distribute power to inverter loads All wiring to this panel must be through
4. Freedom SW 230V Installation Guide Regulatory The Freedom SW 230V Inverter Charger is certified to appropriate European CE and Australian RCM standards For more information see Regulatory Approvals on page 62 The Freedom SW 230V Inverter Charger is intended to be used for mobile or commercial applications This inverter charger is designed for marine applications only when additional drip protection is installed in certain orientations Refer to this guide for installation instructions It is not intended for other applications as it may not comply with the additional safety code requirements needed for those other applications See Limitations On Use below A WARNING LIMITATIONS ON USE Do not use in connection with life support systems or other medical equipment or devices Failure to follow these instructions can result in death or serious injury 975 0697 01 01 vil This guide for use by qualified personnel only Important Safety Instructions isese glad o eso a a E ER 111 Introduction A A A A E E E 1 Materials Lita ner ER Rem eee NE We IE eU A AA A E De pol PESO Installation Information s a RR EP RP ERR RR A RR RR RUBRO e P e eS Ree p Un e ROS RI TUR Run 3 g Before You Begin the Installation se neoe ecen hee e Vee E ib 3 x Installation Codes io Rm ce RR lh te ARE tl AN AA ode GAG Ae Ried 3 About the Xanb s Syster si sitet a ree a e uEEE E NE EL PT NEUE RR shel etes 4 2 AANBUS
5. This guide for use by qualified personnel only 975 0697 01 01 1 Introduction Materials List The Freedom SW 230V ships with the following items one Freedom SW 230V unit owner s and installation guides Battery Temperature Sensor BTS DC terminal covers one red one black with two sets of 46 32 screws two Xanbus network terminators two sets of 5 16 18 nuts and washers for the DC terminals NOTE If any of the items are missing contact customer service or any authorized Xantrex dealer for replacement See Contact Information on page i IMPORTANT Keep the carton and packing material in case you need to return the Freedom SW 230V for servicing Xanbus network terminators nuts and washers Figure 1 Materials List d Yo DC terminal covers with screws Freedom SW 230V Installation Guide Installation Information Before You Begin the Installation Installation Codes Before beginning your installation Applicable installation codes vary depending on the specific e Read the entire Installation Guide so you can plan the location and application of the installation installation from beginning to end e Assemble all the tools and materials you require for the installation e Review the Important Safety Instructions on page iii e Be aware of all safety and electrical codes which must be met A DANGER ELECTRICAL SHOCK AND FIRE HAZARDS All wiring should be done by qualified personnel to ensure
6. 1 800 670 0707 1 408 987 6030 Web www xantrex com 975 0697 01 01 i Information About Your System As soon as you open your product record the following information and be sure to keep your proof of purchase Serial Number Product Number Purchased From Purchase Date To view download or print the latest revision visit the website shown under Contact Information This guide for use by qualified personnel only Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the Freedom SW 230V Inverter Charger Scope The Guide provides safety and installation guidelines as well as information on tools and wiring It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience The information in this Guide is intended for qualified personnel Qualified personnel have training knowledge and experience in e Installing electrical equipment and PV power systems up to 1000 volts Applying all applicable installation codes e Analyzing and reducing the hazards involved in performing electrical work e Selecting and using Personal Protective Equipment PPE Conventions Used The following conventions are used in this guide About This Guide A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury
7. Always use proper lifting techniques during installation to prevent personal injury Failure to follow these instructions can result in minor or moderate injury 975 0697 01 01 To unpack and inspect ns IMPORTANT Keep the carton and packing material in case you need to return the Freedom SW 230V for servicing 1 Unpack the unit and check the materials list If anything is missing from the shipping box contact Customer Service See Contact Information on page i Record the serial number of the Freedom SW 230V and other purchase information for any future warranty issues You wil be asked for this product information if you need to call Customer Service Save your purchase receipt to use as proof of purchase This 1 receipt is required if the inverter charger should need warranty service Save the original shipping carton and packing materials If the inverter charger needs to be returned for service 1t should be shipped in the original carton Packing the Freedom SW 230V in the original shipping carton is also a good way to protect the inverter charger if it ever needs to be moved 15 This guide for use by qualified personnel only Planning Preparations Installation Tools and Materials Tools You will need the following tools to install the Freedom SW 230V and the battery temperature sensor qo0o0000 Wire stripper Crimping tools for fastening lugs and terminal
8. compliance with all applicable installation codes and regulations e Disconnect all AC and DC power sources Disable and secure all AC and DC disconnect devices and automatic generator starting devices This guide for use by qualified personnel only Failure to follow these instructions will result in death or serious injury 975 0697 01 01 3 About the Xanbus System Xanbus System The Xanbus system includes the Freedom SW 230V and other Xanbus enabled devices The Freedom SW 230V is the device in a Xanbus system that typically provides network power 500 mA at 12 volts DC All of the Xanbus enabled devices such as the Freedom SW 230V the SCP and the AGS are able to communicate their settings and activity to each other ee RES ACPand P io M Generator AC Loads Figure 2 Typical Xanbus System Diagram The Xanbus enabled designation see below means that this product works on a Xanbus network Xanbus enabled products are e Simple to operate and routine tasks are automated e Controlled by software that eliminates analog signalling errors e Less susceptible to interference and line loss e Upgradable through new software releases xanbus ENABLED For detailed instructions and a complete list of Xanbus enabled devices visit www xantrex com Freedom SW 230V Installation Guide Xanbus enabled Products and Acce
9. section Also the System Total BULK output current is calculated as 150A that is 75A 75A To set the Max Chg Rate setting in each Freedom SW 3524 230 l Divide the maximum allowable charger output current of 75A by the Freedom SW 3524 230 s maximum charge capacity of 90A So 75 90 gets an approximate value of 0 83 or 83 which can be set exactly to 83 2 Setthe Max Chg Rate setting to 83 which means 83 In this example the actual output current is limited to 83 of 90A which is 74A Therefore the actual System Total BULK output current comes out to just under 150A 50 Freedom SW 230V Installation Guide Inverter Charger Physical Specifications For complete inverter charger specifications refer to the Freedom SW 230V Sine Wave Inverter Charger Owner s Guide The physical specifications of the Freedom SW 230V are described in Table 4 below Table 4 Freedom SW Physical Specifications Length 387 mm Width 343 mm Height 197 mm Weight 21 4 kg Freedom SW 2524 230 27 2 kg 975 0697 01 01 Freedom SW 3524 230 51 This guide for use by qualified personnel only Battery Information Battery Bank Sizing Battery capacity Battery size or capacity is just as important as the battery type selected for use with the Freedom SW 230V The batteries are the most important part of your system so It is recommended that you purchase as much battery capacity as possible A large batter
10. 18 Neutral Wiring for Stacking 44 A WARNING FIRE HAZARD Do not power several loads in excess of 30 amps even in parallel stacked configuration Failure to follow these instructions can result in death or serious injury IMPORTANT In a parallel stacked configuration during operation the AC transfer pass through relay rating remains the same at 30 amps The AC transfer relay rating does not double to become 60 amps Freedom SW 230V Installation Guide Configuring System for Stacked Operation Verify all DC and AC connections Check Xanbus network connections and ensure that terminators are installed at devices at each end of the network The simplest system includes a Xanbus SCP the two Freedom SW 230V inverter chargers to be stacked and two Xanbus terminators For both units to operate in stacked configurations a Master and Slave have to be assigned The default out of box configuration for all Freedom SW 230V inverter chargers is Master which causes a conflict the first time the system is powered up The installer will need to change configuration on one of the inverter chargers to Slave mode To configure the system for stacking 1 Apply DC power to both inverter chargers Power up order has no impact Because there are now two Master units in the system the SCP will display an F66 fault a system configuration fault 2 From the SCP System Status screen press Enter The Select Device screen
11. Also the System Total BULK output current is calculated as 250A that is 125A 125A To set the Max Chg Rate 46 setting in each Freedom SW 3524 230 1 Divide the maximum allowable charger output current of 125A by the Freedom SW 3524 230 s maximum charge capacity of 90A So 125 90 gets an approximate value of 1 39 or 139 which means that even when the charger is operating at 10096 full power the battery bank can more than adequately accept the current the charger is delivering 2 SettheMax Chg Rate 406 setting to 100 which means 100 There is no setting beyond 100 In this example the actual output current is limited to 100 of 90A which is 90A Therefore the actual System Total BULK output current comes out to 180A 49 This guide for use by qualified personnel only Stacking Features Example 4 System composed of two stacked Freedom SW 3524 230s Each Freedom SW 3524 230 has a maximum charge capacity of 90A The two stacked Freedom SW 3524 230 inverter chargers connected to the same battery bank can possibly produce a total of 180A The industry s commonly accepted practice suggests a typical Flooded battery bank capacity C of 600Ah should not be charged beyond 25 of its capacity 150A Therefore when configuring the two stacked Freedom SW chargers each charger may have a maximum charger output current of 75A that is 600 x 25 x 15 into the common battery bank as described in the Calculations
