Xantrex Portawattz 3000 User Guide

DC to AC

POWER INVERTER

OWNER’S MANUAL

	Table of Contents
1 Introduction ................................................................................		1
2 How Your PortawattzTM 3000 Inverter Works ...............................		1
2.1	Principle of Operation .......................................................................................	1
2.2 PortawattzTM 3000 Inverter Output Waveform ................................................		2
3 Physical Layout of the PortawattzTM 3000 Inverter .....................		3
4 Quick Operational Check (optional) ..........................................		5
4.1	DC Power Source ..............................................................................................	5
	4.1.1.Battery ........................................................................................................	5
	4.1.2. DC Power Supply ........................................................................................	5
4.2	DC Cables .........................................................................................................	5
4.3 Test Loads ..........................................................................................................		7
4.4	Connections ......................................................................................................	7
5 Permanent Installation ...............................................................		9
5.1	Where to Install ..................................................................................................	9
5.2	Battery ..............................................................................................................	10
	5.2.1 Battery type ................................................................................................	10
	5.2.2. Battery Sizing ............................................................................................	11
	5.2.3. Using Multiple Batteries .............................................................................	13
	5.2.4. Battery Tips ...............................................................................................	14
	5.2.5. Alternators and Charging Systems .............................................................	15
5.3	Battery Cables .................................................................................................	16
5.4	Connections ....................................................................................................	18
	5.4.1 AC Wiring ...................................................................................................	18
	5.4.2 Ground Wiring ............................................................................................	18
	5.4.3 DC Wiring ...................................................................................................	19
6 Operation ..................................................................................		20
6.1	Front Panel Controls and Indicators .............................................................	20
	6.1.1. ON/OFF Switch .........................................................................................	20
	6.1.2. Remote ON/OFF Jack ...............................................................................	20
	6.1.3. Battery Voltage Indicator ............................................................................	21
	6.1.4. Battery Current Indicator ............................................................................	21
	6.1.5. OVERTEMP Indicator .................................................................................	21
	6.1.6 OVERLOAD Indicator ..................................................................................	21
	6.1.7 ALARM Indicator .........................................................................................	22

6.2 Operating Limits ..............................................................................................	22
6.2.1. Power Output ............................................................................................	22
6.2.2. Input Voltage .............................................................................................	22
7 Accessories ..............................................................................	23
7.1 Remote ON/OFF switch option .....................................................................	23
7.2 DC Box-Lug connectors .................................................................................	23
8 Troubleshooting ........................................................................	24
8.1 Common Problems .........................................................................................	24
8.1.1. Buzz in Audio Systems ..............................................................................	24
8.1.1. Television Interference ...............................................................................	24
8.2 Troubleshooting Guide ...................................................................................	25
9 Maintenance .............................................................................	26
10 Warranty ..................................................................................	26
10.1 Warranty Terms ..............................................................................................	26
10.2 To Obtain Warranty Service ..........................................................................	27
11 Specifications .........................................................................	29
11.1 Electrical Performance .................................................................................	29
11.2 Dimensions ....................................................................................................	29
12. Other Products from Statpower .............................................	30

1 Introduction

Your new Portawattz 3000 inverter is a member of the most advanced line of DC to AC inverters available today. It will give you years of dependable service in your boat, RV, service vehicle or remote home.

To get the most out of your Portawattz 3000, it must be installed and used properly. Please read the installation and operating instructions in this manual carefully before installing and using your Portawattz 3000. Pay special attention to the CAUTION and WARNING statements in this manual and on the unit. CAUTION statements identify conditions or practices which could result in damage to your unit or to other equipment. WARNING statements identify conditions or practices that could result in personal injury or loss of life.

2 How Your PortawattzTM 3000 Inverter Works

An inverter is an electronic device that converts low voltage DC (direct current) electricity from a battery or other power source to standard 115 volt AC (alternating current) household power. In designing the Portawattz 3000, Statpower has used power conversion technology previously employed in computer power supplies to give you an inverter that is smaller, lighter, and easier to use than inverters based on older technology.

