Xantrex CR1012E, CR1012, CR1024E, CR1024, CR1512E User Guide

Xantrex CR Series

e

Backup System
Inverter ⁄ Charger

CR 1012E CR1012
CR 1024E CR1024
CR 1512E CR1512
CR 1524E CR1524
CR 2412E CR2412
CR 2424E CR2424

User Guide

Manu al Typ

Contents

Important Safety In str uctions
1

Introduction

CR Series Function and Operation - - - - - - - - - - - - - - - - - - - - - 7
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

AC End- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
DC End- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

2

Installation

CR Series Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Mounting on Wallboard- - - - - - - - - - - - - - - - - - - - - - - - - 11

Mounting on Other Types of Walls - - - - - - - - - - - - - - - - - 14
Battery Cable Connection - - - - - - - - - - - - - - - - - - - - - - - - - - 14
DC Disconnect and Over-Current Protection - - - - - - - - - - - - - 17
AC Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

3

Operation

Front Panel Controls and LED Indicators - - - - - - - - - - - - - - - - 21

Power On/Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

AC Mode LED- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

Battery Mode LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Charger LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Failed (Fault) LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Battery Bank Capacity- - - - - - - - - - - - - - - - - - - - - - - - - - 22

Audible Alarm (internal) - - - - - - - - - - - - - - - - - - - - - - - - 22

Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

RS232 Communications - - - - - - - - - - - - - - - - - - - - - - - - 23

- - - - - - - - - - - - - - - - - - - -iii

A

Specifications

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Warran ty I nfo rma tion

- - - - - - - - - - - - - - - - - - - - - - - - - - 29

i

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics
and controls with products from 50 watt mobile units to one MW utility-scale
systems for wind, solar, batte r ies, fuel cells, microturbines, and backup power
applications in both grid-connected and stand-alone systems. Xantrex products
include inverters, battery chargers, programmable power s upplies, and variable
speed drives that convert, supply, control, clean, and dist ribute electric al power.

T rademarks

Xantrex CR Series Bac kup S ystem Inverter ⁄ Charger is a trademark of Xantrex
Intern ational. Xantrex is a registered trademark of Xantrex International.

Other trademar ks, r egistere d trad emark s, and pro duc t names ar e t he prope rty of t heir
respective owners and are used herein for identification purposes only.

Notice of Copyright

Xantrex CR Se ries Backup Syste m Inve rter ⁄ Charger User Guide © September 2005
Xantrex International. All rights reserve d.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.
(“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
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.

Date and Revision

September 2005 Revision B

Part Number

975-0252-01-01

Contact Inform a tion

Telephone: [phone] (Europe)

1 360 925 5097 (Direct North America and rest of world)

Fax: [phone] (Europe)

1 360 925 5143 (Direct North America and rest of world)

Email: support.eur [e-mail] (Europe)

[e-mail] (North America and rest of world)

Web: www.xantrex.com

ii 975-0252-01-01

Important Safety Instructions

WARNING

This chapter conta ins important safety and operating instructions.
Read and keep this User Guide for future referenc e.

READ AND SAVE THESE INSTRUCTIONS
Before using the Xantrex CR Series Backup System

Inverter ⁄ Charger (CR Series), read and obey all instructio ns
and cautionary markings on the CR Series, the batteries, and
in all sections of this inst ruction manual.

WARNING

The following warnings identify conditions or practices that could
lead to injury or loss of life

1. To reduce risk of fire and electric shock, Xantrex
recommends that all wiring be done by a qualified
electricia n to ensu re adh er en ce t o the local and national
electrical code s applicable in your application.

2. To reduce risk of injury and damage, charge only deep­cycle lead acid type rechargeable batteries. Other types of
batteries may burst, causing personal injury and damage.

3. To reduce risk of shock or fire, do not disassemble the
CR Series. It contains no user-serviceable parts and
internal capacitors remain charged after all power is
disconnected. Take it to a qualified service center when
service or repair is required. Incorrect re-assembly may
result in risk of shock or fire.

4. To reduce risk of electric shock, disconnect all AC and
DC sources before attempting any maintenance or
cleaning. Turning off the CR Series will not reduce this
risk.

iii

Safety

5. To reduce risk of fire and electric shock, make sure that
existing wiring is in good condition and that wire is not
undersized. Do not operate the CR Series with damaged
or substandard wiring.

6. EXPLOSION HAZARD WORKING IN VICINITY OF
A LEAD ACID BATTER Y IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL OPERATION. Provide ventilation
to outdoors from the battery compartment. The battery
enclosure should be desig ned to prev ent accumulation
and concentratio n of hydrogen gas in "poc kets" at the top
of the compartment. Vent the battery compartment from
the highest point. A sloped lid can also be used to direct
the flow to the vent opening location. Follow the
instructions in this manual and those of the battery
manufacturer regarding charging and ventilation.

