Xantrex Auxiliary Load Module User Manual

Owner’s Manual

Auxiliary Load Module

About Xantrex

Xantrex Technology Inc., is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utilityscale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.

Trademarks

Trace and Xantrex are registered trademarks of Xantrex International.

Notice of Copyright

Disclaimer

While every precaution has been taken to ensure the accuracy of the contents of this guide, Xantrex International assumes no responsibility for errors or omissions. Note as well that specifications and product functionality may change without notice.

Since the use of this manual and the conditions or methods of installation, operation, use and maintenance of the unit are beyond the control of Xantrex Technology Inc., the company does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or any way connected with such installation, operation, use, or maintenance.

Due to continual improvement through product updates, photographs and/or illustrations used in this manual may not Technology Inc., reserves the right to update this product without notice or releasing an updated manual when

fit, form or function

exactly

match your unit. Xantrex

are not affected.

Date and Revision

September 2001, Revision A

Part Number

975-0027-01-01

Contact Information

Web: www.xantrex.com

Email: tracewarranty@traceengineering.com

Phone: 360/435.8826

Fax: 360/435.2229

P/N 975-0027-01-01 Rev A 09/01

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1.0 INTRODUCTION1.0 INTRODUCTION

1.0 INTRODUCTION

1.0 INTRODUCTION1.0 INTRODUCTION

Unpacking and Inspection ...................................................................................1

Controls and Indicators ........................................................................................2

Indicator LEDs ..................................................................................................2

AUX RELAY 9 LED........................................................................................2

AUX RELAY 10 LED......................................................................................2

INVERTER OPERATIONAL LED..................................................................2

Switches ............................................................................................................3

AUX RELAY Switch .......................................................................................3

INVERTER ERROR Switch ........................................................................... 3

Internal Components ............................................................................................4

Relays ....................................................................................................................4

Relay Connections.................................................................................................4

Relay Terminal Block ....................................................................................4

Ground Stud.................................................................................................5

Fuses ..................................................................................................................... 5

2.0 INST2.0 INST

2.0 INST

2.0 INST2.0 INST

3.0 OPERA3.0 OPERA

3.0 OPERA

3.0 OPERA3.0 OPERA

ALLAALLA

TIONTION

ALLA

TION

ALLAALLA

TIONTION

Tools Required ......................................................................................................7

Pre-Installation ......................................................................................................7

Mounting ...............................................................................................................8

Wiring .................................................................................................................. 10

Terminal Block Wiring .................................................................................... 10

RY 11 Error Indicator Wiring .............................................................................. 11

Communication Cable ........................................................................................ 12

Internal Sticker ....................................................................................................13

TIONTION

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TIONTION

Test Procedures ...................................................................................................15

Operation ............................................................................................................ 16

Active-High Type Relay ................................................................................... 16

Active-Low Type Relay .................................................................................... 16

ALM Applications ...............................................................................................16

Active-High Configurations ................................................................................ 17

High-Voltage Alarm ........................................................................................17

Battery Exhaust Fan Controller ...................................................................... 17

Exhaust Fan Electrical Wiring.........................................................................18

Simple Charge Controllers .............................................................................18

Photovoltaic Charge Controller ................................................................. 18

Over-Voltage Protection Using a Grid-Tie Inverter ...................................19

Active-Low Configurations..................................................................................20

DC Load Controller .........................................................................................20

Load Diversion Controller ..............................................................................20

Low-Voltage Alarm ......................................................................................... 21

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4.0 TROUBLESHOOTING4.0 TROUBLESHOOTING

4.0 TROUBLESHOOTING

4.0 TROUBLESHOOTING4.0 TROUBLESHOOTING

5.0 SERVICE INFORMA5.0 SERVICE INFORMA

5.0 SERVICE INFORMA

5.0 SERVICE INFORMA5.0 SERVICE INFORMA

6.0 WARRANTY6.0 WARRANTY

6.0 WARRANTY

6.0 WARRANTY6.0 WARRANTY

7.0 SPECIFICA7.0 SPECIFICA

7.0 SPECIFICA

7.0 SPECIFICA7.0 SPECIFICA

Electrical .............................................................................................................. 29

Mechanical ..........................................................................................................29

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1.0 INTRODUCTION

The Auxiliary Load Module (ALM) is an accessory for selected Trace™/Xantrex

inverter/charger models allowing battery voltage related tasks such as controlling charging sources, loads, etc., and inverter error indication. The unit contains three relays providing normally open (N.O.), normally closed (N.C.) and common (COM) contacts. Relays RY9 and RY10 are independently adjustable DC auxiliary signal relays. Relay RY11 is used to indicate an error condition (via an external indicator) whenever the inverter’s output is shutdown. This could be a bell, buzzer, light, etc.

