Xantrex DR1512, DR2412, DR1524, DR2424, DR3624 User Manual



DR Series

Inverter/Charger

Installation & Operators Manual

DR Series

Inverter/Charger

Table of Contents

Section Description Page

1.0 INTRODUCTION ..........................................................................1

Unpacking and Inspection................................................... 2

Model Identification and Numbering Conventions ............ 3

Certification .......................................................................... 4

2.0 INSTALLATION............................................................................ 5

Features ............................................................................ 5

Modified Sine Wave Power ........................................... 5

Battery Charger/AC Transfer Relay .............................. 5

Simplicity ........................................................................ 5

High Efficiency ............................................................... 5

Low Power Consumption ............................................. 5

Options ............................................................................ 5

RC4/RC8 ......................................................................... 5

DRI ............................................................................ 5

DRCB ............................................................................ 5

Pre-installation ..................................................................... 6

Location .......................................................................... 6

Mounting......................................................................... 6

Ventilation....................................................................... 6

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

Hardware/Materials Required ....................................... 7

Wiring ............................................................................ 7

AC Connections ............................................................. 7

DC Connections ............................................................. 7

Grounding ...................................................................... 7

AC Grounding .......................................................... 7

DC Grounding .......................................................... 7

Batteries ............................................................................ 8

Battery Location ............................................................ 8

Battery Temperature ...................................................... 8

Main Service Panel ............................................................... 10

Sub-Panel ............................................................................ 10

AC Circuit Breakers ............................................................. 10

DC Disconnect ...................................................................... 10

Wire Routing ......................................................................... 10

Inverter Mounting ................................................................. 11

Wiring ............................................................................ 13

DC Wiring (Batteries) ..................................................... 13

Battery Cable Sizing ...................................................... 13

DC Disconnect and Over-current Protection .............. 14

Battery Cable Connections ...........................................15

Battery Bank Sizing ....................................................... 16

Battery Types ................................................................. 16

Battery Configuration .................................................... 16

SERIES ..................................................................... 16

PARALLEL ............................................................... 16

SERIES-PARALLEL ................................................. 16

Continued

Section Description Page

2.0 INSTALLATION (continued)

Wiring the Batteries in Series ............................................. 17

Wiring the Batteries in Parallel ..................................... 18

Wiring the Batteries in Series-parallel ......................... 18

Series/Parallel Configurations and Cross-Tying .........20

Installation Guidelines ......................................................... 22

DC Circuit Grounding .......................................................... 23

General DC Grounding Requirements ......................... 23

Installing the Battery Temperature Sensor ........................ 24

Installing the Sensor...................................................... 24

AC Wiring ............................................................................ 25

Sub-panel and Conduit Installation .............................. 25

Input to the Inverter .......................................................25

AC Input Wiring to the Inverter ..................................... 27

AC Output Wiring to the Sub-panel .............................. 28

AC Input Wiring to the Utility Breaker Box ..................29

Generators ............................................................................ 30

Generator Requirements ............................................... 30

Basic 120 VAC Generator Hookup

(non-utility applications only) ................................ 31

Basic 120 VAC Utility/Generator Hookup..................... 32

Generator Connections

(to manual bypass switch) ............................... 32

Utility Connections (to manual bypass switch) .... 32

Inverter Connections

(to manual bypass switch) ............................... 32

Sub-panel Connections .......................................... 32

Series Stacking..................................................................... 34

3.0 OPERATION ............................................................................ 36

Front Panel Controls and Indicators .................................. 36

Power ON/OFF Switch ................................................... 36

Ports ............................................................................36

COM Port ........................................................................ 36

Remote Controls ..................................................... 36

Stacking Interface ................................................... 36

Battery Sense Port ......................................................... 37

Controls .......................................................................... 38

DC Controls ............................................................. 38

Battery Type Selector ....................................... 38

Switch Positions ............................................... 38

0 and 1Equalize 1 and 2.................................. 38

2Deep Cycle Lead Acid 2................................ 38

3Not Specified ................................................. 38

4GEL Cell 2 ...................................................... 39

5GEL Cell 1 ...................................................... 39

6PbCa - Lead Calcium .................................... 39

7Deep Cycle Lead Acid................................... 39

8NiCad 1 .......................................................... 39

NiCad 2 .............................................................. 39

SEARCH MODE WATTS Potentiometer ....................... 40

Battery Charger Rate ..................................................... 41

Over Discharge Protection/AC Transfer Voltage......... 42

Over Discharge Protection (ODP) ..........................42

AC Transfer Voltage ................................................ 43

Continued

Section Description Page

3.0 OPERATION (continued)

Battery Capacity............................................................. 45

LED Indicators ............................................................... 46

