Xantrex Technology PROsine 2.0 User Manual

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PROsine 2.0 Inverter/Charger

User’s Manual

PROsine 2.0 Inverter/Charger

User’s 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 inclu de inverters, batt ery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.

Trademarks

PROsine 2.0 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

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

(c) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTH ER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED XANTRES CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision

November 2006 Revision C

Part Number

445-0089-01-01

Product Number

805-2000, 805-2020

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 User’s Manual is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the PROsine 2.0 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

Organization

The Manual is intended for anyone who needs to install and operate the PROsine

2.0 Inverter/Charger. Installers should be certified technicians or electricians.

This Manual is organized into seven chapters and three appendixes: Introduction: Chapter 1 introduces you to the PROsine, explains the inverting,

changing and power system management functions Product Orientation: Chapter 2 will familiarize you with the following

components of a PROsine system: Installation: Chapter 3 This section gives complete information for installing a

PROsine system. Configuration: Chapter 4 explains how to configure the PROsine to best meet

your electrical system requirements. It is divided into three parts: Operation: Chapter 5 begins with a system startup check that you carry out after

installation and configuration to verify that the PROsine is operating correctly. The chapter also provides information that will guide you during routine, ongoing operations.

Troubleshooting: Chapter 6 describes how to troubleshoot the PROsine Series Operation: Chapter 7 provides information about installing and operating

two PROsines in series:

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About This Manual

Specifications: Appendix A contains specifications and performance graphs for the PROsine and the display panel.

System Diagrams: Appendix B illustrates typical designs for PROsine customdesigned systems.

Charging Algorithms: Appendix C provides information about the charging algorithms for PROsine 2.0.

iv 445-0089-01-01

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions or practices that could result in personal injury or lo ss of life

CAUTION

Cautions identify conditions or practices that could result in damage to the unit or other equipment.

About This Manual

Important:

serious as a caution or warning.

These notes describe things which are important for you to know, but not as

Abbreviations and Acronyms

Related Documents

PROsine 2.0 Inverter/Charger Quick Installation Guide

Part Number: 445-0099-01-01: This document is included with your PROsine. It

is a job aid that provides instructions for installing the PROsine and its display panel. It also provides a mounting template for the PROsine.

PROsine 2.0 Inverter/Charger Display Panel Mounting Template

Part Number: 445-0101-01-01: This is provided with your PROsine.

PROsine 2.0 Inverter/Charger Quick Reference Guide

Part Number: 445-0100-01-01: This document is included with your PROsine. It

provides frequently used information about configuring and operating the unit as well as system default values.

Related Information

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

445-0089-01-01 v

Important Safety Instructions

WARNING

This chapter contains important safety and operating instructions. Read and keep this User’s Manual for future reference.

WARNING:Limitations on use

The PROsine 2.0 Inverter/Charger is not intended for use in connection with life support systems or other medical equipment or devices.

1. Before installing and using the PROsine 2.0 Inverter/Charger (PROsine), read all instructions and cautionary markings on the PROsine, the batteries, and all appropriate sections of this Manual.

2. Do not expose the PROsine 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 PROsine in a zero-clearance compartment. Overheating may result.

3. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk of fire, electric shock, or injury to persons.

4. The PROsine is designed to be permanently connected to you AC and DC electrical systems. Xantrex recommends that all wiring be done by a certified technician or electrician to ensure adherence to proper electrical wiring regulations.

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 PROsine with damaged or substandard wiring.

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

7. Do not disassemble the PROsine. It contains no user-serviceable parts. See the Warranty section for instructions on obtaining service. Attempting to service the PROsine yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.

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

9. The PROsine must be provided with an equipment-grounding conductor connected to the AC input ground terminal. Grounding and all other wiring must comply with local codes and ordinances.

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Safety

Explosive gas precautions

WARNING: Explosion hazard

1. 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 PROsine.

2. This equipment contains components which tend to produce arcs or sparks. T o prevent fire or explosion, do not install the PROsine in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment. This includes any space containing gasolinepowered machinery , fuel tanks, as well as joints, fittings, or ot her 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 the equipment in which the battery is installed.

Precautions When Working With Batteries

WARNING: Explosion or fire hazard

1. Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed.

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

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

4. 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.

5. 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.

6. Have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery.

7. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

8. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries.

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Safety

9. 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.

10. 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 a spark.

445-0089-01-01 ix

Contents

Important Safety Instructions 1

Introduction

Your PROsine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 The Heart of a Sophisticated, Independent Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Inverting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Power System Management - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Default Values for the PROsine System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9

Product Orientation

PROsine Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

AC End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

AC Panel Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

DC End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

DC Terminal Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

Display Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

DISPLAY Mode Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 INVERTER Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 INVERTER LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 CHARGER Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9 CHARGER LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 LCD Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Data Display Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Configuration Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Menu Navigation and Data Selection Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii

Installation

Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Installation Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Step 1: Designing the Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Step 2: Choosing a Location for the PROsine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Step 3: Mounting the PROsine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10

445-0089-01-01 xi

Contents

Step 4: Connecting the AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11

General AC Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11

AC Input Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Step 5: Configuring the Output Neutral Bonding System - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

AC Output Neutral-to-Ground Bonding System - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Step 6: Connecting the AC Output Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15

Connections for Hardwire Option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15 Connections for Single Hardwire Output With GFCI - - - - - - - - - - - - - - - - - - - - - - - - - - -3–16

Step 7: Connecting the DC Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–17

DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–19 Step 8: Mounting the Display Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20 Step 9: Connecting the Battery Temperature Sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21

Mounting Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21

Mounting to the Negative Battery Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21

Mounting to the Side of the Battery Case - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23 Step 10: Connecting the Remote Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24

Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24

Next Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–25

Configuration

Part 1: General Configuration Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Entering Configure Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Entering Installer-Only Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Changing Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Resetting to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Part 2: Configuration Menus and Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Part 3: Configuration Options- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Clear Errors in PROsine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Configure PROsine—Basic Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Menu Choices or Information Displayed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Configure PROsine—Advanced Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8

Menu Choices or Information Displayed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8

Configure Display Panel Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–11

Menu Choices or Information Displayed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–11

Configure Battery Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–12

Menu Choices or Information Displayed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–13

Diagnostics Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17

Menu Choices or Information Displayed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17

Next Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–18

xii 445-0089-01-01

Operation

Part 1: System Startup Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Part 2: Operating Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

Fan Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 ON/OFF/REMote Control of PROsine Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

Part 3: Operation in Inverter Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5

Load Sensing Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Operating Limits for Inverter Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5

Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6

Part 4: Operation in Charger Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7

Operation in Equalization Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7

Equalization Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8 Operating Limits for Charger Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9 Power Share - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9

Part 5: Display Mode Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10

Contents

Troubleshooting

General Troubleshooting Guidelines- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–2

Shutdown / Restart Without Error Message - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3 Resetting PROsine Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3 AC Bad Causes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3

Warning Messages- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–4 Error Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–6 Display Panel Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–9 Unexplained Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10 Inverter Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11

Resistive Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11 Motor Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11 Long Transfer Times - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11 Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12

Series Operation

Designing a Series System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2

System Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–2

System Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2

AC Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–4

AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–4

Battery Disconnect and Over-Current Protection Requirements - - - - - - - - - - - - - - - - - - 7–4

Series Sync Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–4

445-0089-01-01 xiii

Contents

Installing a Series System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5

Connecting AC Input Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5 Connecting AC Output Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–6 Configuring the Inverter Output Neutral Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–6 Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–6 Connecting the DC Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–7 Installing the Display Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–7 Installing the Battery Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–7

Installing the Series Sync Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–8 Configuring a Series System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–9 Series System Startup Test- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–10 Series System Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–11

Invert Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–11

Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–11

Specifications

Electrical Specifications: Invert Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2 Electrical Specifications: Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4 System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4 Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4 Inverter Overload Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5 Typical Inverter Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5 Invert Power Derating vs. Ambient Temperature- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6 PROsine Charger Output Current vs. AC Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6 PROsine Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7

System Diagrams

Residential Backup System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Marine System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–3

Charging Algorithms

Charge Algorithms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Battery Type—Charge Algorithm Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Warranty and Return Information Index

xiv 445-0089-01-01

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

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

Figures

Figure 1-1 PROsine Materials as Shipped- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Figure 2-1 AC End View (Blank Panel Option)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Figure 2-2 Panel Equipped With GFCI and Circuit Protector- - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Figure 2-3 DC End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Figure 2-4 DC Terminal Cover: Top View on Left; Bottom View on Right - - - - - - - - - - - - - - - - - 2–5 Figure 2-5 PROsine Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6 Figure 2-6 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12 Figure 3-1 Typical Recreational Vehicle and Fleet Vehicle Installation- - - - - - - - - - - - - - - - - - - - 3–4 Figure 3-2 Approved Mounting Orientations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10 Figure 3-3 Interior of AC Wiring Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 Figure 3-4 Incoming AC Cable (Top, cutaway view of wiring compartment)- - - - - - - - - - - - - - - 3–12 Figure 3-5 Hardwire AC Output Option (Top, cutaway view of wiring compartment) - - - - - - - - - 3–15 Figure 3-6 Single Hardwire Output With GFCI- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16 Figure 3-7 DC End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17 Figure 3-8 DC Cable Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19 Figure 3-9 BTS Attached to Negative Battery Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–21 Figure 3-10 BTS Attached to Battery Case- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–23 Figure 3-11 Cabling Details for Remote Shutdown Feature- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Figure 3-12 Schematic for Remote Shutdown Feature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Figure 7-1 Two PROsine Series Operation System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–3 Figure A-1 PROsine Dimensions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7 Figure B-1 Residential Backup System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Figure B-2 Typical Marine System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3

445-0089-01-01 xv

xvi

Tables

Table 1-1 PROsine Default Values- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9 Table 3-1 Required AC Wire Size vs Breaker Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Table 3-2 Required DC Cable and Fuse Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 Table 3-3 Tested GFCI Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Table 3-4 AC Output Neutral-to-Ground Bonding Screw Settings- - - - - - - - - - - - - - - - - - - - - - 3–14 Table 4-1 Menu Structure—Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5 Table 5-1 PROsine Operating Voltage Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6 Table 6-1 AC Bad Causes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3 Table 6-2 Warning Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–4 Table 6-3 Error Messages- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–6 Table 6-4 Panel Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–9 Table 6-5 Unexplained Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10 Table C-1 Charge Algorithms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2 Table C-2 Battery Type – Charge Algorithm Guide- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3

445-0089-01-01 xvii

xviii

Introduction

Chapter 1 introduces you to the PROsine, explains the inverting, changing and power system management functions

Introduction

Your PROsine

Congratulations on your purchase of the PROsine 2.0 Inverter/Charger (PROsine) As part of the PROsine Inverter/Charger family, the PROsine 2.0 gives you quality power, worry-free operation, and outstanding reliability. Its integrated inverting–charging functions and numerous power management features make it ideal for marine installations, recreational and commercial vehicles, and residential back-up systems.

Quality Power The PROsine’s true sine wave output is identical to (or better than) the power

supplied by your utility. A few of the benefits of true sine wave power are less interference on your TV set, more consistent cooking in your microwave, better handling of sensitive loads, and the ability to use dimmer switches and appliances with speed controls. In effect, the PROsine gives you a high quality, mobile wall socket!

Comprehensive Protection

Reliable Back-up If utility-supplied power fails, the PROsine automatically detects the failure and

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

• The adjustable low battery cutout prevents your batteries from becoming

completely discharged.

•The battery temperature sensor ensures that the charge delivered to the

batteries is adjusted according to their actual temperature.

•The multi-stage charging capability ensures that batteries receive the “best”

charge with minimal wear and tear.

