Xantrex Technology Freedom 458 User Manual

Xantrex Freedom 458 Series Inverter/Charger
Freedom 458 10 15 20 25 30
Owner's Manual
Thank you for purchasing a Xantrex Freedom 458 Series Inverter/Charger. Xantrex Technology Inc. takes pride in manufacturing quality products specifically designed to meet your power requirements.
Freedom 458 Inverter/Chargers provide silent, efficient and reliable AC power for a variety of applications. They feature “hands-free” operation, automatic three-stage battery charging and automatic AC transfer switching. For your convenience, service is available world-wide from qualified service centers.
If you have any questions about your Freedom Inverter/Charger, please contact Xantrex at 1-800-670-0707 (toll free) or 1-604-422-2777 (direct).
For technical support and additional information about Xantrex products, visit our Web site at www.xantrex.com or e-mail us at CustomerService@xantrex.com
SAFETY SUMMARY
Definitions:
Warning statements identify conditions or
practices which could result in personal injury, loss of life, damage to equipment or other property.
Fuse Replacement For continued protection against the possibility of fire, replace the fuse only with a fuse of the specified voltage, current and type ratings.
Power Source To avoid damage, operate the equipment only within the specified AC (line) and DC (battery) voltages.
Servicing To reduce the risk of electric shock do not open this unit. There are no user serviceable parts inside. Refer all service to qualified personnel.
Notice of Copyright
Xantrex Freedom 458 Series Inverter/Charger © December 2002 Xantrex International. All rights reserved. Xantrex is a registered trademark of Xantrex International.
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 December 2002, Revision 2 Part Number 445-0193-01-01
Contact Information Web: www.xantrex.com Email: CustomerService@xantrex.com
Phone: 1-800-670-0707 (toll free in North America), 1-604-422-2777 (direct) Fax: 1-604-420-2145
2
TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 4
Things You Should Know . . . . . . . . . . . . . 5
Circuit Breaker Protection Thermostat Controlled Cooling Inverter Idle Circuit Low and High Battery Shutdown Power Sharing Temperature Sensitive Charging
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Optional Remote Control Panels . . . . . . . . .10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Types Battery Interconnection Battery Bank Ratings and Sizing
Battery Charging. . . . . . . . . . . . . . . . . . . . 15
Freedom Battery Chargers
Battery Charger Voltage Settings . . . . . . .20
Installation Precautions . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 22
Key Installation Points Grounding Neutral Bonding AC Wiring AC Input AC Output Ground Fault Circuit Interrupters Remote Control Wiring TSC Temperature Sensor DC Wiring Battery Cable Fusing Power ON Checks
Troubleshooting . . . . . . . . . . . . . . . . . . . . .31
LED Fault Status
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation Examples. . . . . . . . . . . . . . . . . . . 39
Not recommended for use in a marine environment
3
INTRODUCTION
This owner’s manual describes the Freedom 458 Series Xantrex. These units perform three distinct functions:
1. DC to AC power inverting.
2. Automatic transfer switching between inverter power and incoming AC power.
3. Automatic three-stage battery charging plus manual battery equalizing.
• The inverter provides regulated 120 volt AC power at a crystal controlled frequency from a deep cycle battery bank and is rated at:
Freedom 10 1000 watts
Freedom 15 & 15D 1500 watts Freedom 20 & 20D 2000 watts Freedom 25 2500 watts Freedom 30 3000 watts The output is a modified sine wave and is
compatible with most appliances, tools and other 120 VAC equipment. (Note: Certain laser printers, breadmakers, digital clocks and small battery chargers may not operate on modified sine wave.) An idle mode reduces battery power consumption when loads are removed from the inverter. There is a low battery cutout protection circuit and momentary surge power of more than twice the inverter rating for start­ing electric motors. High efficiency ensures the longest possible battery life between charges.
• The internal transfer switch allows the Freedom Inverter/Charger to be connected to an external AC source and transfer the source power through directly to the loads. When the external AC power source is disconnected, the transfer switch allows automatic switching back to the inverter.