7. EXPLOSION HAZARD: This equipment contains
components which tend to produce arcs or can spark. To
prevent fire or explosi on, do not install the CR Series in
compartments containing batteries or flammable
materials or in locations that require ignition-protected
equipment. This includes any space containing gasoline­powered machiner y, fuel tanks, or joints , fi tting s, or other
connectio ns bet ween compone nts of the fuel sys tem.

8. Do not operate the inverter/charger if it has received a
sharp blow, been dropped, or otherwise damaged in any
way . If the unit is damage d, see the Warranty information
elsewhere in this manual.

9. To reduce risk of shock hazard and damage, do not
expose the CR Series to r ain, snow or li quids of a ny type.
The CR Series is designed for indoor mounting only.
Protect the CR Series from splashing if used in vehicle
applications.

10. The inverter/charger must be properly grounded and
provided with AC and DC disconnects and overcurr ent
protection as speci fied in this manual and in accordance
with appli cable electrical codes.

iv

Safety

11. Be extra cautious when working with metal tools on, or
around batteries . The pot ential exists to drop a tool and
short-circuit the batteries or other electrical parts
resulting in sparks that could cause an explosion.

WARNING

Obey the following pe rsonal precautions while working with and
charging batteries. These warnings concern condit ions or practices
that could lead to injury or loss of life.

1. Someone should be within range of your voice to come to
your aid when you work near batteries.

2. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, or e yes.

3. Wear complete eye protection and clothing protection.
Avoid touching eyes while working near batteries. Wash
your hands when done.

4. If battery acid contacts skin or clothing, wash
immediat ely with so ap and wat er. If acid enters ey es,
immediately flood eyes wit h running cool water for at
least 15 minutes and get medical attention immediately.
Baking soda neutralize s lead acid ba ttery electrolyte.
Keep a supply on hand in the area of the batteries

5. NEVER smoke or allow a spark or flame in vicinity of a
battery or generator.

6. Be extra cautious when working with metal tools on, and
around batteries . Pot ential exists to short-circuit the
batteries or other electrical parts which may result in a
spark which could cause an explosion.

7. Remove personal metal items such as rings, bracelets,
necklaces, and wa tches when working with a battery. A
battery can pr oduce a s hort-ci rcuit c urrent high enough t o
weld a ring, or the like, to metal causi ng severe burns.

v

Safety

CAUTION

The following cautions identify cond itions or practice s that could
result in damage to the inverter/charger or other equipment

1. To reduce the risk of overheating, keep the ventilation
openings clear and do not install the CR Series in a
com partment with limited a i r flow. Maintain adequ ate
clearance around the sides of the unit. Refer to the
installation instructions in this manual.

2. Never charge a frozen battery.

vi

Introduction

1

CR Serie s Function and Operation

The following sections describe important aspects of the
Xantrex CR Series Backup System Inverter ⁄ Charger (CR
Series) operati on. Rea d this to understand how the CR Series
functions.

Inverter to Charger Transition

The internal battery charger and automatic transfer relay allow
the unit to operate as either a battery charger or inverter (but
not both at the same time). The CR Series automatic ally
becomes a battery charger whenever AC power is supplied to
its AC input, while also passing the incoming AC power
through to the loads on the CR Series' AC output (load)
terminals.

Charger Terminology

Constant current stage During this stage of the charge

cycle, the batteries are charged at a constant current, ensuring
rapid replacement of most of the bat tery's charge.

Constant voltage stage During this stage of the ch arge
cycle, the batteries are held at a constant voltage and accept
whatever current is required to maintain this voltage. This
stage ensures replacement of the remaining charge not replaced
during the constant curre nt sta ge, while preventing the
batteries from being over-charged.

7

Introduction

Transfer Switching Speed

While the CR Series is not designed speci ficall y to operate as
an uninterruptib le power supply system (UPS), its transfer
time is normally fast enough to maint ain the power for
computers. The relay transf er time is a maximum of 20
milliseconds.

2 Stage Operation

The CR Series is a simple 2 stage charger which holds the
voltage steady (flo at) afte r charging. Both the charging and
float voltage are 13.5 VDC (for 12 V models) and 27 VDC
(for 24 V model s).

CAUTION

To avoid damage to your batteries, ensure that your batteries are
rated to withs tand the constant float voltage.

8

Features

The following sections illustr ate the features of the CR
Series. Figure 1-1 shows the features of the front side of the
CR Series and identifies the AC end from the DC end.

Features

DC End

Battery Connec tions

Figure 1-1

Front Panel Features

Front Panel LED

Indicators

AC End

9