• If the PROsine detects “bad” AC voltage, it switches seamlessly to Invert

mode and supplies your equipment with pure sine wave power derived from the batteries. When “good” AC becomes available again, the PROsine allows the AC to pass through to your loads and automatically begins to recharge the batteries.

instantly becomes an independent power source that supplies quality AC to your loads. There’s no interruption in service and no de gradation in performance.

1–2 445-0089-01-01

The Heart of a Sophisticated, Independent Power System

Your PROsine has been designed to be the heart of a sophisticated, independent power system. While the PROsine is an extremely “friendly” product to operate, Xantrex wants to ensure that you get the best performance from your system. So please take a few minutes to read the next few pages: they’ll give you an excellent understanding of the PROsine’s features and capabilities.

In basic terms, the PROsine is designed to:

p Invert p Charge p Manage your power system

Inverting

The PROsine’ s in v ertin g functio n:

p Produces 120Vac from your 12V batteries p Delivers 2kW of power on a continuous basis and 4.5kW of surge power to

start heavy loads like air conditioners, fridges, and pumps

Low Standby Battery Demand

Load Sense (Search) Mode

Much of the time the inverter may not be powering loads. During these times, you don’t want power to be drawn needlessly from the batteries. T o redu ce idle current to an absolute minimum, Xantrex has included three features:

p Low standby battery demand p Load sense (search) mode p Remote Shutdown

When the PROsine is inverting (producing 120Vac output without a load), it draws less than 2A of current from the batteries.

To reduce battery draw even further, you can turn on Load Sense mode. In Load Sense mode, the PROsine periodically sends out a search pulse to see whether a load is present. If it finds a load, it will turn on. You can adjust the interval between search pulses, and you can also adjust the load power at which the PROsine will turn on.

Note that in Load Sense mode, there’s a short time delay (up to the interval you’ve set) between the time you turn on a load and the time the PROsine delivers power. Of course, you can disable Load Sense mode at any time if you find the delay inconvenient.

445-0089-01-01 1–3

Introduction

Remote Shutdown Naturally, when you are not using the PROsine, you will disable the inverter to

conserve your battery. The PROsine still draws up to 50mA of battery current, however—and this will eventually discharge the battery. So when you don’t need the PROsine for an extended period of time, you can reduce battery draw to less than 1mA by setting the PROsine’s ON/OFF/REM switch to OFF.

This disables all circuitry in the PROsine and removes all power from the display panel. Setting the PROsine’s ON/OFF/REM to REMOTE lets you achieve the same result using a conveniently located system “kill” switch. This feature is particularly valuable for vehicles like ambulances where it is imperative that the system not draw power when the vehicle motor is not running.

Charging

Built-in Charge Formulas

Battery Temperature Sensor

Manual Equalization Mode

Dead Battery Charging

For the inverter to perform at the highest level, the batteries must be charged correctly. Every battery has a unique charge formula (or “algorithm”) dictated by the manufacturer for optimal performance. The PROsine has twenty-one built-in formulas to charge your batteries correctly—and you have the ability to fine tune these formulas to meet the needs of new models or specialized batteries.

Since battery temperature is a key factor in correct charging, the charging formula must be adjusted (automatically and in real time) according to the actual battery temperature to ensure that batteries are fully, but not over charged. For this reason, Xantrex has included a battery temperature sensor with your PROsine and has temperature compensated the charge algorithm.

Over a period of time, the cells in a flooded battery can develop uneven chemical states. This can result in a weak (undercharged) cell which, in turn, can reduce the overall capacity of the battery. To improve the life and performance of a nonsealed flooded battery, the PROsine’s multi-stage charging cycle includes a manual Equalize mode that should be used occasionally to restore an equal chemical state to all cells.

In addition to the numerous features which let you maximize your battery’s life and performance, the PROsine—unlike many chargers—also has the ability to recharge batteries even if the voltage is near zero.

1–4 445-0089-01-01

The Heart of a Sophisticated, Independent Power System

Power System Management

As we pointed out at the beginning of this introduction, the PROsine is designed to be the heart of your power system. In addition to refined charging and inverting functions, the PROsine is the control center for managing your power system. As the interface between your batteries, loads, and AC source, the PROsine:

p Takes 12Vdc and produces 120Vac to power your loads p Takes 120Vac, when available and, via its intelligent, automatic, and fast

Transfer Relay, passes the 120Vac to your loads

p Uses its Power Share capability to tap off power to charge the batteries while

120Vac is being passed to the loads

And finally, the PROsine allows for the expansion of your system to meet changing power requirements.

Load Management The PROsine has a built-in Transfer Relay that connects AC shorepower or

inverter output to your loads. Because the usual AC power sources (marina and campground outlets or small generators, for example) often have limited current availability, having the ability to manage your AC loads is extremely valuable, and therefore the PROsine provides a number of features to facilitate this:

p The charger is power factor corrected to use AC current as efficiently as

possible and only requires 15 amps to provide rated charger output—some other chargers require as much as 22 amps to provide the same output. Minimizing the AC current used by the charger means more current for your loads.

p The PROsine uses a Power Share feature which senses the AC load on the

system and gives priority to your AC loads, thereby reducing the charger current to avoid nuisance tripping of the breaker.

p Sometimes the usual AC shorepower sources have low voltage. To avoid

loading these weak sources any further, the charger automatically reduces its AC current draw as the AC voltage approaches the minimum acceptable level (as set by the user).

Expandability As your power needs grow, you can connect two PROsines in series mode to

create a 120/240Vac split phase system which is capable of supplying 4kW (continuously).

Both of these PROsines can be connected to operate from a single (but larger) battery bank, and will work in tandem to provide the fastest possible, accurate charge.

445-0089-01-01 1–5

Introduction

Auto Restart After Errors

The PROsine protects itself against numerous conditions (e.g. AC overload or over temperature) by shutting down. You can program the PROsine to restart automatically when the cause of the shutdown has corrected itself.

Important:

cause the

Auto Restart After Errors is factory-set to OFF since this feature can

PROsine to start unexpectedly and supply AC.

Run Without Panel The Run Without Panel configuration setting is an excellent recovery feature that

enables your PROsine to continue running if the display panel is disconnected or if its communication cable is damaged.

Run Without Panel is factory-set to OFF.

Materials List

Your PROsine 2.0 Inverter/Charger package includes the items listed below. See Table 1-1.

• 1 PROsine 2.0 Inverter/Charger

• 1 Display panel

• 1 Communications cable (70ft; 21m)

• 1 Battery temperature sensor with a 25ft (8m) cable

• 2 DC terminal covers

• 1 User’s Manual

• 1 Quick Installation Guide (includes PROsine mounting template)

• 1 Mounting template for display panel

• 1 Quick Reference Guide

• 1 ABYC Warning label

1–6 445-0089-01-01

Materials List

Important:

p DC Wiring Enclosure

For residential installations, some installation codes may require a wiring enclosure for DC connections and cables. (Installation procedures are shipped with the DC Wiring Enclosure.)

p Crimp-On Ring Terminals (for DC Wiring Enclosure)

If you are using the DC Wiring Enclosure, you should use crimp-on ring terminals on the PROsine end of your DC cables. Most box connectors (set screw types) are too large to fit in the enclosure without the risk of the connector shorting to the wall of the DC Wiring Enclosure. Do not use any connector that does not provide at least 2mm clearance to the inside wall with the wire in place and the set screw tightened.

p Series Sync Cable

If you are connecting two PROsine’s in series, you will need a Series Sync cable. This is a standard 4-connector telephone cable and may be purchased from most electronics retailers.

Contact Xantrex or your distributor about the Wiring Enclosure. Purchase the crimp-on ring terminals from a local supplier.

If any of these materials are missing or are unsatisfactory in any manner, please contact Customer Service. See page WA–1.

445-0089-01-01 1–7

Introduction

PROsine 2.0 Inverter•Charger

Battery temperature sensor

Communications cable

DC terminal covers

Display panel

’

User’s Manual Quick Installation Guide Quick Reference Card ABYC Warning Label

Figure 1-1

PROsine Materials as Shipped

Important::

For Marine Installations

For marine installations, you must attach the ABYC Warning label in a conspicuous location on the AC load panel. The Warning labe l is supplie d with you r

PROsine and

is illustrated below.

1–8 445-0089-01-01

Default Values for the PROsine System

T able 1-1 lists the default settings for the PROsine system. Record your settings in the right-hand column after you have configured the PROsine. This information will be valuable if you need to reconfigure your system or call Xantrex Customer Service

Default Values for the PROsine System

Table 1-1

Item Default Value Your Settings

NOTE

At a minimum, configure the items marked with a ** after installation.

Adjustable From the Configur e PROsine—Basic Menu

AC Breaker Size 15 amps **

Adjustable From the Configure PROsine—Advanced Menu

Load Sensing Disabled Load Sense Power 100 Watts Load Sense Interval 1 second Low AC Transfer (V) 90V Low AC Transfer (Hz) 55Hz Hi AC Transfer (V) 130V Hi AC Transfer (Hz) 65Hz AC Series Mode Standalone Inverter Low V Shutdown 10V Inverter Low V Warning +0.5V Iverter Low V Restart

Hysteresis Run Without Panel NO Inverter Enabled on Reset

Without Panel Charger Enabled on Reset

Without Panel Auto Restart After Error NO **

PROsine Default Values

2.5V

Disabled

Adjustable From the Configure Display Panel Menu

Audible Alarm OFF LCD Backlight Mode Auto LCD Backlight Brightness 50% LCD Backlight Timeout 20 seconds Temperature Farenheit

445-0089-01-01 1–9

Introduction

Table 1-1

Item Default Value Your Settings

Adjustable From the Configure Battery Menu

NOTE

Settings below are for Battery Type = Generic Gel.

Battery Size 200Ah ** Default Battery Temperature Warm Battery Type Generic Gel ** Battery Temp. Coefficient –27mV/°C Bulk Mode Settings:

• Max Voltage

• Max Current (%C)

• Threshold Voltage

• Threshold Timeout Absorption Mode Settings:

• Max Voltage

• Max Current (%C)

• Max Timeout

• Threshold Current (%C)

• Threshold Timeout Overcharge Mode Settings:

• Max Voltage

• Max Current (%C)

• Max Timeout Float Mode Settings:

• Max Voltage

• Max Current (%C)

• Max Timeout

• Threshold Voltage

• Threshold Timeout Equalize Mode Settings:

• Max Voltage

• Max Current (%C)

• Max Timeout

• Threshold Voltage

• Threshold Timeout Constant Mode Settings:

• Voltage Setpoint

• Current Setpoint Charger Mode Standalone Charger Type 3-Step Charger High Battery V

Warning Offset

PROsine Default Values

•14.2V

•25%

•13.8V

•3min

•14.2V

•25%

•8hr

•1%

•3min

•14.2V

•20%

•0

•13.8V

•200%

•21days

•12.5V

• 15min

•13.8V

•200%

•0

•13.5V

•100A

1.0V

NOTE

The values opposite the gray bar are set when you select a battery type. If you did not subsequently change these settings, they do not need to be recorded.

1–10 445-0089-01-01

Product Orientation

Chapter 2 will familiarize you with the following components of a PROsine system:

• PROsine features. (Start on page 2–2.)

• Display panel features. (Start on page 2–6.)

• Battery temperature sensor. (See page 2–12.)

Product Orientation

PROsine Features

AC End

Temperature

Figure 2-1

Feature Description

1 ON/OFF/REM Switch:

2 DISPLAY: Jack for the display panel.

AC End View (Blank Panel Option)

ON: Normal operation according to the way the unit has been configured via the display panel. OFF: The inverter and charger are of f; shorepower is not passed through to the loads. The unit draws the lowest battery current possible (less than 2mA). REM: With the switch in this position, the unit can be turned on and off remotely. (For details, see “ON/OFF/REMote Control of PROsine Operation” on page 5–3.)