2.1 Principle of Operation

The Portawattz 3000 converts power in two stages. The first stage is a DC-to-DC converter which raises the low voltage DC at the inverter input to 145 volts DC. The second stage is the actual inverter stage. It converts the high voltage DC into 115 volts, 60 Hz AC.

The DC-to-DC converter stage uses modern high frequency power conversion techniques that eliminate the bulky transformers found in inverters based on older technology. The inverter stage uses advanced power MOSFET transistors in a full bridge configuration. This gives you excellent overload capability and the ability to operate tough reactive loads like lamp ballasts and induction motors.

Figure

- Principle of Operation

2.2 PortawattzTM 3000 Inverter Output Waveform

The AC output waveform of the Portawattz 3000 is called a “quasisine wave” or a “modified sine wave”(see Figure 2). It is a stepped waveform that is designed to have characteristics similar to the sine wave shape of utility power. A waveform of this type is suitable for most AC loads, including linear and switching power supplies used in electronic equipment, transformers, and motors. This waveform is much superior to the square wave produced by many other DC to AC inverters.

Figure

Modified Sine Wave

The modified sine wave produced by the Portawattz 3000 is designed to have an RMS voltage of 115 volts, the same as standard household power. Most AC voltmeters (both digital and analog), are sensitive to the average value of the waveform rather than the RMS value. They are calibrated for RMS voltage under the assumption that the

waveform measured will be a pure sine wave. These meters will not read the RMS voltage of a modified sine wave correctly. They will read about 2 to 20 volts low when measuring the output of the Portawattz 3000. For accurate measurement of the output voltage, a true RMS reading voltmeter, such as a Fluke 87, Fluke 27, Tektronix DMM 249, or B&K Precision Model 391, must be used.

CAUTION!

RECHARGEABLE APPLIANCES. DO NOT USE THE PORTAWATTZTM 3000 WITH THE EQUIPMENT LISTED BELOW.

Certain rechargers for small nickel cadmium batteries can be damaged if connected to the unit. Two particular types of equipment are prone to this problem:

1)small battery operated appliances such as flashlights, razors, and night lights that can be plugged directly into an AC receptacle to recharge.

2)certain battery chargers for battery packs used in hand power tools. These chargers will have a warning label stating dangerous voltages are present at the battery terminals.

This problem does not occur with the vast majority of battery operated equipment. Most of this equipment uses a separate charger or transformer that is plugged into the AC receptacle and produces a low voltage output. If the label on the AC adapter or charger states that the adapter or charger produces a low voltage AC or DC output (less than 30 volts), the Portawattz will have no trouble powering this charger or adapter safely.

3 Physical Layout of the PortawattzTM 3000 Inverter

Your inverter was designed with a logical and efficient back to front flow in mind. Battery power is applied to the large terminals on the rear of the unit and flows forward to the AC receptacles on the front panel. All of the indicators, controls, and output connections that you will need to access after a permanent installation are conveniently located on the front panel (see Figure 3). See Section 6.1, Front Panel Controls and Indicators, for a detailed explanation of the functions of the various controls and indicators on your Portawattz 3000.

Forced air cooling also flows in the same direction, with the fan drawing air in from the rear and blowing it out through the vents on the front panel.

NOTE: It is important to provide an adequate airspace around these surfaces to allow for convection cooling. See Section 5.1 for installation notes.

Figure 3 - Front and Rear panel

Example:

Test load is rated at 250 watts.

Power supply must be able to deliver

250 ÷ 10 = 25 Amps

4 Quick Operational Check (optional)

This section will give you the information you need if you wish to quickly hook-up your Portawattz 3000 and check its performance before going ahead with permanent installation. You will need the following:

a) a 12 volt DC power source

b)two cables to connect the DC power source to the Portawattz 3000

c)a test load of 100 - 1000 Watts.

d)a line cord to connect the test load to the AC receptacle.

4.1 DC Power Source

The power source must provide between 11 and 15 volts DC and must be able to supply sufficient current to operate the test load. As a rough guide, divide the wattage of the test load by 10 to obtain the current (Amps) the power source must deliver (see example).