12. Bt tow eb bt ashe P Eae eo bue eb t ba ae baestobude b ter p 52 This guide for use by qualified installers only Estimating Battery Requirements esireast oeat cee e ete he 53 Calculating Battery SIZE ese minean pra p pe e e da EE EE 53 hpurad u D 55 Battery Bank Sizing Worksheet ceca a tee Oba ea ERR Rp eg 55 Restrictions on Motor Size esce ey ee Aka OL CW EUREN NUR AUR ERE NO b Poe RARIOR S GEN E e VERRE YE ETUR 55 Battery Cabling and Hook up Configurations lleleseeseeeeeeeee nee I eee e he 57 Batiery Series Connection pu obe ep ee tee lb Durban este tescne e dede eod eb Ee ep eb tb 57 Battery Series Parallel Connections haret 0 IH ehe 58 Specifications socer t Ren e Yarro gol aeg aea ed a Rea an ERREUR H EAS qat ented quU 59 Inverter Drip Shield Installation Introduction The Installation Guide provides detailed information for installing the Freedom SW 230V Inverter Charger and the battery temperature sensor wiring the inverter charger to the AC and DC circuits and connecting the inverter charger to the Xanbus system The Freedom SW 230V is a Xanbus enabled device that typically powers the Xanbus system This Installation Guide provides e safety instructions that must be observed during installation e atypical Xanbus system diagram if applicable e information on additional required AC and DC components e a list of installation tools and materials e detailed procedures for a typical installation
13. Freedom SW 230V inverter chargers that are stacked in parallel IMPORTANT Follow the same guidelines in Installing the Inverter Charger on page 17 when choosing cables and or wires for AC and DC connections A DANGER FIRE ELECTRICAL SHOCK AND ENERGY HAZARDS Make sure all wiring being used to make stacking configurations between inverter chargers is disconnected physically or by opening the breaker from all electrical sources before handling All wiring must be done in accordance with local and national electrical wiring codes Failure to follow these instructions will result in death or serious injury Freedom SW 230V Installation Guide Stacking Features Charger Settings in a Dual Freedom SW Configuration The Freedom SW 3524 230 includes a maximum 90A charger When using two stacked Freedom SW 3524 230 inverter chargers connected to the same battery bank a total of 180A 90A x 2 of bulk charging is possible into that single common battery bank For small battery banks and or certain battery types this bulk mode current may be too high therefore Freedom SW 230V models include a battery bank capacity Batt Capacity setting and a maximum charge rate Max Chg Rate setting The battery bank capacity C is the bank s total Amp hour capacity which is best determined by a qualified RV electrical technician The Max Chg Rate depends on the battery manufacturer s maximum charge rate for the specific batter
14. SW 230V Installation Guide Battery Cabling and Hook up Configurations Several smaller batteries can be connected to create a battery bank Battery Series Connection of substantial size You can connect batteries in series see Battery t i T e Series Connection on the right or series parallel see Battery When batteries are connected with the positive terminal of one Series Parallel Connections on the next page battery to the negative terminal of the next battery they are connected in series In a series configuration the battery bank has the same Ah rating of a single battery but an overall voltage equal to the sum of the individual batteries See below To make a larger battery bank connect individual batteries with heavy cables The actual size of the cable depends on whether the batteries are connected in parallel or series Generally the cable should not be smaller than the inverter cables if the main cables are 120 mm the battery interconnects should be 120 mm Fused Disconnect The best configuration is to connect the batteries in series parallel This requires additional cables but reduces imbalances in the battery bank and can improve the overall performance Consult your battery supplier for more information regarding the hook up configuration required for your system Connections to DC terminals on inverter charger 24 V 100 Ah Figure 20 Batteries Connected in Series This gui
15. appears 3 Select the inverter to configure as a Slave unit from the list then press Enter 4 Bring up the Advanced Settings screen by pressing Enter Up and Down arrow buttons all together 975 0697 01 01 Stacking Features 5 Select Advanced Settings and press Enter The Advanced Settings screen appears 6 Scroll down to select Stacking At this point all devices in the system will be automatically placed in standby mode All three LEDs on the inverter to be configured will start flashing FSW3524 00 Stacking 00 01 Dev Name Dev Number Stack Mode Battery Master Master Slave L2Master Batt1 Figure 19 Stacking Menu Screen 7 Select Stack Mode and press Enter 8 For Parallel Stacking Select Slave and press Enter 9 Press the Func button repeatedly until the System Status screen appears NOTES The only situation in which the Slave may shut down the Master inverter is during fault conditions such as high or low battery voltage overcurrent or over temperature conditions Both inverters will auto reset after a fault condition has been cleared The exception is that an overcurrent condition will generate a shutdown for both inverters that will require a manual restart of the system 45 This guide for use by qualified personnel only Stacking Features Search Mode Operation in Parallel Stacking When two inverter chargers are stacked for parallel operation search mod
16. installed wiring Failure to follow these instructions can damage the unit and or damage other equipment When making the AC input and AC output connections observe the correct color code for the appropriate AC wire as described in Table 1 on page 12 To make the AC input connections 1 Locate the wiring compartment cover panel and remove the four screws 2 Remove the cover panel from the unit to access the wiring compartment 3 Remove one of the AC knockouts from the front or side of the unit Do not leave the knockout inside the wiring compartment Install a strain relief clamp in the AC knockout 5 Run the AC wiring through the strain relief clamp Strip approximately 50 mm off the jacket from the AC cable and separate the wires 25 This guide for use by qualified personnel only Installing the Inverter Charger 7 10 11 26 Using a 6 mm blade slot screwdriver loosen the terminal screws on the terminals Do not remove the screws Connect the line and neutral wires to the input terminals labeled AC Input on the terminal block Figure 6 on page 25 as follows Connect Line to INPUT L Neutral to INPUT N Tighten the terminal screws Leave some slack wire inside the wiring box Connect the ground wires to a free position on the ground bus Figure 6 on page 25 If solid ground wire is being used the wire can be connected directly under the screw heads If stranded ground wire is being
17. sensor The surface where the sensor is to be mounted must be flat and free from reinforcing ribs or other raised features This surface must be in direct internal contact with the battery electrolyte Do not install the sensor near the top of the battery or on the battery s top surface Freedom SW 230V Installation Guide Step 6 Connecting to the Network For your reference Figure 14 shows where the network connections are made on the Freedom SW 230V To connect the Freedom SW 230V to the Xanbus network Plug a network cable connected to the Xanbus network into either one of the two Xanbus Interface network ports on the Freedom SW 230V NOTICE EQUIPMENT DAMAGE Connect the Freedom SW 230V only to other Xanbus compatible devices Although the cabling and connectors used in this network system are the same as Ethernet connectors this network is not an Ethernet system Equipment damage may result from attempting to connect two different systems Do not attach the Freedom SW 230V On Off switch to these ports Failure to follow these instructions can damage the unit and or damage other equipment Detailed information on planning and installing your network is available in the Xanbus System Installation Guide Refer to the this guide to determine the type of network layout to install as well as guidelines for installing the network 975 0697 01 01 Installing the Inverter Charger The Xanbus System Instal
18. system performance Mounting Location of the Freedom SW 230V To choose an appropriate location for mounting the inverter charger see Step 1 Choosing a Location for the Inverter Charger on page 18 Freedom SW 230V Installation Guide Planning Preparations AC DC and Network Components For a successful installation you need to plan for AC DC and Network considerations for Freedom SW only include network components of the power system The AC and DC e Cables connectors network connectors and terminators for the 2 components are described in this section and illustrated in Figure 3 SCP and Automatic Generator Start if installing on page 8 Detailed information on planning and installing your network is AC components include available in the Xanbus System Installation Guide Refer to the e AC Input AC Output system guide to determine the type of network layout to install e AC Loads as well as guidelines for installing the network This guide is AC Disconnect and Over Current Protection Device available for download at www xantrex com e Distribution Panels e AC Wiring DC components include e 24 volt Batteries e DC Cabling e DC Disconnects and Over Current Devices DC Grounding This guide for use by qualified personnel only 975 0697 01 01 7 Planning Preparations Sine Wave nverter Charger s P AC Panel
19. the two stacked Freedom SW chargers each charger may have a maximum allowable charger output current of 50A 400 x 25 x ib into the common battery bank as described in the Calculations section Also the System Total BULK output current is calculated as 100A 50A 50A To set the Max Chg Rate setting in each Freedom SW 3524 230 1 Divide the maximum allowable charger output current of 50A by the Freedom SW 3524 230 s maximum charge capacity of 90A So 50 90 gets an approximate value of 0 56 or 56 which can be roughly reduced to 5596 2 Setthe Max Chg Rate setting to 55 which means 55 In this example the actual output current is limited to 55 of 90A which is 49A Therefore the actual System Total BULK output current comes out just under 100A 975 0697 01 01 Stacking Features Example 3 System composed of two stacked Freedom SW 3524 2305 Each Freedom SW 3524 230 has a maximum charge capacity of 90A The two stacked Freedom SW 3524 230 inverter chargers connected to the same battery bank can possibly produce a total of 180A The industry s commonly accepted practice suggests a typical Flooded battery bank capacity C of 1000Ah should not be charged beyond 25 of its capacity 250A Therefore when configuring the two stacked Freedom SW chargers each charger may have a maximum charger output current of 125A that is 1000 x 2596 x 1p into the common battery bank as described in the Calculations section
20. used ring terminals must also be used Secure the strain relief clamp on the AC input cable jacket Freedom SW 230V Installation Guide Connecting the AC Output Wires NOTICE EQUIPMENT DAMAGE Do not connect the output of the inverter to any AC source Failure to follow these instructions can damage the unit and or damage other equipment To make the AC output wiring connections 1 Remove one of the AC knockouts from the front or side of the unit Do not leave the knockout inside the wiring compartment IMPORTANT The applicable installation code may not allow you to run the AC input and AC output wiring through the same AC knockout 2 Install a strain relief clamp in the AC knockout and run the AC wiring through the strain relief clamp 3 Strip approximately 50 mm off the jacket from the AC cable and separate the wires 4 Using a 6 mm blade slot screwdriver loosen the terminal screws on the AC output terminals Do not remove the screws 5 Connect the line and neutral wires to the output terminals labeled AC Output on the terminal block Figure 6 on page 25 as follows Connect Line to OUTPUT L Neutral to OUTPUT N 975 0697 01 01 10 Installing the Inverter Charger Tighten the terminal screws Leave some slack wire inside the wiring box Connect the ground wires to a free position on the ground bus Figure 6 on page 25 If solid ground wire is being used the wire can be conn