The unit interfaces with the inverter through a phone-type cable. Commands

from the inverter control the relays when defined parameters (programmed via the inverter’s control device, e.g., display panel or remote control) are met. Refer to the inverter operator’s manual for setting the various parameters for operation.

Front panel LEDs provide a visual display of relay activity whenever a relay

contact receives an engage command from the inverter. A highly visible blue LED indicates the connected inverter is operational.

Unpacking and Inspection

Carefully inspect the contents of the shipping carton for damages. Report any

damages to the carrier immediately.

The following items are packed with the ALM:

• Auxiliary Load Module unit (ALM)

• 25-foot cable

• Operator’s manual

• Warranty Card Report any missing items to your dealer immediately.

Auxiliary Load Module (ALM)

P/N 975-0027-01-01 Rev A 09/01

Figure 1-1

1.0 INTRODUCTION

Controls and Indicators

Indicator LEDs

Three LEDs located on the front panel of the ALM indicate the relay control

signal status from the inverter.

NOTE: The LEDs are unaffected by the ALM’s switch positions or fuse condition.

AUX RELAY 9 LED

The yellow LED indicates whether relay RY9 has engaged or not. If this LED is

illuminated, the N.O. to COM contacts are connected. If this LED is not illuminated, the N.C. to COM contacts are connected.

AUX RELAY 10 LED

The green LED indicates whether relay RY10 has engaged or not. If this LED is

illuminated, the N.O. to COM contacts are connected. If this LED is not illuminated, the N.C. to COM contacts are connected.

INVERTER OPERATIONAL LED

The blue LED indicates the inverter’s operational status. If the inverter is

powered and ready for operation, the blue SYSTEM OPERATIONAL LED turns ON as soon as the phone-type cable is plugged into the inverter. If the blue LED does not turn ON, the inverter is either not powered, is set to the CHG-only mode without any utility pass-through, or has no AC output which may be caused by an error condition.

Yellow LED

AUX RELAY 9

Green LED

AUX RELAY 10

Blue LED

INVERTER OPERATIONAL

OFF = INVERTER ERROR

Figure 1-2

Indicator LEDs

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1.0 INTRODUCTION

Controls and Indicators (continued)

Switches

Two switches are provided on the right side of the ALM to effectively

disconnect the relay coils from the inverter’s supply voltage (11 VDC), thus preventing the relays from engaging if a control signal is sent out from the inverter. This safety feature allows you to work with the auxiliary relays without having to power-down the connected inverter.

AUX RELAY Switch

The AUX RELAY switch enables the relays by providing the operating voltage to

the relay coils RY9 and RY10. When the relays are enabled, they will respond to the control signals provided by the inverter. When the switch is in the RELAYS DISABLED position, the inverter control signals have no effect on relay operation (i.e., the COM and N.C. contacts engage). This switch does not affect the operation of the LEDs which continue to light whenever the inverter sends a CLOSE CONTACT command to the relays.

INVERTER ERROR Switch

The INVERTER ERROR switch provides a simple way to test an externally

connected alarm. Once the alarm is tested, this switch should be set to the RELAY READY position.

P/N 975-0027-01-01 Rev A 09/01

Figure 1-3

Switches

AUX RELAY Switch

(RY9 and RY10)

INVERTER ERROR

Switch (RY 11)

1.0 INTRODUCTION

Internal Components

The Auxiliary Load Module (ALM) is designed for multiple applications and

allows for simple installation. Components provided are listed below.

Relays

There are three single-pole, double-throw relays, rated at 10 amps/250 VAC

(8 amps/30 VDC–for resistive loads), with gold contacts providing “dry contact” closures to increase the low-end signal range.

