Studer Innotec XPC 1648, XPC 1112, XPC 1624 User Manual

STUDER INNOTEC

Combi Inverter, Battery charger

User and installer Manual

XP-COMPACT

and Transfersystem

XP-COMPACT XPC 1112

XP-COMPACT XPC 1624
XP-COMPACT XPC 1648

Remote control

Temperature sensor

Solar charge controller

AC cable cover

IP-23 top cover

RCC-01

CT-35

XPCxxxx-S

CFC-01

C-IP23

STUDER INNOTEC TEL: ++41 (0)27 205 60 80
Rue des Casernes 57 FAX: ++41 (0)27 205 60 88
CH-1950 SION EMAIL : [e-mail]

User manual XP-COMPACT V2.0 E

STUDER INNOTEC

XP-COMPACT

Summary

1

General Information .................................................................................................................3

1.1 OPERATING INSTRUCTIONS ................................................................................................................................3

1.2 QUALITY AND WARRANTY................................................................................................................................. 3

1.3 WARRANTY DISCLAIMER ...................................................................................................................................3

1.4 LIABILITY DISCLAIMER ......................................................................................................................................3

1.5 PRECAUTIONS .................................................................................................................................................... 4

1.6 SPECIAL PRECAUTIONS ......................................................................................................................................4

2 Introduction...............................................................................................................................5

2.1 PRINCIPLE SCHEMATIC .......................................................................................................................................5

2.2 DESCRIPTION OF MAIN FUNCTIONS .....................................................................................................................5

2.2.1 The inverter...................................................................................................................................................5

2.2.2 The transfer system ....................................................................................................................................... 5

2.2.3 The battery charger.......................................................................................................................................5

2.2.4 The solar charge controller (optional)..........................................................................................................6

2.2.5 Remote control..............................................................................................................................................6

2.3 BATTERY CONNECTIONS .................................................................................................................................... 6

2.3.1 Connection in parallel ..................................................................................................................................6

2.3.2 Connection in serie .......................................................................................................................................6

2.3.3 Connection in parallel and in serie...............................................................................................................7

3 Mounting and installing ...........................................................................................................7

3.1 INSTALLATION PLACE.........................................................................................................................................7

3.2 FIXING................................................................................................................................................................7

3.2.1 XP-COMPACT..............................................................................................................................................7

3.3 PROTECTION COVER IP23................................................................................................................................... 7

3.4 CONNECTIONS ....................................................................................................................................................7

3.4.1 General instructions on connecting .............................................................................................................. 7

3.4.2 Protection cover for the terminals connections ............................................................................................8

3.5 CONNECTING PANEL / FRONT SIDE .....................................................................................................................8

3.6 CABLING/WIRING ...............................................................................................................................................9

3.6.1 Pre-installation settings ................................................................................................................................9

3.6.2 Connection to battery.................................................................................................................................... 9

3.6.3 Connecting the 230Vac-Consumer Appliance (AC OUTPUT) .....................................................................9

3.6.4 Connecting the 230Vac Input (AC INPUT)...................................................................................................9

3.6.5 Connecting the Solar modules: SOLAR +/- (Only with solar option)........................................................... 9

3.6.6 Connection to Auxiliary Contact.................................................................................................................10

3.6.7 Connection to Temperature Sensor (Temp.) ...............................................................................................10

4 Control.....................................................................................................................................10

4.1 DISPLAY AND CONTROL PARAMETERS.............................................................................................................. 10

4.2 DISPLAY AND CONTROL PARAMETERS ON REMOTE CONTROL PANEL (OPTIONAL) ............................................11

4.3 LIGHT EMITTING DIODES (LED) ......................................................................................................................11

4.4 PUSH BUTTONS.................................................................................................................................................12

4.5 TURNING KNOBS ..............................................................................................................................................12

4.6 THE INVERTER ................................................................................................................................................. 12

4.6.1 Charge detection system „Standby“ ...........................................................................................................12

4.6.2 Overload .....................................................................................................................................................12

4.6.3 Overheating (Over Temp) ...........................................................................................................................12

4.6.4 Battery Condition........................................................................................................................................13

4.7 THE BATTERY CHARGER ..................................................................................................................................13