21. 30V Installation Guide DC Components Batteries The Freedom SW 230V system requires a 24 volt lead acid deep cycle battery or group of batteries to provide the DC current that the inverter charger converts to AC power The battery may be a flooded gel or AGM type See Battery Information on page 52 for information on e Estimating the battery size that will meet your requirements e Designing battery banks e Restrictions on the size of appliances For information on cabling and hooking up batteries see Battery Cabling and Hook up Configurations on page 57 For detailed information about specific brands of batteries consult individual battery manufacturers DC Cabling Definition DC cabling includes all of the cables and connectors between the batteries the DC disconnect and overcurrent protection device and the inverter charger Type All installations require multi strand insulated cables The DC cables must be copper and must be rated 75 C minimum In Australia they must be rated 90 C minimum 975 0697 01 01 Planning Preparations Size and Length See Table 2 for required DC cable length and cable size and Table 3 for required fuse size for the Freedom SW 230V Wire size is usually marked on the cables Table 2 Minimum Recommended Battery Cable Sizes Conduit Free Air Typical Model Amps Cable Length Cable Length A 15m 1 5 to 3 0 m Freedom SW 2524 230 140 50 mm 25 mm 70 m
22. 35 mm stud size to connect to the Freedom SW 230V If a crimp connector is used it should be crimped using the tool indicated by the connector manufacturer 3 Attach the connectors to the ends of both cables Make sure no stray wire strands protrude from the connectors 28 Freedom SW 230V Installation Guide Installing the Inverter Charger Guidelines for Routing the DC Cables Follow these guidelines to ensure maximum performance A WARNING ELECTRICAL SHOCK AND FIRE HAZARD Route the cables away from sharp edges that might damage the insulation Avoid sharp bends in the cable Failure to follow these instructions can result in minor or moderate injury e Do not attempt to use the chassis in place of the battery negative connection for grounding The inverter requires a reliable return path directly to the battery e To reduce the chance of radio frequency interference keep the positive and negative cables close together ideally held together by straps loom or insulated clamps at regular intervals e To ensure maximum performance from the inverter charger do not route your DC cables through a DC distribution panel battery isolator or other device that will cause additional voltage drops The exception is the DC fuse and Disconnect or the DC circuit breaker which is required at the battery to protect the DC wiring e To help avoid damage caused by reverse polarity battery connection it is a good idea to m
23. 65A The industry s commonly accepted practice suggests a typical Flooded battery bank capacity C of 400Ah should not be charged beyond 25 of its capacity 100A Therefore when configuring the two stacked Freedom SW chargers each charger may have a maximum allowable charger output current of 50A 400 x 25 x 17 into the common battery bank as described in the Calculations section Also the System Total BULK output current is calculated as 100A 50A 50A To set the Max Chg Rate setting in each Freedom SW 2524 230 1 Divide the maximum allowable charger output current of 50A by the Freedom SW 2524 230 s maximum charge capacity of 65A So 50 65 gets an approximate value of 0 77 or 77 which can be roughly reduced to 75 2 Set the Max Chg Rate 406 setting to 75 which means 75 In this example the actual output current is limited to 7596 of 65A which is 48A Therefore the actual System Total BULK output current comes out to just under 100A Freedom SW 230V Installation Guide Example 2 System composed of two stacked Freedom SW 3524 230s Each Freedom SW 3524 230 has a maximum charge capacity of 90A The two stacked Freedom SW 3524 230 inverter chargers connected to the same battery bank can possibly produce a total of 180A The industry s commonly accepted practice suggests a typical Flooded battery bank capacity C of 400Ah should not be charged beyond 25 of its capacity 100A Therefore when configuring
24. Bulk Absorption Float Two stage charge Bulk Absorption The default charging method is three stage Without a battery temperature sensor Three settings with the following temperature values Cool 10 C Warm 25 C Hot 40 C The default setting is Warm and it can only be changed by the factory a dealer or a service centre With a battery temperature sensor included The temperature compensation coefficients on a 24 volt battery are as follows Flooded 54 mV x 25 C BTS C Gel 54 mV x 25 C BTS C AGM 42 mV x 25 C BTS C Output current maximum 65 ADC 90 ADC Output voltage 24 VDC 24 VDC Output voltage range 12 0 32 0 VDC 12 0 32 0 VDC Equalization cycle Automatic Manual by Xanbus SCP Automatic Manual by Xanbus SCP Optimal charging efficiency gt 85 gt 85 AC input power factor at full charge rate gt 0 98 gt 0 98 AC input current 10 6A max excluding pass through 14A max excluding pass through AC input voltage 230 VAC 230 VAC AC input voltage range 170 270 VAC 170 270 VAC Dead battery charge voltage gt 12 0 VDC gt 12 0 VDC AC input type Single input up to 30A Single input up to 30A Circuit breaker resettable 30A 30A 975 0697 01 01 61 This guide for use by qualified personnel only Specifications NOTE All transfer specifications are at nominal conditions ambient temperature of 25 C 230 VAC 50 Hz input unless
25. Connecting to the Network 37 Step 7 Performing Checks Prior to Initial Start Up 0 ec I e enn eee 38 Step 8 Testing Your Installation eco A cates WS me e testes b ety 39 Testingan Invert Mode css a tae bed pees eC Rp NC REDE REP RR ER e lid eRe ada oe CR ORE 39 Testing in Charge Mode and AC Bypass Mode lssseleleeeeeeeee ms 40 Installation Complete 5 sesta eee e Sh UO XU up EE NM eee eee te ks 40 Stacking Features zuo ny wastes eee ees Se E ete PE En e ERSTER NA a Wee EN A Caen o Cac pd 41 Parallel Stacking 55 ee tale e eg Sao ba als edb ebb athe Lethal et eed 42 DC Connections for Stacked Inverters o 43 Neutral Wiring for Stacked Inverters vos a e se Retos bel abe ew RD REI E RR RR eee CE sons 44 Configuring System for Stacked Operation 0 0 cee cee me e 45 Search Mode Operation in Parallel Stacking 1 0 2 ccc I 46 Disabling Search Mode on the Master Unit 0 0 0 0 m eens 46 Setting Search Mode on the Slave Unit 0 0 46 Witins Schematies uet hee bebe il 46 Charger Settings in a Dual Freedom SW Configuration 0 0 ee eet e 47 Calculations ii ee e eon beats ete tt hie kat ee E Es A Gi eae RA A ee yee ad 47 Examples e c ate ee Bete DA eos Seals UA Saeed ee wes ala 48 Inverter Charger Physical Specifications sestese eeit eee nent I meme I he 51 Battery Information zz 6 5 4 0 tie ce tr etit Soto als willy Sete E E None g ms ER EE Guay 52 Battery Bank Sizing ta foot aeu
26. DC disconnect switch is turned on or the DC circuit breaker is closed so be sure step 3 is done before proceeding 975 0697 01 01 9 10 Installing the Inverter Charger Connect the other end of the cable to the NEGATIVE terminal on the battery Use a wrench to tighten the bolt to a torque of 20 4 21 7 Nm at the inverter charger end To protect the DC terminals attach the DC terminal covers Figure 8 to the inverter charger using the screws provided v Sv Figure 8 DC Terminal Covers 31 This guide for use by qualified personnel only Installing the Inverter Charger DC Grounding The Chassis Ground point on the inverter charger is used to connect the chassis of the inverter charger to your system s DC grounding point as required by regulations for some installations Use copper wire that is either bare or provided with green yellow insulation The grounding guideline given below assumes you are using the code compliant DC supply cable and fuse sizes indicated on page 13 If you are using different sizes refer to the applicable code for DC grounding detail To connect the chassis ground 1 Using the appropriate wrench loosen the nut on the chassis ground point bolt shown in Figure 9 2 Connect the grounding cable between the chassis ground point and the DC grounding point for your system In an RV or vehicle installation the DC grounding point will usually be the vehicle chassis or a dedicate
27. W 230V to the test load by closing the AC breaker that controls the circuit that the test load is connected to If the light bulb illuminates the Invert mode is working 5 Press the Inverter Enable button to disable the inverter The INVERTER ENABLED LED status light is off Testing in Charge Mode and AC Bypass Mode 1 Close the AC supply breaker to supply AC power to the unit To verify that the Freedom SW 230V starts charging 2 After a few seconds verify that the AC Charge light on the front panel is turned on indicating that the batteries are being charged To verify that Freedom SW 230V correctly switches to Bypass mode 3 Disable the AC source and turn off the inverter by pressing the Inverter Enable button Connect the test load to the AC output connection of the unit 5 Enable the AC source and the test load should turn on after ten seconds 40 Installation Complete Your installation is now complete The Freedom SW 230V Inverter Charger is ready for use The preceding tests use a light test load a light bulb as a test case If you encounter problems when using a load over 1000 watts for example a hair dryer or microwave see the troubleshooting information in the Freedom SW 230V Sine Wave Inverter Charger Owner s Guide Freedom SW 230V Installation Guide Stacking Features The Freedom SW 230V inverter chargers provide support for a parallel stacking configuration This gives the system enginee
28. anded wire is required if single conductors are used All wiring must be rated 75 C or higher In Australia all wiring must be rated 90 C or higher Size of AC Input Wiring Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved in accordance with the electrical codes or regulations applicable to your installation Therefore the wiring used between the AC input circuit breaker and the inverter charger input must be sized to match the input breaker rating 11 This guide for use by qualified personnel only Planning Preparations Table 1 AC Wire Size In and Out of the Inverter Chargers MODELS Freedom SW 230V Breaker Size Used 30 amps Wire Size 4 mm minimum Color Coding L brown black or grey N blue G green with yellow stripe For dual input the wire may be red or black consult the documentation provided with the AC source utility or generator Size of AC Output Wiring Wire size must be coordinated with the current the wiring will carry This current may be determined by the 15 amp Freedom SW 3524 230 and 11 amp Freedom SW 2524 230 maximum inverter current or by the bypass current which is determined by the overcurrent protection provided ahead of the Freedom SW 230V Size of Wiring Downstream of the AC Output Breaker The wiring used between the AC output breaker and your loads must be sized in accordance with the rating of the output breaker Freedom SW 2
