Xantrex 815-3012, 815-2024, 815-3024, 815-2012 Installation Manual
TM
TM
This guide for use by qualified installers only.
Freedom SW
Sine Wave Inverter/Chargers
Installation Guide
FREEDOM SW 3012
FREEDOM SW 3012
FREEDOM SW
3012
FREEDOM SW 3012
CLEAR FAULT
RESET
INVERTER
ENABLE
INVERTER
ENABLED AC IN FAULT
GEN
SUPPORT
CHARGINGWARNING
CLEAR FAULT
RESET
INVERTER
ENABLE
INVERTER
ENABLED
AC IN
FAULT
GEN
SUPPORT
CHARGINGWARNING
Freedom SW 3012 shown.
Model Numbers
815-3012, 815-3024
815-2012, 815-2024
Freedom SW 3K2K InvChg Install Guide.book Page i Wednesday, October 12, 2011 4:40 PM
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97-0020-01-01 i
This guide for use by qualified installers only.
Trademarks
Xantrex and Smart choice for power are trademarks of Schneider Electric Services
International sprl, registered in the United Sates and other countries. Other
trademarks, registered trademarks, and product names are the property of their
respective owners and are used herein for identification purposes only.
Notice of Copyright
Freedom SW Sine Wave Inverter/Chargers Installation Guide © September 2011
Xantrex Technology USA Inc. All rights reserved . No part of this document may be
reproduced in any form or disclosed to third parties without the express written
consent of: Xantrex Technology USA Inc., 541 Roske Drive, Suite A, Elkhart,
Indiana, USA 46516. Xantrex Technology USA Inc. reserves the right to revise this
document and to periodically make changes to the content hereof without obligation
or organization of such revisions or changes unless required to do so by prior
arrangement.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY USA INC. (“XANTREX”)
(
A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(
B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER’S RISK; AND
(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 XANTREX CONTENT IS CONTAINED WITH THE
ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
September 2011 Rev A
T o view, download, or print the latest revision, visit the website shown under Contact
Information.
Document Part Number
97-0020-01-01
Product Numbers
815-2012 (Freedom SW 2012), 815-2024 (Freedom SW 2024)
815-3012 (Freedom SW 3012), 815-3024 (Freedom SW 3024)
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 408 987 6030 (direct)
Web: www.xantrex.com
Freedom SW 3K2K InvChg Install Guide.book Page i Wednesday, October 12, 2011 4:40 PM
ii Freedom SW Installation Guide
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for installing the Freedom SW Inverter/Charger.
Scope
The Guide provides safety and installation guidelines as well as information
on tools and wiring. It does not provide details abou t particular brands of
batteries. You need to consult individual battery manufacturers for this
information.
Audience
The guide is intended for qualified installers and technicians of the
Freedom SW Inverter/Charger.
Conventions Used
The following conventions are used in this guide.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions will result in death or serious
injury.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in death or serious
injury.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in minor or moderate
injury.
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97-0020-01-01 iii
This guide for use by qualified installers only.
Related Information
Y ou can find more information about Xantrex Technology USA Inc. as well
as its products and services at www.xantrex.com.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
IMPORTANT:
These notes describe things which are important for you to
know, however, they are not as serious as a caution or warning.
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iv Freedom SW Installation Guide
Important Safety Instructions
IMPORTANT: READ AND SAVE THIS INSTALLATION GUIDE FOR
FUTURE REFERENCE.
This chapter contains important safety and installation instructions for the
Freedom SW Inverter/Charger (Freedom SW). Each time, before using the
Freedom SW, READ ALL instructions and cautionary markings on or
provided with the inverter/char ger , the batteries, and all appropriate sections
of this guide.
NOTE: The Freedom SW contains no user-serviceable parts. See “Warranty
and Return Information” on the Owner’s Guide for guidance.
NOTE: Turning off the inverter/charger using the on/off switch on the front
panel will not reduce an electrical shock hazard.
