Xantrex Technology HW 1000 User Manual

Freedom HW 1000 Inverter/Charger

Owner’s Guide

Freedom HW 1000 Inverter/Charger

Owner’s Guide

About Xantrex

Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in the development, manufacturing and marketing of advanced power electronic products and systems for the renewable and mobile power markets. The company's products convert and control raw electrical power from any central, distributed, renewable, or backup power source into high-quality power required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver, Canada, with facilities in the United States, Germany, Spain, and a joint venture in China.

About Schneider Electric

As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in energy and infrastructure, industrial processes, building automation, and data centres/networks, as well as a broad presence in residential applications. Focused on making energy safe, reliable, and efficient, the company's 120,000 employees achieved sales of more than 17.3 billion euros in 2007, through an active commitment to help individuals and organizations “Make the most of their energy™”.

Trademarks

Xantrex, Freedom, Smart Choice for Power, and Make the most of their energy are trademarks of Schneider Electric Services International sprl, registered in the U.S. and other countries.

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

Xantrex Freedom HW Inverter/Charger Owner’s Guide © December 2008 Xantrex Technology Inc. All

rights reserved. No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of: Xantrex Technology Inc., 5917-195th St NE, Arlington, WA

98223. Xantrex Technology Inc. reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement.

Exclusion for Documentation

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 LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, 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; AND

STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision Document Part Number Product Number

December 2008 Rev A 975-0467-01-01 806-1055

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

1 408 987 6030 (direct)

Fax: 1 800 994 7828 (toll free North America)

Email: customerservice@xantrex.com

Web: www.xantrex.com

About This Guide

Purpose

The purpose of this Owner’s Guide is to provide explanations and procedures for operating, maintaining, and troubleshooting a Freedom

HW Installation*.

For complete information to help in setting up a Freedom HW Installation see the Freedom HF Inverter/Charger Installation Guide (Doc. Part

Number: 975-0468-01-01).

* Recreational or Fleet Vehicle installation.

Scope

The Guide provides safety guidelines, as well as information about operating and troubleshooting the installation. It does not provide details about particular brands of batteries. You need to consult individual battery manufacturers for this information.

Audience

Organization

iii

The Guide is intended for users and operators of the Freedom HW

Inverter/Charger unit.

This Guide is organized into five chapters and one appendix. Chapter 1 introduces you to the Freedom HW, explains the inverting,

charging, and power system management functions. Chapter 2 contains information and labeled illustrations to help identify

the various features of the Freedom HW. Chapter 3 explains how to configure the Freedom HW to best meet your

electrical system requirements.

About This Guide

Chapter 4 explains how to operate the Freedom HW efficiently and effectively.

Chapter 5 describes how to troubleshoot the Freedom HW Inverter/ Charger during operation.

Appendix A contains electrical performance information and product specifications.

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:

but not as serious as a caution or warning.

These notes describe things which are important for you to know,

Related Information

You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com

iv 975-0467-01-01

Important Safety Instructions

READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE

REFERENCE.

This chapter contains important safety and operating instructions for the

Freedom HW Inverter/Charger unit.

WARNING: Limitations on use

The Freedom HW is not intended for use in connection with life support systems or other medical equipment or devices.

1. Before installing and using the Freedom HW, read all instructions and cautionary markings on the Freedom HW, the batteries, and all appropriate sections of this guide.

CAUTION: Risk of injury

To reduce the risk of injury, charge only 12 Vdc lead-acid (GEL, AGM, or Flooded) rechargeable batteries. Other battery types may burst, causing personal injury and damage.

2. Do not expose the Freedom HW to rain, snow, spray, or bilge water. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the Freedom HW in a zero-clearance compartment. Overheating may result.

3. 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 Freedom HW with damaged or substandard wiring.

4. The use of any attachments not recommended or sold by Xantrex, may result in risk of fire, electric shock, or injury to persons.

5. Do not operate the Freedom HW if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the Freedom HW is damaged, see the Warranty section.

Safety

6. Do not disassemble the Freedom HW. It contains no user-serviceable parts. See Warranty for instructions on obtaining service. Attempting to service the Freedom HW yourself may result in a risk of electrical shock or fire and will void your warranty. Internal capacitors remain charged after all power is disconnected.

7. To reduce the risk of electrical shock, disconnect both AC and DC power from the Freedom HW before attempting any maintenance or cleaning or working on any circuits connected to the Freedom HW. Turning off controls will not reduce this risk.