4.7.1 Cycle of charge ........................................................................................................................................... 13

4.7.2 Equalization charging................................................................................................................................. 14

4.7.3 Default value for battery charger ...............................................................................................................14

4.7.4 Charging current ........................................................................................................................................14

4.8 THE TRANSFER SYSTEM ...................................................................................................................................14

4.8.1 Set the transfer voltage threshold ...............................................................................................................15

4.8.2 FAST (UPS)- MODE for the Transfer Switch.............................................................................................15

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XP-COMPACT

4.8.3 Delayed mode of the Transfer System.........................................................................................................15

4.9 THE SOLAR CHARGE CONTROLLER (OPTION)....................................................................................................15

4.10 THE MULTIFUNCTIONAL CONTACT..................................................................................................................16

4.11 THE TEMPERATURE SENSOR.............................................................................................................................16

5 The Remote Control ...............................................................................................................16

5.1 REMOTE CONTROL PLUG-IN..............................................................................................................................16

5.2 POWER MONITOR.............................................................................................................................................. 16

5.3 BATTERY CONDITION:......................................................................................................................................17

5.4 FAULT INDICATOR ............................................................................................................................................17

5.4.1 Overtemp. (10) ............................................................................................................................................17

5.4.2 Overload (11).............................................................................................................................................. 17

5.4.3 Battery low/high.......................................................................................................................................... 17

5.5 DEPORTED ALARM CONTACT AND ON/OFF CONTROL ........................................................................................17

5.6 MANUAL CONTROL OF THE AUXILIARY CONTACT ............................................................................................ 17

6 Programming:.........................................................................................................................17

6.1 STANDARD SETTING .........................................................................................................................................18

6.1.1 Battery voltage............................................................................................................................................18

6.1.2 Auxiliary contact.........................................................................................................................................18

6.2 RESET VALUE ...................................................................................................................................................18

6.3 BATTERY VOLTAGES AND ABSORPTION TIME: .................................................................................................. 18

6.3.1 Table of voltage and timing threshold.........................................................................................................18

6.3.2 Set the voltage and timing threshold...........................................................................................................18

6.4 PROGRAM THE AUXILIARY CONTACT ............................................................................................................... 19

6.4.1 Principle......................................................................................................................................................19

6.4.2 The programming of the Auxiliary Contact is carried out in the following Steps.......................................19

6.4.3 Example ......................................................................................................................................................19

6.5 DISABLING SOME OF THE XP-COMPACT FUNCTIONS..................................................................................... 20

6.5.1 Diagram of the different mode ....................................................................................................................20

7 Maintenance............................................................................................................................20

8 EC Compliance .......................................................................................................................20

9 Technical Data ........................................................................................................................21

User manual XP-COMPACT V2.0 E 2

STUDER INNOTEC

XP-COMPACT

1 General Information

1.1 Operating instructions

This manual is a part of the delivery package of every XP-COMPACT inverter-charger. It serves as
guidelines for safe and efficient operation of XP-COMPACT. The instructions are only valid for use
with the following appliances and options:

- XP-COMPACT XPC1112

- XP-COMPACT XPC1624

- XP-COMPACT XPC1648

- Temperature sensor CT-35

- Remote control RCC-01

- Solar charge controller. XPCxxxx-S

- AC cable cover CFC-01

- IP-23 top cover C-IP23

Every person who installs a XP-COMPACT and/or works with it must be fully familiar with the con­tents of this manual and must follow exactly all the warnings and safety instructions. Installation of
or any work on the XP-COMPACT must be carried out by a qualified and trained staff. Installation
and application must comply with the respective local installations codes and safety regulations.

1.2 Quality and Warranty

During production and assembling, all XP-COMPACT appliances go through many controls and
tests. Production, controls and tests are carried out in accordance with firm and established pro­cedures. Every XP-COMPACT has its own serial number, which helps to refer back to its original
data in the event of controls or repairs. That is why you should never remove the identification
plate showing the serial number. The production assembly and tests on all XP-COMPACT appli­ances are totally carried out in our company in Sion, Switzerland. The warranty for these appli­ances is valid for uses and operating possibilities mentioned in this manual.
The warranty period for the XP-COMPACT is 2 Years.