29. ark each end of each cable to identify it as a positive red or negative black cable before routing the wiring 975 0697 01 01 29 This guide for use by qualified personnel only Installing the Inverter Charger Connecting the DC Cables to the Inverter Charger A WARNING FIRE HAZARD Use only appropriately sized copper cable Loose connections improper connections and under rated cables will overheat Make sure that the supplied bolts on the inverter charger are tightened to a torque of 20 4 21 7 Nm Torque all other connections to the manufacturer s specifications Make sure the DC cable washers and bolt are assembled in the order shown in Figure 7 Failure to follow these instructions can result in death or serious injury NOTICE EQUIPMENT DAMAGE DUE TO REVERSE POLARITY Before making the final DC connection or closing the DC breaker or disconnect check cable polarity at both the battery and the inverter charger Positive must be connected to positive Negative must be connected to negative Failure to follow these instructions can damage the unit and or damage other equipment 30 To connect the DC cables 1 Route the DC cables from the battery bank to the inverter charger Observe the Guidelines for Routing the DC Cables on page 29 2 Install a DC fuse and disconnect switch or a DC circuit breaker between the inverter charger and the battery It must be
30. d chassis ground bus For marine installations refer to the applicable local code for marine DC grounding detail 3 Tighten the nut to a torque of 1 47 1 7 Nm 32 Chassis ground point Figure 9 DC Wiring and DC Grounding Freedom SW 230V Installation Guide Installing the Inverter Charger Step 5 Connecting the Battery Temperature Sensor BTS Installing a battery temperature sensor BTS extends the life of a battery by preventing overcharging in warm temperatures and undercharging in cold temperatures With a BTS monitoring the battery temperature the voltage delivered to the battery is adjusted according to the battery s actual temperature The BTS has a self adhesive backing and attaches to the side of the battery A 7 6 m cable is supplied with the BTS Mounting Options You can mount the BTS in one of two ways e Mounting the sensor to the negative battery post allows the internal battery temperature to be sensed and provides the most accurate results e Attaching the sensor to the side of the battery using the self adhesive backing also provides good results in most situations 975 0697 01 01 Sensor cable Figure 10 BTS with Cable NOTICE EQUIPMENT DAMAGE Use only the Freedom SW 230V compatible Battery Temperature Sensor BTS To order a spare BTS call customer service and order part number 809 0946 Failure to follow these instructions can damage the unit and or damag
31. de for use by qualified personnel only 975 0697 01 01 57 Battery Cabling and Hook up Configurations Battery Series Parallel Connections As the name series parallel implies both the series and parallel configurations are used in combination The result is an increase in both the voltage and the capacity of the total battery bank This is common with all battery inverter system voltages The smaller lower voltage batteries are first connected in series to obtain the necessary voltage and then these batteries connected in series sets are connected in parallel to increase the battery bank capacity See below 1 1 Fused Disconnect 12VDC 12VDC 250 Ah 250 Ah M S 12VDC 12VDC 250 Ah 250 Ah J Connections to DC terminals on inverter charger 24 V 500 Ah Figure 21 Batteries in Series Parallel Connections 58 Freedom SW 230V Installation Guide Specifications NOTE Specifications are subject to change without prior notice Physical Specifications Freedom SW 2524 230 Freedom SW 3524 230 LxWxH 387x343x197 mm 387x343x197 mm Net Weight 21 4 kg 27 2 kg o g Freedom SW 2524 230 Freedom SW 3524 230 5 Nominal Ambient temperature 25 C 25 C g Invert mode yo Operating range full power 20 to 25 C 20 to 25 C d Load maximum ambient 2000W 60 C 3000W 60 C 7T Charge mode e Operating range full power 20 to 25 C 20 to 25 C ES C
32. e battery Table 3 Recommended Fuse Sizes Model Minimum Fuse Size A Freedom SW 2524 230 200 Freedom SW 3524 230 250 Marine Applications A charger needs to be equipped with a disconnect and an over current protection device usually within 18 cm of each battery s positive terminal and another over current protection device 18 cm near the charger s positive terminal 1 Refer to local electrical codes 14 DC Grounding Recreational Vehicles The inverter charger DC chassis ground terminal needs to be connected to the vehicle chassis by a minimum 8 mm copper conductor that is either insulated green with yellow stripe wire rated 75 C or bare copper Marine Applications The DC grounding conductor may be one size smaller than the minimum size conductor required for the DC current carrying conductors providing the overcurrent protection device in the DC positive conductor is rated no greater than 135 of the ampacity of the DC grounding conductor and the conductor is no smaller than 2 mm 2 Refer to local electrical codes Freedom SW 230V Installation Guide Planning Preparatio Unpacking and Inspecting the Freedom SW 230V Inverter Charger Ax CAUTION HEAVY ITEM The Freedom SW 230V Inverter Charger is heavy see Inverter Charger Physical Specifications on page 51 The unit is too heavy for one person to safely lift and mount It is recommended that two people lift and mount the unit
33. e behavior on the Slave unit is modified and is dependent on how much total load is on the system Disabling Search Mode on the Master Unit In parallel stacking search mode on the Master unit will not function properly When the Master sends out a load search pulse a small current also flows into the output of the Slave unit since the two outputs are in parallel This Master unit falsely detects a load causing erratic search mode operation For this reason it is highly recommended to disable search mode on the Master unit in a parallel stacking system Setting Search Mode on the Slave Unit The Slave unit will behave in one of two ways depending on whether its search mode is enabled or disabled Search mode enabled This is the recommended mode for parallel stacking and it helps minimize battery draw The Slave unit continuously monitors the output of the Master unit If the Master unit has more than 60 of the rated load for example 2100 watts on Freedom SW 3524 230 the Slave unit will assist the Master and 46 the two will share the load equally Should the load on the Master drop below 20 of rated load 700 watts for Freedom SW 3524 230 the Slave unit disengages and returns to a waiting state Search mode disabled The Slave unit operates continuously along with the Master unit and shares the load Wiring Schematic NOTE Please refer to the Stacking Configuration sheet that shows the wiring schematic employed between two
34. e other equipment 33 This guide for use by qualified personnel only Installing the Inverter Charger Mounting to the Negative Battery Terminal To mount the sensor on the negative battery terminal Negative battery terminal Figure 11 BTS Mounted on the Negative Battery Terminal 1 Select the battery to be monitored The BTS should be connected to the battery bank that is directly connected to the inverter charger 34 2 Switch off all devices operating from the battery or open the battery switch if present to disconnect the battery 3 Wait 10 minutes for any explosive battery gases to dissipate Remove the nut that connects existing wiring ring terminals to the battery negative terminal stud 5 Move or reorient the existing wiring ring terminals on the battery negative terminal stud so there is a flat surface on which to seat the BTS mounting plate You may need to bend the ring terminal crimp and or wires slightly downward to allow the sensor to seat flush to the top surface of the upper ring terminal 6 Mount the sensor directly on top of the ring terminal as shown in Figure 11 and firmly tighten the terminal nut A WARNING FIRE HAZARD In this procedure you must install the DC wire on the battery terminal then install the sensor on top of the DC wire This sequence is required to provide the best connection to the battery and to ensure correct performance of the sensor Fa
35. ected directly under the screw heads If stranded ground wire is being used ring terminals must also be used Secure the strain relief clamp on the AC output cable jacket Attach the wiring compartment cover panel and tighten the four screws Connect the outgoing AC wires to an AC load panel equipped with circuit breakers 27 This guide for use by qualified personnel only Installing the Inverter Charger Step 4 Connecting the DC Cables DC Connection Precautions Preparing the Cables To prepare the DC cables ADAN GER 1 Cut the negative and positive cables to the required length Strip off enough insulation so you can install the terminals you will be using ELECTRICAL SHOCK HAZARD Connect and disconnect DC wiring only after opening the disconnect switches or breakers at all AC and DC sources Use crimp connectors The connector should be designed for a 9 5 mm stud size to connect to the Freedom SW 230V If a crimp connector is used it should be crimped using the tool indicated by the connector manufacturer Failure to follow these instructions will result in death or serious injury 2 Cut the DC ground cable to the required length Strip off Recommended Cable Sizes and Lengths and l enough insulation so you can install the terminals you will be Fuse Size using For recommended DC cables and fuse sizes see Table 2 and Table 3 Use crimp connectors The connector should be designed for a on page 14 6
36. eries pair branches may be connected in parallel to create a higher capacity 400 Ah 224 volts battery bank Freedom SW 230V Installation Guide Estimating Battery Requirements Calculating Battery Size Step 1 Compute Amp hours For each appliance compute the number of amp hours that will be used between charging cycles as follows 1 Obtain the wattage If the wattage is marked on the nameplate rating use that Otherwise multiply the marked voltage and amperage WATTS VOLTS x AMPS Obtain the Watt hours by multiplying that amount by the hours the appliance will be used WATT HOURS WATTS x HOURS Obtain the amp hours that the appliance requires by dividing that amount by 20 the factor for the Freedom SW 230V which is a 24 volt system BATTERY AMP HOURS USED AC WATT HOURS 10 For example a 100 W light bulb that is used for 4 hours will use 400 watt hours Wh and the inverter will consume approximately 40 Ah from a 12 volt battery 4 Enter this information on the blank calculation worksheet page 56 975 0697 01 01 Battery Information Step 2 Calculate Battery Size 5 Complete the rest of the worksheet see Table 5 Battery Sizing Example on page 54 for an example Size the batteries at approximately twice the estimated total amp hour usage Doubling the expected amp hour usage ensures that the batteries will not be overly discharged and extends battery life Do not skip this doubling ste