Inverter Mode LED - Green ..................................... 46

Over Temp LED - Red/Green .................................. 46

Battery Hi/Battery Low LED - Red/Green .............. 47

Charger LED - Orange/Green ................................. 47

Audible Indicator ........................................................... 47

Circuit Breakers .............................................................48

Start-up ............................................................................ 49

Charger Mode .......................................................................50

3-Stage Charging Process ............................................ 50

Bulk Charge ............................................................. 50

Absorption Charge .................................................. 50

Float Charge ............................................................ 50

Equalize Charging ......................................................... 51

Setting the Equalize Charge ................................... 51

4.0 TROUBLESHOOTING ................................................................. 53

5.0 APPENDIX ............................................................................ 55

Batteries ............................................................................ 55

Selection of a Battery Type ................................................. 55

Flooded Lead Acid (FLA) .............................................. 55

RV and Marine ......................................................... 55

Golf Cart ................................................................... 55

Industrial (electric forklift) ......................................55

Sealed Batteries ............................................................. 55

Gel Cell ..................................................................... 55

Absorbed Glass Mat ................................................ 55

NiCad and NiFe Batteries .............................................. 56

Battery Bank Sizing ............................................................. 57

Estimating Battery Requirements ................................ 57

Example ................................................................... 58

Typical Appliance Wattages ................................................ 60

Battery Care and Maintenance ............................................ 61

Charge Rate ................................................................... 61

Bulk Charge ................................................................... 61

Float Voltage................................................................... 61

Temperature Compensation ......................................... 61

Equalization Charging ................................................... 61

Replenish Water Levels................................................. 62

Clean Battery Cables and Posts ................................... 62

Torque Battery Connections ......................................... 62

Check Battery State of Charge ..................................... 63

Problem Loads ..................................................................... 64

Multiwire Branch Circuits .................................................... 66

Identifying Multiwire Branch Circuits .......................... 67

Correcting Multiwire Branch Circuit Wiring ................ 68

6.0 LIMITED WARRANTY ................................................................. 69

7.0 SERVICE INFORMATION ............................................................71

8.0 SPECIFICATIONS ........................................................................ 72

iii

Disclaimer of Liability

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.

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation

and maintenance of this product.

To reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.

WARNING - A dangerous voltage or condition exists in this area. Use extreme caution when performing these tasks.

AVERTISSEMENT - Une tension ou condition dangereuse existe dans cette zone. Faire preuve dextrême prudence lors de la réalisation de ces tâches.

CAUTION - This procedure is critical to the safe installation or operation of the unit. Follow these instructions closely.

ATTENTION - Cette procédure est essentielle à linstallation ou lutilisation de lunité en toute sécurité. Suivre ces instructions de près.

NOTE - This statement is important. Follow instructions closely.

NOTE - Cette déclaration est importante. Suivre les instructions de près.

All electrical work must be done in accordance with local, national and/or international electrical

codes.

Before installing or using this device, read all instructions and cautionary markings located in (or

on) the manual, the inverter, the controller, the batteries and the PV array.

Do not expose this unit to rain, snow or liquids of any type. This product is designed only for

indoor installation.

To reduce the chance of short-circuits when installing or working with the inverter, the batteries

or the PV array, use insulated tools.

Remove all jewelry such as rings, bracelets, necklaces, etc., prior to installing this system. This

will greatly reduce the chance of accidental exposure to live circuits.

The inverter contains more than one live circuit (batteries and AC line). Power may be present

at more than one source.

This product contains no user serviceable parts. Do not attempt to repair this unit.

Do not install 120 volt AC stand-alone inverters onto 120/240 volt AC multi-branch circuit wiring.

This could pose a fire hazard due to an overloaded neutral return wire in this configuration.

SAVE THESE INSTRUCTIONS

BATTERY SAFETY INFORMATION

Always wear eye protection, such as safety glasses, when working with batteries.

Remove all loose jewelry before working with batteries.

Never work alone. Have someone assist you with the installation or be close enough to come to your aid when working with batteries.

Always use proper lifting techniques when handling batteries.

Always use identical types of batteries.

Never install old or untested batteries. Check each batterys date code or label to ensure age and type.

Batteries are temperature sensitive. For optimum performance, they should be installed in a stable temperature environment.

Batteries should be installed in a well vented area to prevent the possible buildup of explosive gasses. If the batteries are installed inside an enclosure, vent its highest point to the outdoors.

When installing batteries, allow at least 1 inch of air space between batteries to promote cooling and ventilation.

NEVER smoke in the vicinity of a battery or generator.