TEMP

BATTERY SYNC

DISPLAY

f e d

3 BATTERY TEMP/REMOTE: Jack for the battery temperature sensor.

Also provides a connection for remote shutdown. See “Step 10: Connecting the Remote Shutdown” on page 3–24.

4 SYNC: Jack for synchronizing a second PROsine to produce 120/240V

split phase AC. For details, see Chapter 7, “Series Operation”.

5 Removable panel. The blank panel option is shown. For details, see “AC

Panel Options” on page 2–3. The AC wiring compartment is located

behind the panel. 6 Knockouts for AC wiring 7 Mounting flange

2–2 445-0089-01-01

AC Panel Options

PROsine Features

The PROsine has two AC panel options, each of which includes one 30A hardwire output circuit:

• Blank access panel: one hardwire output circuit. See Figure 2-1.

• Panel equipped with 15A GFCI receptacle and one hardwire output circuit. See Figure 2-2.

Figure 2-2

Feature Description

1 GFCI Duplex Receptacle 2 15A circuit protector for GFCI

Panel Equipped With GFCI and Circuit Protector

445-0089-01-01 2–3

Product Orientation

DC End

Figure 2-3

Feature Description

1 Positive DC cabling terminal, 8 mm stud 2 Negative DC cabling terminal, 8 mm stud 3 Cooling fan. (For details, see “Fan Operation” on page 5–3.) 4 Screw holes for mounting accessory modules

DC End

5 Chassis ground lug. Provides a ground path for the PROsine chassis to the

DC system ground.

6 Screw holes for mounting the optional DC wiring enclosure. See

“Materials List” on page 1–6 for information about the crimp-on ring terminals to be used with this option.

2–4 445-0089-01-01

DC Terminal Covers

PROsine Features

Two covers—red for positive and black for negative—are supplied to prevent accidental contact with the cabling connectors after installation.

Figure 2-4

DC Terminal Cover: Top View on Left; Bottom View on Right

445-0089-01-01 2–5

Product Orientation

Display Panel Features

The display panel lets you monitor and control the PROsine system. For convenience, the liquid crystal display (LCD) is backlit and the panel can be configured so an audible tone alerts you to any warnings or system faults that occur. The panel’s features are described below.

Figure 2-5

Feature Description

1 DISPLAY mode switch 2 INVERTER switch and status LEDs 3 CHARGER switch and status LEDs 4 Menu navigation and data selection buttons 5 LCD display 6 Two input jacks (not illustrated) on the bottom of the unit behind the

PROsine Display Panel

faceplate. Either jack can be used for the communication cable that connects the panel to the PROsine. The second jack can be used to connect future accessories.

2–6 445-0089-01-01

DISPLAY Mode Switch

Display Panel Features

Switch Position Description

ON Puts the unit in Display mode. Data Display screens are shown so

you can monitor system performance.

OFF Power continues to be available to the panel so vital data like

system errors and warning statuses can be checked.

CONFIGURE Puts the inverter in Configure mode. Configuration screens are

available, and you can configure the system without turning on the inverter and charger functions.

445-0089-01-01 2–7

Product Orientation

INVERTER Switch

INVERTER LEDs

This switch is active in all Display modes: ON, OFF, CONFIGURE.

Switch Position Description

ENABLE The inverter is enabled and will run if there is no shorepower.

(

NOTE: Throughout this manual, the term “shorepower” refers to

AC input power from a utility grid, generator, or other source.)

DISABLE When the AC power does not meet configuration parameters (i.e. is

“bad”), the inverter is off and will consume minimal power. When the AC power is good, the inverter is off and will consume minimal power. The PROsine’s transfer relay is in the “Pass Through” position. (The transfer relay allows shorepower to pass through the PROsine to the AC output terminals whenever AC is connected unless there is an error, or the PROsine is turned Off with the PROsine ON/OFF/REM switch.)

The LEDs are continuously updated whenever the Display Mode switch is set to ON or CONFIGURE.

LED Description

STANDBY LED Status

STANDBY

OFF OFF Inverter is not running because it has not been enabled or a

OFF ON The unit is inverting.

and

ON OFF Invert is enabled, but the unit is not inverting because of an

INVERTING

AC IN

INVERT FLASHING Unit is searching in Load Sense mode.

FLASHING Shorepower line and neutral are reversed or neutral is

INVERTING LED Status

system error has occurred.

error or because shorepower is “good.”

OFF “Good” shorepower has not been detected.

ON “Good” shorepower has been detected.

disconnected. Have an electrician check the wiring.

2–8 445-0089-01-01

CHARGER Switch

CHARGER LEDs

LED Description

Display Panel Features

This switch is active in all Display modes: ON, OFF, CONFIGURE.

Switch Position Description

ENABLE The charger is enabled and will charge the battery according to

the way the unit is configured if shorepower is “good.”

DISABLE The charger is off and will consume minimal power.

The LEDs are continuously updated whenever the Display Mode switch is set to ON or CONFIGURE.

STANDBY LED Status

STANDBY

and

CHARGING ON OFF The charger is enabled but is not running becaus e shorepower

EQUALIZE

READY

OFF OFF The charger is not running because it is not enabled, the charge

OFF ON The charger is running.

OFF Equalize mode has not been selected. ON The charger is in Equalize mode and the batteries are charging.

FLASHING Equalize mode has been selected; the charger is presently

OFF The charger is not running, or the Charge cycle is not finished. ON The Charge cycle is complete. The battery is fully charged.

CHARGING LED Status

cycle has been completed, or a system error has occurred.

is not “good.”

CAUTION: Battery voltage may go up to 17V.

executing the basic charge cycle in preparation for Equalization mode. (The CHARGING LED is also on in this stage.)

445-0089-01-01 2–9

Product Orientation

LCD Panel

Data Display Mode

The LCD panel lets you monitor the PROsine system and change its configuration settings. It operates in two basic modes: Data Display and Configuration.

• In Data Display mode the screens provide information about PROsine system performance.

• You can cycle through them by pressing the Up s and Down t buttons. (In Data Display mode, the other buttons have no function.)

• T ypically, the top line indicates the type of data being displayed and the actual data appears on the bottom line. A sample screen is shown below:

PROsine: Battery

Configuration Mode

12.0V +10A 22

• Examples of all the Display screens are shown on page 5–10.

• In Configuration mode, the screens show data that can be changed as well as read-only data. (For details about each Configuration screen, see, Chapter 4, “Configuration”.) Using these screens, you can:

• Define the operating parameters of the PROsine (including AC breaker

size, battery size, battery type, types of charge, load sense capability, etc.)

• Adjust the display characteristics of the panel (including an audible alert,

screen contrast, and screen backlighting)

• View current operational data, Warning messages, Error messages, and

Panel fault messages in order to monitor and troubleshoot system performance

• Two sample screens are shown below:

Menu 1: Configure PROsine—General

°C

AC Breaker Size

*15A

2–10 445-0089-01-01

Menu Navigation and Data Selection Buttons

When the DISPLAY switch is set to CONFIGURE, the menu navigation and data selection buttons operate as follows:

Press This Button To

ESCAPE • Cancel changes made to data

• Back up one menu level

MENU Up Back up one menu item

MENU Down Proceed to next menu item

DATA Up Increase data value or cycle through available options

Display Panel Features

DATA Down Decrease data value or cycle through available options

ENTER Save changes or proceed to next menu level

Examples of how to change configuration settings are given on page 4–3. Further information about viewing Display mode screens is provided on page 5–

445-0089-01-01 2–11

Product Orientation

Battery Temperature Sensor

The temperature sensor continuously measures the temperature of the battery and adjusts charger output for a more accurate, temperature-compensated charge.

Figure 2-6

Feature Description

1 Mounting plate. Connects to the negative battery terminal. 2 Sensor. Reverse side has peel-off backing and self-adhesive strip so you

3 Sensor cable (25ft; 8m). 4 Connector. Plugs into the Battery Temp jack on the PROsine. NOTE: The battery temperature sensor is electrically isolated from the mounting plate.

2–12 445-0089-01-01

Battery Temperature Sensor

can attach the sensor to the side of the battery case.

Installation

Chapter 3 This section gives complete information for installing a PROsine system.

Specifically, this section describes:

• Safety instructions and installation codes that must be observed during installation

• Installation tools and materials

• Appropriate locations and environments for mounting the PROsine, display panel, and battery temperature sensor

• AC cabling, DC cabling, and grounding information

• Detailed installation procedures on page 3–3.

For information about installing two PROsines in series, see Chapter 7, “Series Operation”.

Installation

Safety Instructions

WARNING: Shock hazard

Xantrex Technology recommends that all wiring be done by a certified technician or electrician to ensure adherence to approved electrical wiring regulations.

• Before you begin the installation, review the “Important Safety Instructions” on “Important Safety Instructions” on page vii, and read the entire “Installation” section so you can plan your installation from beginning to end.

• Disconnect all AC and DC power sources to prevent accidental shock. Disable and secure all AC and DC disconnect devices and automatic generator starting devices.

Installation Codes

Governing installation codes vary depending on the specific location and application of the installation. Some examples include the following:

• The U.S. National Electrical Code (NEC)

• The Canadian Electrical Code (CEC)

• The American Boat and Yacht Council (ABYC) and the US Coast Guard requirements for installations on marine vessels

• The U.S. Code of Federal Regulations (CFRs)

• Canadian Standards Association (CSA) and the RV Industry Association (RVIA) for installations in RVs

It is the installer’s responsibility to ensure that all applicable installation requirements are met.

3–2 445-0089-01-01

Installation Tools and Materials

You will need the following to install the PROsine, display panel, and battery temperature sensor:

p Wire stripper p Mounting screws or bolts p #2 Phillips screwdriver p Wrench for DC terminals (1/2 inch or 13mm or adjustable) p AC cable (i.e. 2-conductor-plus-ground cable), sized appropriately for load

and application

p Wire nuts or crimp connectors for AC wire and appropriate tools p Two 1/2 inch strain-relief clamps for AC cables p DC cable, sized appropriately for load and application p Lugs for DC cables to fit 8 mm (5/16 in.) DC stud terminals) as well as

appropriate tools (e.g. crimping tool)

p AC and DC disconnects and over-current protective devices

Safety Instructions

Important:

enclosure for DC connections and cables. Contact Xantrex or your distributor for this part.

Installation Procedures

This section provides detailed installation information. For your convenience, the overall procedure is divided into ten main steps:

p Step 1: Designing an installation. (Start on page 3–4.) p Step 2: Choosing a location for the PROsine. (Start on page 3–9.) p Step 3: Mounting the PROsine. (Start on page 3–10.) p Step 4: Connecting the AC input wiring. (Start on page 3–11.) p Step 5: Configuring the output neutral bonding system. (Start on page 3–13.) p Step 6: Connecting the AC output wires. (Start on page 3–15.) p Step 7: Connecting the DC cables. (Start on page 3–17.) p Step 8: Mounting the display panel. (Start on page 3–20.) p Step 9: Connecting the ba ttery temperature sensor. (Start on page 3–21.) p Step 10: Connecting the remote shutdown feature. (Start on page 3–24.)

For residential installations, installation codes may require a wiring

445-0089-01-01 3–3

Installation

Step 1: Designing the Installation

All types of PROsine installations share common components, and these are briefly described below. Figure 3-1 shows these components and their relationship to each other in a typical recreational vehicle or fleet vehicle installation. (For diagrams of typical residential backup and marine systems as well as series installations, see Appendix B, “System Diagrams”.)

