Xantrex Technology DR2424, DR2424E, DR1524E, DR1512E, DR1524W User Manual
...
DR1512
DR2412
DR1524
DR2424
DR3624
DR1512W
DR1524W
DR1512E
DR1524E
DR1548E
DR2424E
Installation and Operations Manual
DR Inverter/Charger
DR Inverter/Charger
Installation and Operation Manual
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, 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
DR Inverter/Charger is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex
International.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used
herein for identification purposes only.
Notice of Copyright
DR Inverter/Charger Installation and Operations Manual © March 2005 Xantrex International. All rights reserved.
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
March 2005 Revision
Part Number
975-0012-01-02 Rev A
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct)
Fax: 1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email: customerservice@xantrex.com
Web: www.xantrex.com
About This Manual
Purpose
The purpose of this Installation and Operation Manual is to provide explanations
and procedures for installing, operating, maintaining, and troubleshooting the DR
Inverter/Charger.
Scope
The Manual provides safety guidelines, detailed planning and setup information,
procedures for installing the inverter, as well as information about operating and
troubleshooting the unit. It does not provide details about particular brands of
batteries. You need to consult individual battery manufacturers for this
information.
Audience
The Manual is intended for anyone who needs to install and operate the DR
Inverter/Charger. Installers should be certified technicians or electricians.
Organization
This Manual is organized into four chapters and three appendices.
Chapter 1, “Introduction” contains information about the features and functions of
the DR Inverter/Charger.
Chapter 2, “Installation” contains information about how to plan for and install
the DR Inverter/Charger.
Chapter 3, “Operation” contains information about how to operate the DR
Inverter/Charger.
Chapter 4, “Troubleshooting” contains information about how to troubleshoot
possible error conditions while using the DR Inverter/Charger.
Appendix A, “Specifications” contains information about the electrical
specifications and environmental specifications of the DR Inverter/Charger.
Appendix B, “Appendix B, “Battery Information” supplies general information
about batteries such as battery types, battery bank sizing, battery configurations,
and battery care. For detailed information, see your battery manufacturer or your
system designer.”
Appendix C, “Multi-wire Branch Circuit Wiring” supplies information about
Multi-wire Branch Circuit Wiring Precautions when using stand-alone 120 Vac
inverters or generators.
975-0012-01-02 Rev A iii
About This Manual
Conventions Used
The following conventions are used in this guide.
WARNING
Warnings identify conditions or practices that could result in personal injury or loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other
equipment.
Important:
serious as a caution or warning.
These notes describe things which are important for you to know, but not as
Abbreviations and Acronyms
AC Alternating Current
ASC Authorized Service Center
AHJ Authority Having Jurisdiction
COM COMmunications Port
CW Clockwise (rotates to the right)
CCW Counter-clockwise (rotates to the left)
DC Direct Current
DR Inverter DR Inverter/Charger
DRI DR Interface (for stacking)
LED Light Emitting Diode
PV Photovoltaic
PVGFP PV Ground Fault Protection
RE Renewable Energy
RMA Return Material Authorization
Related Information
You can find more information about Xantrex Technology Inc. as well as its
products and services at www.xantrex.com.
iv 975-0012-01-02 Rev A
Important Safety Instructions
SAVE THESE INSTRUCTIONS
This manual contains important instructions for all DR Inverter/Charger models
that shall be followed during installation and maintenance of the inverter.
General
1. Before installing and using the DR Inverter/Charger, read all instructions and
cautionary markings on the DR Inverter/Charger and all appropriate sections
of this guide. Be sure to read all instructions and cautionary markings for any
equipment attached to this unit.
2. This unit is designed for indoor use only. Do not expose the DR Inverter/
Charger to rain, snow, or spray.
3. To reduce risk of fire hazard, do not cover or obstruct the ventilation
openings. Do not install the DR Inverter/Charger in a zero-clearance
compartment. Overheating may result.
4. Use only attachments recommended or sold by the manufacturer. Doing
otherwise may result in a risk of fire, electric shock, or injury to persons.
5. To avoid a 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 DR
Inverter/Charger with damaged or substandard wiring.
6. Do not operate the DR Inverter/Charger if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the DR Inverter/Charger is
damaged, see the Warranty section.