1.3 Warranty Disclaimer

We do not accept any responsibility for any damages occurring through use, manipulation, working
situation and handling, which are not explicitly mentioned in these operating instructions.
Following cases are not covered by the warranty:

• High voltage at INPUT (i.e. 48V at the Battery INPUT of XP-COMPACT 1112)

• Reverse polarity on Battery connections (+/- reversed)

• Running liquid or oxidation through condensation in the appliance

• Defects caused by force, physical or mechanical means

• Changes not explicitly authorized by STUDER INNOTEC

• Not or only partly tightened screws and nuts after change of fuses or connecting cables

• Connecting other sources of energy such as PV-Modules on the INPUT „SOLAR +/-„

• Transport damage, i.e. through bad handling and /or packing

• Damage from atmospheric overvoltage

1.4 Liability Disclaimer

Respecting this manual, servicing and method of installation, functioning, application and mainte­nance of the appliance can not be controlled or supervised by STUDER INNOTEC. Hence we do
not accept any liability and responsibility for damages, loses and costs which result through the
use of this appliance or which result through incorrect installation, incorrect operation or wrong
application and maintenance or which by some other means maybe connected together to these.
Similarly, we do not accept any responsibility for any violation of the patents rights or violation of
any third party’s rights resulting from the use of this appliance
STUDER INNOTEC reserves the right to modify the technical data or these operating instructions
without issuing any prior notice.

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XP-COMPACT

1.5 Precautions

This manual must be readily available for the user at all times. The user must be familiar with the
precautions and safety aspects.
During operation of XP-COMPACT, high voltages are generated at the connections and inside of
the appliance which could be deadly fatal. Work on the appliance and on the installation should
only be carried out by qualified and trained personnel.
The whole installation connected with the XP-COMPACT must comply with the respective valid
codes and ordinances.
Persons without the written authorization from STUDER INNOTEC are strictly forbidden to carry
out any changes or repairs on the appliances. For authorized changes only original parts are to be
used.
The XP-COMPACT may only be used when it has been installed in accordance with these instruc­tions and all parts have been correctly assembled and installed.
On the IN- and OUTPUT points of the XP-COMPACT only the already selected energy sources
and consumer appliances should be connected.
In order to carry out any maintenance or repair work on the XP-COMPACT without danger, all
connections must be disconnected beforehand.

Caution: Even when a XP-COMPACT has been disconnected from the all connections, at the

OUTPUT point there could still be deadly fatal voltages present. To remove these voltages
you must switch the XP-COMPACT ON with the ON/OFF switch. After one minute the elec-

tronics are discharged and any work can now be safely carried out.

The XP-COMPACT is only suitable for internal use and under no circumstances should it be sub­jected to snow, rain, or any other wet conditions
By installations in motorized vehicles the XP-COMPACT must be protected from water-spray and
any other wet conditions..
The XP-COMPACT may only be connected to lead –acid or lead-gel batteries.

Caution: In normal use lead-acid and lead-gel batteries give out explosive gases. Never smoke or
allow a spark or flame in the vicinity of batteries. The batteries must always be stored or placed in
a well ventilated area, they should be placed in such a way that there is no danger of short circuit­ing through carelessness. Never charge frozen batteries.

The XP-COMPACT is not to be used or sold for life support equipment or applications.

1.6 Special Precautions

While working on batteries there should always be a second person close to you or within your
voice range, in case help is needed.
Plenty of fresh water and soap must be ready at hand so that in case of acid coming in contact with
skin, eyes and clothes, the areas in question can be thoroughly washed.
If acid enters the eyes, you must thoroughly wash the eyes with cold running water for at least 15
minutes. It is recommended that you immediately consult a medical doctor.
Baking powder neutralizes battery acid electrolyte. Always keep some at hand.
Special care must be taken when working with metal tools near or on the batteries. With tools such
as screwdrivers, spanners etc. short-circuits can result. Sparks produced by the short-circuit can
cause an explosion.
When working on batteries all personal metal items such as rings, necklaces and bracelets must
be removed. Batteries are so powerful that short-circuit with these items can melt them and thus
cause severe burns. Always follow the battery manufacturer’s instructions.
Under certain conditions the XP-COMPACT or a connected generator can start automatically.
While working on an electrical installation you must ensure that these appliances are disconnected
beforehand from the installation.