Always connect the batteries first, then connect the cables to the inverter or controller. This will greatly reduce the chance of spark in the vicinity of the batteries.

Use insulated tools when working with batteries.

When connecting batteries, always verify proper voltage and polarity.

Do not short-circuit battery cables. Fire or explosion can occur.

In the event of exposure to battery electrolyte, wash the area with soap and water. If acid enters the eyes, flood them with running cold water for at least 15 minutes and get immediate medical attention.

Always recycle old batteries. Contact your local recycling center for proper disposal information.

1.0 INTRODUCTION

Thank you for purchasing the DR Series inverter/charger from Xantrex Technology Inc. The DR Series is one of the finest inverter/chargers on the market today, incorporating state-of-the-art technology and high reliability. The inverter features an AC pass-through circuit, powering your home appliances from utility or generator power while charging the batteries. When utility power fails, the battery backup system keeps your appliances powered until utility power is restored. Internal protection circuits prevent over-discharge of the batteries by shutting down the inverter when a low battery condition occurs. When utility or generator power is restored, the inverter transfers to the AC source and recharges the batteries.

The front panel features LEDs for reading system status, and controls to customize the inverter

settings for your battery bank.

Figure 1

The DR Series Inverter/Charger

1.0 INTRODUCTION

Unpacking and Inspection

 Carefully unpack the inverter/charger from its shipping carton.

NOTE: The unit weighs 3545 lb/15.920.4 kg (depending on model). Have additional help available if necessary, to assist in lifting the unit during installation.

 Verify all of the items listed on the packing material sheet are present. Please call Xantrex

Customer Service at (360) 435-8826 if any items are missing.

 Save your proof-of-purchase. This is required if the unit should require warranty service.

 Save the original shipping carton and packing materials! If the inverter ever needs to be returned

for service, it should be shipped in the original carton. This is also a good way to protect the inverter if it ever needs to be moved.

 Record the units model, serial number and date of purchase in the appropriate fields in section

10.0 SERVICE INFORMATION.

NOTE: Due to continual improvement through product updates, photographs and/or illustrations used in this manual may not exactly match your unit. Xantrex Technology Inc. reserves the right to update this product without notice or releasing an updated manual when fit, form or function are not affected.

1.0 INTRODUCTION

Model Identification and Numbering Conventions

The DR Series inverter/charger is identified by the model/serial number label located next to the AC access cover. All the necessary information is provided on the label such as AC output voltage, power and frequency (punch holes).

The inverter also has a letter designator followed by 4 or 5 digits (depending on revision). The model number describes the type of inverter, the output specifications, the required battery voltage and the output voltage and frequency.

DR indicates the type of inverter/charger - DR Series.

15 the first two digits of the numerical designator indicate the inverters output power - 1500

Watts.

12 the second two digits indicate the required nominal battery bank voltage - 12 VDC.

E the letter suffix code indicates the output voltage and frequency of the inverter - 230

VAC/50 Hz.

Product Family

Example: DR 1512 E

Output Power

Letter Suffix Output Voltage Output Frequency

(no letter) 120 VAC 60 Hz E 230 VAC 50 Hz J 105 VAC 50 Hz K 105 VAC 60 Hz W 220 VAC 60 Hz

Figure 2

Product Identification

Country Code

Battery Voltage

Figure 3

Model/Serial Number Sticker

1.0 INTRODUCTION

Certification

120 VAC/60 Hz models of the DR Series inverter/charger models are listed to UL Standard 1741, Power Conditioning Units for use in Residential and Commercial Photovoltaic Power Systems. These units are also ETL listed to CAN/CSA-22.2, No. 107.1-M91, the Canadian safety standard. These standards guarantee that the inverter/charger has been tested to nationally recognized safety standards (UL for the US and CSA for Canada) and have been found to be free from reasonably foreseeable risk of fire, electric shock and related hazards.

The inverter/charger is intended to be used for residential or commercial applications. Do NOT use this unit for applications for which it is not listed (i.e., land vehicles or marine craft). It may not comply with the safety code requirements, or could possibly present other operational or safety hazards.

Figure 4

UL/CSA Certification Sticker

Certification Sticker

2.0 INSTALLATION

The DR Series inverter/charger is an economical product designed to provide a reliable supply of electricity to all the essential circuits in the home or business during a power outage. The critical loads can be powered for hours or days, depending on the size of the system battery bank. When utility grid power returns, the batteries are quickly recharged to ensure they will be ready to supply backup power during the next outage.

Accessories allow the DR Series to also serve as a central hub of a renewable energy system.

Features

 Modified Sine Wave Power

The DR Series inverters provide a modified sine wave output which operates most AC appliances

and equipment.

