Xantrex Prowatt 1500 User Guide

	Table of Contents
1 Introduction ...........................................................................................................................................................		1
2 How Your PROwatt 1500 Works ........................................................................................................................		1
2.1	Principle of Operation .............................................................................................................................	1
2.2 PROwatt 1500 Output Waveform ...........................................................................................................		3
3 Quick Checkout ....................................................................................................................................................		4
3.1	Power Source...........................................................................................................................................	4
3.2	Cables ......................................................................................................................................................	4
3.3	Test Loads ...............................................................................................................................................	5
3.4	Connections .............................................................................................................................................	5
4 Installation ............................................................................................................................................................		6
4.1	Where to Install .......................................................................................................................................	6
4.2	Battery .....................................................................................................................................................	7
	Battery type ......................................................................................................................................	7
	Battery Sizing ...................................................................................................................................	8
	Using Multiple Batteries ..................................................................................................................	9
	Battery Tips ....................................................................................................................................	10
	Alternators and Charging Systems .................................................................................................	11
4.3	Cables ....................................................................................................................................................	12
4.4	Connections ...........................................................................................................................................	12
	AC Wiring ......................................................................................................................................	12
	Ground Wiring ..............................................................................................................................	15
	DC Wiring ......................................................................................................................................	16
4.5	Remote Panel.........................................................................................................................................	17
	Installation Instructions ..................................................................................................................	17
	Operating Instructions ....................................................................................................................	17
5 Operation ............................................................................................................................................................		18
5.1	Outlets, Controls and Indicators............................................................................................................	18
5.2	Operating Limits ..................................................................................................................................	19
6 Troubleshooting..................................................................................................................................................		20
6.1 Common Problems ................................................................................................................................		20
6.2	Troubleshooting Guide..........................................................................................................................	21
7 Maintenance........................................................................................................................................................		22
8 Warranty.............................................................................................................................................................		22
9 Specifications ......................................................................................................................................................		24
9.1	Electrical Performance ..........................................................................................................................	24
9.2	Dimensions............................................................................................................................................	24

1 Introduction

Your new PROwatt 1500 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 PROwatt 1500, it must be installed and used properly. Please read the installation and operating instructions in this manual carefully before installing and using your PROwatt 1500. Pay special attention to the CAUTION and WARNING statements in this manual and on the PROwatt 1500. CAUTION statements identify conditions or practices which could result in damage to your PROwatt 1500 or to other equipment. WARNING statements identify conditions or practices that could result in personal injury or loss of life.

2 How Your PROwatt 1500 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 PROwatt 1500, 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 PROwatt 1500 converts power in two stages. voltage DC at the inverter input to 145 volts DC. high voltage DC into 115 volts, 60 Hz AC.

The first stage is a DC-to-DC converter that raises the low The second stage is the actual inverter stage. It converts the

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 1. Principle of Operation

Figure 2. Modified Sine Wave

2.2 PROwatt 1500 Output Waveform

The AC output waveform of the PROwatt 1500 is called a "quasi-sine wave" or a "modified sine wave". 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 some other dc to ac inverters.

CAUTION! RECHARGEABLE APPLIANCES

Certain rechargers for small nickel cadmium batteries can be damaged if connected to the PROwatt. 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 have a WARNING label stating that dangerous voltages are present at the battery terminals.

Do NOT use the PROwatt with the above equipment.

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 PROwatt will have no trouble powering this charger or adapter safely.

The modified sine wave produced by the PROwatt 1500 is designed to have an RMS

(root mean square) 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 PROwatt 1500. For accurate measurement of the output voltage of the PROwatt 1500, a true RMS reading voltmeter, such as a Fluke 87, Fluke 27, Tektronix DMM 249, or B&K Precision Model 391, must be used.

3 Quick Checkout

This section will give you the information you need to quickly hook-up your PROwatt 1500 and check its performance before going ahead with permanent installation. You will need the following:

a)a 12 volt DC power source (24 volt for PW1500/24)

b)two cables to connect the power source to the PROwatt 1500

c)a test load that can be plugged into the AC receptacle on the PROwatt 1500.

3.1Power Source

The power source must provide between 11 and 15 volts (22 and 30 volts for PW1500/24) DC and must be able to supply sufficient current to operate the test load. As a rough guideline, divide the wattage of the test load by 10 (by 20 for PW1500/24) to obtain the current (in amperes) the power source must deliver.

Example: Test load is rated at 250 watts. Power source must be able to deliver 250 ÷ 10 = 25 amperes (or 12.5Amps for 24 volt model).

Battery

Use a fully-charged 12 volt (nominal) battery that can deliver the required current while maintaining its voltage above 11 volts (22 volts for 24 volt battery system). A fully-charged (12 volt) automobile battery is capable of delivering up to 50 amperes without an excessive voltage drop.

DC Power Supply

Use a well regulated DC power supply that has an output voltage between 11 volts and 14 volts (22-28 volts for PW1500/24) 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 14 volts (22-28 volts for PW1500/24). The inverter may shut down if the voltage is outside these limits and may be damaged if the voltage is above 16 volts (32 volts for PW1500/24). Also ensure that any current limit control is set so that the power supply can deliver the required current.