AC Load Panel

DC Fuse / Disconnect or

Circuit Breaker

Shorepower

Figure 3-1

to engine

AC Source Panel

Automatic or Manual AC Source Selector Switch

–

Vehicle Starting Battery

{

Typical Recreational Vehicle and Fleet Vehic le Installation

3–4 445-0089-01-01

Step 1: Designing the Installation

AC shorepower A source of 120 volt, 60Hz alternating current is needed to provide energy for

charging batteries and to pass through to AC loads. This source could be the utility grid (power company) or an AC generator. An automatic or manual AC source selector switch can be used to connect one of the multiple sources of shorepower to the PROsine system.

Important:

from a utility grid, generator, or other source.

Throughout this manual, the term “shorepower” refers to AC input power

Generator The PROsine is compatible with virtually all generators which produce nominally

120Vac 60Hz power. The best generators produce a sinewave output, others produce a distorted sinewave, and the lower quality generators produce a "modified sinewave" (MSW) or squarewave output. The PROsine will operate correctly on sinewave or distorted-sinewave generators; it will also operate correctly on most MSW or squarewave generators but some models of these generators may prove incompatible. See Chapter 6, “Troubleshooting” for errors related to generator incompatibility.

Since the charging current limit of the PROsine may be configured all the way down to 0A it is possible to use very small generators with the PROsine to charge batteries. Xantrex has operated the PROsine from a generator as small as 700W. To do this, configure the "AC Breaker Size" (found in Configure PROsine — Basic Menu on page 4–7) to a current rating compatible with the generator size. For example, 6A should work well with a 700W generator, 8A sh ould work with a 1000W generator - experiment to find the largest setting that the generator can accommodate. To operate the PROsine at the full 100A charging current rating Xantrex recommends a 2kW generator or larger and a breaker size setting of 20A.

AC Disconnect and Over-Current Protection Device

To meet CSA, UL, and electrical code requirements, the PROsine’s AC and DC inputs and outputs must be provided with over-current protection (such as a circuit breaker or fuse) and a disconnect device, as follows:

AC Input: The circuit breaker or fuse used to protect the PROsine must be

rated no more than 30A and must be approved for use on 120Vac branch circuits. The wire used between the breaker and the PROsine input must be sized to match the circuit breaker, in accordance with the electrical codes or regulations applicable to your installation. The “AC Service Rating” setting of the PROsine must also be set to match the size of the breaker provided. (See Chapter 4, “Configuration” and the following section.)

AC Output: The circuit breaker or fuse must be rated at no more than 30A

and must be approved for use on 120Vac branch circuits. The wire used between the PROsine and the AC output breaker must be sized to match the AC input circuit breaker’s rating. The wire from the AC output breaker to your loads must be matched to the rating of the AC output breakers.

Disconnect Devices: Each system requires a method of disconnecting the

AC circuits. If the over-current protection device is a circuit breaker, it will also serve as the disconnect. If fuses are used, separate AC disconnect switches will be needed ahead of the fuses.

445-0089-01-01 3–5

Installation

AC Distribution Panels

Most systems incorporate distribution centers both ahead of the PROsine (the AC source panel) and between the PROsine and the loads (the AC load panel). A source panel includes a main circuit breaker, which serves as over-current protection and as a disconnect for the AC shorepower supply line. Additional circuit breakers serve individual circuits, one of which serves the PROsine. The AC load panel can incorporate both the main 30A AC output circuit breaker and breakers for individual load circuits.

Important:

“multi-wire branch circuit”. These are 4-wire circuits consisting of a ground, neutral, and two lines that are 180 degrees out of phase with each other (from a standard 120/240V “split phase” circuit). These circuits are commonly used in kitchens to power “split receptacles” where the top and bottom halves of a duplex receptacle are connected to different lines. If you need to run multi-wire branch circuits from your inverter system, you will need to use two PROsine units in a series system to create 120/240V ac split-phase power. For details, see Chapter 7, “Series Operation”. For more information about multiwire branch circuits, refer to the US National Electrical Code (NFPA 70, 1999) para 210– 4 and the Canadian Electrical Code (CSA C22.1-1998) section 26–710.

Do not connect the output of a single PROsine to what is known as a

AC Cabling AC cabling includes all the wires and connectors between the AC source and the

PROsine and all cabling between the PROsine and the AC panels, circuit breakers, and loads. The type and size of the wiring varies with the installation and load. For marine and some RV applications, flexible multiple-strand wire is required. For residential installations, solid Romex™ cable is often used. Installation codes may specify solid or stranded, overall size of the conductors, and type and temperature rating of the insulation around the wire.

AC Output Neutral Bonding

AC wiring must be sized to match the current rating of the AC breakers you provide on the input and output AC circuits in accordance with the electrical codes or regulations applicable to your installation. Table 3-1 is based on the U.S. National Electrical Code and the Canadian Electrical Code, assuming 2conductor-plus-ground cable. Other codes and regulations may be applicable to your installation.

Table 3-1

Breaker Size Minimum Wire S ize

Required AC Wire Size vs Breaker Rating

10A 15A 20A 30A 14AWG 14AWG 12AWG 10AWG

The neutral conductor of the PROsine’s AC output circuit is automatically connected to the safety ground during inverter operation. When AC utility power is present and the PROsine is in Charger mode, this connection is not present, so that the utility neutral is only connected to ground at your source panel. This conforms to National Electrical Code requirements that separately derived AC sources (such as inverters and generators) have their neutral conductors tied to ground in the same way that the neutral conductor from the utility is tied to ground at the AC source panel.

3–6 445-0089-01-01

Step 1: Designing the Installation

DC Cabling This includes all the cables and connectors between the batteries, the DC

disconnect and over-current protection device, and the PROsine. All installations require multi-strand insulated cables as well as disconnect and over-current devices. DC cable sizes are indicated by AWG notation or MCM notation. Under the AWG standard, a larger gauge number indicates a smaller wire diameter. Under the MCM standard, a larger number indicates a larger cable. Wire size is usually marked on the cables for sizes this large. Table 3-2 specifies the minimum DC cable size and maximum fuse size for the PROsine. The DC cables must be copper and must be rated 75°C minimum. The cables should be terminated with lugs that fit the DC stud terminals snugly (8 mm or 5/16 in. hole size).

DC Disconnects and Over-Current Devices

Table 3-2

DC Cable Length Cable Size Fuse Amps

Less than 6 feet 250MCM 300A class T Between 6 and 12 feet 350MCM 300A class T

Important:

the PROsine unit. When starting a heavy load the PROsine can draw current surges from the battery of up to 600A. If the wire is too small the voltage drop from this surge will result in a voltage at the PROsine terminals that is too low for the PROsine to operate correctly. The PROsine may appear to operate correctly with smaller cables until a heavy load such as an air conditioner attempts to start - then the unit may work correctly sometimes and not work correctly other times.

Required DC Cable and Fuse Size

Using the correct cable size is critical to achieving the rated performance of

The DC circuit from the battery to the PROsine must be equipped with a disconnect and over-current device. This usually consists of a circuit breaker, a “fused-disconnect,” or a separate fuse and DC disconnect. Do not confuse AC circuit breakers with DC circuit breakers. They are not interchangeable. The rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes. The breaker or disconnect and fuse should be located as close as possible to the battery, in the positive cable. Applicable codes may limit how far the protection can be from the battery.

Batteries Every PROsine system requires a deep-cycle battery or group of batteries that

provide the DC current that the PROsine converts to AC. Different battery types and sizes are available; many of these are discussed in Application Note: Battery Banks for Inverter Systems (976-0114-01-01). Automotive-type starting or “cranking” batteries are not recommended, except for temporary emergency use. The PROsine uses 12-volt battery banks.

Ground Fault Circuit Interrupters (GFCIs)

A GFCI is a device that de-energizes a circuit when a current to ground exceeds a specified value that is less than that required to blow the circuit breaker. GFCIs are intended to protect people from electric shocks and are usually required in wet or damp locations.

445-0089-01-01 3–7

Installation

Installations in marine and recreational vehicles may require GFCI protection of branch circuits connected to the AC output of the PROsine. In addition, electrical codes require GFCI protection of certain receptacles in residential installations.

While the true sine wave output of the PROsine is equivalent to the waveform provided by utilities, compliance with UL standards requires that Xantrex test and recommend specific GFCIs. As of October 2005, Xantrex has tested the GFCIprotected 15A receptacles listed in Table 3-3 and found that they function properly when connected to the AC output of the PROsine.

Table 3-3

Manufacturer Model Number

Leviton Cooper/Eagle Pass & Seymore Hubbell/Bryant

8598, 8599, 8898, 8899, 6598 XGF15, XGF20, GF15 1594, 2094, 1591 GF52*A

GF8300*A

Tested GFCI Models

, 6599

, GF53*Ac, GF82*Ac, GF83*Ac, GFR5252*Ac, GFR5352*Ac, GF8200*Ac,

, GF52b, GF53b, GF82b, GF83b, GF5252b, GF5352b, GF8200b, GF8300

, GF20

a.GFCI models may change over time. Refer to the Application Note “Using GFCI Receptacles on Xantrex Inverters and Inverter Chargers” on the Xantrex website for up-to-date test results. b.This is an old model and is generally no longer sold as it does not offer the same level of protection as the newer models. c.The asterisk * represents one or two letters to indicate the front color of the receptacle. The A indicates that this is the newer model which meets the latest safety standard.

3–8 445-0089-01-01

Step 2: Choosing a Location for the PROsine

WARNING: Fire and explosion hazard

This equipment contains components that tend to produce arcs or sparks. T o prevent fire or explosion, do not install the PROsine 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, or joints, fittings, or other connections between components of the fuel system.

WARNING: Fire hazard

To reduce the risk of fire, do not cover or obstruct the ventilation openings. Do not install the PROsine in a zero-clearance compartment. Overheating may result.

The PROsine should only be installed in locations that meet the following requirements:

p Dry. Do not allow water or other fluids to drip or splash on the PROsine. Do

not mount the PROsine in an area subject to splashing water or bilge water.

p Cool. Normal air temperature should be between 32°F and 104°F (0°C and

40°C)—the cooler the better.

p Ventilated. Allow at least 5 in. (13cm) of clearance at the DC end of the

PROsine for air flow, 1 in. (2.5cm) on each side, and 2 in. (5cm) at the AC end. For cooling, the volume of the enclosure is not as important as the overall supply of air. The more clearance for ventilation around the unit, the better the performance. Do not allow the ventilation openings on the ends of the unit to become obstructed.

p Safe. Do not install the PROsine in the same compartment as batteries or in

any compartment capable of storing flammable liquids like gasoline.

p Close to the battery compartment and the AC source and load panels.

Avoid excessive cable lengths (which reduce input and output power due to wire resistance). Use the recommended cable lengths and sizes.

p Protected from battery acid and gases. Never allow battery acid to drip on

the PROsine or its wiring when reading specific gravity or filling the battery. Also do not mount the unit where it will be exposed to gases produced by the batteries. These gases are very corrosive, and prolonged exposure will damage the PROsine.

445-0089-01-01 3–9

Installation

Step 3: Mounting the PROsine

To mount the PROsine:

1. Remove the PROsine from its shipping container, verify that all components are present, and record relevant product information on “Information About Your System” on page WA–4.