 Battery Charger/AC Transfer Relay

The inverter/charger includes a 3-stage battery charger designed to recharge any type of battery

in the shortest possible time. The built-in, fully automatic AC transfer relay automatically transfers

power from the utility to the inverter and handles a full 60 amps of current at 120 VAC (30 amps

for pass-through plus 30 amps for charging).

 Simplicity

The DR Series is simple to operate. All inverter and battery charger controls are located on the

front panel.

 High Efficiency

The inverter/charger operates at over 90% efficiency through most of its power range.

 Low Power Consumption

DR Series inverters use extremely low current while in the search mode, consuming little more

than one watt of power. In the ON mode, the inverter/charger uses less than 20 watts of power.

Options

The following options are available for the DR Series inverter/chargers:

 RC4/RC8

The RC4/RC8 allows the inverter to be switched ON or OFF remotely and includes an LED status

indicator.

 DRI

The DRI stacking interface provides 3-wire 120/240 VAC at twice the power using dual DR Series

inverters (120 VAC/60 Hz units only).

 DRCB

The DRCB conduit box connects to the DC side of the inverter and accepts a DC conduit run.

2.0 INSTALLATION

Pre-installation

NOTE: Before installing the inverter/charger, read all instructions and cautionary markings located in this manual.

NOTE: The inverter/charger can weigh up to 45 lb. (20.4 kg) depending upon configuration. Always use proper lifting techniques during installation to prevent personal injury.

Location

 Inverters contain sophisticated electronic components and should be located in a well

protected, dry environment away from sources of fluctuating or extreme temperatures and moisture. Exposure to saltwater is particularly destructive and potentially hazardous.

NOTE: If the inverter is installed in a location where it is exposed to a corrosive or condensing environment, and fails due to corrosion, it will not be covered under warranty.

 Locate the inverter as close to the batteries as possible in order to keep the battery cable

length short. However, do not locate the inverter above the batteries or in the same compartment as vented batteries. Batteries generate hydrogen sulfide gas which is corrosive to electronic equipment. They also generate hydrogen and oxygen. If accumulated, an arc caused by connecting the battery cables or switching a relay could ignite this mixture. Mounting the inverter in a ventilated enclosure with sealed batteries is acceptable.

NOTE: Inverters can generate RFI (Radio Frequency Interference). Locate any sensitive electronic equipment susceptible to RFI as far away from the inverter as possible. This includes radios and TVs.

Mounting

 UL Standard 1741 requires the inverter be mounted on a vertical surface (or wall). The

keyhole slots must not be used as the only method of mounting. The purpose of the wall mounting requirement is to orient the inverter so that its bottom cover, which has no holes, will not allow burning material to be ejected in the event of an internal fire. Use 0.25 inch diameter bolts for mounting. The mounting surface must be capable of supporting twice the weight of the inverter to comply with UL 1741.

Ventilation

 Install the inverter in a well ventilated area/enclosure for proper operation. The inverters

thermal shutdown point will be reached sooner than normal in a poorly ventilated environment, resulting in reduced peak power output and surge capability, as well as shorter inverter life.

 The inverter contains an internal fan. Ensure the air vents and intakes are not obstructed in

any way. Provide a minimum clearance of 1-1/2 inches around the top and sides of the inverter for ventilation.

2.0 INSTALLATION

Pre-Installation (continued)

Tools required:

#2 Phillips screw driver Level Slotted screw driver Wire strippers Assorted open-end wrenches Torque wrench Socket wrench and fittings Electrical tape Multimeter (True rms) Pencil Hole saw Utility knife

Hardware / Materials required:

4 ft. x 4 ft. sheet of 3/4" plywood or 2 x 4s studding material #12 wood screws (or 1/2" x 1-1/4" lag bolts) Conduit and appropriate fittings Wire nuts

Wiring:

 All wiring and installation methods should conform to applicable electrical and building codes.

 Pre-plan the wire and conduit runs. The AC circuits accept cable sizes up to #6 AWG. The DC

circuits accept cable sizes up to #4/0 AWG.

 For maximum safety, run both AC and DC cables in conduit.

 Refer to the Figure 25 (page 29) for an example of AC wiring to the sub-panel for 120 VAC

circuits.

AC Connections:

 Use #6 AWG THHN wire for all AC wiring.

DC Connections:

 Battery to inverter cabling should be only as long as required. If #4/0 AWG cables are used

for example, do not exceed 5 feet (one way) in 12 VDC systems; do not exceed 10 feet (one way) in 24 VDC systems. For optimum performance, use pre-assembled battery cables designed specifically for this application (available from Xantrex).