Inverter/Chargers from
The Freedom Inverter/Charger operates as a self-contained backup power system— just add batteries.
• Freedom battery chargers are electronically controlled and rated at a maximum output current:
Freedom 10 50 amps DC
Freedom 15 & 15D 75 amps DC Freedom 20 & 20D 100 amps DC Freedom 25 130 amps DC Freedom 30 140 amps DC
They are designed to rapidly and optimally charge wet, gel, or Absorbed Glass Mat (AGM)** cell deep-cycle batteries. Battery charging is automatically accomplished in three stages: Bulk Charge, Acceptance Charge and Float Charge.
Using a Remote Control Panel or Link Instrumentation, a manually engaged Equalizing Charge cycle is possible. Simple, automatic operation is made possible by the microprocessor in the Freedom Inverter/Charger. In most cases, no attention or maintenance is required.
Electronic Protection
Fast-acting electronic circuits protect the inverter from overloads and short circuits. Other protection includes a low and high battery voltage cutoff and automatic shutdown if an over-temperature condition occurs. When the fault condition is corrected, the unit will automatically reset. Example: remove overload, charge batteries or allow to cool.
**Battery type selection is set on the front of the unit or with an optional remote (Remote Control Panel or Link Instrument).
4
THINGS YOU SHOULD KNOW
Circuit Breaker Protection
The Freedom Inverter/Charger is supplemental breaker protected. The INVERT/CHARGE breaker on the front of the unit protects against sustained inverter/ charger over-current conditions. These breakers are reset by pushing the button back in. The output circuit breakers protect the output AC circuits. Models are available with one or two outputs.
Thermostat Controlled Cooling
Freedom Inverter/Chargers are equipped with a thermostatically controlled fan that cools the unit so it can operate continually at its rated units with only supplemental circuit breakers between the unit and the load. Appropriate wire gauges must be used throughout the installation. Refer to NEC specifications.
Circuit Breaker Protection
INV/CHG
10
15
15D
20
20D 25
25
30
*Circuit breaker configurations include 15/15,
*Note: Supplemental circuit breakers are reset by pushing the button back in. The fault must be removed before resetting the circuit breaker. Inte­gral branch circuit rated breakers are reset by setting the appropriate breaker switch to the “on” position. The fault must be removed before re­setting the circuit breaker. If a 30-ampere service supplies the input to the unit, a model with integral branch circuit rated breakers allows direct wiring from the unit to the load.
15
20
20
25
25
30
30
15/20, and 20/20
OUT 1
N/A
N/A
15/20*
N/A
15/20*
N/A
N/A
OUT 2
N/A
N/A
15/20*
N/A
15/20*
N/A
N/A
Inverter Idle Circuit
This automatic energy saving feature reduces battery power consumption when no AC load is present. Response from idle is instantaneous. In most cases, the operation of the idle circuit is not noticeable. Use of the Remote Control Panel or Link Instrumentation allows the idle threshold to be adjusted. The unit does not put out 120 volts when in idle. To bring the unit out of the idle condition, apply a load.
Low and High Battery Shutdown
When in invert mode, if the battery voltage drops to 10.0 volts, the inverter will automatically shut off. Charge the batteries to
13.5 volts to automatically resume operation.
Voltage shutdown also occurs for a high battery condition at 15.5 volts. Operation will resume automatically when the battery voltage drops below 15.5 volts. Check all DC sources on the system for the reason for the excessive voltage.
Power Sharing
When connected to an external AC source the battery charger and transfer functions are engaged. A unique Power Sharing feature automatically reduces the AC power consumption of the battery charger allowing necessary AC power to go to the load. This prevents the source AC INPUT circuit breaker from tripping within the specified rating of the AC circuit breaker.
The Power Sharing set point of each unit has a factory default setting of 30 amps. This can be changed using the Remote Control Panel or Link Instrumentation.