2. Turn off the ON/OFF/REM switch on the AC end.

3. Select an appropriate mounting location and orientation. meet regulatory requirements, the PROsine must be mounted in one of the following orientations:

• In a horizontal position on a vertical surface with the AC knockouts near

the top as shown in

• On a horizontal surface

• Under a horizontal surface

Side near AC

knockouts

must be up.

(See Figure 3-2.) To

Figure 3-2

Approved Mounting Orientations

4. The PROsine Quick Installation Guide has a mounting template printed on it. T ape it to the mounting surface and pilo t-drill the desired number of mounting holes. Remove the template.

5. Fasten the PROsine to the mounting surface. If you are mounting the unit on a wall or bulkhead, use #12 or #14 pan-head wood or sheet metal screws to secure it to the framing behind the wall or bulkhead. Alternatively, use nut inserts and 1/4-20 machine screws.

3–10 445-0089-01-01

Step 4: Connecting the AC Input Wires

WARNING: Fire, Shock and Energy hazards

Make sure wiring is disconnected from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes. Do not connect the output terminals of the PROsine to any incoming AC source.

General AC Wiring Considerations

Step 4: Connecting the AC Input Wires

AC Wiring Connectors

AC and DC Wiring Separation

AC Wiring Compartment

Connect AC wires with twist-on wire nuts or crimp-on splice connecto rs according to the type of installation:

• On a boat, use crimp-on splice connectors to meet the Americ a n Boat an d Yacht Council’s Standards and Recommended Practices for Small Craft, which do not allow twist-on connectors for AC connections.

• For non-marine installations subject to vibration, you should still use crimpon connectors.

• For non-marine installations in locations not subject to vibration, twist-on wire nuts may be used instead of crimp-on connectors.

• The amount of insulation you strip off individual wires will be specified by the connector manufacturer and is different for different types of connectors.

Do not mix AC and DC wiring in the same conduit or panel. Where DC and AC wires must cross, make sure they do so at 90° to one another. Consult code for details about DC and AC wiring in vicinity to each other.

For your reference, the AC Wiring Compartment is shown in Figure 3-3.

Figure 3-3

445-0089-01-01 3–11

Interior of AC Wiring Compartment

Installation

AC Input Connections

Figure 3-4 is a cutaway top view of the PROsine wiring compartment. It shows one incoming AC cable and its connections to the PROsine wires.

To make the AC input connections:

1. Run 10AWG 2-conductor-plus-ground cable through one of the cable clamps on the AC end.

2. Strip about two inches of the jacket from the AC cable and separate the three wires.

3. Connect the incoming black and white (line and neutral) wires to the PROsine AC input black and white wires.

4. Connect the incoming ground wire to the screw on the chassis marked . Use a crimp-on ring terminal if the AC input ground wire is stranded. Solid wire can be screwed directly under the head of the screw.

grounding screw

AC cable

Figure 3-4

Cutaway view of PROsine wiring

compartment as seen from the top.

wire nuts or crimp

connections (depending

on type of installation)

clamp

for AC cable

Incoming AC Cable (Top, cutaway view of wiring compartment)

3–12 445-0089-01-01

Step 5: Configuring the Output Neutral Bonding System

AC Output Neutral-to-Ground Bonding System

The PROsine provides an installer-defeatable system that automatically connects the neutral conductor of the inverter AC output circuit to safety ground (“bonding” it) during inverter operation, and disconnects it (“un-bonding” it) when the PROsine has connected to AC shorepower. This system is designed to conform to installation codes that require single-phase AC sources such as inverters and generators to have their neutral conductors tied to ground in the same way that the neutral conductor from the utility is tied to ground.

These same codes specify that the neutral can only be connected to ground in one place at any one time. Any AC source feeding the PROsine is required to have its neutral already connected to ground. Therefore, to keep from connecting the neutral to ground in a second place, the PROsine transfer relay breaks its own neutral ground connection when connected to shorepower.

This automatic neutral-to-ground bonding system is suited for installations in which the AC shorepower source is known to have a bonded neutral. This will be the case in most situations: in a utility feed after the AC source panel, at an RV park hook-up, at a marina’s shorepower hook-up, or with a generator with a bonded neutral.

In some installations, however, the AC shor epower sour ce wi ll not have a bon ded neutral. This is true on some generators and it is true in certain utility-feed situations. To accommodate these situations, the PROsine automatic neutral bonding system can be defeated, so the PROsine will not bond the neutral in any mode of operation. This allows the installer to bond the neutral in the AC load panel to provide the required single-point bonding of the neutral.

To enable and disable the automatic AC output neutral-to-ground bonding system

WARNING: Fire and Shock hazard

AC neutral bonding system settings should only be changed by a qualified installer aware of the implications of the changes. Disconnect all AC and DC sources before working in the AC wiring compartment or before making a setting change.

You enable and disable the system using a screw in the AC wiring compartment, identified as the “Invert Mode Output Neutral-to-Ground Bonding Screw”. (See Figure 3-3.) This screw is identified with a label that indicates two different holes that the screw can be mounted in. One hole is identified as the one that enables the automatic bonding system, and the other hole defeats it so that the neutral is not bonded by the PROsine in any mode.

445-0089-01-01 3–13

Installation

The PROsine is shipped with the screw in the position that enables the automatic bonding system.

• To disable the system, move the screw to the other hole.

• Do not remove the screw from the product: make sure it is always installed in one position or the other, as appropriate for the configuration of the rest of the system.

Table 3-4

Bonding Screw Setting

Automatic bonding

Un-bonded in all modes

AC Output Neutral-to-Ground Bonding Screw Settings

Status of Bonding Internal to the PROsine

AC shorepower not present (unit Inverting or in Standby)

Output neutral bonded Output neutral

Output neutral unbonded

AC shorepower present (unit Charging or in Standby)

un-bonded Output neutral un-

bonded

Neutral Bonding Required External to the PROsine

In the AC input shorepower source

Yes No

No Yes

In the AC load panel

3–14 445-0089-01-01

Step 6: Connecting the AC Output Wires

Two options are available for AC output wiring:

• Hardwire output.

• Single hardwire output plus GFCI receptacle.

Connections for Hardwire Option

To make the AC output wiring connections

1. Run 10AWG 2-conductor-plus-ground cable through one of the cable clamps on the AC end.

2. Strip about two inches of the jacket from the AC cable and separate the three wires. Strip insulation from each of the wires according to the guidelines given by the connector manufacturer.

3. Connect the outgoing black and white (line and neutral) AC wires to the PROsine AC output black and white wires.

4. Connect the incoming ground wire to the chassis using one of the screws marked .

Step 6: Connecting the AC Output Wires

5. Connect the outgoing AC wires to an AC load panel equipped with circuit breakers.

grounding screw

AC cable

clamp

for AC cable

Cutaway view of PROsine wiring

compartment as seen from the top.

wire nuts or crimp

connections (depending

on type of installation)

Figure 3-5

Hardwire AC Output Option (Top, cutaway view of wiring

compartment)

445-0089-01-01 3–15

Installation

Connections for Single Hardwire Ou tput With GFCI

Figure 3-6 is a cutaway top view of the PROsine wiring compartment showing one set of outgoing AC wires with the GFCI option.

To make the AC output wiring connections

1. Run 10A WG 2-conductor-plus-ground through one of the cable clamps on the AC end.

2. Strip about two inches of the jacket from the AC cable and separate the wires. Strip insulation from each of the wires according to the guidelines given by the connector manufacturer.

3. Connect the outgoing black and white (line and neutral) AC wires to the PROsine black and white AC output wires.

4. Connect the outgoing ground wire to the chassis using one of the screws marked .

5. Tuck the wires into the left-hand side of the wiring compartment so they don’t interfere with the GFCI assembly.

WARNING: Shock hazard

If you are not using the hardwire output circuit, you must cap off its line and neutral wires. Use twist-on wire nuts where allowed; use crimp-on wire caps in other applications.

grounding screw

outgoing AC cable

Figure 3-6

wire nuts or crimp-on wire caps (depending on type of installation)

Single Hardwire Output With GFCI

Cutaway view of PROsine 2.0 wiring

compartment as seen from the top.

Do not disturb factory wiring.

GFCI

3–16 445-0089-01-01

Step 7: Connecting the DC Cables

CAUTION

Before making the final DC connection, check cable polarity at both the battery and the PROsine. Positive must be connected to positive; negative must be connected to negative. Reversing the positive and negative battery cables will damage the PROsine and void your warranty. This type of damage is easily detected.

WARNING: Fire hazard

Use only copper wire rated 75°C minimum. Make sure all DC connections are tight to a torque of 216–240 inch-pounds (24–27Nm). Loose connections will overheat.

Follow the procedure given below to connect the battery leads to the terminals on the DC end. The cables should be as short as possible and large enough to handle the required current, in accordance with the electrical codes or regulations applicable to your installation. <Xref>Table 3-2 on page 7 specifies the minimum DC cable size and maximum fuse size for the PROsine.

Do not route your DC cables through an electrical distribution panel, battery isolator, or other device that will cause additional voltage drops.

Figure 3-7 shows the DC end for your reference.

Step 7: Connecting the DC Cables

Figure 3-7

445-0089-01-01 3–17

DC End

Installation

To make the DC connections

Refer to Figure 3-8.

1. Cut the cables to the correct length with enough insulation stripped off so you can properly install the type of terminals you will be using.

The terminals on the DC end are designed to fit up to 500MCM crimp-on ring terminals (either AMP or ILSCO) or box connectors.

2. Attach the connectors to both cables. If you are using crimp connectors, use the tool recommended by the terminal

manufacturer. Make sure no stray wire strands protrude from the terminals.

Important:

enclosure for DC connections and cables. If you are using this accessory, secure it to the PROsine before routing cables. Be sure to use crimp-on ring terminals on the PROsine end of the DC cables (as specified on “Materials List” on page 1–6), and follow the installation procedure provided with the wiring enclosure. Contact Xantrex or your distributor for this part.

For residential installations, the installation code may require a DC wiring

3. Route the DC supply cables from the battery bank to the PROsine.

4. Install a fuse and disconnect or breaker between the PROsine and the battery. They must be installed in the positive side of the DC circuit, as close as possible to the battery. This protects your battery and wiring in case of accidental shorting. (See Table 3-2 on page 3–7 for required fuse size.)

5. Attach one connector on the positive cable to the positive DC terminal on the DC end, and then attach the other co nn ector to the POSITIVE (+) terminal on the fuse or breaker.

Observe the polarities carefully while completing the installation. Use a wrench to tighten to a torque of 216–240 inch-po unds (24–27Nm). Test that the cable is secure.

6. Connect one connector on the negative cable to the negative terminal on the DC end. Before proceeding, check that cable polarity is correct, and then connect the other end of the cable to the NEGATIVE (–) terminal on the battery.

This is the last cable connection you make. A spark is normal when it is made. Use a wrench to tighten to a torque of 216–240 inch-po unds (24– 27Nm). Test that the cable is secure.

7. Attach the DC terminal covers. (See Figure 3-8.)

3–18 445-0089-01-01

Step 7: Connecting the DC Cables

DC Grounding

Figure 3-8

DC Cable Connections

To connect the DC ground:

The Chassis Ground lug on the DC end of the PROsine is used to connect the chassis of the PROsine to your system’s DC grounding point as required by regulations for some installations. Use copper wire that is either bare or provided with green insulation. Do not use the DC Ground Lug for your AC grounding. (See the AC wiring instructions in this section.)

Follow the guidelines below that correspond to your type of installation. These guidelines assume you are using the code-compliant DC supply cable and fuse sizes indicated in this manual. If you are using different sizes, refer to the applicable code for DC grounding details.