3.2 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 current 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 (20 volts on PW1500/24).

We recommend #2 AWG (#4 AWG on PW1500/24) stranded copper cable that is no longer than 4 ft (1.2 m) if you want to test the PROwatt 1500 to its maximum ratings. For short term testing at reduced power levels, the guidelines below should be followed:

Test Load Power	Minimum Cable Size	Minimum Cable Size
Consumption For	PW1500/12 volt	PW1500/24 volt
Short Term Test
100 watts	#16 AWG copper	#18 AWG copper
250 watts	#12 AWG copper	#16 AWG copper
500 watts	#8 AWG copper	#12 AWG copper

Ideally, the cable should be no more than 4 ft (1.2 m) long.

Attach 5/16 inch ring terminals to the ends of the cables to be attached to the DC terminal studs on the PROwatt 1500. The ring terminals must be crimped with a proper crimping tool. Another option is to use Ilsco or equivalent box-lug terminals ( available at electrical parts suppliers ) sized for the wire gauge and a 5/16 inch stud. The bare cable end is inserted into the lug terminal and secured with a set-screw.

The other end of the cable, which is connected to the power source, must be terminated with a lug or other connector that allows a secure, low resistance connection to be made to the power source. For instance, if the power source is a battery, the cable must be terminated with a battery terminal that clamps to the post on the battery.

A solid, low resistance connection to the power source is essential for proper operation of the PROwatt 1500.

3.3 Test Loads

Use only equipment rated for 110-120 volt, 60 Hz AC operation that has a power consumption of 1500 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.

Figure 3. Connections to the PROwatt 1500

3.4 Connections

Follow the connection sequence described below.

STEP 1 Ensure that the ON/OFF switch on the PROwatt 1500 is in the OFF position. If the power source is a DC power supply, switch it off as well.

STEP 2 Connect the cables to the power input terminals on the rear panel of the PROwatt 1500. The red terminal is positive (+) and the black terminal is negative (-). Place the cable connector (ring terminal or box lug) on the stud and then install the supplied lock washer and nut. Tighten the nut with a wrench to a torque of 9 –10 ft-lbs (12 – 13 Nm).

STEP 3 Connect the cable from the negative (black) terminal of the PROwatt 1500 to the negative terminal of the power source. Make a secure connection.

CAUTION! Loosely tightened connectors result in excessive voltage drop and may cause overheated wires and melted insulation.

STEP 4 Before proceeding further, carefully check that the cable you have just connected connects the negative terminal of the PROwatt 1500 to the negative output terminal of the power source. Power connections to the PROwatt 1500 must be positive to positive and negative to negative.

If you are using a DC power supply as the power source, switch it on. Set the ON/OFF switch on the PROwatt 1500 to the ON position. Check the meters and indicators on the front panel of the PROwatt 1500. The voltage bar graph should indicate 11 to 14 volts (22-28 volts for PW1500/24), depending on the voltage of the power source. If it does not, check your power source and the connections to the PROwatt 1500. The other indicators should be off.

Set the PROwatt 1500 ON/OFF switch to the OFF position. The indicator lights may blink and the internal alarm may sound momentarily. This is normal. Plug the test load into the AC receptacle on the front panel of the PROwatt 1500. Leave the test load switched off.

Set the PROwatt 1500 ON/OFF switch to the ON position and turn the test load on. The PROwatt 1500 should supply power to the load. If it does not, refer to the troubleshooting section of this manual. If you plan to measure the output voltage of the PROwatt 1500, refer to Section 2.2 of this manual.

CAUTION! Reverse polarity connection (positive to negative) will blow the fuses in the PROwatt 1500 and may permanently damage the PROwatt 1500. Damage caused by reverse polarity connection is not covered by your warranty.

STEP 5 Connect the cable from the positive (red) terminal of the PROwatt 1500 to the positive terminal of the power source. Make a secure connection.

WARNING! You may observe a spark when you make this connection since current may flow to charge capacitors in the PROwatt 1500. Do not make this connection in the presence of flammable fumes. Explosion or fire may result.

STEP 6

STEP 7

STEP 8

4 Installation

4.1Where to Install The PROwatt 1500 should be installed in a location that meets the following requirements:

a)Dry - do not allow water to drip or splash on the PROwatt 1500.

b)Cool - ambient air temperature should be between 0o C and 40o C (30o F and 105o F) - the cooler the better.

c)Ventilated - allow at least 1 inch (2.5cm) of clearance around the PROwatt 1500 for air flow. Ensure that ventilation openings on the rear and bottom of the unit are not obstructed.

d)Safe - do not install the PROwatt in the same compartment as batteries or in any compartment capable of storing flammable liquids such as gasoline.

e)Close to Battery - install as close to the battery as possible in order to minimize the length of cable required to connect the inverter to the battery. It is better and cheaper to run longer AC wires than longer DC cables.

CAUTION! To prevent fire, do not cover or obstruct ventilation openings. Do not install the PROwatt 1500 in a zero-clearance compartment. Overheating may result.

WARNING! This equipment contains components which tend to produce arcs or sparks. To prevent fire or explosion do not install in compartments containing batteries or flammable materials or in locations which require ignition protected equipment.

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