ELECTRICAL SHOCK HAZARD
• Do not expose the Freedom SW to rain, snow, spray, or bilge water.
This inverter/charger is designed for marine applications only when
additional drip protection is installed in certain orientations. See the
installation guide for information.
• Do not operate the inverter/charger if it has received a sharp blow,
been dropped, has cracks or openings in the enclosure including if the
fuse 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
charged after all power is disconnected.
• Disconnect both AC and DC power from the inverter/charger before
attempting any maintenance or cleaning or working on any circuits
connected to the inverter/charger. See note below.
• 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.
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97-0020-01-01 v
This guide for use by qualified installers only.
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. Re view 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.
FIRE AND BURN HAZARD
• Do not cover or obstruct the air intake vent openings 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.
EXPLOSION HAZARD
• Charge only properly rated (such as 12 V) lead-acid (GEL, AGM,
Flooded, or lead-calcium) rechargeable batteries because other
battery types may explode and burst.
• Do not work in the vicinity of lead-acid batteries. Batteries generate
explosive gases during normal operation. See note #1.
• 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.
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vi Freedom SW Installation Guide
Precautions When Working With Batteries
NOTES:
1. Mount and place the Freedom SW Inverter/Charger unit away from
batteries in a well ventilated compartment.
2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
4. 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.
5. Use extra caution to reduce the risk or dropping a metal tool on the
battery. It could spark or short circ uit the battery or other electrical
parts and could cause an explosion.
6. 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.
7. 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.
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 watc hes
when working with batteries. See notes #5 and #6 below.
• Never 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.
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This guide for use by qualified installers only.
Precautions When Preparing to Charge
NOTES:
• 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.
Precautions When Placing the Inverter/Charger
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.
RISK OF DAMAGE TO THE INVERTER/CHARGER
• Never allow battery acid to drip on the inverter/charger when reading
gravity, or filling battery.
• Never place the Freedom SW 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.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
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viii Freedom SW Installation Guide
Regulatory
The Freedom SW Inverter/Charger is certified to appropriate US and
Canadian standards. For more information see “Regulatory Approvals” on
the Specifications section in the Owner’s Guide.
The Freedom SW 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.
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.
FCC Information to the User
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. Thes e limits
are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to
radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
LIMITATIONS ON USE
• Do not use in connection with life support systems or other medical
equipment or devices.
• Do not use in ambulances or other life-saving emergency vehicles.
Failure to follow these instructions can result in death or serious
injury.
Unauthorized changes or modifications to the equipment could void the
user’s authority to operate the equipment.
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This guide for use by qualified installers only.
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Before You Begin the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
About the Xanbus System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Xanbus System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Xanbus-enabled Products and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Planning the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Two Key Performance Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Size and Length of DC Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Mounting Location of the Freedom SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Planning Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AC, DC, and Network Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
AC Input for Single AC Line Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
AC Input for Dual AC Line Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
AC Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
AC Disconnect and Over-Current Protection Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Distribution Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
AC Output Neutral Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Contents
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DC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DC Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DC Disconnects and Over-Current Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
DC Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Unpacking and Inspecting the Freedom SW Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Installation Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Installing the Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Step 1: Choosing a Location for the Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Step 2: Mounting the Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Step 3: Connecting the AC Input and AC Output Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
General AC Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Connecting AC Input Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Connecting the AC Output Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Step 4: Connecting the DC Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
DC Connection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Recommended Cable Sizes and Lengths and Fuse Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Preparing the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Guidelines for Routing the DC Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Connecting the DC Cables to the Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
DC Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
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This guide for use by qualified installers only.