4.1.1. Battery

Use a fully-charged 12 volt (nominal) battery that can deliver the required current while maintaining

its voltage above 11 volts. A fullycharged 12 volt automobile battery is capable of delivering up to 50 amperes without an excessive voltage drop.

4.1.2. DC Power Supply

Use a well regulated DC power supply that has an output voltage between 11 volts and 15 volts and can deliver the required current. If the supply is adjustable, make sure that the output voltage is adjusted to be between 11 volts and 15 volts. The inverter may shut down if the voltage is outside these limits and may be damaged if the voltage is above 16 volts. Also ensure that any current limit control is set so that the power supply can deliver the required current.

4.2 DC Cables

Your cables must be as short as possible and large enough to handle the required current. This is to minimize the voltage drop between the power source and the inverter when the inverter is drawing large currents from the power source. If the cables introduce an excessive voltage drop, the inverter may shut down when drawing higher currents because the voltage at the inverter drops below 10 volts.

Also, longer and/or thinner cables will reduce the efficiency of the overall system, since excessive power will be dissipated in the cabling.

For temporary operation at reduced power levels, the guidelines listed in Table 1 may be followed, or you can use the cable sizes in Table 6.

Ideally, the cables should be no more than 4 ft (1.5m) long. See table 2 for a pictorial representation of the wire gauges.

	Max. Test Load	Min. Cable Size
	Max. Test Load
	Power
	Power	(Copper material
	Consumption for	(Copper material
	Consumption for	only)
	Short Term Test	only)
	Short Term Test
	100 Watts	#16 AWG

	250 Watts	#12 AWG

	500 Watts	#8 AWG

Table 1 - Temporary		Load Wire Gauge
	C h a r t

CAUTION!

DO NOT operate your inverter for more than 5 minutes or at a higher power using these cable sizes. Refer to table 6.

Strip approximately 1/2” (1.25cm) of insulation from the ends of the cables being connected to the inverter. Attach 5/16” ring terminals to the ends of the wires to be attached to the DC terminals on the Portawattz 3000. The ring terminals should be crimped with a proper crimping tool.

Another option is to use Ilsco, or equivalent, box-lug terminals (available at electrical parts suppliers). The bare cable end can then be inserted into the lug terminal.

The other ends of the cables, which are connected to the power source, must be terminated with lugs or other connectors that allow a secure, low resistance connection to be made to the power source. For instance, if the power source is a battery, the cables must be terminated with battery terminals that clamp to the posts on the battery.

A solid, low resistance connection to the DC power source is essential for proper operation.

4.3 Test Loads

Use only equipment rated for 110 - 120 volt, 60 Hz AC operation that has a power consumption of 500 watts or less. We recommend that you start with a relatively low power load, such as a 100 watt lamp, to verify your test set-up before trying high power loads.

4.4 Connections

Follow the connection sequence described below:

ALPHA Neoprene

Welding Cable

	Wire Size	Overall Outside
	(AWG)	Diameter
	(AWG)	(inches/mm)
		(inches/mm)
#6		0.35/8.89

#4		0.42/10.70

#2		0.48/12.19

#1		0.52/13.21

#1/0		0.58/14.77

#2/0		0.64/16.26

#3/0		0.70/17.78

#4/0		0.82/20.83

STEP 1 - Ensure the ON/OFF switch on Table 2 - Wire size Chart the Portawattz 3000 is in the

OFF position. If the power

source is a DC power supply, switch it off as well.

Figure 4. Connections to the Portawattz 3000

STEP 2 - Connect the DC cables to the power input terminals on the rear panel of the Portawattz 3000. The Red terminal is positive (+) and the Black terminal is negative (-). Tighten the wire connections securely. (see figure 4).

STEP 3- Connect the cable from the negative (Black) terminal of the Portawattz 3000 to the negative terminal of the power source (battery or power supply). Make a secure connection.

CAUTION!

Loose connectors result in excessive voltage drop and may cause overheated wires and melted insulation.

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