7. Do not disassemble the DR Inverter/Charger. It contains no user-serviceable
parts. See Warranty for instructions on obtaining service. Attempting to
service the DR Inverter/Charger yourself may result in a risk of electrical
shock or fire. Internal capacitors remain charged after all power is
disconnected.
8. The DR Inverter contains more than one live circuit (batteries and AC line).
Power may be present at more than one source. To reduce the risk of electrical
shock, disconnect both AC and DC power from the DR Inverter/Charger
before attempting any maintenance or cleaning or working on any circuits
connected to the DR Inverter/Charger. Turning off controls will not reduce
this risk.
9. Use insulated tools to reduce the chance of short-circuits when installing or
working with the inverter, the batteries, or a PV array.
975-0012-01-02 Rev A v
Safety
Wiring Requirements
1. All wiring methods and materials shall be in accordance with the National
Electrical Code ANSI/NFPA 70 (Current Edition). When sizing conductors
and conduits interfacing to the DR Inverter, both shall be in accordance with
the National Electric Code ANSI/NFPA 70, as well as all state and local code
requirements.
2. This product is intended to be installed as part of a permanently grounded
electrical system per the National Electric Code ANSI/NFPA 70 (current
edition). This is the single point earth ground for the inverter system.
3. Use copper conductors only with insulation rated for 75 °C.
4. The grounds on the DR Inverter are marked with this symbol:
5. The AC voltage and current on the DR Inverter is marked with this symbol:
6. The DC voltage and current on the DR Inverter is marked with this
symbol:
7. Phase on the DR Inverter is marked with this symbol:
WARNING Fire Hazard:
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. See “Multi-wire Branch Circuit Wiring” on page C–1 for details.
Explosive gas precautions
WARNING: Explosion Hazard
Working in the vicinity of lead-acid batteries is dangerous. Batteries generate
explosive gases during normal operation. Therefore, you must read this guide and
follow the instructions exactly before installing or using your DR Inverter/
Charger.
1. This equipment contains components which tend to produce arcs or sparks.
To prevent fire or explosion, do not install the DR Inverter/Charger in
compartments containing batteries or flammable materials, or in locations
that require ignition-protected equipment. This includes any space containing
gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other
connections between components of the fuel system.
2. To reduce the risk of battery explosion, follow these instructions and those
published by the battery manufacturer and the manufacturer of the equipment
in which the battery is installed.
vi 975-0012-01-02 Rev A
Precautions When Working With Batteries
WARNING: Explosion or Fire Hazard
Follow all instructions published by the battery manufacturer and the
manufacturer of the equipment in which the battery is installed.
1. Make sure the area around the battery is well ventilated.
2. Never smoke or allow a spark or flame near the engine or batteries.
3. Use caution to reduce the risk or dropping a metal tool on the battery. It could
spark or short circuit the battery or other electrical parts and could cause an
explosion.
4. Remove all metal items, like rings, bracelets, and watches when working with
lead-acid batteries. Lead-acid batteries produce a short circuit current high
enough to weld metal to skin, causing a severe burn.
5. Have someone within range of your voice or close enough to come to your aid
when you work near a lead-acid battery.
6. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
7. Wear complete eye protection and clothing protection. Avoid touching your
eyes while working near batteries.
8. If battery acid contacts skin or clothing, wash immediately with soap and
water. If acid enters your eye, immediately flood it with running cold water
for at least twenty minutes and get medical attention immediately.
Safety
9. If you need to remove a battery, always remove the grounded terminal from
the battery first. Make sure all accessories are off so you don’t cause a spark.
10. Always use identical types of batteries.
11. Never install old or untested batteries. Check each battery’s date code or label
to ensure age and type.
12. Batteries are temperature sensitive. For optimum performance, the should be
installed in a stable temperature environment.
13. Always recycle old batteries. Contact your local recycling center for proper
disposal information.