Step 5: Connecting the Battery Temperature Sensor (BTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mounting to the Negative Battery Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Mounting to the Side of the Battery Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Step 6: Connecting to the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Step 7: Performing Checks Prior to Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Step 8: Testing Your Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Testing in Invert Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Testing in Charge Mode and AC Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Installation Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Stacking Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Parallel Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Series Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Stacking Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Theory of Series Stacking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
DC Connections for Stacked Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Neutral Wiring for Stacked Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Configuring System for Stacked Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Search Mode in Series Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Search Mode Operation in Parallel Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Disabling Search Mode on the Master Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setting Search Mode on the Slave Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Freedom SW 3K2K InvChg Install Guide.book Page iii Wednesday, October 12, 2011 4:40 PM
Inverter/Charger Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Battery Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Battery Bank Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Estimating Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Calculating Battery Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Battery Banks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Battery Bank Sizing Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Restrictions on Motor Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Battery Cabling and Hook-up Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Battery Parallel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Battery Series Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Battery Series-Parallel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Freedom SW 3K2K InvChg Install Guide.book Page iv Wednesday, October 12, 2011 4:40 PM
97-0020-01-01 1
This guide for use by qualified installers only.
Introduction
The Installation Guide provides detailed information for installing the
Freedom SW 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 is a Xanbus-enabled device that typically powers the
Xanbus system.
This Installation Guide provides:
• safety instructions that must be observed during installation,
• a typical Xanbus system diagram (if applicable),
• information on additional required AC and DC components,
• a list of installation tools and materials, and
• detailed procedures for a typical installation.
Freedom SW 3K2K InvChg Install Guide.book Page 1 Wednesday, October 12, 2011 4:40 PM
2 Freedom SW Installation Guide
Introduction
Materials List
The Freedom SW ships with the following items:
• one Freedom SW unit,
• owner’s and installation guides,
• Battery Temperature Sensor (BTS),
• DC terminal covers (one red, one black) with two sets of screws,
• two Xanbus network terminators, and
• two sets of nuts and washers for the DC terminals.
NOTE: If any of the items are missing, contact Xantrex 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 for servicing.
Figure 1
Materials List
FREEDOM SW 3012
FREEDOM SW
3012
CLEAR FAULT
RESET
INVERTER
ENABLE
INVERTER
ENABLED AC IN
FAULT
GEN
SUPPORT
CHARGINGWARNING
BTS
DC terminal covers
with screws
nuts and washers
Freedom SW 3012 shown
Installation and
Owner’s Guides
Xanbus network
terminators
Freedom SW 3K2K InvChg Install Guide.book Page 2 Wednesday, October 12, 2011 4:40 PM
97-0020-01-01 3
This guide for use by qualified installers only.
Installation Information
Before You Begin the Installation
Before beginning your installation:
• Read the entire Installation Guide so you can plan the installation from
beginning to end.
• Assemble all the tools and materials you require for the installation.
• Review the Important Safety Instructions on page iv.
• Be aware of all safety and electrical codes which must be met.
Installation Codes
Applicable installation codes vary depending on the specific location and
application of the installation. Some examples are:
• The U.S. National Electrical Code (NEC),
• The Canadian Electrical Code (CEC),
• Canadian Standards Association (CSA) and RV Industry Association
(RVIA) for installation in RVs, and
• ABYC E11 - Alternating Current and Direct Current Electrical
Systems on Boats, and
• ABYC A31 - Battery Chargers and Inverters.
ELECTRICAL SHOCK AND FIRE HAZARDS
• All wiring should be done by qualified personnel to ensure
compliance with all applicable installation codes and regulations.
• Disconnect all AC and DC power sources.
• Disable and secure all AC and DC disconnect devices and automatic
generator starting devices.
Failure to follow these instructions will result in death or serious
injury.
Freedom SW 3K2K InvChg Install Guide.book Page 3 Wednesday, October 12, 2011 4:40 PM
4 Freedom SW Installation Guide
About the Xanbus System
Xanbus System
The Xanbus system includes the Freedom SW and other Xanbus-enabled
devices. The Freedom SW is the device in a Xanbus system that typically
provides network power—500 mA at 12 volts DC. All of the Xanbusenabled devices, such as the Freedom SW, the SCP, and the AGS are able to
communicate their settings and activity to each other.