5
THINGS YOU SHOULD KNOW
Freedom 458 Series
with Branch Circuit Rated Breakers
Branch Circuit Breakers
20 Amp
15 Amp
Shown: Freedom 20D 81-2022-12
Integral Branch Circuit Rated Breakers Models 15D&20D
Inverter/Charger
Branch Circuit Rated Breaker
INPUT
To LOADS
Temperature Sensitive Charging When the supplied battery temperature
sensor is connected to the unit and the batteries, the charge voltage is controlled based on battery temperature. The charger adjusts the charge voltage to the best level, minimizing water loss in wet cell batteries. Charge voltage regulation optimizes the bat­tery life cycle.
TSC Sensor
Battery
Units with integral branch circuit rated breaker protection require a branch circuit rated breaker at the input only. The output to two branch loads may be connected directly at the unit output.
NOTE: The INPUT branch rated circuit breaker may be at the source of AC power (such as shorepower or generator, or from a main AC distribution panel located before the input of the unit).
Supplemental Branch Circuit Rated Breakers
Inverter/Charger
Models
10,15,20,25,30
Branch Circuit Rated Breaker
6
INPUT
*Models 25 and 30 include a
second input and output
Branch Circuit Rated Breaker
OPERATION
The Freedom 458 Inverter/Charger provides 120 volt AC power from auxiliary DC batteries, automatic battery charging and automatic AC transfer switching between an external AC source and inverter mode.
External AC Power
When external AC power is available, the three-stage battery charger, transfer switching, and Power Sharing automatically function.
When external AC power is not available and the INVERT switch is ON (either through the auxiliary switch or the INVERT button on the remote), the inverter will automatically turn ON. If the INVERT switch is OFF (the INVERT LED will not be illuminated), the inverter will be OFF.
If installed with the Remote Control Panel or Link Instrumentation, the unit will be set up and controlled from the remote. Refer to the remote manual for more information.
Front Panel Controls and Indicators
INVERT MODE
The INVERT push-button switch is located on the front of the unit and has two functions:
• Turn the inverter ON/OFF and reset after a fault condition. Pressing the INVERT switch turns the inverter ON. The green INVERT LED will be ON when the inverter is inverting. When the inverter is ON, pressing the INVERT switch turns the inverter OFF.
INVERT
CHARGE
• Battery type setup. To enter the battery type select mode, press and hold the INVERT switch for five seconds. The status LEDs will change from indicating status information to indicating battery type. The selection of the battery type is made with the Charge switch.
Turning the INVERT OFF will reduce battery power consumption to a very low level. This is recommended if the unit will not be used for an extended period of time.
CHARGE MODE
The CHARGE push-button switch has two functions:
Turn the charger ON and OFF If external AC is present, pressing the CHARGE switch will turn the charger ON. The green CHARGE LED will be ON when the charger is charging. When the charger is ON, pressing this switch will turn the charger OFF.
Select the battery type After holding the INVERT switch for five seconds, press the CHARGE switch to select the battery type. One of the four LEDs will rapidly blink, indicating the present battery type setting. Press the CHARGE switch again to change the battery type. Continue to press until the desired battery type is selected. If the CHARGE switch is not pressed for five seconds, the unit will return to normal operation and the battery type selection will have been made.
When the 12-volt input to the unit is disconnected, the battery type setting is stored in non-volatile memory. When the unit is reconnected, the battery type selection conveniently returns to the setting.
Freedom 20
7
OPERATION
STATUS LEDs
Each Status LED performs two functions, providing battery type selection and operation status.
Status LEDs
INVERT
CHARGE
OVERTEMP OVERLOAD / AGM
LOW BATTERY / GEL 2
CHARGE / GEL1
INVERT / WET
REMOTE
TSC
Battery Type Selection
After holding the INVERT button down for five seconds, use the CHARGE button to select battery type:
WET GEL 1 GEL 2 AGM
Operation Status
INVERT - Green LED
The INVERT push-button switch is located on the front of the unit.
• When the LED is solid green, the unit is in invert mode. This occurs by pressing the INVERT switch for (three to five seconds).