8. The Freedom HW must be provided with an equipment-grounding conductor connected to the AC input ground.

WARNING: Explosion hazard

1. Working in the vicinity of batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, it is of utmost importance that each time before servicing the unit in the vicinity of the battery , that you read this manual and follow the instructions exactly.

2. This equipment contains components which tend to produce arcs or sparks. To prevent fire or explosion, do not install the Freedom HW 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.

3. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of any unit you intend to use in the vicinity of the battery.

vi 975-0467-01-01

Personal Precautions When Working With Batteries

Safety

WARNING: B

URN FROM HIGH SHORT-CIRCUIT CURRENT

XPLOSION FROM VENTED GASES

RECAUTIONS

1. Study and follow all of the battery manufacturer's specific

precautions, such as removing or not removing cell caps while charging, and recommended rates of charge.

2. Add distilled water in each cell until battery acid reaches the level

specified by the battery manufacturer. This helps to purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully follow manufacturer's recharging instructions.

3. Make sure the area around the battery is well ventilated.

4. Never smoke or allow a spark or flame near the engine or batteries.

5. Use extra 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.

6. Remove all metal items, like rings, bracelets, and watches when

working with batteries. Batteries can produce a short circuit current high enough to weld metal to skin, causing a severe burn.

7. Have someone within range of your voice or close enough to come to

your aid when you work near a lead-acid battery.

ATTERIES PRESENT RISK OF ELECTRICAL SHOCK

, F

. O

BSERVE PROPER

IRE OR

8. Have plenty of fresh water and soap nearby in case battery acid

contacts skin, clothing, or eyes.

9. Wear complete eye protection and clothing protection. Avoid

touching your eyes while working near batteries.

975-0467-01-01 vii

Safety

10. 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.

11. If you need to remove a battery, always remove the ground terminal from the battery first. Make sure all accessories are off so you don’t cause an arc.

12. Never charge a frozen battery.

13. Clean battery terminals. Be careful to keep corrosion from coming into contact with your eyes.

14. Locate the Freedom HW unit away from batteries in a separate, well ventilated compartment.

15. Never place the Freedom HW unit directly above batteries; gases from a battery will corrode and damage the unit

16. Never allow battery acid to drip on the unit when reading gravity, or filling battery.

17. Do not operate the unit in a closed in area, or restrict the ventilation in any way.

DC CONNECTION PRECAUTION

18. Connect and disconnect DC output connections only after setting any recreational vehicle unit switches to off position and opening AC disconnect.

19. Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

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Precautions for Using Rechargeable Appliances

CAUTION: Equipment damage

Most rechargeable battery-operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage charging output.

Some chargers for small rechargeable batteries can be damaged if connected to the Freedom HW. Do not use the following with the

Freedom HW:

• Small battery-operated appliances like flashlights, razors, and night

lights that can be plugged directly into an AC receptacle to recharge.

• Some chargers for battery packs used in powerhand tools. These

affected chargers display a warning label stating that dangerous voltages are present at the battery terminals.

Safety

Important:

Freedom HW, contact the equipment manufacturer to find out if the appliance is

acceptable for use with modified sine wave input voltage. See the detailed description of the Freedom HW waveform in Appendix A, “Specifications” under “Electrical Specifications: Inverter Mode” on page A–2.

if you are unsure about using your rechargeable appliance with the

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Contents

Important Safety Instructions 1

Introduction

Freedom HW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Independent Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3

Features

Materials List- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Default Settings for the Freedom HW System - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3 Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Side Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4 Rear Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Display Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

Configuration

Setting Battery Types on the Main Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Viewing Inverter/Charger Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Adjusting Feature Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

Operation

Display Panel Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2 Operating in Shore Power Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3

Inverter Mode Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3

Operating in Inverter Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–4

Disabling the Inverter Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Checking Battery Status - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Checking Output Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5 Adjusting the Audible Alarm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–5 Status LED During Inverter Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–6

Operating During Transition Between Shore Power and Inverter Mode- - - - - - - - - - 4–8

Transitioning from Shore Power to Inverter Mode - - - - - - - - - - - - - - - - - - - - - 4–8 Transitioning from Inverter Mode to Shore Power - - - - - - - - - - - - - - - - - - - - - 4–8

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Contents

Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9

Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9 Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9

Inverter Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10

Overload Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10 High Surge Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10 Trouble Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11

Over-temperature Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11 Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12 Routine Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14

Freedom HW Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14

Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–14

Troubleshooting

General Troubleshooting Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Common Problems- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4

Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4

Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Warning Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8 Inverter Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10