37. f this guide been dropped has cracks or openings in the enclosure including if the NOTE The Freedom SW 230V contains no user serviceable parts AC terminal cover has been lost damaged or will not close or otherwise damaged in any other way Do not disassemble the inverter charger Internal capacitors remain A DIANY G E R charged after all power is disconnected ELECTRICAL SHOCK AND FIRE HAZARD Disconnect both AC and DC power from the inverter charger before Installation must be done by qualified personnel to ensure compliance attempting any maintenance or cleaning or working on any circuits with all applicable installation and electrical codes and regulations connected to the inverter charger The INVERTER ENABLE button Instructions for installing the Freedom SW 230V Inverter Charger are on the front panel does not function like a power switch that energizes provided here for use by qualified personnel only or de energizes the unit When AC and DC power sources are connected and present the unit is always energized Do not operate the inverter charger with damaged or substandard wiring Make sure that all wiring is in good condition and is not undersized Failure to follow these instructions will result in death or serious injury Failure to follow these instructions will result in death or serious injury 975 0697 01 01 iii A DANGER FIRE AND BURN HAZARD Do not cover or obstruct the air intake vent o
38. ilure to follow these instructions can result in death or serious injury 7 Check to ensure that the sensor and all wires are held firmly and cannot be moved Freedom SW 230V Installation Guide 8 Turn the battery switch on again if you opened it in Step 2 9 Route the sensor cable to the inverter charger and plug it into the blue BTS port as shown in Figure 12 Secure the cable along its length Figure 12 Connecting the BTS Cable to BTS Port 975 0697 01 01 Installing the Inverter Charger 35 This guide for use by qualified personnel only Installing the Inverter Charger Mounting to the Side of the Battery Case To mount the sensor on the battery case 3 Clean the selected area thoroughly to remove any oil or grease that could prevent the sensor from adhering to the battery case Allow the battery case to dry thoroughly 4 Peel the protective backing from the self adhesive strip on the rear of the sensor 5 Press the sensor firmly against the clean side of the battery to fix it in place as shown in Figure 13 6 Route the sensor cable to the inverter charger and plug it into the Battery Temp jack as shown in Figure 12 Secure the cable along its length Figure 13 BTS Mounted on the Battery Case 1 36 Select the battery to be monitored The BTS should be connected to the battery bank that is directly connected to the inverter charger Select a side suitable for attaching the
39. in length between the two inverter chargers should not exceed 30 cm Connect the stacked system as follows 1 Connect each negative terminal to the battery 2 Connect a earth ground wire to the common negative 3 Connect each positive terminal of the inverter to the battery through a DC disconnect in each positive line Do not tie the positives together between inverters 4 Connect the earth ground bonding wire from each inverter to the same location on the vehicle chassis Use that same length and gauge wire for both inverter chargers 5 Connect the battery temperature sensors BTS if needed 975 0697 01 01 Stacking Features Two Freedom SW 3524 230 units shown Earth Ground Figure 17 Connecting Battery Cables and DC Earth Ground Wires 43 This guide for use by qualified personnel only Stacking Features Neutral Wiring for Stacked Inverters Due to the neutral ground switching design of the Freedom SW Inverter charger it is mandatory that the AC INPUT and AC OUTPUT Neutrals be isolated from one another In a stacked pair configuration connect the two AC input neutrals together at the main distribution panel and the two AC output neutrals at an isolated neutral location in the inverter AC distribution panel o 200000000000 Two Freedom SW 3524 230 units shown Figure
40. installation to prevent personal injury Failure to follow these instructions can result in minor or moderate injury The Freedom SW 230V dimensions and location of the mounting holes are provided in Figure 5 on page 21 Mount your inverter charger before you connect any wires or cables 20 To mount the inverter charger 1 Remove the inverter charger from its shipping container 2 Verify that all components are present 3 Select an appropriate mounting location and orientation To meet regulatory requirements the Freedom SW 230V must be mounted in one of the orientations shown in Figure 5 on page 21 Mark the position of the mounting holes 5 Pilot drill the six mounting holes Fasten the inverter charger to the mounting surface with six M6 steel screws or bolts Freedom SW 230V Installation Guide Figure 5 Mounting Orientations Orientation Approved Mounting Orientation Installing the Inverter Charger Comment Desktop Mount A Yes B Yes when used with inverter drip shield PN 808 9004 for marine installations A Suitable only for non marine applications with no risk of condensation or dripping water B The drip shield is installed on top of the inverter with some clearance See Drip Shield Placement Desktop Mount on page 64 Upside down Mount 975 0697 01 01 Yes for non marine applications o
41. installed in the positive side of the DC circuit as close as possible to the battery This protects your battery and wiring in case of accidental shorting See Table 3 on page 14 for required fuse or breaker size 3 Open the DC disconnect switch or turn off the DC circuit breaker 4 Connect one connector on the POSITIVE cable to the POSITIVE DC terminal on the inverter charger as shown in Figure 7 The connector goes on first then the lock washer and bolt 5 Connect the other connector to the POSITIVE terminal on the fuse or breaker Observe polarity carefully while completing the installation Use a wrench to tighten the bolt to a torque of 20 4 21 7 Nm at the inverter charger end Observe the fuse holder or breaker manufacturer s recommendation at the other end Freedom SW 230V Installation Guide Connect one connector on the NEGATIVE cable to the NEGATIVE DC terminal on the inverter charger as shown in Figure 7 The connector goes on first then the lock washer and bolt DC terminal connector lock washer bolt Figure 7 DC Cable Connections 7 Before proceeding check that the cable polarity is correct POSITIVE on the inverter charger is connected to the POSITIVE on the battery and NEGATIVE cable is connected to the NEGATIVE terminal on the inverter charger IMPORTANT The next step is the last cable connection you need to make A spark is normal when the
42. lation Guide is available for download at www xantrex com Connect only Xanbus enabled devices Ports are not intended for the On Off Switch Figure 14 Connecting to a Xanbus Network Port 37 This guide for use by qualified personnel only Installing the Inverter Charger Step 7 Performing Checks Prior to Initial Start Up Before testing your installation ensure these conditions are met Cl Chassis and AC grounds are properly installed C1 AC input connections and AC output connections are wired correctly on the terminal block and not reversed C1 Positive battery cable is connected to the positive battery terminal through the DC fuse and disconnect switch or DC circuit breaker a Negative battery cable is connected to the negative battery terminal Battery voltage is within the proper range of 20 32 volts DC DC disconnect switch or breaker is turned off AC input and output breakers are turned off OQ ucc All connections are tight 38 Freedom SW 230V Installation Guide Step 8 Testing Your Installation A WARNING ELECTRICAL SHOCK HAZARD The Inverter Enable button on the Freedom SW 230V and the optional accessories do not disconnect DC or AC input power to the Freedom SW 230V Failure to follow these instructions can result in death or serious injury There are several tests to be performed to verify that the installation is successful These tests will ve
43. lt in death or serious injury You may purchase the inverter drip shield by contacting an authorized dealer When ordering mention part number 808 9004 This guide for use by qualified personnel only 975 0697 01 01 63 Inverter Drip Shield Installation side view 10mm clearance required here gt M 55 mm Figure 22 Drip Shield Placement Desktop Mount 64 side view sd ee Figure 23 Drip Shield Placement Inverter Front Panel Facing Up Freedom SW 230V Installation Guide Inverter Drip Shield Installation side view No clearance required here Figure 24 Drip Shield Placement Inverter Front Panel Facing Down 975 0697 01 01 65 This guide for use by qualified personnel only Schneider Electric Solar Inverters USA Inc 1 800 670 0707 1 408 987 6030 www xantrex com 975 0697 01 01 Printed in China
44. m 35 mm Freedom SW 3524 230 200 240 mm 120 mm 300 mm 150 mm a Copper conductors with thermoplastic insulation rated at 75C or higher In Australia thermoplastic insulation must be rated at 90C or higher IMPORTANT Longer cables may cause the inverter to shut down under a heavy load A WARNING FIRE HAZARD Undersized cables will overheat Consult local electrical codes to determine minimum required size Failure to follow these instructions can result in death or serious injury 13 This guide for use by qualified personnel only Planning Preparations DC Disconnects and Over Current Devices The DC circuit from the battery to the inverter charger must be equipped with a disconnect and overcurrent protection device In Australia disconnect and overcurrent protection devices must be approved for use in Australia Refer to your applicable installation code for guidance Type This device 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 Rating The rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes Location The breaker or fuse and disconnect 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 th
45. mage the inverter charger If the inverter charger is installed in a compartment above the batteries make sure there is a solid gas impermeable wall dividing the two compartments However flooded or wet cell batteries produce flammable gases that can potentially be ignited and therefore a safety hazard If the batteries are sealed no caps to add water then the Freedom SW 230V can be mounted above the batteries if so desired a position outlined in the manual Never allow battery acid to drip on the inverter charger or its wiring when filling the batteries or reading their specific gravity Orientation Installing the Inverter Charger To meet regulatory requirements the Freedom SW 230V must be mounted in one of the approved mounting orientations See Figure 5 on page 21 19 This guide for use by qualified personnel only Installing the Inverter Charger Step 2 Mounting the Inverter Charger Considerations Before mounting the Freedom SW 230V take the following two factors into account 1 The weight of the inverter charger requires two people to install it 2 Mounting considerations are shown in Figure 5 on page 21 A CAUTION HEAVY ITEM The Freedom SW 230V Inverter Charger is heavy see Inverter Charger Physical Specifications on page 51 The unit is too heavy for one person to install safely It is recommended that two people lift and mount the unit Always use proper lifting techniques during