• When the LED is blinking slowly (once per second), the inverter is in standby with AC power applied and the transfer switch engaged
• Press the INVERT switch again to turn the inverter OFF.
CHARGE - Green LED
• The CHARGE push-button switch is located on the front of the unit.
When external AC is applied to the AC input of the unit, the charger automatically turns ON. The CHARGE LED will be solid green.
• When the LED is blinking slowly (once per second), the charger is ready, but external AC power is not available.
• Press the CHARGE switch again to turn the charger OFF. The charger defaults to ON when operation without a remote or with the Freedom Remote Control Panel.
• When the LED is OFF, the charger has been manually turned OFF. This can only be accomplished while AC power is being supplied.
NOTE: When AC power is available, the default setting for the charger is ON. If the unit was manually turned OFF and AC power is interrupted and becomes available again, the charger will return to ON.
LOW BATTERY - Red LED
When the LED is OFF the battery
voltage is normal, between 10.5 and 15.0 volts DC.
• When the LED is solid red, it indicates a battery warning condition, the battery voltage is below 10.5 volts DC or above 15.0 volts DC.
• When the LED is blinking slowly, (once per second), a battery shutdown has occurred. The voltage is either below 10.0 volts DC or above 15.5 volts DC.
• When the LED is blinking rapidly (five times per second), a potential problem in the DC system has been detected. Check your batteries, battery cables and DC loads.
OVERTEMP/OVERLOAD - Red LED
When the LED is Off, operation is
normal.
• When the LED is red, there is an over temp or overload condition. Check for excessive loads or a short circuit on the output of the inverter. Correct the condition and restart by pushing the INVERT switch.
8
• When the LED is blinking slowly (once per second), an over-current condition or a short circuit has occured. The system has shut OFF and will not automatically restart. Correct the fault condition and manually restart the system.
LOW BATTERY AND OVERTEMP/OVER­LOAD - Red LEDs
• When both LEDs are blinking, an AC backfeed has been detected. A backfeed occurs when AC power from an external source is connected to the output of the inverter. Inspect wiring for possible input/output wiring error. This condition will damage the unit and must be corrected before further operation.
TSC (Temperature Sensitive Charging)
This provides for the connection of a sensor to measure battery temperature for compensated charging. If no sensor is connected the charge voltage levels are set to defaults based on battery type.
Low Battery
Overtemp
Remote
OPERATION
TSC
Auxiliary Port
OPTIONAL REMOTES
If using one of the remotes, refer to the installation instructions included with the remote.
Note: When a Freedom Remote Control Panel or Link is installed, the jumper included in the parts plastic bag is Auxiliary Switch Port (AUX SWITCH) on the front panel of the inverter/charger. See page 23 for more details.
not used in the
9
OPTIONAL REMOTE CONTROL PANELS
Freedom Remote Control Panel
An optional remote control panel is available. The LED bar graphs on the remote control panel show battery voltage and DC current in both inverter and charger modes.
Easy-to-see red, yellow and green LEDs show the battery state of charge. Power Sharing, charger ON/OFF, inverter ON/OFF controls are provided. Setup features include selection of Idle Threshold, Battery Type and Battery Capacity.
Freedom Remote Control Panel
LINK 2000
The Link 2000 has the same features as the Link 1000, providing inverter/charger control and complete battery state of charge information. It monitors two battery banks.
LINK 2000
LINK 2000-R
The Link 2000-R adds the ability to regulate an engine-driven alternator. The precision regulator in the Link 2000-R allows the alternator to be controlled as a three-stage battery charging system.
ADVANCED REMOTE CONTROL PANELS Link Instrument
Advanced remote control panels are also
available: the Link 1000, 2000 and 2000-R.
LINK 1000
Link 1000 controls the Freedom Inverter/ Charger and provides complete battery state of charge information including DC voltage, current, amp hours consumed, Time Remaining and historical data for a single battery bank.