Grounding:

AC Grounding

 The inverter/charger should be connected to a grounded, permanent wiring system. Neutral

and ground conductors should only be bonded at the main utility service panel.

DC Grounding

 The negative battery conductor should be bonded to the grounding system at only one point

in the system. The size for the conductor is usually based on the size of the largest conductor in the DC system.

2.0 INSTALLATION

Pre-Installation (continued)

Batteries:

 The battery voltage MUST match the voltage requirements of the inverter. To determine the

correct voltage for the system, check the last two digits on the inverters model number. For example, the DR1512 is a 12 volt inverter and requires a 12 VDC battery system. The DR2424 is a 24 volt inverter and requires a 24 VDC battery system.

Battery Location:

 Locate the batteries in an accessible location. Two feet clearance above the batteries is

recommended for access to the battery caps. They should be located as close to the inverter as possible without limiting access to the inverters disconnects. Install the batteries to the left of a wall mounted inverter for easy access to the DC side of the inverter and shorter cable runs.

 For safety and to limit access to the batteries, a lockable, ventilated, battery enclosure or

dedicated room should be used. If an enclosure is used, it should be vented to the outside via a one inch vent pipe located at the top of the enclosure. Install an intake vent at the bottom of the enclosure to promote air circulation. These vents exhaust explosive hydrogen gases and must not be overlooked when designing an enclosure.

 The enclosure should be made of an acid resistant material or have a finish that resists acid

to prevent corrosion. It should be capable of holding the electrolyte from at least one battery should a leak occur.

 Place a layer of baking soda on the shelves to neutralize any acid that may be spilled in the

future (lead-acid batteries only).

 Enclosures located outside must be rainproof and screened to prevent access by rodents or

insects.

Battery Temperature

The battery enclosure should provide a fairly stable temperature for the batteries. If it is installed in a cold environment, insulation should be used to protect the batteries from the cold. The insulation also provides a more consistent temperature and better system performance.

The battery enclosure should not be installed in direct sunlight where the summer sun can overheat the batteries. Locate the enclosure where it will be protected from the afternoon sun and provide vents in the top and bottom of the enclosure to provide air flow. High battery temperatures greatly shortens the life of the batteries.

Pre-Installation (continued)

DISCONNECT

DC CONDUIT

(if used)

BATTERIES

BATTERY

ENCLOSURE

(if used)

2.0 INSTALLATION

CONDUIT

VENT

(outlet)

BOX

(if used)

INVERTER/CHARGER

MAIN PANEL

AC CONDUIT

FROM MAIN

PANEL

AC CONDUIT TO SUB-PANEL

SUB-PANEL

VENT (inlet)

DISCONNECT

AND PVGFP

DC CHARGE

CONTROLLER

SOLAR

ALTERNATE DC ENERGY SOURCES

DC CONDUIT

(if used)

Figure 5

Planning Example Layout

Basic Setup

WIND

CONDUIT

VENT

(outlet)

BOX

(if used)

INVERTER/CHARGER

BATTERY

ENCLOSURE

(if used)

DC CONDUIT

(if used)

BATTERI ES

DISCONNECT

MANUAL AC

TRANSFER

SWITCH

N.C.

COM.

N.O.

AC CONDUIT

AC CONDUIT TO SUB-PANEL

FROM GENERATOR

MAIN PANEL

975-0012-001

AC CONDUIT

UTILITY

SUB-PANEL

AC GENERATOR

(externally located)

DC GROUND

WIRE

VENT (inlet)

GROUND

975-0012-002

Figure 6

Planning Example Layout

RE Setup

2.0 INSTALLATION

Main Service Panel:

The input to the inverter requires a minimum 60 amp breaker (for each inverter if stacked). This

circuit breaker must be located in the utility service panel.

Sub-Panel:

Loads backed up by the inverter will need to be rerouted from the main service panel to a sub-

panel. This can be done several different ways, depending upon the installation. Always refer to electrical codes for safe wiring practices.

AC Circuit Breakers:

Always use a properly rated circuit breaker. Depending upon the application, circuit breakers

used to protect the load can be removed from the main service panel and put into the sub-panel ONLY if the two panels are from the same manufacturer.

DC Disconnect:

Install a DC disconnect breaker or fuse in the positive battery line. This breaker protects the DC

wiring in the event of an accidental short. Size the breaker in accordance with the battery cables. Switch this breaker OFF whenever servicing the batteries.