46. necting the DC Cables on page 28 Step 5 Connecting the Battery Temperature Sensor BTS on page 33 Step 6 Connecting to the Network on page 37 Step 7 Performing Checks Prior to Initial Start Up on page 38 Step 8 Testing Your Installation on page 39 975 0697 01 01 17 This guide for use by qualified personnel only Installing the Inverter Charger Step 1 Choosing a Location for the Inverter Charger A DANGER FIRE AND EXPLOSION HAZARD This equipment contains components that could produce arcs or sparks To reduce the risk of fire or explosion do not install this equipment in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing gasoline powered machinery fuel tanks or joints fittings or other connections between components of the fuel system Failure to follow these instructions will result in death or serious injury Ax CAUTION HEAT HAZARD Do not cover or obstruct the ventilation openings Do not install this equipment in a compartment with limited airflow Overheating may result Failure to follow these instructions can result in minor or moderate injury 18 The inverter should only be installed in a location that meets the following requirements Ventilated Do not operate the inverter charger in a closed in area or restrict ventilation in any way The inverter charger requires air circula
47. nly Suitable only for non marine applications with no risk of condensation or dripping water 21 This guide for use by qualified personnel only Installing the Inverter Charger Approved Mounting Orientation Orientation Comment Wall Mount DC on Left A Yes B Yes when used with inverter drip shield PN 808 9004 for marine installations A Ona vertical surface with DC terminals facing left B Ona vertical surface with DC terminals facing left with the front panel facing up The drip shield is installed on top of the inverter with some clearance See Drip Shield Placement Inverter Front Panel Facing Up on page 64 Wall Mount DC on Right A Yes B Yes when used with an inverter drip shield PN 808 9004 for marine installations Ges 22 A Ona vertical surface with DC terminals facing left B On a vertical surface with DC terminals facing right with the front panel facing down The drip shield is installed directly on top of the inverter See Drip Shield Placement Inverter Front Panel Facing Down on page 65 Freedom SW 230V Installation Guide Approved Mounting Installing the Inverter Charger Orientation Orientation Comment Wall Mount DC Up No Not acceptable This orientation does not meet regulatory requirements 3 t H Bo Wall Mount DC Down No Not acceptable
48. o Shes Swed MOREA A E 4 3 Xanbus enabled Products and Accessories 0 5 d Planning the Installation 33 000 x e CD RAIL RA AS Bed are E ARUBA UTE ARE AERE WINE SAL ae AA 6 E Two Key Performance Factors 2240 E pe bed ts it A ii SE Es 6 zi size and Length ot DC Cables cis RA OE Be BY AAR PER RE EAA RG LIO ECRIRE EOS 6 pe Mounting Location of the Freedom SW 230V LL 6 25 Planning Preparations sare Sena PS Pte CERERI be Pete EX PRI A ien bol Mand ben ede CA ae dux e ep e PRECOR Y HAAS 7 8 hf AC DC and Network Components eraran ee eR eer o hee ok re sles Re diee RR UC RR STR E UAR RR e CUN RR EORR enlace 7 2 AG Components siene e AUR aana ia aar A a esse eats gta phen bees trades a e a e a pila 10 3 Penn A AA A E Tn aede 1 ACOMPLIA eyo e t 10 AC Loads osi dex A E E EE A ERES EE E e ER ik seeks EE 10 AC Disconnect and Over Current Protection Device 0 0 ccc eee eee 10 Distribution Panels mt bd Rabe da a e ee etek ep Bh aida 11 AC WINE certi E SAEPE ee CREER A ee Gore aoe ale Syed as yee 11 DE Components mui A Hew Mea A Rie ees Eee by ental Hears ae eer Se 13 Batteries Sha ewe ek A toed AAA Rca aces Reed Ma Sadat tA Sen ated ele Oe ee ee Saas 13 DE Cabling xo A A ds sa 13 DC Disconnects and Over Current Devices o 14 DC Groundiin st a A A A A A EN ew ec p ER AC 14 Unpacking and Inspecting the Freedom SW 230V Inverter Charger 0 00 ccc e 15 Installation Tools and Materials e Gee dep gon dees 16 TOONS
49. oads connected to Line out In AC Bypass mode the source connected to the AC input is passed through to the load Only 230 volts 50 Hz AC appliances can be connected to the Freedom SW 230V output 10 AC Disconnect and Over Current Protection Device To meet mobile electrical code requirements and to protect system wiring the AC inputs and outputs of the inverter charger must be provided with overcurrent protection on both the AC input and output This protection may be a circuit breaker or a fuse with a disconnect device for simplicity the following refers to breakers Refer to your applicable installation codes and the following requirements AC Input Protection The breaker protecting the AC input of the Freedom SW 230V must be approved for use on 230 volts AC branch circuit The breaker must be rated no more than 30 amps maximum AC Output Protection The breaker between the Freedom SW 230V AC output and the AC loads must be rated to protect the AC output wire size used If the AC output wiring is based on the full 30 amp pass through rating then a 30 amp output breaker is acceptable If the AC output wiring is smaller then the breaker size will have to be smaller as well in accordance with applicable electrical installation codes Freedom SW 230V Installation Guide GFCI Requirements A GFCI ground fault circuit interrupter is a device that de energizes a circuit when a current to ground exceeds a specified value tha
50. otherwise specified Transfer and General Specifications All Models Transfer time utility to invert lt 20 ms Minimum AC input voltage for transfer 170 VAC Maximum AC input voltage for transfer 270 VAC Minimum AC input frequency for transfer 45 Hz Maximum AC input frequency for transfer 68 Hz Cooling Fan cooled temperature controlled Safety CE mark Europe EN62040 1 RCM mark Australia AS 62040 1 1 AS NZS 60335 2 29 EMC CE Europe and RCM Australia EN 62040 2 62 Freedom SW 230V Installation Guide Inverter Drip Shield Installation The inverter drip shield helps to protect the unit from dripping or To install the drip shield splashing liquids which causes a shock hazard The inverter drip 1 Acquire ten 6 3 4 screws needed to fasten the inverter drip shield is especially useful in marine installations where water from shield to the wall condensation rain or sea may come into contact with the Freedom 2 Locate an appropriate setting for the drip shield above the os Freedom SW 230V making sure you cover the entire width of the unit A WARNING 3 Fasten the screws through the holes in the drip shield into the SHOCK HAZARD wall Do not operate the unit under wet conditions and when the unit is wet This product is intended only for use in dry areas Installing the inverter drip shield may not entirely protect you from this hazard Failure to follow these instructions can resu
51. p More capacity is better since you will have more reserve capacity be better able to handle large loads and surge loads and your battery won t be discharged as deeply Battery life is directly dependent on how deeply the battery is discharged The deeper the discharge the shorter the battery life Troubleshooting If you find that the system shuts down when appliances with large motors are started the problem may be that this motor is too much for the battery Even though you calculated the amp hour requirements appropriately the startup of a large motor makes high demands on the battery You may find that adding more amp hours in the form of extra batteries or replacement with a bigger battery solves the problem This guide for use by qualified personnel only 53 Battery Information Table 5 Battery Sizing Example Daily watt hours needed A Power Consumption B Operating Time per for this appliance Appliance Watts Day Hours A x B TV amp VCR 200 W 2 hours 400 Wh Small microwave oven 800 W 15 min 1 4 hour 200 Wh 3 lamps 60 W each 180 W 4 hours 720 Wh Coffee maker 600 W 15 min 1 4 hour 150 Wh Hair dryer 1500 W 6 min 1 10 hour 150 Wh Total daily watt hours of AC load 1620 Wh x Number of days between charges 3 Total watt hours of AC Toad between charges 4860 Wh Battery Ah used between charges divide by 10 for 12 volt system divide by 20 for 24 volt sy
52. penings and or install in a zero clearance compartment Do not use transformerless battery chargers in conjunction with the inverter charger due to overheating Failure to follow these instructions will result in death or serious injury A DANGER EXPLOSION HAZARD e Charge only properly rated such as two 12 V in series for a 24 V battery bank lead acid GEL AGM Flooded or lead calcium rechargeable batteries because other battery types may explode Do not work in the vicinity of lead acid batteries Batteries generate explosive gases during normal operation See note 1 e Do not install and or operate in compartments containing flammable materials or in locations that require ignition protected equipment See notes 2 and 3 Failure to follow these instructions will result in death or serious injury NOTES 1 Follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery Review cautionary markings on these products and on the engine 2 This inverter charger contains components which tend to produce arcs or sparks 3 Locations include any space containing gasoline powered machinery fuel tanks as well as joints fittings or other connections between components of the fuel system 4 Freedom SW 230V inverter charger products are designed for deep cycle lead acid batteries only Charging lithium ion bat
53. r and or installer more options to work with when tailoring a system to meet load demands In parallel stacking mode only two Freedom SW 230V inverter chargers of the same model can be parallel stacked For example two Freedom SW 2524 230s can be stacked in parallel as both units each have a 24 volt rating and a power rating of up to 2500 watts This guide for use by qualified personnel only 975 0697 01 01 41 Stacking Features Parallel Stacking Allows the inverter and charger capacity of a system to be doubled Parallel stacked inverter chargers can operate from different battery banks meaning each unit is connected to its own battery bank However it is highly recommended to only use a single battery bank See DC Connections for Stacked Inverters on page 43 Do NOT connect a stacking cable to the STACKING port on the front panel of a Freedom SW 230V to configure two units for parallel stacking The port is reserved for future use Two Freedom SW 3524 230 units shown 42 poooooooooQo H ms 680000600000 a Two Freedom SW 3524 230 units shown Figure 16 Parallel Stacking Using Two Freedom SW 3524 230s Freedom SW 230V Installation Guide DC Connections for Stacked Inverters Individual overcurrent devices are to be used between the battery positive and each inverter Keep cable lengths to the two inverter chargers the same in order to balance cable losses If not the battery cable difference