LINK 1000
10
If a Link Instrument is used to control the inverter/charger, refer to the Link Owner’s Manual for setup and control information.
Refer to the Freedom Remote Control Panel
or Link Owner’s Manual for
installation and operation instructions
The jumper is not installed in the AUX Switch Port on the front panel of the inverter when the Freedom Remote Control Panel or Link Instrument is used. See page 23 for more details.
BATTERIES
Wet cell batteries will give off gas as a natural result of charging and will experience some water loss. It is very important that the electrolyte level be checked frequently and topped off with distilled water when necessary. Follow the battery manufacturer’s recommendations for maintenance.
Never allow the top of the battery plates to be exposed to air, as contamination of the cell will result. Keep the top of batteries clean. Always provide adequate ventilation for the battery storage compartment.
BATTERY TYPES
Use only deep-cycle batteries with your Freedom Inverter/Charger. These fall into three broad categories: wet cell, gel cell and Advanced AGM (Absorbed Glass Mat) batteries.
Wet Cell Batteries
True deep-cycle wet cell batteries are characterized by relatively thick internal plates that are alloyed with antimony.
Common 12-volt marine/RV deep-cycle batteries are acceptable. Golf cart batteries perform well and may have a longer life. These 6-volt batteries must be used in series connected in pairs. High quality deep-cycle batteries offer good performance and are available in a wide
variety of sizes.
Do not use ordinary car batteries or engine starting batteries with your inverter/ charger. Beware of any battery that is rated in Cold Cranking Amps (CCA). This is a rating which applies only to engine starting batteries. In general, most wet cell batteries that are described as hybrid type batteries, suitable for either engine starting or deep-cycle applications are a compromise and will have limited life if deeply discharged.
11
BATTERIES
Beware of so-called maintenance-free
batteries. These batteries have calcium
alloyed with the lead and hold the liquid electrolyte in a sponge-like material. They are sealed and water cannot be added. Do not confuse them with true gel cell or AGM batteries—they will not hold up well to deep discharging and repeated cycling.
Gel Cell Batteries
Gel cell batteries are lead-acid batteries similar in many ways to the common wet cell battery, but differences in the chemistry and construction provide some unique features.
• No Maintenance
• Low Self-Discharge Rate
• Low Internal Resistance
Even though gel cells are sealed batteries, the battery compartment should still be ventilated.
Series
Connecting two batteries in series will double the voltage of the battery bank. For instance, two 6-volt batteries connected in series will produce 12 volts. The amp-hour capacity of the battery bank will be the same as each individual battery. Example, two 6-volt 220 amp-hour batteries in series will produce one 12-volt 220 amp-hour battery bank.
+
+
+
Series
Advanced AGM (Absorbed Glass Mat) Batteries
This battery is lead acid but maintenance­free. The performance is similar to gel cell batteries. The charge parameters are similar to wet cell batteries.
Battery Selection
The most important feature to consider in making your battery selection is to select true deep cycle batteries rated in amp hours (Ah) and sized to match your power requirements.
BATTERY INTERCONNECTION
In most cases, you will be using a bank of two or more batteries with your inverter/ charger. You may connect batteries together in two configurations—series and parallel— depending on their voltage.
12
Series Increase Voltage
+
6 V
_
EACH BATTERY
CAPACITY:
220
AMP HOURS
@ 6 VDC
+
6 V
_
+
12 V INVERTER
_
TOTAL BATTERY
BANK CAPACITY:
220
AMP HOURS
@ 12 VDC
BATTERIES
Parallel
Connecting two batteries in parallel will double the amp-hour rating of the battery bank, while the voltage will be the same as each individual battery. For example, two 12-volt 105 amp-hour batteries in parallel will produce one 12-volt 210 amp-hour battery bank.
+
+
Parallel
Parallel Increase Amp-Hour Capacity
+
12 V
_
EACH BATTERY
CAPACITY:
105
AMP HOURS
@ 12 VDC
12 V
_
+
+
1
2 V INVERTER
_
TOTAL BATTERY
BANK CAPACITY:
210
AMP HOURS
@ 12 VDC
Note: It is not advisable to connect batteries of different case sizes or amp-hour ratings in the same battery bank.