Resistive Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10

Motor Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11

Long Transfer Times - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11

High Surge When Powering Incandescent and CFL Bulbs - - - - - - - - - - - - - - 5–11

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Contents

Specifications

Electrical Specifications: Inverter Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

Electrical Specifications: Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5

Inverter Overload Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5

Invert Power Derating vs. Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - A–6

Charger Output Current vs. AC Input Voltage- - - - - - - - - - - - - - - - - - - - - - - - - - A–7

Warranty and Return Information

- - - - - - - - - - - - - - - - - - - - - - - - - - -WA–1

975-0467-01-01 xiii

Contents

xiv 975-0467-01-01

Figures

Figure 2-1 What’s In The Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Figure 3-1 Dip Switches (Factory Setting Shown) - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Figure 3-2 Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Figure 4-1 Three-stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12

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xvi

Tables

Table 2-1 Freedom HW Default Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Table 3-1 Charging Current Guidelines- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Table 4-1 Status LED during Inverter Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6 Table 4-2 Battery Charging Status LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–13 Table 4-3 Battery Charging Voltage and Current Settings - - - - - - - - - - - - - - - - - - 4–14 Table 5-1 Error Codes Displayed on the Display Panel Screen - - - - - - - - - - - - - - - 5–5 Table 5-2 Troubleshooting Reference- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8 Table A-1 Charging Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7

975-0467-01-01 xvii

xviii

1 Introduction

Chapter 1 introduces you to the Freedom HW, explains

the inverting, charging, and power system management functions.

It covers the following:

• Freedom HW’s major features, and

• Freedom HW’s function as an independent power system.

1–1

Freedom HW Inverter/Charger

Congratulations on your purchase of the Freedom HW Inverter/Charger (Freedom HW). As part of the Xantrex Inverter/Charger family, the

Freedom HW gives you quality power, worry-free operation, and

outstanding reliability. The Freedom HW’s integrated inverting–charging functions and numerous power management features make it ideal for recreational and commercial vehicles.

Quality Power The Freedom HW provides up to 1000 watts of continuous modified sine

wave power from a battery bank. It is designed to handle loads such as a 600-watt microwave, TVs, VCRs, and midsized power tools.

The Freedom HW’s high surge capability lets you handle many hard-tostart loads, including large TVs and small refrigerators.

The built-in transfer switch automatically transfers between inverter power and incoming AC power (shore power) to ensure power is always available.

The built-in charger automatically charges the battery bank when the

Freedom HW is connected to incoming AC power (shore power).

Comprehensive Protection

Reliable Back-up

1–2 975-0467-01-01

The Freedom HW’s built-in protection features safeguard your batteries and equipment to give you worry-free operation:

•The low battery voltage alarm and shutdown prevents your

batteries from becoming completely discharged.

•The three-stage charging capability ensures that batteries receive

the “best” charge with minimal wear and tear.

• If the Freedom HW detects low AC voltage, it switches automatically to Inverter mode and supplies your equipment with modified sine wave power derived from the batteries. When AC voltage returns within range again, the Freedom HW allows the AC to pass through to your loads and automatically begins to recharge the batteries.

If incoming shore power fails, the Freedom HW automatically detects the failure and instantly becomes an independent power source that supplies quality AC to your loads.

Independent Power System

Overload Alarm and Shutdown

Over-temp Alarm and Shutdown

During Inverter mode, the Freedom HW automatically alerts you if the loads that are connected and drawing power from the unit are close to the maximum operating limit.

The Freedom HW automatically shuts down when the maximum operating limit is exceeded.

During Inverter mode, the Freedom HW automatically alerts you if it is overheating and approaching the over-temperature shutdown limit.

The Freedom HW automatically shuts down when the limit is exceeded.

Independent Power System

Your Freedom HW has been designed to be the heart of a sophisticated, independent power system. While the Freedom HW is an extremely “friendly” product to operate, Xantrex wants to ensure that you get the best performance from your system.

Inverting Freedom HW produces 120 Vac from your 12V batteries and is capable

of starting heavy loads like refrigerators and pumps. When the Freedom HW is inverting (producing 120 Vac output) with out a

load, it draws less than 1A of current from the battery (or battery bank). This feature allows the unit to operate without draining too much stored

energy.

Charging For the inverter to perform effectively, the batteries must be charged

correctly . The unit has a built-in three-stage charging system that extends the life and optimizes the performance of the batteries.

In addition to the numerous features which let you maximize your battery’s life and performance, the Freedom HW—unlike many chargers—also has the ability to recharge batteries even if the voltage is near zero (sometimes called dead battery charging).

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1–4

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