54. rify that e the Freedom SW 230V works in invert mode e the Freedom SW 230V works in charge mode e the Freedom SW 230V works in AC bypass mode If any of the tests fails at any point go to Step 7 Performing Checks Prior to Initial Start Up on page 38 and go through the checklist again to check against the installation Perform the tests again If any test fails again see the troubleshooting section in the Freedom SW 230V Sine Wave Inverter Charger Owner s Guide 975 0697 01 01 Installing the Inverter Charger FREEDOM SW INVERTER CHARGER Figure 15 Freedom SW 230V Front Panel Testing in Invert Mode To test the Freedom SW 230V in invert mode using a 100 watt light bulb as the test load 1 Close the DC disconnect switch or the DC circuit breaker to supply DC power to the Freedom SW 230V Wait for all the lights on the front panel to flash on and off indicating that the unit has successfully initialized 10 to 30 seconds If the light does not come on make sure the voltage at the DC terminals on the Freedom SW 230V is correct as described in Step 7 Performing Checks Prior to Initial Start Up on page 38 2 After initialization observe that none of the lights on the front panel should remain illuminated 39 This guide for use by qualified personnel only Installing the Inverter Charger 3 Press the INVERTER ENABLE button Verify that the INVERTER ENABLED LED status light illuminates 4 Connect the Freedom S
55. ring to Charge Precautions When Placing the Inverter Charger A WARNING NOTICE EXPOSURE TO CHEMICALS AND GASES HAZARD Make sure the area around the battery is well ventilated Make sure the voltage of the batteries matches the output voltage of the inverter charger Be careful to keep corrosion from coming into contact with your eyes and skin when cleaning battery terminals Failure to follow these instructions can result in death or serious injury NOTES vi Study and follow all of the battery manufacturer s specific precautions such as removing or not removing cell caps while charging whether equalization is acceptable for your battery and recommended rates of charge For flooded non sealed batteries add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer This helps to purge excessive gas from cells Do not overfill For a battery without removable cell caps carefully follow manufacturer s instructions RISK OF DAMAGE TO THE INVERTER CHARGER Failure to follow these instructions can damage the unit and or damage other equipment Never allow battery acid to drip on the inverter charger when reading gravity or filling battery Never place the Freedom SW 230V Inverter Charger unit directly above batteries gases from a battery will corrode and damage the inverter charger Do not place a battery on top of the inverter charger
56. s on DC cables Phillips screwdriver 2 Slot screwdriver 6 mm wide blade max Needle nose pliers Wrench for DC terminals 15 mm Materials You will need the following materials to complete your installation OO 009 00 OOO OF Strain relief clamp s for AC cables not provided trade sizes are 3 4 028 3mm and or 1 034 6mm DC battery cables Lugs for DC cables for 10 mm stud size Copper wire for DC grounding 8 mm See DC Grounding on page 14 Lugs for DC grounding cable for M6 stud size AC and DC disconnect switches and overcurrent protective devices and connectors as required See page 13 AC output and input wire See Figure 3 on page 8 If the AC ground wire is stranded each ground wire requires a ring terminal Six M6 steel screws or bolts to mount the unit Inverter drip shield PN 808 9004 if mounting in marine installation NOTE For a list of tools and materials required to install the network refer to the Xanbus System Installation Guide which is available for download at www xantrex com Freedom SW 230V Installation Guide Installing the Inverter Charger Overview This section provides detailed information on installing the Freedom SW 230V The overall procedure is divided into eight steps Step 1 Choosing a Location for the Inverter Charger on page 18 Step 2 Mounting the Inverter Charger on page 20 Step 3 Connecting the AC Input and AC Output Wires on page 24 Step 4 Con
57. ssories Xanbus enabled Products Shown above 3 ft cable 25 ft cable 75 ft cable Inverter drip shield Product Number s Xanbus System Control Panel SCP 809 0921 Xanbus Automatic Generator Start AGS 809 0915 3 ft network cable 0 9 m 809 0935 25 ft network cable 7 6 m 809 0940 75 ft network cable 22 9 m 809 0942 Accessories Shown above Product Number s Freedom SW On Off Switch Not shown 808 9002 Inverter drip shield 808 9004 975 0697 01 01 About the Xanbus System This guide for use by qualified personnel only Planning the Installation This section provides information to help you plan for a basic installation of the Freedom SW 230V As your system configuration is determined record the details in Information About Your System in the Freedom SW 230V Sine Wave Inverter Charger Owner s Guide Two Key Performance Factors Two key factors in particular will have a major impact on system performance Size and Length of DC Cables To select the appropriate size and length of DC cables see DC Cabling on page 13 The DC 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 If there are long battery cables which are in excess of 3 meters each and not of sufficient size the voltage drop across the cables will have a negative impact on overall
58. stem 243 Ah 24 V Recommended Battery Bank Size in Ah multiply by 2 486 Ah 024 V This example illustrates how quickly your battery needs can escalate To reduce the required battery bank size you can either conserve energy by eliminating or reducing the use of some loads or recharge more frequently 54 Freedom SW 230V Installation Guide Battery Banks As your power requirements increase you may need to use more than one battery to obtain sufficient capacity Batteries can be connected in parallel in series or in series parallel to create higher capacity systems See Battery Cabling and Hook up Configurations on page 57 for more information about battery inter connection schemes Mixing Batteries Batteries connected in parallel should be of the same type and amp hour rating and from the same manufacturer It is not recommended to connect batteries of different types amp hour ratings or manufacturers Improper charging and decreased battery life will result Battery Bank Sizing Worksheet The following worksheet is a guide to help you determine your battery needs Be generous in estimating the time for which you will run each of the loads to ensure sufficient battery capacity 975 0697 01 01 Battery Information Restrictions on Motor Size An appliance may require three to six times its normal running current in order to start The Freedom SW 3524 230 can handle surges to 6800 watts for five seconds which
59. t is less than that required to open the circuit breaker GFCIs are intended to protect people from electric shocks and are usually required in wet or damp locations Installation in recreational vehicles may require GFCI protection of certain branch circuits Consult all applicable codes Disconnect Devices Each system requires a method of disconnecting the AC circuits If the overcurrent protection device is a circuit breaker it will also serve as the disconnect If fuses are used separate AC disconnect switches will be needed between the source and the fuses 975 0697 01 01 Planning Preparations Distribution Panels Some systems incorporate distribution panels both ahead of the inverter charger the AC source panel and between the inverter charger and the loads the AC load panel The AC source panel includes a main circuit breaker which serves as overcurrent protection for the panel Additional circuit breakers serve individual circuits one of which serves the inverter charger AC Wiring Definition AC wiring includes input wiring all the wires and connectors between the AC source and the inverter charger input and output wiring all the wires between the inverter charger and the AC load panels circuit breakers and loads Type Thetype of wiring required varies according to the electrical codes or regulations applicable to your installation For RV applications this may be solid wire in multi conductor cables but str
60. teries are currently not supported and doing so is an explosion hazard Lithium ion battery cells are individually monitored for voltage and temperature The Freedom SW 230V does not support this individual cell monitoring on lithium ion batteries Ax CAUTION PHYSICAL INJURY HAZARD This Freedom SW 230V Inverter Charger is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the appliance Failure to follow these instructions can result in minor or moderate injury Freedom SW 230V Installation Guide Precautions When Working With Batteries IMPORTANT Battery work and maintenance must be done by qualified personnel knowledgeable about batteries to ensure compliance with battery handling and maintenance safety precautions A WARNING BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE AND EXPLOSION FROM VENTED GASES HAZARDS Always wear proper non absorbent gloves complete eye protection and clothing protection Avoid touching your eyes and wiping your forehead while working near batteries See note 4 Remove all personal metal items like rings bracelets and watches when working with batteries See notes 5 and 6 below Ne
61. the inverter charger and none to the main panel upstream of the inverter charger IMPORTANT Wiring the output inverter to back to the main panel could result in ground bonding to occur in multiple locations in contravention of applicable wiring codes and may result in nuisance tripping of Ground fault protection equipment All wiring must be performed by a qualified electrician AC Wiring Compartment For your reference the AC wiring compartment is shown in Figure 6 on page 25 AC Knockouts There are two dual 1 0 34 6mm and 3 4 028 3mm trade size knockouts on the side panel for AC wiring Use the same trade size of strain relief as the trade size of the knockout s you are using AC Wiring Terminals The AC wiring terminals accept cables of a specific size See AC Wiring on page 11 for required sizes Freedom SW 230V Installation Guide Connecting AC Input Wires Figure 6 shows the wiring compartment which contains a grounding bus used to wire the AC input and output ground wires and a terminal block used to wire the AC input and AC output connections BATTER PY e e efe To ground bus Figure 6 AC Wiring Compartment 975 0697 01 01 Installing the Inverter Charger NOTICE EQUIPMENT DAMAGE The terminal block is split into INPUT and OUTPUT sections Damage may occur if the unit is wired incorrectly Do not remove or loosen factory
62. the utility grid inverter Charger ow TE o a must follow local and national wiring rules 230V ACIN 7 HOT BROWN BLACK OR GREY Em NEUTRAL BLUE m GND GREEN WITH YELLOW STRIPE 4 Battery Bank 24V Neutral NOTE The DC grounding conductor may be one size smaller than the minimum size conductor required for the DC current carrying conductors providing the overcurrent protection device in the DC positive conductor is rated no greater than 135 of the ampacity of the DC grounding conductor and the conductor is no smaller than 2mm Figure 4 Wiring and Breakers Block Diagram for Freedom SW 230V 2524 3524 975 0697 01 01 9 This guide for use by qualified personnel only Planning Preparations AC Components NOTE Unless otherwise referenced specifically by product name the components refer to all models of Freedom SW inverter chargers AC Input AC input can be supplied from a single phase 230 volt 50 Hz AC source such as the utility grid power company a generator or the output of a transfer switch AC Output The output voltage on Freedom SW inverter chargers is 230 volts AC The Freedom SW 2524 230 and Freedom SW 3524 230 models have a Single Input and Single Output line SI SO configuration AC Loads The Freedom SW 230V is intended to power loads consisting of 230 volts 50 Hz AC appliances In Invert mode the Freedom SW 230V provides 230 volts 50 Hz AC to l