Wire Routing:

Determine all wire routes both to and from the inverter and which knockouts are best suited for

connecting the AC conduits. Possible routing scenarios include:

 AC Input wiring from the main utility service panel to the inverter/charger

 AC Input wiring from the generator to the inverter/charger (if used)

 DC Input wiring from the PV array (wind, hydro, etc.) to the inverter/charger (if used)

 DC Input wiring from the batteries to the inverter/charger

 AC Output wiring from the inverter/charger to the sub-panel

 Battery Temperature Sensor cable from the batteries to the inverter/charger (if used)

 Remote Control cable to the inverter/charger (if used)

 DC Ground from the batteries to an external ground rod

 Load circuit wiring rerouted from the main service panel to the sub-panel

Check for existing electrical or plumbing prior to making cuts in the walls. Cut holes in the walls

at appropriate locations for routing wiring/cables.

Inverter Mounting (continued)

Ceiling

Wall studs 16 inches on

center

2.0 INSTALLATION

7–5/8" c-c

Approximately

4–5 ft

975-0012-003

2 x 4 mounting

supports

Wallboard

Floor

Figure 7

Suggested Mounting Method

Inverter Mounting

The DR Series inverter can weigh as much as 45 lb. (20.4 kg). Wallboard is not strong enough to support its weight so additional support must be added. The easiest method for securing it to an existing wall is to place two 2 x 4s horizontally on the wall (spanning at least three studs) and securing the inverter to the 2 x 4s.

WARNING: USE APPROPRIATE LIFTING TECHNIQUES. HAVE EXTRA PEOPLE ON HAND TO ASSIST IN LIFTING THE INVERTER INTO POSITION WHILE IT IS BEING SECURED.

Procedure

 Locate the studs and mark their location on the wall.

 Measure the desired height from the floor for the inverter to be mounted.

 Using a level, run a horizontal line. The length of the line must span at least 3 studs.

 Place a pre-cut 2 x 4 on the marked location and drill pilot holes through the 2 x 4s and

studs.

 Secure the 2 x 4 with #10 wood screws (length to penetrate 1-1/2 inches into the studs).

 Repeat the procedure for the remaining 2 x 4.

2.0 INSTALLATION

 Referring to Figure 8, drill out the mounting hole locations for the inverter.

 With assistance, lift the inverter into position and install it onto the 2 x 4s using 1/4 x 1-1/2

inch lag bolts and washers.

Alternatively, a half or quarter sheet of 3/4 inch plywood can also be used as a backing, with the inverter mounted directly to the plywood using 1/4 inch diameter lag bolts and washers. The plywood must span three studs for adequate support.

0.281 DIA 10 PLACES

0.375 DIA 4 PLACES

TERMINAL

–

TERMINAL

DC SIDE

AC SID E

21.25 cm

19.40 cm

8.370 inches

7.640 inches

1.00 inches

2.54 cm

1.90 inches

4.83 cm

7.00 inches

17.8 cm

8.00 inches

20.32 cm

7.00

16.00

20.175

14.00 inches

35.56 cm

16.00 inches

40.64 cm

20.175 inches

51.244 cm

8.00

7.00 inches

17.8 cm

1.00

0.365 inche

0.93 cm

975-0012-D-011

G N I

E E N

G N E

E C A

R T

E E N

I G

E C A R

6.970

G N

7.640

.281 DIA. 5 PLACES

8.370

.375 DIA. 2 PLACES

1.900

0.365

975-0012-D-012

Figure 8

Dimensional Drawings for Screw Hole Placement

2.0 INSTALLATION

Wiring

DC Wiring (Batteries) Battery Cable Sizing

Proper cable sizing (diameter and length) is critical to the safe and efficient operation of an inverter system. Larger diameter cables (smaller AWG number) have less voltage drop and are, therefore, more efficient when transferring power to and from the batteries. If a cable is undersized (diameter too small), it could potentially overheat, creating a fire hazard.

Cable length is another important factor. Runs should be kept as short as practical. Longer cable runs increase resistance, thus lowering the overall efficiency of the system. This is especially true in lower voltage systems (i.e., 12 VDC) where, depending upon the length of the cable run, it may be necessary to oversize the diameter of the wire, or parallel (double) the cables.

Always use a properly sized cable and length rated for the amperage of the inverter and batteries.

WARNING: UNDERSIZED CABLES CAN OVERHEAT AND MELT, CREATING A FIRE HAZARD WHEN SUBJECTED TO HEAVY (PEAK) LOADS.

NOTE: If the system will be operated at the inverters peak power rating exceeding one hour, larger cables and disconnects MUST be used (see Tables 1 and 2).

NOTE: If the system includes a large battery bank or large DC source (such as a micro-hydroelectric plant or wind generator), increasing the size of the cables and disconnects will greatly reduce the number of nuisance outages associated with breaker tripping and open fuses.