•

Recreational Vehicle Use 8AWG copper wire and connect it between the

Chassis Ground lug and the vehicle’s DC grounding point (usually the vehicle chassis or a dedicated DC ground bus).

•

Marine Use 2AWG copper wire that is bare or has insulation rated min.

105

°C, and connect it between the Chassis Ground lug and the boat’s DC

grounding bus or engine negative bus.

Residential Use 4AWG wire and connect it between the Chassis Ground lug

• and your system’s DC grounding point. This will usually be the AC service entrance grounding point or a separate ground rod. For a solar PV installation, this will usually be the same ground rod used to ground the PV array.

445-0089-01-01 3–19

Installation

Step 8: Mounting the Display Panel

The communications cable supplied with the display panel is 70 feet long (21 meters). If you want to replace the cable with one that is longer or shorter, use a high quality , 6-wire telephone extension cable. You can install the panel up to 100 feet (30 meters) away from the PROsine.

Flush mounting the panel on a wall, bulkhead, or panel requires an opening that is approximately 4 inches x 4 inches (10cm x 10cm). About 1 1/4 inches (3cm) of free space is required within the wall to accommodate the depth of the panel. Be sure there is no wiring or other obstructions within the wall before you make an opening.

To mount the display panel:

1. Choose a location that is dry, out of direct sunlight, free from corrosive or explosive fumes, and otherwise appropriate for mounting an electronic device.

2. T ape the mounting template (in the PROsine package) to the mounting surface and mark the locations of the mounting holes and the area to be cut away.

3. Pilot-drill the mounting holes and cut out the hole in which the panel will be inserted.

4. Route the communications cable(s) inside the wall and through the opening.

5. Insert one of the cable’s connectors in either jack on the bottom of the panel.

6. Place the panel in the opening and secure it with appropriate fasteners.

7. Route the communications cable to the PROsine and insert the connector in the jack labelled DISPLAY.

3–20 445-0089-01-01

Step 9: Connecting the Battery Temperature Sensor

Mounting Options

You can mount the battery temperature sensor (BTS) in one of two ways:

• Mounting the sensor to the negative battery post allows the internal battery temperature to be sensed and provides the most accurate results.

• Attaching the sensor to the side of the battery using the self-adhesive backing also provides good results in most situations.

WARNING: Energy and Explosion hazard

Review the “Important Safety Instructions” on page vii.

Mounting to the Negative Battery Terminal

To mount the sensor on the negative battery terminal:

See Figure 3-9.

Figure 3-9

445-0089-01-01 3–21

BTS Attached to Negative Battery Terminal

Installation

1. Decide which battery is to be monitored. When all battery banks are located in the same compartment, select the

battery that requires the most frequent charging (in a boat or an RV, this is usually the “house” battery). Where a battery is located in a separate compartment from other batteries, and where temperatures are constantly high (as in an engine room), it is a good idea to monitor this battery to keep it from being overcharged as a result of its constant high temperature. In this situation, the cooler battery bank will be slightly undercharged since it will be at a lower temperature than the battery being monitored, but this procedure will prolong the warmer battery’s life.

2. Switch off all devices operating from the battery , or open the battery switch, if present, to disconnect the battery.

3. If the charger has been operating, wait ten minutes for any explosive battery gasses to dissipate.

4. Remove the nut that secures the existing negative DC wire to the battery.

5. Move or reorient the existing negative DC wire so there is a flat surface on which to seat the battery temperature sensor mounting plate. Y ou may need to bend the ring terminal and/or wires downward to allow the sensor to seat on the top surface of the upper ring terminal.

6. Mount the sensor directly on top of the negative DC wire terminal, as shown in Figure 3-9, and tighten the terminal nut firmly.

7. Check that the sensor and all wires are fastened securely.

8. Turn the battery switch on again (if you opened it in step 2).

9. Route the sensor cable to the PROsine and plug it into the

BATTERY TEMP

jack. Secure the cable along its length.

Important:

Then the sensor is installed on top of the DC wire. This sequence is required to provide the best connection to the battery and to thereby ensure correct performance of the sensor.

In this procedure, you must install the DC wire on the battery terminal first.

3–22 445-0089-01-01

Mounting to the Side of the Battery Case

To mount the sensor on the battery case

See Figure 3-10.

Step 9: Connecting the Battery Temperature Sensor

Adhesive backing allows for easy mounting on side of battery.

Figure 3-10

BTS Attached to Battery Case

1. Select the battery to be monitored (see step 1 in the preceding procedure).

2. Select a side suitable for attaching the sensor. The surface where the sensor is to be mounted must be flat and free from

reinforcing ribs or other raised features. As well, this surface must be in direct internal contact with battery electrolyte, so do not install the sensor on a side near the top of the battery or on the battery’s top surface.

3. Clean the selected area thoroughly to remove any oil or grease that could prevent the sensor from adhering to the battery case, and allow the battery case to dry thoroughly.

4. Peel the protective backing from the self-adhesive strip on the rear of the sensor.

5. Press the sensor firmly against the clean side of the battery to fix it in place.

6. Route the sensor cable to the PROsine and plug it into the

BATTERY TEMP

jack. Secure the cable along its length.

445-0089-01-01 3–23

Installation

Step 10: Connecting the Remote Shutdown

WARNING: Shock hazard

This step should only be completed by qualified installers or technicians who have a knowledge of DC circuits. Connect only to an isolated Class 2 extra-low voltage power source as described below.

Some installations may require remote shutdown capability. This feature enables you disable all circuitry in the PROsine and remove all power from the display panel using a remote shutdown switch (e.g. the ignition switch in a vehicle). This also removes all power (inverter and shorepower) from the AC loads.

The remote shutdown signal (RS+/RS–) requires a source of 5–18Vdc, which is capable of supplying 5–18mA, to enable the PROsine. This power source must be limited to Class 2 levels by an approved 1A fuse. The power source will often be one of the existing system batteries: the vehicle starting battery or the PROsine battery. In this case, the 1A fuse must be located in the positive (+) side of the circuit, as close as possible to the power source.

Note that the remote shutdown feature will only function when the ON/OFF/REM switch is set to REM.

Materials Required You need two high quality 26AWG, 4-conductor telephone cables with connectors

attached (one 10 feet maximum; one 100 feet maximum), one 1:2 phone line splitter, and a 1A fuse and in-line fuseholder. In addition, you might require a single pole, single throw switch (or alternatively, you can use a vehicle ignitionswitched circuit). You can obtain these from local hardware, electronics, and automotive stores.

Installation Steps

See Figure 3-11 and Figure 3-12.

To connect the remote shutdown feature

1. Select one of the two cables and cut it at a convenient location for connecting to your Remote Shutdown Switch.

2. See Figure 3-11 to identify the RS+ and RS– wires.

3. Insulate the two middle wires so they don’t short.

4. Connect RS+ to the positive of a switched, fused voltage source of 5–18V.

5. Connect the RS– to the return of this voltage source.

6. Plug the cables into the splitter and connect to the PROsine as shown in Figure 3-11.

The Remote Shutdown feature is now ready for use. For operating information, see “ON/OFF/REMote Control of PROsine Operation” on page 5–3.

3–24 445-0089-01-01

Step 10: Connecting the Remote Shutdown

Plug into

10 feet max.

NOTE:

on the opposite side of the connector

Figure 3-11

Battery Temp

26AWG, 4-conductor telephone cable

1:2 phone line splitter

100 feet max.

Battery Temperature Sensor cablejack on PROsine

Top view of cable and connector

The retaining clip is

Cabling Details for Remote Shutdown Feature

Do not use.

–

Do not use.

–

Next Steps

Do not connect to

these wires; they are used for the Battery Temperature Sensor.

Figure 3-12

At this point, you have installed the PROsine system and are now ready to configure it.

1. Read the configuration procedures in Chapter 4, “Configuration”.

2. Reconnect the AC shorepower supply.

3. Use the display panel to configure the PROsine.

Schematic for Remote Shutdown Feature

445-0089-01-01 3–25

Installation

3–26 445-0089-01-01

Configuration

Chapter 4 explains how to configure the PROsine to best meet your electrical system requirements. It is divided into three parts:

• General Configuration Information on page 4–2. Tells you how to enter Configure mode and Installer mode, how to scroll through the configuration screens, and how to change configuration settings.

• Configuration Screens on page 4–4. Shows how the configuration menus and screens are organized.

• Configuration Options on page 4–6. Lists all the configuration options as well as the available configuration values or settings. Refer to Part 3 when you want to set specific configuration values.

Important:

provides an overview of the configuration menus and options as well as a list of selected default settings.

he PROsine Quick Reference Guide supplied with your PROsine

Configuration

Part 1: General Configuration Information

All changes to the operation of the PROsine are made via the display panel. The unit must be in Configure mode or Installer-Only mode before you can change system settings. It is essential that you understand the implications of changing User and Installer settings. Be sure to study Chapter 3, “Installation” before you configure your system. Procedures for changing modes and values are given below.

Entering Configure Mode

To enter Configure mode:

• Set the This gives you access to all user-configurable items.

Entering Installer-Only Mode

WARNING: Fire hazard

The following information is for qualified installation/service personnel only. Incorrect configuration can lead to battery damage and risk of fire. If a parameter is “Installer-Only,” it is meant to be configured by a professional installer who is not only familiar with the system settings on the inverter but also the ramifications of changing those settings. Setting these parameters incorrectly could damage connected equipment (e.g. batteries) or could severely affect the performance of your system. You will not be able to change parameters that are Installer-Only unless you place the display panel in Installer-Only mode.

DISPLAY switch to CONFIGURE.

If you try to change settings on a screen that contains installer-only data and the panel is not in Installer mode, this message appears for one second:

To Change; Enter Installer Mode

To enter Installer-Only mode:

• While the unit is in Configure mode, hold down the

buttons for 3–4 seconds.

A message cautions you that the panel is now in Installer mode and explains how to exit Installer mode.

The next time you press a key, a message appears to remind you that the pane l is still in Installer mode.

Exit Installer-Only mode before you put the PROsine into service.

4–2 445-0089-01-01

ESCAPE and DATA Down

Changing Settings

Part 1: General Configuration Information

Changing Settings: Example 1

Important:

will not be lost even if all power is disconnected.

All configuration settings are stored in the PROsine’s memory and

To change system settings:

1. Set the

2. Press Up s

3. Press

DISPLAY switch to CONFIGURE.

MENU or Down t MENU to display the menu you want.

ENTER once, and then press Up s MENU or Down t MENU until the

menu item you want appears.

4. Press Up s

5. Press Up s

DATA or Down t DATA until the value you want appears. MENU or Down t MENU until the setting you want appears.

6. When the correct value is displayed, you can do one of three things:

• Press ENTER to save the new setting.

• Press ESCAPE to restore the old setting.

• Press Up s

MENU or Down t MENU to restore the old setting and

move to another item on the same menu.

Important:

by repeatedly pressing ESCAPE.

Wherever you are in the menu structure, you can return to the highest level

The Audible Alarm is set to Disabled by default.

To change the Audible Alarm to All Faults:

1. Set the

DISPLAY switch to CONFIGURE.

2. Press Down t

3. Press

ENTER once. The Audible Alarm menu item appears with an asterisk

MENU until Configure Display Panel appears.

(*) beside Disabled.

Changing Settings: Example 2

4. Press down t

5. Press

ENTER to save this setting. (An * appears to the left of All Faults.)

To adjust the Breaker Size setting:

1. Set the

DISPLAY switch to CONFIGURE.

DATA until All Faults appears.

2. Press Down t MENU until Configure PROsine—Basic Menu appears.

3. Press the

4. Press Down t DATA or Up s

5. Press

445-0089-01-01 4–3

ENTER button once. AC Breaker Size appears.