Figure 2
Typical Xanbus System Diagram
Xanbus System Control Panel
Xanbus Automatic Generator Start
System Control Panel
network terminator network terminator
Automatic Generator Start
Freedom Sequence
Freedom SW Inverter/Charger
FREEDOMSW 3012
FREEDOM SW 3012
I
nv
e
r
t
er
Re
set Enable
I
nve
r
ter A
C/
On
C
ha
r
ge Fault
Generator
Shore
Power
AC Loads
AC Panel
BATTERY
Inverter
Load Panel
Freedom SW 3K2K InvChg Install Guide.book Page 4 Wednesday, October 12, 2011 4:40 PM
97-0020-01-01 5
About the Xanbus System
This guide for use by qualified installers only.
The Xanbus-enabled designation (see below) means that this product works
on a Xanbus network. Xanbus-enabled products are:
• Simple to operate and routine tasks are automated,
• Controlled by software that eliminates analog signalling errors,
• Less susceptible to interference and line loss, and
• Upgradable through new software releases.
For detailed instructions and a complete list of Xanbus-enabled devices,
visit www.xantrex.com
Xanbus-enabled Products and Accessories
Product/Accessory (Not Shown) Product Number/s
Freedom SW On/Off Switch 808-9002
GFCI receptacles 808-9003
Drip shields 808-9004
Stacking cable 808-9005
Product/Accessory (Shown above) Product Number/s
Freedom Sequence Intelligent Power Manager 809-0912 / 809-0913
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
XanbusSystem C ontrol Panel (SCP)
FGA:809-092 1
ACIn/Charge
InverterOn
LowBattery
Fault
STBY/ON
Fault Clea r
TM
Enter Func
Freedom
Sequence
SCP
AGS
25-ft cable 75-ft cable3-ft cable
Freedom SW 3K2K InvChg Install Guide.book Page 5 Wednesday, October 12, 2011 4:40 PM
6 Freedom SW Installation Guide
Planning the Installation
This section provides information to help you plan for a basic installation of
the Freedom SW.
As your system configuration is determined, record the detail s in
“Information About Your System” in the Freedom SW 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 Cab ling” on
page 16.
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 10 feet each and not of sufficient size, the voltage drop across the
cables will have a negative impact on overall system performance.
Mounting Location of the Freedom SW
To choose an appropriate location for mounting the inverter/charger, see
“Step 1: Choosing a Location for the Inverter/Charger” on page 21.
Freedom SW 3K2K InvChg Install Guide.book Page 6 Wednesday, October 12, 2011 4:40 PM
97-0020-01-01 7
This guide for use by qualified installers only.
Planning Preparations
AC, DC, and Network Components
For a successful installation, you need to plan for AC, DC, and network
components of the power system. The AC and DC components are
described in this section and illustrated in Figure 3 on page 8.
AC components include:
• AC Input for Dual AC Line Models,
AC Input for Single AC Line Models
•AC Loads
• AC Disconnect and Over-Current Protection Device
• Distribution Panels
•AC Wiring
• AC Output Neutral Bonding
DC components include:
• Batteries
• DC Cabling
• DC Cabling
• DC Grounding
Network considerations for Freedom SW only include:
• Cables, connectors, network connectors, and terminators for the SCP
and Automatic Generator Start, if installing.
Detailed information on planning and installing your network is
available in the Xanbus System Installation Guide. Refer to the system
guide to determine the type of network layout to install, as well as
guidelines for installing the network. This guide is available for
download at www.xantrex.com
Freedom SW 3K2K InvChg Install Guide.book Page 7 Wednesday, October 12, 2011 4:40 PM
8 Freedom SW Installation Guide
Planning Preparations
Figure 3
Typical Recreational Vehicle Electrical System
FREEDOM SW 3012
Inv
erter
R
eset Enable
In
ver
t
er
AC/
On
Cha
r
ge Fault
FREEDOM SW 3012
Non-Inverter Lo ads
Sine Wave
Inverter/Charger
System Control Panel (SCP) Automatic Generator Start (AGS)
Legend:
Xanbus Network
AC Out
DC +
DC –
House
Battery
BTS
Generator
Transfer Switch
AC In
AC Main
Panel
Inverter
AC Panel
Isolator
Engine Battery
Alternator
Utility Power
RESET
TEST
AC
DC
Low Voltage DC
DC Fuse
IMPORTANT:
Figure 3 does not show
all required grounding or overcurrent
protection. Always hire or you yourself
must be a qualified installer to ensure
that all electrical safety requirements are
met before, during, and after installation.