975-0012-01-02 Rev A vii
viii
Contents
Important Safety Instructions
1
Introduction
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
DC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Remote Control (RC8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Stacking Interface (DRI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Conduit Box (DRCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Unpacking and Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
2
Installation
Pre-installation Planning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Ventilation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Hardware / Materials Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
DC Terminal Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Grounding Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
AC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Wire Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Electrical Panels and Circuit Breaker Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
AC Distribution Panel (Sub-Panel) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
DC Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Battery Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Battery Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Basic Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Inverter Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
DC Circuit Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
General DC Grounding Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
975-0012-01-02 Rev A ix
Contents
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15
Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15
Battery Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15
Battery Cable Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–16
DC Disconnect and Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17
Battery Cable Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18
Connecting the Battery Bank to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–19
Installing a Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–21
AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22
AC Distribution Panel (Sub-panel) Mounting and Conduit Installation - - - - - - - - - - - - - - -2–22
Accessing the AC Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22
AC Output Wiring to the AC Distribution Panel (Sub-panel) - - - - - - - - - - - - - - - - - - - - - -2–25
AC Input Wiring - On-Grid Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–26
AC Input Wiring using a Generator in an On-Grid Application - - - - - - - - - - - - - - - - - - - - -2–27
AC Input Wiring - Off-Grid Applications using a 120 Vac Generator - - - - - - - - - - - - - - - -2–28
AC Input Wiring - Off-Grid Applications using a 240 Vac Generator for 120 Vac Loads - - -2–29
Series Stacking (120 Vac/60 Hz Models only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–30
3
Operation
Front Panel Controls and Indicators- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
POWER ON/OFF Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
BATTERY SENSE Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
COM Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Remote Controls (RC8/RC4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Stacking Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Battery Type Selector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
SEARCH MODE WATTS Potentiometer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Battery Charger Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Over Discharge Protection/AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Over Discharge Protection (ODP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10
Battery Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12
LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13
Inverter Mode LED - Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13
Over Temp / Overload LED - Red / Green (error condition) - - - - - - - - - - - - - - - - - - - -3–13
Battery High/Battery Low LED - Red/Green (error condition) - - - - - - - - - - - - - - - - - -3–13
Charger LED - Orange / Green - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14
Audible Indicator (internal) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14
Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15
x 975-0012-01-02 Rev A
Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16
Charger Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17
3-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17
Equalize Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18
4
Troubleshooting
Troubleshooting the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Ceiling Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Cell Phones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Computers and Sensitive Electronics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Consumer Electronics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Clocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Decreasing Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Dimmer Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Fluorescent Lights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Heavy Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Microwave Ovens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Rechargeable Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Undersized Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Contents
A
Specifications
Specifications of the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
B
Battery Information
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Deep-cycle Flooded Lead Acid (FLA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Sealed Batteries (Gel and AGM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
Understanding Battery Capacity Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
Understanding Amp-hour Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5
Calculating Amp Hours - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5
Amp Hour Example Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6
Battery bank size worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
Battery Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8
Wiring Batteries in Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8
Wiring Batteries in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–9
Wiring Batteries in Series-Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–10
Battery Connections for Stacked Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12
975-0012-01-02 Rev A xi
Contents
Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13
Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13
Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–15
General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–16
C
Multi-wire Branch Circuit Wiring
Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2
Identifying Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4
Correcting Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5
Warranty and Return Information
Index
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1
xii 975-0012-01-02 Rev A
Figures