DATA until the value you want appears.

ENTER to save this setting.

Configuration

Resetting to Factory Defaults

To reset the PROsine to the factory defaults:

1. Disable Invert and Charge mode.

2. Set the

3. Press Down t

4. Press the

5. Press Down t

6. Press the

7. Hold down the Installer mode.

8. Press Down t DATA or Up s

9. Press the

DISPLAY switch to CONFIGURE.

MENU until Configure PROsine—Advanced Menu appears.

ENTER button once.

MENU until Reset to Dflts appears.

ENTER button once.

ESCAPE and DATA Down t buttons for 3–4 seconds to enter

DATA until Load Factory appears.

ENTER button once.

Part 2: Configuration Menus and Screens

Table 4-1 shows the organization of the configuration menus and screens. The screens are grouped into five menus:

• Configure PROsine—Basic

• Configure PROsine–Advanced

• Configure Display Panel

• Configure Battery

• Diagnostics

4–4 445-0089-01-01

Part 2: Configuration Menus and Screens

Table 4-1

Configure PROsine—Basic Configure PROsine— Adva nced Configure Display Panel Configure Battery Diagnostics

AC Breaker Size Load Sensing Equalize

Menu Structure—Overview

Load Sensing Load Sense Power Load Sense Interval Low AC Transfer (V) Low AC Transfer (Hz) High AC Transfer (V) High AC Transfer (Hz) AC Series Mode Inverter Low V Shutdown Inverter Low V Warning Inverter Low V Restart Hysteresis Run Without Panel Inverter After Reset Without Panel Charger After Reset Without Panel Auto Restart After Error Reset to Defaults

Audible Alarm LCD Backlight Mode LCD Backlight Brightness LCD Backlight Timeout Temperature (C/F)

Battery Size Default Battery Temp Battery Type View/Change Battery Details:

• Battery Temp. Coefficient

• Bulk Charge Mode Settings

• Max Voltage

• Max Current (%C)

• Threshold Voltage

• Threshold Timeout

• Absorption Mode Settings:

• Max Voltage

• Max Current (%C)

•Max Timeout

• Threshold Current (%C)

• Threshold Timeout

• Overcharge Mode Settings:

• Max Voltage

• Max Current (%C)

•Max Timeout

• Float Mode Settings:

• Max Voltage

• Max Current (%C)

•Max Timeout

• Threshold Voltage

• Threshold Timeout

• Equalize Mode Settings:

• Max Voltage

• Max Current (%C)

•Max Timeout

• Threshold Change

• Threshold Timeout

• Constant Mode Settings:

• Voltage Setpoint

• Current Setpoint

Charger Mode Charger Type Charger High Battery V Warning Offset

PS System Mode View Last 20 PROsine Faults Clear PROsine Fault Log View Last 10 Panel Faults AC Bad Cause View Software Versions:

• LVP Software Revision

• HVP Software Revision

• Display Software Revision

• Display EEPROM Revision View System Temperatures:

• Temperature at Panel

• PROsine Unit Temp. 1

• PROsine Unit Temp. 2 PROsine HVDC

445-0089-01-01 4–5

Configuration

Part 3: Configuration Options

This section gives you information about the options on each configuration menu . Refer to this section when you are changing system settings.

The information in this section is arranged as follows:

• Each configuration menu is identified by a heading (e.g.

PROsine—Basic Menu

• The heading is followed by a two-column table that gives you a “thumb nail” overview of the menu.

• The left column lists the items on this menu.

• The right column indicates whether the access mode is: User, Installer-

• The menu items or information displayed is explained after the table.

Important:

following message appears for one second:

u Read-Only Data

Press any key to remove this message.

Clear Errors in PROsine

Menu Item Access

Clear Errors Note: This configuration menu only appears when an error is active in the PROsine.

Configure

Only, or Read-Only.

If you try to change data on a screen that contains read-only data, the

User

Menu Choices or Information Displayed Wh en an error has occurred, you can select:

•Yes

•No

This acknowledges the error and tells the PROsine that you have attempted to clear the error condition and it should attempt a restart.

Whichever action you choose, the last twenty faults are recorded, and you can view them for diagnostic or troubleshooting purposes. For information about Warnings, Errors, and Panel Faults, see Chapter 6, “Troubleshooting”.

4–6 445-0089-01-01

Part 3: Configuration Options

Configure PROsine—Basic Menu

Menu Items Access

AC Breaker Size User Load Sensing User Equalize User

Menu Choices or Information Displayed

AC Breaker Size Set the AC breaker size to match the shorepower circuit breaker size to reduce

circuit breaker “nuisance” tripping. Values range from 0–30 amps.

Load Sensing Select Enabled if you want the unit to only turn on when a load is present. In

Load Sense mode, the unit will periodically search for the presence of an AC load while it is inverting. The unit will “sleep” if the load it detects is less than the Load Sensing setting or if there is no load. Select Disabled if you want the inverter on full-time rather than only when a load is present. For further information about load sensing, see “Load Sensing Mode” on page 5–

Equalize Select Enabled or Disabled. You can only select Enabled when the unit is

charging and battery type is set to Flooded. An equalization charge must only be performed on flooded (non-sealed or “wet”) batteries and only as often as recommended by the battery manufacturer.

WARNING: Fire hazard

If you select Enabled, you must monitor the electrolyte specific gravity and level during the equalization phase to prevent over-heating and battery damage.

CAUTION

During the equalization phase, the DC system voltage may exceed 17VDC, and therefore you should disconnect any sensitive DC loads.

445-0089-01-01 4–7

Configuration

Configure PROsine—Advanced Menu

Menu Display

(if different from Menu Item)

High AC Transfr (V) High AC Transfer (V) User High AC Transfr (Hz) High AC Transfer (Hz) User

INV Low V Restrt Hyst Inverter Low V Restart Hysteresis User

Menu Items Access

Load Sensing User Load Sense Power User Load Sense Interval User Low AC Transfer (V) User Low AC Transfer (Hz) User

AC Series Mode Installer Inverter Low V Shutdown User Inverter Low V Warning User

Run Without Panel User Inverter After Reset (Without Panel) User Charger After Reset (Without Panel) User Auto Restart After Error User

Reset to Dflts Reset to Defaults Installer

Menu Choices or Information Displayed

Load Sensing Select Enabled if you want the unit to periodically search for the presence of an

AC load while it is inverting. The unit will “sleep” if the load it detects is less than the Load Sensing setting. Select Disabled if you do not want the unit to search for an AC load. For further information about load sensing, see “Load Sensing Mode” on page 5–

Load Sense Power This setting determines what power the inverter needs to detect before it will start

automatically (if Load Sensing is Enabled). Settings range between 10 and 255W.

Load Sense Interval This is the amount of time between checks for the presence of an AC power load.

To save power while the unit is load sensing, increase the interval. The range is

0.5 to 25 seconds.

4–8 445-0089-01-01

Part 3: Configuration Options

Low AC Transfer (V)

This is the voltage below which the unit will no longer recognize AC as “good”, will open the relay, and will attempt to transfer to Invert mode if Invert is Enabled. The range of values is 85–110Vac.

Low AC Transfer (Hz)

High AC Transfer (V)

High AC Transfer (Hz)

This the frequency at which the unit will no longer recognize AC as “good” and will attempt to transfer to Invert mode. The range is 40–59Hz.

This is the voltage above which the unit will no longer recognize AC as “good” and will attempt to transfer to Invert. The range is 120–135Vac.

This the frequency at which the unit will no longer recognize AC as “good” and will attempt to transfer to Invert. The range is 61–70Hz.

AC Series Mode Select Standalone if you are operating a single PROsine to produce 120V single

phase. If you are installing two PROsines as a 240 split-phase system, set one PROsine as Master and the other as Slave.

Inverter Low V Shutdown

Inverter Low V Warning

At or below this battery voltage, the inverter will shut down. The values range from 10–16Vdc.

This is an offset voltage ranging from 0 to 3.0V. When the battery voltage drops below the sum of Low V Shutdown and Low V Warning, the PROsine will sound a warning.

Inverter Low V Restart Hysteresis

This is an offset voltage ranging from 0.5 to 2.5V. When the unit has shut down due to low battery voltage it will not automatically restart until the battery voltage recovers to the sum of Inverter Low V Shutdown and Inverter Low V Restart Hysteresis. When the PROsine shuts down the battery voltage will rise and may cause the PROsine to restart, which drops the voltage again so the PROsine shuts down, etc. This hysteresis setting reduces this problem. The default value is 2.5V and should not be changed unless there is a special reason for doing so or this problem will return.

Run Without Panel Select Yes if you want the PROsine to continue running if the display panel is

disconnected or the communication cable is damaged.

Inverter Enabled on Reset Without Panel

Charger Enabled on Reset Without Panel

Select Yes if you want the inverter to be enabled on startup if no panel is detected after 10 seconds.

Select

Yes if you want the charger to be enabled on startup if no panel is detected

after 10 seconds.

445-0089-01-01 4–9

Configuration

Auto Restart After Error

WARNING: Shock hazard

If Auto Restart is selected, AC voltage can reappear at the loads without notice after a fault has occurred and cleared.

If you select Yes, the PROsine will attempt to restart (five attempts) after a fault has occurred. If you select No, the PROsine ceases operation when an error occurs. It then requires that you manually restart the unit by going to the Configuration menu and clearing the error. Exception: If the PROsine shuts down in Invert mode because of lo w battery and the charger is enabled and AC is then supplied to the PROsine, it will automatically charge the battery.

Reset to Defaults You can only apply Load Factory, Save as Custom, or Load Custom if both the

charger and the inverter are disabled. The display panel should respond with OK. If Error appears, disable invert and charge and try again.

Load Factory If you select Load Factory, all PROsine settings will be reset to their default

values.

Save Custom If you want to change the settings temporarily, you may want to save your current

system settings. To save the current configuration of the PROsine, select Save Custom. You can then restore this configuration to the PROsine at a later time.

Load Custom Select Load Custom to restore your custom settings to overwrite the current

PROsine settings.

4–10 445-0089-01-01

Part 3: Configuration Options

Configure Display Panel Menu

Menu Items Access

Audible Alarm User LCD Backlight Mode User LCD Backlight Brightness User LCD Backlight Timeout User Temperature (C/F) User

Menu Choices or Information Displayed

This menu lets you change display panel settings to suit your preferences and environment.

Audible Alarm Select All Faults if you want a beeper to alert you to each Warning and Error that

occurs. If you prefer, choose Err o rs Only. Or choose Off if you don’t want to hear any alerts.

LCD Backlight Mode

The default setting is Auto, which means that the display remains off until an Error or a W arning occurs o r until you press any button on the display panel. Auto is a power-save feature. You can also choose to have the backlight On at all times or Off at all times.

LCD Backlight Brightness

Depending on the location of the display panel, you may want to adjust the brightness of the LCD. The default setting is 50%, and you can adjust this down to 0% or up to 100% in 10% increments.

LCD Backlight Timeout

If you set the LCD Backlight Mode to Auto, you can then choose when the display will turn off automatically. Time ranges are from 15 seconds to 10 minutes.

Temperature Choose to display temperatures in Celsius or Fahrenheit (default) according to

your preference.