Table 1 provides recommended minimum cable sizes for various cable lengths and inverter amperages. These recommendations may not meet all local or NEC requirements.

NOTE: Use only copper cables.

NOTE: Run the positive and negative battery cables as close to each other as possible by taping them together. This reduces the effects of inductance and produces a better waveform thus increasing efficiency.

Inverter

Model

DR1512

DR2412

DR1524

DR2424

DR3624

Typical

Amperage

150 A #2/0 AWG (67.4 mm

240 A #4/0 AWG (107 mm

75 A #2/0 AWG (67.4 mm

120 A #2/0 AWG (67.4 mm

180 A #4/0 AWG (107 mm

1 to 3 Feet (one-way) 3 to 5 Feet (one-way) 5 to 10 Feet (one-way)

) #2/0 AWG (67.4 mm2) #4/0 AWG (107 mm2)

) #4/0 AWG (107 mm2) NOT RECOMMENDED

) #2/0 AWG (67.4 mm2) #4/0 AWG (107 mm2)

) #4/0 AWG (107 mm2) #4/0 AWG (107 mm2)

975-0012-004

Minimum Recommended Battery Cable Size VS. Length

Table 1

2.0 INSTALLATION

Wiring (continued)

DC Disconnect and Over-current Protection

For safety and to comply with regulations, battery over-current protection is required. Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability.

The National Electrical Code (NEC) requires both over-current protection and a disconnect switch for residential and commercial electrical systems. These items are not supplied as part of the inverter. However, Xantrex offers a DC rated, DC250/175 ETL listed, circuit breaker disconnect module specifically designed for use with Trace inverters to meet NEC compliance. Two amperage ratings are available: a DC250 (250 amps) and a DC175 (175 amps) in either single or dual breaker configurations for single or dual inverter installations.

NOTE: Trace DC disconnects are not designed to accept doubled (paralleled) cables which may be required for long cable runs. Also, the plastic red and black covers on the DC inverter inputs are not designed to accommodate dual cables. If dual cables are used, the optional conduit box (DRCB) must be used.

Some installations may not require conduit or a disconnect device, although over-current protection is still required. Xantrex offers a fuse block (TFB) providing the code required inverter over-current protection for these applications. Refer to the table below for the proper size disconnect device for specific cable diameters.

Cable Size

Required

#2 AWG 115 amps max N/A 170 amps max TFB200

#2/0 AWG 175 amps max DC175 265 amps max TFB300

#4/0 AWG 250 amps max DC250 360 amps max TFB400

Rating in

Conduit

Maximum

Breaker Size

Rating in "Free

Air"

Maximum Fuse

Size

975-0012-005

Table 2

Battery Cable to Maximum Breaker/Fuse Size

NOTE: The NEC allows rounding to the next standard fuse size from the cable rating (i.e., 150 amp cable size rounds up to a standard 175 amp size). The term free air is defined by the NEC as cabling that is not enclosed in a conduit or a raceway. Cables enclosed in conduit or raceways have substantially lower continuous current carrying ability due to heating factors.

2.0 INSTALLATION

Wiring (continued)

Battery Cable Connections

Battery cables must have crimped (or preferably, soldered and crimped) copper compression lugs unless aluminum mechanical lugs are used. Soldered connections alone are not acceptable. High quality, UL-listed battery cables are available from Trace Engineering in an assortment of lengths: 1-1/2 to 10 feet, and in #2/0 AWG or #4/0 AWG sizes. These cables are color-coded with pressure crimped, sealed ring terminals.

Figure 9 illustrates the proper method to connect the battery cables to the DR Series inverter/ charger terminals.

Do not place anything

between battery cable lug

and terminal surface.

Assemble exactly as shown.

2/0 Copper Compression Lug 2/0 Aluminum Mechanical Lug

Figure 9

Battery Cable Connections to Inverter

CAUTION: THE INVERTER IS NOT REVERSE POLARITY PROTECTED. REVERSING THE BATTERY POLARITY ON THE DC INPUT CONNECTIONS WILL CAUSE PERMANENT DAMAGE TO THE INVERTER WHICH IS NOT COVERED UNDER WARRANTY. ALWAYS CHECK POLARITY BEFORE MAKING CONNECTIONS TO THE INVERTER.

WARNING: ENSURE THE INVERTER IS OFF BEFORE CONNECTING OR DISCONNECTING THE BATTERY CABLES, AND THAT AC POWER IS DISCONNECTED FROM THE INVERTER INPUT.