User manual XP-COMPACT V2.0 E 4

STUDER INNOTEC

A

T

R

A

A

A

A

A

XP-COMPACT

2 Introduction

The XP-COMPACT is a sine wave inverter with integrated battery charger and solar charge con­troller with many additional functions, it has been developed to be used as stand-alone (no grid
feeding) AC provider, or as continuous / break-free current supply provider (UPS).

2.1 Principle schematic

C IN

C OUT

L

Output

PE

230Vac

N

UX. CONT

.

Input

230Vac

Battery

BATTERY

L

PE

N

150A

100nF

4x2,7M

1uF

10nF

10nF

Ω

Filter

Inverter
Charger

CT35

1uF

1uF

Temp. Sensor

Microprocessor,

SOLAR

Solarmodule

Max. 6m

Temp.

6p 8p

Control, Adjustment

RJ11

Remote control

Display

Max. 40m

Remote control

Remote control

INVERTER - CHARGE

RCC-01

COMPAC

TRANSFER

%

C OUT

AC IN

SOLAR CHARGE

EQUALIZE

Program

Contact active

Contact manual

AUXILIARY CONTACT ON/OFF

(Program) (C han ge sta tus )

160

130

INVERTERCHARGER

100

70

RESET

80

60

LARM

(Select)

60

50

40

40

20

30

Over Temp.

10

20

Overload

Battery

5

10
Ch

Low/High

Inv

arg

ert

er

er

OFF

2.2 Description of main functions

2.2.1 The inverter

The sinewave inverter built in the XP-COMPACT generates a sinusoidal AC voltage with an excep­tionally precise voltage and stabilized frequency. In order to start large electric motors, the user
has the possibility to employ a short-start-power which is 3-times the nominal power of the XP­COMPACT.
The inverter is protected against overload and short-circuits. A power stage with the latest MOS­FET power transistors, a toroidal transformer and a fast regulating system make-up a robust and
reliable inverter with highest efficiency. A 1-20 Watt adjustable charge detection system serves to
provide the smallest energy consumption and ensures a long life for the battery.

2.2.2 The transfer system

XP-COMPACT can be connected to an AC source, for example a stand-by emergency generator
or the AC network. With the transfer system, on one side you have an alternating voltage at the
output for use by the connected consumer appliances. On the other side the batteries are charged.
The distribution of energy between the consumer appliances and battery charger is automatic.

2.2.3 The battery charger

The built-in battery charger is so designed that it can charge the battery quickly and fully. A micro­processor controlled, 3 to 4 Step charging process ensures the optimum charging of the batteries.
The desired charging current can be set continuously from 0 to maximum, according with particular

User manual XP-COMPACT V2.0 E 5

STUDER INNOTEC

XP-COMPACT

technical specification (chap.6). The battery charger is meant for the lead-acid and lead-gel batter­ies. Thanks to the floating charge system the battery can remain continuously connected.

2.2.4 The solar charge controller (optional)

With the built-in solar charge controller, the XP-COMPACT is a complete solar-power-center. In a
solar installation this controller ensures that the batteries are charged correctly. With the XP­COMPACT, batteries can be charged with a generator and with the solar modules at the same
time. The charging of batteries with both energy sources is carried out fully automatically.

2.2.5 Remote control

As an option, a remote control can be connected to XP-COMPACT. Extra display and program­ming possibilities are available on the remote control (see Chap.5). The remote control is supplied
with a 20m long cable. This cable can go to 40m long. On the remote control output power and
charging current are also monitored.

2.3 Battery connections

Lead-acid batteries are normally available in blocks of 2V, 6V or 12V. In most cases, to generate
the necessary operating voltage and the capacity of the batteries for the XP-COMPACT many bat­teries have to be connected together in parallel and or in series. Following three examples are
shown:

2.3.1 Connection in parallel

12V 12V 12V

2.3.2 Connection in serie

2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V

12V

12V

24V

2V 2V 2V 2V 2V 2V

12V 12V 12V 12V

48V

User manual XP-COMPACT V2.0 E 6