Always use properly sized wire and terminals for your interconnecting battery cables. For size information refer to NEC requirements or contact your local electrician.
BATTERY BANK RATINGS AND SIZING
Deep-cycle batteries are usually rated in amp hours. The amp-hour rating is based on a 20-hour discharge rate; therefore, a 100 amp-hour battery can deliver 5 amps for 20 hours. If the discharge rate is greater than 5 amps, the available amp hours are decreased. For example, if the load is increased to 100 amps, only about 45 amp hours will be avail­able at this rate of discharge.
Deep-cycle batteries can be discharged about 80% of capacity before damage occurs. Shallow cycling will result in much longer battery life. Calculating a battery bank size based on 50% discharge cycling is generally considered to be a good compromise between long battery life and size.
Only similar batteries should be
connected together in one bank. Do not
connect old and new batteries together or wet and gel cell batteries together. In the above drawing, the load is connected to the positive terminal of the first battery and the negative terminal of the last battery. This practice helps to balance the battery bank and is called cross-connecting the battery bank.
13
BATTERIES
To achieve 50% cycling you should calculate your amp-hour consumption between charging cycles and use a battery bank with twice that capacity**. Each AC appliance or tool has a rating plate on it and will be rated in either AC amps or watts or AC VA (volt-amps) apparent power. To calculate amp­hour consumption, use one of the formulas to the right to calculate the DC amp-hour draw for a 12-volt system.
Calculate the amp hours for every AC appliance or tool that will be operated on the inverter. This will provide the total number of amp hours used between recharges. Size the battery bank using this number as a guideline. A good rule to follow is to size the battery bank a minimum of two times larger than the total amp-hour load requirement. Plan on recharging when 50% discharged.
**Batteries are typically charged to 85% of full charge when charging with alternators without three­stage regulators.
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14
AMP-HOUR CONSUMPTION FORMULAS
(AC amps x 10) x 1.1 x hours of operation = DC amp hours
(watts/ DC voltage) x 1.1 x hours of operation = DC amp hours
(AC VA/ DC voltage) x 1.1 x hours of operation = DC amp hours
DC voltage is 12, 24 or 32 depending on
your system.
In all formulas, 1.1 is the correction factor for
inverter efficiency.
Typical Power Consumptlon
The chart identifies typical power consumption for common AC loads. Use it as a guide when identifying your power requirements.
Many electric motors have momentary starting requirements well above their operational rating. Start up watts are listed where
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appropriate. Individual styles and brands of appliances may vary.
If using the same battery bank for the inverter and other DC loads, be sure to consider the power consumption of the DC loads when sizing the battery bank.
NOTE Certain laser printers, breadmakers, digital clocks and appliance/tool chargers
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may not operate on modified sine wave.
BATTERY CHARGING
Battery Charging
Completely charging wet cell deep-cycle batteries requires the battery voltage to be raised beyond what is known as the gassing point. This is the voltage at which the battery begins to bubble and gas is given off. If charging stops short of this point, sulfate is left on the plates and deterioration of the battery begins. The gassing point will vary with battery temperature.
At 77 °F, the gassing point of a 12-volt battery is about 14.0 volts.
AGM and Gel cell batteries must not be charged to their gassing point. In fact, high­voltage charging that gasses these batteries is harmful to them. They typically require a lower bulk charge voltage and a higher float voltage than wet cell batteries. Consult the battery manufacturer for specifications.
Freedom Battery Chargers
Freedom battery chargers are designed to overcome the limitations of conventional chargers by utilizing three distinct charge stages, each designed for optimal charging of wet, gel cell and AGM deep-cycle batteries. Battery type selection is made on the front panel of the inverter/charger or through the Freedom Remote Control Panel or Link Instru­mentation. For more information on battery type selection, see page 7 or refer to the Freedom Remote Control Panel manual.
15
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