POSITIVE (+) RED TERMINAL

NEGATIVE (-) BLACK TERMINAL

Figure 10

Battery Cable Connections

2.0 INSTALLATION

Wiring (continued)

Battery Bank Sizing

The size of the battery bank determines how long the AC loads will operate in a backup mode without utility power. The larger the battery bank, the longer the run time. Size the battery bank to the systems AC load requirements and length of time required to run from the batteries. In general, the battery bank should not be discharged more than 50%. Additional DC charging devices such as solar, wind, hydro, etc., can provide longer run times by recharging the batteries in the absence of AC utility or generator power.

Additional details on estimating battery bank size and capacity can be found in the Appendix

section of this manual.

Battery Types

Batteries are available in different sizes, amp-hour ratings, voltage, liquid or gel, vented or nonvented, chemistries, etc. They are also available for starting applications (such as an automobile starting battery) and deep discharge applications. Only the deep discharge types are recommended for inverter applications. Choose the batteries best suited for the inverter installation and cost. Use only the same battery type for all batteries in the bank. For best performance, all batteries should be from the same lot and date. This information is usually printed on a label located on the battery.

Additional information regarding batteries can be found in the Appendix section of this manual.

Battery Configuration

The battery bank must be wired to match the inverters DC input voltage specifications (12, 24 or 48 VDC). In addition, the batteries can be wired to provide additional run time. The various wiring configurations are:

SERIES

Wiring batteries in series increases the total bank output voltage (to match the inverters DC

requirements).

PARALLEL

Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads.

SERIES-PARALLEL

Series-parallel configurations increase both the battery voltage (to match the inverters DC

requirements) and run-time for operating the AC loads.

2.0 INSTALLATION

Wiring (continued)

Wiring Batteries in Series

Wiring the batteries in a series configuration increases the voltage of the battery string. 6 volt batteries can be combined to form 12 V, 24 V, or 48 V battery banks. In the same way, 12 volt batteries connected in series form 24 V or 48 V battery banks. The total current capacity of the bank does not increase and it retains the same amp-hour rating as a single battery.

+ - + -

6 V 6 V

+ -

12 V INVERTER

(Total battery capacity = 100 Ah)

+ - + -

6 V 6 V

+ - + -

6 V 6 V

Each batterys amp-

hour rating is 100 Ah

3597-F00-D21

+ - + -

6 V 6 V

+ - + -

6 V 6 V

+ -

48 V INVERTER

(Total battery capacity = 100 Ah)

Figure 11

6 Volt Battery WiringSeries Configuration

+ - +

6 V 6 V

+ -

24 V INVERTER

(Total battery capacity = 100 Ah)

+ - + -

3597-F00-D22

6 V 6 V

3597-F00-D23

+ - + -

12 V 12 V

+ -

24 V INVERTER

(Total battery capacity = 50 Ah)

+ - + -

12 V 12 V

(Total battery capacity = 50 Ah)

3597-F00-D24

Each batterys amp-hour

rating is 50 Ah

Figure 12

12 Volt Battery WiringSeries Configuration

+ - + -

12 V 12 V

+ -

48 V INVERTER

3597-F00-D25

2.0 INSTALLATION

Wiring (continued)

Wiring Batteries in Parallel

Wiring the batteries in a parallel configuration increases the current of the battery string. This is commonly used in 12 volt configurations. The voltage of the battery bank remains the same as an individual battery. Parallel configurations extend the run times of the AC loads by providing increased current for the inverter to draw from. In a parallel configuration, all of the negative battery terminals are connected together and all of the positive battery terminals are connected together.

–

12 V

–

12 V

–

12 V

Each batterys amp-hour

rating is 50 Ah

+ –

12 V INVERTER

(Total battery capacity = 200 Ah)

3597-F00-D26

Figure 13

12 Volt Battery WiringParallel Configuration

Wiring Batteries in Series-Parallel

Wiring the batteries in a series-parallel configuration increases the

current and voltage of the battery bank. Series-parallel wiring is more complicated and care should be taken when wiring these banks.

To construct a series-parallel battery bank follow these instructions:

Step 1

 First wire the batteries in series (voltage adds) with the positive terminal of one battery

connected to the negative terminal of the next battery to meet the inverters DC input requirements.

 Repeat this step for the next battery string.

 Two identical strings of batteries are now wired in series.

+ – + –

12 V 12 V

+ – + –

12 V 12 V

+ – + –

12 V 12 V

+ – + –

12 V 12 V

Figure 14

Step 1Wire Batteries in Series

Series String 1

Series String 2

3597-F00-D27

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Xantrex DR1512, DR2412, DR1524, DR2424, DR3624 User Manual

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Frequently Asked Questions

User Manual