Figure 1-1 Front Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Figure 1-2 AC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Figure 1-3 DC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Figure 1-4 Product Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Figure 1-5 Model/Serial Number Sticker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Figure 2-1 On-Grid Basic Configuration (Utility Backup)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Figure 2-2 Off-Grid Configuration (Generator only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Figure 2-3 On-Grid Configuration - with Renewable Energy Sources - - - - - - - - - - - - - - - - - - - - - 2–8
Figure 2-4 Off-Grid Configuration - with Renewable Energy Sources- - - - - - - - - - - - - - - - - - - - - 2–9
Figure 2-5 Charge Rate versus Peak AC Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Figure 2-6 Dimensions (not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Figure 2-7 Suggested Mounting Method - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Figure 2-8 Mounting on Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Figure 2-9 DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Figure 2-10 Battery Cable Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18
Figure 2-11 DC Terminals on the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19
Figure 2-12 Connecting the Battery Bank to the DR Inverter/Charger- - - - - - - - - - - - - - - - - - - - - 2–20
Figure 2-13 Battery Temperature Sensor (BTS) RJ11 Jack Location - - - - - - - - - - - - - - - - - - - - - 2–21
Figure 2-14 Connecting the BTS to the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21
Figure 2-15 AC Side Cover Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Figure 2-16 AC Terminals for AC Input to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
Figure 2-17 AC Terminals for AC output to the Sub-panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Figure 2-18 AC Wiring- On-Grid Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Figure 2-19 AC Wiring using a Generator - On-Grid Application - - - - - - - - - - - - - - - - - - - - - - - 2–27
Figure 2-20 AC Wiring using a 120 Vac Generator - Off-Grid Application - - - - - - - - - - - - - - - - - 2–28
Figure 2-21 AC Wiring using a 240 Vac Generator with 120 Vac Loads only- Off-Grid Application2–29
Figure 2-22 AC Wiring for dual-inverters - On-Grid Application (120 Vac models only) - - - - - - - 2–31
Figure 2-23 Wiring for dual-inverters - On-Grid Application (120 Vac models only) - - - - - - - - - - 2–32
Figure 3-1 Front Panel Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Figure 3-2 Battery Type Selector Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Figure 3-3 Battery Type Selector Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Figure 3-4 Battery Charger Rate Potentiometer (DR1512 values used) - - - - - - - - - - - - - - - - - - - - 3–8
Figure 3-5 ODP Enabled/Disabled Positions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Figure 3-6 Automatically Calculated Discharge Cutoff Voltage per Cell - - - - - - - - - - - - - - - - - - - 3–9
Figure 3-7 ODP Enabled/Disabled Positions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Figure 3-8 Typical Setting for Most Utility Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
975-0012-01-02 Rev A xiii
Figures
Figure 3-9 Battery Capacity Potentiometer (new) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12
Figure 3-10 Battery Capacity Potentiometer (old)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12
Figure 3-11 LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13
Figure 3-12 AC Pass-through and Charger AC Input Circuit Breakers- - - - - - - - - - - - - - - - - - - - -3–15
Figure 3-13 Startup Items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–16
Figure 3-14 Charger Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–18
Figure 3-15 Equalize Positions on Battery Type Selector Switch - - - - - - - - - - - - - - - - - - - - - - - -3–19
Figure 3-16 Equalize 1 Battery Charger Rate Potentiometer (Position “1”)- - - - - - - - - - - - - - - - - -3–20
Figure 3-17 Equalize 2 Battery Capacity Rate Potentiometer (Position “0”) - - - - - - - - - - - - - - - - -3–20
Figure B-1 6-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8
Figure B-2 12-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - B–9
Figure B-3 Battery Wiring in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–9
Figure B-4 Battery Wiring 24-volt - Parallel Configuration - Step 1 - - - - - - - - - - - - - - - - - - - - - B–10
Figure B-5 Battery Wiring 24-volt - Parallel Configuration - Step 2 - - - - - - - - - - - - - - - - - - - - - B–10
Figure B-6 Battery Wiring 24-volt - Parallel Configuration - Step 3 - - - - - - - - - - - - - - - - - - - - - B–11
Figure B-7 Example of Battery Connections for Stacked Inverters (24 Vdc shown) - - - - - - - - - - B–12
Figure C-1 Conventional Home-type Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2
Figure C-2 Multi-wire Branch Circuit Wiring and Current Flow - - - - - - - - - - - - - - - - - - - - - - - - C–3
Figure C-3 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit - - - - - - - - - - - - - - C–3
Figure C-4 Multi-wire Branch Circuit Wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4
Figure C-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring - - - - - - - - C–6S
xiv 975-0012-01-02 Rev A
Tables
Table 1-1 Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Table 1-2 Letter Suffix Code Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Table 2-1 Peak Input Filtrate versus Charging Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-2 Safety Ground Conductor Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Table 2-3 Minimum Recommended Battery Cable Size versus Length - - - - - - - - - - - - - - - - - - 2–16
Table 2-4 Battery Cable to Maximum Breaker/Fuse Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17
Table 2-5 Minimum Recommended Wire Size, Torque Values (Input and Output),
and Maximum Output Breaker Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Table 3-1 Battery Type Selector Switch Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Table 3-2 Approximate Charge rate Setting/Amperage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Table 3-3 ODP/AC Transfer Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10
Table 3-4 AC Pass-through Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
Table 3-5 Battery Charger Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
Table 4-1 Troubleshooting the DR Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Table A-1 Electrical Specifications for the DR Inverter/Charger - 120 Vac/60 Hz Models- - - - - - -A–2
Table A-2 Electrical Specifications for the DR Inverter/Chargers - 220 Vac/60 Hz Models - - - - - -A–4
Table A-3 Electrical Specifications for the DR Inverter/Charger - 230 Vac/50 Hz Models- - - - - - -A–5
Table A-4 Environmental Specifications for the DR Inverter/Charger - - - - - - - - - - - - - - - - - - - -A–7
Table B-1 Determining Average Daily Load in Amp-hours (Example - - - - - - - - - - - - - - - - - - - -B–6
Table B-2 Determining Battery Bank Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
Table B-3 Typical Appliance Wattage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
Table B-4 Variances in Charging Voltage based on Battery Temperature - - - - - - - - - - - - - - - - - B–14
Table B-5 Temperature Compensation Calculation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–14
Table B-6 Battery State-of-Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–17
975-0012-01-02 Rev A xv
xvi
1
Introduction
Chapter 1, “Introduction” contains information about the features and
functions of the DR Inverter/Charger.