63. tion to maintain optimum operating temperature and provide best performance If the unit has inadequate ventilation it may shut down due to overheating The air vented through the openings should also have a path to circulate away from the inverter charger Dry Do not allow water or other fluids to drip or splash on the inverter charger Do not expose to rain snow or water Use an optional inverter drip shield PN 808 9004 for marine installations Cool Normal air temperature should be between 0 C and 60 C the cooler the better within this range Clearance Allow as much space around the inverter charger as possible It is recommended that other objects and surfaces be at least 76 mm away from the ventilation openings for best performance Freedom SW 230V Installation Guide Safe Close to battery compartment Protected from battery acid and gases 975 0697 01 01 Locate the inverter charger away from battery in a separate well ventilated compartment Do not install the inverter charger in any compartment containing flammable gases or liquids like gasoline The length and size of your DC cables will affect performance Use the DC cables recommended in Table 2 on page 13 The unit should not be installed in the battery compartment due to the possible presence of explosive hydrogen gas from the batteries Never place the inverter charger directly above the batteries gases from battery will corrode and da
64. translates to a locked rotor amp rating of no more than 50 amps The locked rotor amp may be specified on the motor nameplate as LRA or LRT When considering appliances with large motors follow these guidelines Make sure that the motor s LRA rating is no more than 50 amps The Freedom SW 230V may not be able to start a motor with a higher LRA and the Freedom SW 230V will shut down if the attempt is made Make sure the battery bank DC cables and DC fuses are capable of handling up to 600 amps DC for five seconds A weaker circuit may not be able to provide sufficient power to the Freedom SW 230V to allow the Freedom SW 230V to start up the appliance Again if the circuit cannot deliver the required current the system may shut down or the fuse may open 55 This guide for use by qualified personnel only Battery Information Table 6 Battery Sizing Worksheet A Power Consumption B Operating Time per Daily watt hours needed for this appliance Appliance Watts Day Hours A x B W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh Total daily watt hours of AC load Wh x Number of days between charges Total watt hours of AC load between charges Wh Battery Ah used between charges divide by 20 for 24 volt system Ah Recommended Battery Bank Size in Ah multiply by 2 Ah 56 Freedom
65. tributed within the bank through each individual parallel and or series connected battery Therefore the current each battery sees must not exceed each individual battery s maximum allowed charge current as specified by the battery manufacturer Since most battery banks are comprised of the same battery type model and length of interconnecting cables current sharing is roughly equal through 47 This guide for use by qualified personnel only Stacking Features each parallel branch of batteries Therefore the above generalizations of maximum charge rate can be made for the entire battery bank The Freedom SW 230V s Max Chg Rate setting defaults to 100 adjustable from 0 to 100 So if the Freedom SW 3524 230 charger with a maximum possible 90A charger capacity is set to a Max Chg Rate of 100 then its full 90A of current can be delivered into the battery bank However if this is too high the installer operator may reduce the Max Chg Rate setting to suit the system battery type and bank requirements and limitations to avoid overheating the battery bank The user installer is responsible of configuring the charger to ensure that the battery manufacturer s recommended maximum charge rate current in Amps is not exceeded to prolong battery life and to exhibit best performance 48 Examples Example 1 System composed of two stacked Freedom SW 2524 230s Each Freedom SW 2524 230 has a maximum charge capacity of
66. urrent maximum ambient 58 A 60 C 80 A 60 C g Storage temperature range 55 to 75 C 40 to 85 C 3 Humidity Operation Storage lt 95 RH non condensing Altitude Operating lt 2 000 m 3 Mounting deck mount wall mount with fans and DC AC sides facing sideward 2 E 975 0697 01 01 59 Specifications NOTE All inverter specifications are at nominal conditions 24 VDC unless otherwise specified Inverter Specifications Freedom SW 2524 230 Freedom SW 3524 230 Output waveform sine wave sine wave Output power continuous 2500 W up to 25 C 3400 W up to 25 C Output power 5 seconds 5000 W 6800 W Output current 11A 15A Output frequency 50 Hz 50 Hz Output voltage 230 VAC 230 VAC AC output connection Single phase Single phase Peak efficiency 90 90 No load current draw Inverter On lt 1 9 ADC lt 2 2 ADC Standby current draw Inverter Off lt 0 15 ADC lt 0 15 ADC Input DC voltage range 20 32 VDC 20 32 VDC Low battery voltage shutdown cut off 21 0 V selectable 21 0 V selectable High battery voltage shutdown cut off 33 0 V selectable 33 0 V selectable 60 Freedom SW 230V Installation Guide Specifications NOTE All charging specifications are at nominal conditions ambient temperature of 25 C 230 VAC 50 Hz input unless otherwise specified Charger Specifications Freedom SW 2524 230 Freedom SW 3524 230 Charging method Three stage charge
67. ver smoke or allow a spark or flame near the engine or batteries Never charge a frozen battery Failure to follow these instructions can result in death or serious injury NOTES 1 Mount and place the Freedom SW 230V Inverter Charger unit away from batteries in a well ventilated compartment Always have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery Always have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 975 0697 01 01 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 Use extra caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Batteries can produce a short circuit current high enough to weld a ring or metal bracelet or the like to the battery terminal causing a severe burn When removing a battery always remove the negative terminal from the battery first for systems with grounded negative If it is grounded positive remove the positive terminal first Make sure all loads connected to the battery and all accessories are off so you don t cause an arc This guide for use by qualified personnel only Precautions When Prepa
68. wax ees gem pe rep Nu ch ta ec pc t t A A sale eked 16 Materials erena Sis REI Re epee Miedo HIR eedem e ense e re e WEES d 16 Installing the Inverter Charger ke oe eRe a ME RE Re E eed elle 17 ONERVIEW i det tete b OPEM ago eet ab O 17 Step 1 Choosing a Location for the Inverter Charger 0 0 ce eee I e 18 Step 2 Mounting the Inverter Charger etuis aoa e e E a E eee me e e Ihe 20 Considerations osse S LCL SS ERN Ok Ed DRE EI RE DR EAR SR 20 Step 3 Connecting the AC Input and AC Output Wires 0 0 m e 24 General AC Wiring Considerations 1 0 2 0 e I m he 24 Connecting AC Input Wires 2 4 us eee awit A pee p ween EP RAPI Geben te atte d 25 Connecting tbe AC Output WISIN e QURE A RA eR EIS AT IA A O 27 Step 4 Connecting the DC Cables ici A A E ad wes tt 28 DE Connection Precautions cet A Ea RIA ee Mee gle 28 Recommended Cable Sizes and Lengths and Fuse Size 28 Preparing the Cables s ea iy te ee eA Ae OI REL AIR ES Be WR Be EC eS 28 Guidelines for Routing the DC Cables scesi erii snn ee EE EE TEE EAE E E TERE E OEE E ES 29 Connecting the DC Cables to the Inverter Charger 0 0 0 ee cnet tenet teens 30 DC Gro nding pit edit it eA A p hain canted A PLE 32 Step 5 Connecting the Battery Temperature Sensor BTS 0 0 ee ccc I enn eae 33 Mounting Options so aa sake tikes Ae ete eel Mee ee ge puede 33 Mounting to the Negative Battery Terminal 34 Mounting to the Side of the Battery Case 36 Step 6
69. xantrex Kquo SJoT eISUI pargrrenb Aq asn 10 apm3 sr L 5 5 o E E lt o WHO a O Exa gt eae LE 22 2 Z NA ec s o Lg lt Y Ke con e 010 LEM moo Xu Smart choice for power Freedom SW 3524 230 shown Freedom SW 230V Sine Wave Inverter Chargers Copyright 2013 2014 Schneider Electric All Rights Reserved All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING SELLER 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 C REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW XANTREX COM Document Part Number 975 0697 01 01 Date and Revision June 2014 Rev B Product Numbers 815 3524 02 Freedom SW 3524 230 815 2524 02 Freedom SW 2524 230 Contact Information Telephone
70. y model being used to construct the bank This total bank maximum charge rate is best determined by a qualified RV electrical technician Suitable battery types include Flooded GEL and AGM Do not mix different battery types within the same battery bank For a Flooded type battery bank the preferred charge rate in Amps is usually 10 15 of C where C battery bank s total Amp hour capacity However the industry accepted maximum charge rate is 25 of C Some AGM or Gel battery models may have a maximum charge rate as high as 50 of C and in rare cases up to 100 of C Do not exceed the battery manufacturer s recommended maximum charge specifications because the resulting battery temperature rise shortens battery life 975 0697 01 01 Calculations Once installed and configured each Freedom SW 230V charger in the dual configuration should be set to its own bulk charge current limit as follows Industry accepted maximum charge rate x battery bank s total Amp hour capacity C x ihi for one of the chargers Maximum charger 1 output current in Amps allowed in bulk mode also limited to the charger s maximum capacity To calculate the system total bulk output for the stacked pair Charger 1 output current in Amps Charger 2 Actual output current in Amps System Total BULK output current in Amps The System Total BULK output current flows into the battery bank As such this total bulk current is split dis
71. y will extend running time and ensure that your inverter charger delivers full rated surge It is recommended a minimum battery size of 200 amp hours Ah for moderate loads lt 1000 watts and greater than 400 Ah for heavy loads See Estimating Battery Requirements for information on a more detailed calculation About Amp hours A number of different standards are used to rate battery energy storage capacity Automotive and marine starting batteries are normally rated in cranking amps This is not a relevant rating for continuous loads like an inverter Deep cycle batteries use a more suitable rating system such as amp hours Ah Amp hour capacity is the number of amps a battery can continuously deliver during a specified number of hours It is represented by the product of the two amps multiplied by hours 52 A typical single marine or RV battery rated for 100 Ah can deliver 5 amps 12 volts for 20 hours 5 amps x 20 hours 100 Ah 12 volts This same battery can deliver a higher or lower current for less or more time limited approximately by the 100 Ah figure 50 amps for 2 hours or 200 amps for a half hour but usually the capacity figure given is only accurate for the specified duration 20 hours For Freedom SW 230V inverter systems requiring a 24 volt battery bank e apair of 200 Ah 12 volts batteries may be connected in series to create a 24 volt bank of 200 Ah 224 volts capacity while two of these s

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