• Relay RY9 and RY10 are used for battery voltage related functions.

• Relay RY11 can be connected to an external indicator device to display or

sound an alarm whenever the inverter AC output is lost.

• The common, normally open , and normally closed contacts are available on

each relay.

Relay Connections

• Common (COM) - The COM contact switches between the N.C. and N.O.

terminals depending on whether the relay is energized or not (de-energized).

• Normally Closed (N.C.) - The N.C. contact is connected to the COM terminal

of the relay when the relay is de-energized.

• Normally Open (N.O.) - The N.O. contact is connected to the COM terminal

of the relay when the relay is energized.

CAUTION: These relays are not intended to directly

control a load or charging source. Rather they are used to send a signal or operate the coil of another, higher amperage device which does the actual switching of power. A 6.3-amp fuse is included to help protect each of the relays. Connection to a high amperage device will open the fuse in the common line and possibly damage the relay. Damage to these relays from overloading is not covered by warranty and requires the ALM to be returned to a repair center.

Relay Terminal Block

Connections to the ALM are accomplished by the nine position, spring-clamp,

terminal block with quick connect levers. All relay contacts (N.O., COM, and N.C.) are available at this connector, which accepts wire sizes from #28 AWG to #14 AWG. No tools are required to secure the wires as the spring clamp holds the wires securely in place.

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1.0 INTRODUCTION

Internal Components (continued)

Ground Stud

A ground screw is provided in the ALM to provide a safety ground path when

hazardous voltages are connected to the relays. Connect this screw to a grounded conductor whenever high voltages (i.e., above 60 volts) are connected to the relays.

NOTE: No hazardous voltages are supplied from the inverter to power or control the relays; however, 120 VAC

could be used to power an external error indicator.

Fuses

Each relay’s common (COM) contact is protected with a 6.3 amp (5 mm x 20 mm) 250 VAC fuse which will open if excess current is drawn through the relay contacts. Always replace this fuse with the same type and rating. Type GDC (Bussman) or 218 (Littlefuse) is recommended.

NOTE: These fuses can be replaced with fuses to also protect the connected circuitry, if desired. In no no

no case, should this fuse be replaced with one of a

no no amperage.

F1 protects

RY 9

Communication jack

GROUNDING screw

F2 protects

RY 10

Figure 1-4

Internal Components

lower lower

lower amperage

lower lower

higherhigher

higher

higherhigher

F3 protects

Terminal Block

RY 11

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1.0 INTRODUCTION

Notes:

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2.0 INSTALLATION

The ALM is required to be installed in a clean, dry, protected environment and

should be mounted close to the load in a location where it is easily accessible. Dual knockouts, in the sizes of ½, ¾ and 1 inch, are provided for cable routing and conduit connections. Mount the ALM to a flat, vertical surface, such as a wall.

Tools Required

screwdrivers (Phillips and flat blade) wood screws (#10) drill and assorted bits anchors (if required) wire strippers

WARNING: BEFORE MAKING ANY CONNECTIONS TO THE LOAD OR INVERTER, ENSURE THAT ALL AC AND DC POWER IS DISCONNECTED FROM THE INVERTER AND THE ALM.

Pre-Installation

Before installing the ALM, read all instructions and cautionary markings

located in this manual.

Determine the wire route (or conduit runs) to the ALM and loads.

NOTE: Check for existing electrical, plumbing, or other potential areas of accidental damage prior to making cuts in structural surfaces.

6-9/64

4-27/32

1-13/64

19/32

Dimensional Drawing (Not to Scale)

P/N 975-0027-01-01 Rev A 09/01

19/32

SW1

SW2

3-11/16

4-7/8

Figure 2-1

+ 25 hidden pages

Xantrex Auxiliary Load Module User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 INTRODUCTION

Unpacking and Inspection

Controls and Indicators

Indicator LEDs

AUX RELAY 9 LED

AUX RELAY 10 LED

INVERTER OPERATIONAL LED

Switches

AUX RELAY Switch

INVERTER ERROR Switch

Internal Components

Relays

Relay Connections

Relay Terminal Block

Ground Stud

Fuses

2.0 INSTALLATION

Tools Required

Pre-Installation