Introduction
Introduction
Thank you for purchasing the DR Inverter/Charger from Xantrex Technology Inc.
The DR Inverter 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.
The DR Inverter 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.
Modified Sine
Wave P owe r
Battery Charger/AC
Transfer Relay
Simplicity The DR Inverter is simple to operate. All inverter and battery charger controls are
High Efficiency The inverter/charger operates at over 90% efficiency through most of its power
Low Power
Consumption
The DR Inverter provide a modified sine wave output which operates most AC
appliances and equipment.
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
20 to 30 amps for charging - depending on the model).
located on the front panel.
range in Invert-mode.
DR Inverter use extremely low current while in the search mode, consuming less
than 1 watt of power. In the O
of power.
N mode, the inverter/charger uses less than 12 watts
Features
The following sections illustrate the features of the DR Inverter. Figure 1-1 shows
the features of the front side of the DR Inverter and identifies the AC side from the
DC side.
1–2 975-0012-01-02 Rev A
Features
Battery Caps
Figure 1-1
AC Side
DC End
COM Port
Front Panel Features
The AC side of the DR Inverter has one 30-amp breaker for pass-thru AC Input,
and one 30-amp (20 amp in certain models) breaker for charger AC input.
Front Panel Controls
and Indicators
AC End
Battery Sense Port
30 Amp Breaker for
Pass-thru AC Input
20 or 30 Amp Breaker
for Charger AC Input
Ventilation Holes
Cover plate is not shown
in this photo.
Figure 1-2
AC Side of the DR Inverter
975-0012-01-02 Rev A 1–3
Introduction
DC Side
The DC side of the DR Inverter has the equipment ground lug, the positive (+)
battery terminal, and the negative (–) battery terminal.
Battery Positive
(+) Terminal
Ventilation Holes
Figure 1-3
DC Side of the DR Inverter
Optional Equipment
The following options are available for the DR Inverter/Chargers.
Remote Control (RC8)
The RC8 allows the inverter to be switched ON or OFF remotely and includes an
LED status indicator. This unit is also compatible with the RC4 (the predecessor
to the RC8); although the RC4 is no longer available for purchase from Xantrex.
Ventilation Holes
Battery Negative
(–) Terminal
Ground Lug
Stacking Interface (DRI)
The DRI stacking interface provides 3-wire 120/240 Vac at twice the power using
dual DR Inverters (120 Vac/60 Hz units only).
Conduit Box (DRCB)
The DRCB conduit box connects to the DC side of the inverter and accepts a DC
conduit run.
Unpacking and Inspection
Carefully unpack the inverter/charger from its shipping carton.
1–4 975-0012-01-02 Rev A
Features
Important:
additional help available if necessary, to assist in lifting the unit during installation.
The unit weighs 35–45 lb/15.9–20.4 kg (depending on model). Have
❐ Verify all of the items listed on the packing material sheet are present. Please
call Xantrex Customer Service at (800) 670-0707 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 “Information About Your System” on page WA–4.
Important:
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.
Due to continual improvement through product updates, photographs and/
Model Identification and Numbering Conventions
The DR Inverter is identified by the model/serial number labels. The Serial
Number can be located on the mounting rail or inside the top cover. Model
Number labels may be located on the bottom side of the front cover or possibly
inside the front 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
Table 1-1
DR
15
12
E
Product Family
Output Power
Figure 1-4
975-0012-01-02 Rev A 1–5
Model Identification and Numbering Conventions
indicates the type of inverter/charger - DR Series.
the first two digits of the numerical designator indicate the inverter’s output
power - 1500 Watts.
the second two digits indicate the required nominal battery bank voltage 12 Vdc.
the letter suffix code indicates the output voltage and frequency of the inverter 230 Vac/50 Hz.