Freedom SW 3K2K InvChg Install Guide.book Page 8 Wednesday, October 12, 2011 4:40 PM
97-0020-01-01 9
Planning Preparations
This guide for use by qualified installers only.
Figure 4
Wiring and Breakers Block Diagram for Freedom SW 2012 / 2024
2012 and 2024
Inverter/Charger
120 V AC OUT
120 V AC IN
Battery (Bank)
12 or 24 V
4 AWG
†
150 A fuse
†††
2/0 AWG
†
275 A fuse
††
8 AWG Chassis GND*
10 AWG
10 AWG
HOT = BLACK
NEUTRAL = WHITE
GND = GREEN/Bare
HOT BUS
HOT BUS
TO AC APPLIANCE
LOADS
MAIN ELECTRICAL PANEL
FROM SHORE OR
GENERATOR POWER
OPTIONAL
GFCI duplex receptacle special kit
15 A output limit
HARDWIRE CONNECTIONS
20 A MAX in inverter
30 A MAX in pass-through
Neutral
GND
15 A
20 A
Neutral
GND
30 A
MAIN
* Recreational Vehicles only. For Marine applications see NOTE below.
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 16 AWG.
††
Class T or equivalent
Freedom SW 2012
†
In free air, as per NEC Table 310.17
for 75 C rated copper conductor.
†††
Class T or equivalent
Freedom SW 2024
IMPORTANT:
Read Owner’s and Installation Guides prior to installation.
Always refer to local and national
electrical codes for proper wire and
breaker sizes prior to installation.
Freedom SW 3K2K InvChg Install Guide.book Page 9 Wednesday, October 12, 2011 4:40 PM
10 Freedom SW Installation Guide
Planning Preparations
Figure 5
Wiring and Breakers Block Diagram for Freedom SW 3012 / 3024
3012 and 3024
Inverter/Charger
120 V AC OUT
120 V AC IN
Battery (Bank)
12 or 24 V
8 AWG Chassis GND*
10 AWG
6 AWG (Dual Input) / 10 AWG (Split phase)
HOT = BLACK
NEUTRAL = WHITE
GND = GREEN/Bare
HOT BUS
HOT BUS
TO AC APPLIANCE
LOADS
INVERTER AC SUB PANEL (TYPICAL)
MAIN ELECTRICAL PANEL
FROM SHORE OR
GENERATOR POWER
HARDWIRE CONNECTIONS
30 A MAX in inverter
30 A MAX in pass-through
Neutral
GND
30 A
Neutral
GND
30 A
30 A
MAIN
OPTIONAL
GFCI duplex receptacle special kit
15 A output limit
* Recreational Vehicles only. For Marine applications see NOTE below.
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 16 AWG.
1 AWG
†
200 A fuse
†††
4/0 AWG
†
350 A fuse
††
††
Class T or equivalent
Freedom SW 3012
†††
Class T or equivalent
Freedom SW 3024
†
In free air, as per NEC Table 310.17
for 75 C rated copper conductor.
IMPORTANT:
Read Owner’s and Installation Guides prior to installation.
Always refer to local and national
electrical codes for proper wire and
breaker sizes prior to installation.
Freedom SW 3K2K InvChg Install Guide.book Page 10 Wednesday, October 12, 2011 4:40 PM
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