Country Code
(Letter Suffix)
Example: DR 1512 E
Battery Voltage
Product Identification
Introduction
Table 1-2
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
Letter Suffix Code Definitions
Figure 1-5
Model Number Sticker
Regulatory
The 120 Vac/60 Hz models of the DR Series inverter/charger (models DR1512,
DR1524, DR2412, DR2424, and DR3624) are ETL Listed to UL Standard 1741,
(First Edition) Power Conditioning Units for use in Residential and Commercial
Photovoltaic Power Systems.
These standards guarantee that the DR Inverter/Charger has been tested to
nationally recognized safety standards (UL for the US) and have been found to be
free from reasonably foreseeable risk of fire, electric shock and related hazards.
The DR 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.
1–6 975-0012-01-02 Rev A
2
Installation
Chapter 2, “Installation” contains information about how to plan for
and install the DR Inverter/Charger.
Installation
Pre-installation Planning
Location
Important:
and cautionary markings on the DR Inverter/Charger and all appropriate sections of this
guide. Be sure to read all instructions and cautionary markings for any equipment attached
to this unit.
Take some time prior to installing the equipment to pre-plan the installation.
Location, mounting, and ventilation should be taking into consideration before
any cabling can be done.
Before installing and using the DR Inverter/Charger, read all instructions
CAUTION: Personal Injury
The inverter/charger can weigh up to 45 lbs (20.4 kg) depending upon configuration.
Always use proper lifting techniques during installation to prevent personal injury.
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.
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.
CAUTION: Corrosion Damage
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.
Important:
sensitive electronic equipment susceptible to RFI as far away from the inverter as
possible. This includes radios and TVs.
2–2 975-0012-01-02 Rev A
Inverters can generate RFI (Radio Frequency Interference). Locate any
Mounting
Ventilation
Pre-installation Planning
The National Building Code 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.
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 6 inches around the top
and sides of the inverter for ventilation.
Tools Required
The following tools may be required to complete this installation.
❐ #2 Phillips screw driver
❐ Slotted screw driver
❐ Assorted open-end wrenches
❐ Socket wrench and fittings
❐ Multimeter (True rms)
❐ Hole saw
❐ Level
❐ Wire strippers
❐ Torque wrench
❐ Electrical tape
❐ Pencil
❐ Utility knife
975-0012-01-02 Rev A 2–3
Installation
Hardware / Materials Required
The following hardware or materials may be required to complete this installation.
❐ 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 Considerations
All wiring and installation methods should conform to applicable electrical and
building codes.
Pre-plan the wire and conduit runs.
• The AC terminals accept cable sizes up to #6 AWG.
• The DC terminals accept cable sizes up to #4/0 AWG that use ring terminals
with 5/16" holes.
For maximum safety, run both AC and DC cables in conduit.
DC Terminal Connections
Battery-to-inverter cabling should be only as long as required.
For Example: If #4/0 AWG cables are used, 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 Considerations
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
electrical 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.
2–4 975-0012-01-02 Rev A
Wire Routing
Pre-installation Planning
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 electrical service panel to the inverter/charger
(if used)
• AC input wiring from the generator to the inverter/charger (if used)
• DC input wiring from the RE 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.
Electrical Panels and Circuit Breaker Requirements
The following electrical panels and circuit breakers may be required for this
installation.
AC Distribution Panel (Sub-Panel)
Loads backed up by the inverter will need to be rerouted from the main electrical
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.
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.
Battery Considerations
The DR Inverter can support either 12-volt battery banks or 24-volt battery banks.
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.
975-0012-01-02 Rev A 2–5
Installation
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.
Basic Configurations
The following illustrations show basic applications for the DR Inverter/Charger.
They include the following configurations.
• On-Grid Configuration - Utility Backup
• Off-Grid Configuration - Generator only
• On-Grid Configuration with Renewable Energy Sources
• Off-Grid Configuration with Renewable Energy Sources and a Generator
Consult with your system design for other possible configurations depending on
site and code requirements.
2–6 975-0012-01-02 Rev A
Loading...