445-0089-01-01 4–11

Configuration

Configure Battery Menu

Menu Display

(if different from Menu Item)

Dflt Batt Temp Default Batt Temp User

Menu Items Access

Battery Size Installer

Battery Type Installer

View / Change Battery Details: Batt Temp Coeff Mode Settings: Bulk Charge

• Bulk - Maximum Voltage

• Bulk - Maximum Current (%C)

• Bulk - Threshold Voltage

• Bulk - Threshold Timeout

Mode Settings: Absorption Chrge

• Absorption - Max Voltage

• Absorption - Max Current (%C)

• Absorption - Max Timeout

• Absrptn - Threshld Current (%C)

• Absrptn - Threshld Timeout

Mode Settings: Overcharge

• OverChg - Maximum Voltage

• OverChg - Maximum Current (%C)

• OverChg - Maximum Timeout

Mode Settings: Float

• Float - Maximum Voltage

• Float - Maximum Current (%C

• Float - Maximum Timeout

• Float - Threshold Voltage

• Float - Threshold Timeout

Mode Settings: Equalize Charge

• Equalize - Maximum Voltage

• Equalize - Maximum Current (%C)

• Equalize - Maximum Timeout

• Equalize - Threshld Change

• Equalize - Threshld Timeout

View / Change Battery Details: Battery Temp. Coefficient Mode Settings: Bulk Charge

• Max Voltage

• Max Current (%C)

• Threshold Voltage

• Threshold Timeout

Installer Installer

Installer Installer Installer

Mode Settings: Absorption

• Max Voltage

• Max Current (%C)

• Max Timeout

• Threshold Current (%C)

• Threshold Timeout

Installer Installer Installer Installer Installer

Mode Settings: Overcharge

• Max Voltage

• Max Current (%C)

• Max Timeout

Installer Installer Installer

Mode Settings: Float

)

• Max Voltage

• Max Current (%C

)

• Max Timeout

• Threshold Voltage

• Threshold Timeout

Installer Installer Installer Installer Installer

Mode Settings: Equalize

• Max Voltage

• Max Current (%C)

• Max Timeout

• Threshold Change

• Threshold Timeout

Installer Installer Installer Installer Installer

Mode Settings: Constant Charge

• Constant Voltage Setpoint

• Constant Current Setpoint

Mode Settings: Constant

• Voltage Setpoint

• Current Setpoint

Installer Installer

Charger Mode Charger Mode Installer Charger Type Charger Type Installer CHG Hi V Warning Offset Charger Hi V Warning Offset Installer

a.%C is used as the unit of measure for the current setpoints in the Configure Battery menu. The meaning of %C is as follows: Charging current generally varies with battery bank size. Therefore, current setpoints are generally expressed as %C where C is the capacity (Ah) of the battery bank. For example, to charge a 200Ah battery bank at 40A, a setting of 20% should be used.

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Part 3: Configuration Options

Menu Choices or Information Displayed

WARNING: Risk of Fire or Explosion

Incorrect settings can damage or destroy your batteries. When making any battery configuration settings, ensure that the values are correct according to the battery manufacturer’s specifications. Settings should be changed by qualified personnel only.

The Configure Battery menu lets you read (as a user) and change (installer-only) settings associated with the battery system. The parameters that can be set include battery size, temperature, and type.

Battery Size This is the capacity of the battery or battery bank in ampere-hours. The PROsine

will alter the charging rate based on battery bank size. Charging at a rate that is too high for your batteries can damage or destroy them. Select the appropriate value between 50 and 2000 Ah.

Default Batt Temp Select a battery temperature that is closest to the average ambient temperature in

the location where the battery is installed. The choices are:

p Cold: 5°C (41°F) p Warm: 20°C (68°F) p Hot: 35°C (95°F)

When the battery temperature sensor is installed, this setting is ignored and the actual battery temperature is used.

Battery Type From the list of options available, select the type of battery(s) that you have

installed. See Application Note: Battery Banks for Inverter Systems (976-011401-01). When you select a charging algorithm, the battery details listed below (see “V iew / Change Battery Details” on page 4–13) are automatically given default settings. These default values are the most appropriate for the selected battery type.

If you have a battery type that isn’t on the list, you can modify the charging algorithm settings according to the manufacturer’s guidelines. (This requires you to be in Installer mode.)

View / Change Battery Details

Battery Temp Coefficient

The screens associated with these menu items display information about the way the PROsine will charge the battery.

This is the relationship between temperature and vo ltage levels on the battery. The correct value depends on battery type. For the correct value, consult the battery manufacturer.

445-0089-01-01 4–13

Configuration

Bulk Charge Mode Settings

Absorption Mode Settings

• Max Voltage This is the maximum available charging voltage for the Bulk charging stage.

• Max Current (%C) The maximum available charging current (in A) as a percentage of battery capacity (in Ah) for the Bulk charging stage.

• Threshold Voltage an d Timeout When the battery voltage goes above this value for the Threshold Timeout specified, the unit goes into Absorption charging stage.

• Max Voltage This is the maximum charging voltage for the Absorption charging stage. Typically, the battery will be at this voltage for the duration of this stage.

• Max Current (%C) The maximum available charging current (in A) as a percentage of battery capacity (in Ah) for the Absorption charging stage.

• Max Timeout This is the maximum amount of time that the unit will stay in the Absorption stage.

• Threshold Current (%C) and Timeout When battery current goes below this value (A as % of battery capacity in Ah) for the Threshold Timeout, the unit goes into the next charging stage.

Overcharge Mode Settings

• Max Voltage This is the maximum charging voltage for the Overcharge charging stage. Typically the battery will be at this voltage for the duration of this stage.

• Max Current (%C) The maximum available charging current (in A) as a percentage of battery capacity (in Ah) for the Overcharge charging stage.

• Max Timeout The amount of time that the Overcharge stage will run.

Float Mode Settings • Max Voltage

This is the maximum available charging voltage for the Float charging stage. Typically the battery will be at this voltage for the duration of this stage.

• Max Current (%C) The maximum available charging current (in A) as a percentage of battery capacity (in Ah) for the Float charging stage.

• Max Timeout This is the maximum amount of time that the charger will be in Float stage.

• Threshold Voltage an d Timeout When the battery voltage goes below this value for the Threshold Timeout specified, the unit goes into Bulk charging mode.

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Part 3: Configuration Options

Equalize Mode Settings

Constant Mode Settings

• Max Voltage This is the maximum available charging voltage for the Equalize charging stage.

• Max Current (%C) This is the maximum available charging current (in A) as % of battery capacity in (Ah) for the Equalize charging stage.

• Max Timeout This is the maximum amount of time that the unit will stay in Equalize stage.

• Threshold Change and Timeout When the battery voltage changes by less than the change value over the Threshold Timeout specified, the unit goes to Float charging.

Voltage and current setpoints will be set, but the unit will likely be able to satisfy only one of these setpoints at any given time.

Example: For setpoints of 13.5V and 50A, the unit will supply 13.5V up to 50A and at higher loads, the current is held at 50A and the voltage will drop.

• Voltage Setpoint The PROsine will attempt to charge the battery at this target voltage. The default value is 13.5V.

• Current Setpoint The PROsine will attempt to charge the battery at this target current. The default value is 100A.

• Exit Criteria None. Unless a fault occurs, the unit will run continuously. Care must be taken to ensure that the voltage and current setpoints are correct for your battery type and loads to avoid damage.

Charger Mode Select Standalone when a single PROsine is being used to charge a battery.

When multiple PROsines are charging a single battery bank, the secondary chargers only operate during the Bulk charge phase, and the primary charger finishes charging the battery. In this situation, select one charger as primary and all others as secondary.

p Standalone p Primary p Secondary

445-0089-01-01 4–15

Configuration

Charger Type Choose one of the three charger types listed below. For information about multi-

stage charging, see Application Note: Battery Banks for Inverter Systems (9760114-01-01).

p 3-step

The PROsine will perform the Bulk, Absorption/Overcharge, and Float steps

p 2-step

The PROsine will only perform the Bulk, Absorption/Overcharge, and Standby steps. Some battery manufacturers and users believe that batteries should not be Float charged.

p CVCC

Constant Voltage Constant Current mode (also called “Constant Mode”). This mode is not intended as a standalone battery charger. It may be used as a power supply mode but still requires the presence of a battery in the system.

Charger Hi V Warning Of fset

This is an offset voltage ranging from 1.0 to 4.0V. If the battery voltage exceeds the sum of the Maximum Voltage in the present charging stage and the Charge Hi V Warning Offset the PROsine will sound a warning. If there are other sources charging the battery this value can be increased from the default 1.0V value to prevent nuisance warnings from the PROsine. High voltages can reduce the life of the batteries and pose a safety hazard; the charge high battery voltage warning is intended to warn of an unsafe condition.

4–16 445-0089-01-01

Diagnostics Menu

Menu Items Access

PS System Mode Read-Only View Last 20 PROsine Faults

• PROsine Fault #0

•—

• PROsine Fault #19 Clear PROsine Fault Log User View Last 10 Panel Faults

• Panel Fault #0

•—

• Panel Fault #9 AC Bad Cause Read-Only View Software Versions:

• LVP Software Revision

• HVP Software Revision

• Display Software Revision

• Display EEPROM Revision

Read-Only

Part 3: Configuration Options

View System Temperatures:

• Panel ambient temp

• Unit Temp #1

• Unit Temp #2 PROsine HVDC Read-Only

Read-Only

Menu Choices or Information Displayed

The screens on the Diagnostics menu are Read-Only. They let you monitor and troubleshoot the status of your PROsine system. For example, if the unit is continually recording Warnings about low battery voltage, you can view the messages and take appropriate corrective action.

The following items appear on this menu:

PS System Mode This screen indicates the present operating mode of the PROsine: invert, bulk

charge, absorption charge, etc.

Vi ew Last 20 PROsine Faults

The PROsine records the last twenty PROsine Warnings and Errors. You can examine these for diagnostic and troubleshooting purposes. See Chapter 6, “Troubleshooting”. Warnings end with these characters: -W (e.g,. Batt too hot -W). Error message are displayed in the same way without the -W at the end.

Clear PROsine Fault Log

When reviewing a log containing errors it is not always clear what faults are recent and which are old and not relevant. Select "OK" to clear all entries in the PROsine fault log - after this any errors in the log must be recent.

445-0089-01-01 4–17

Configuration

View Last 10 Panel Faults

AC Bad Cause If the input AC is not acceptable according to the configuration values you set,

View Software Versions

View System Temperatures

PROsine HVDC This shows the voltage on the internal DC bus of the PROsine, when it’s operating

The display panel records the last ten faults that have occurred in the display panel. You can view these for diagnostic and troubles hooting purposes. See “Display Panel Faults” on page 6–9.

this screen indicates why: causes included low frequency, low voltage, etc. For a complete list of causes, see “AC Bad Causes” on page 6–3.

This information can help Xantrex Customer Service Representatives troubleshoot problems you might have with the PROsine.

p LVP Software Revision p HVP Software Revision p Display Software Revision p Display EEPROM Revision

These readings show temperatures in the PROsine and the display panel.

in Invert mode, Bypass, or Charge mode. This parameter will show 0V when the unit is faulty or off mode. This can be helpful when troubleshooting with Xantrex technical support.

Next Steps

At this point, you have configured the PROsine and display panel, and you are now ready test and use the unit.

Go to “Part 1: System Startup Check” on page 5–2.

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Operation

Chapter 5 begins with a system startup check that you carry out after installation and configuration to verify that the PROsine is operating correctly. The chapter also provides information that will guide you during routine, ongoing operations.

For your convenience, the information is divided into four parts:

• System Startup Check on page 5–2.

• Operating Considerations on page 5–3.

• Operation in Inverter Mode on page 5–5.

• Operation in Charger Mode on page 5–7.

• Display Mode Screens on page 5–10.

Operation

Part 1: System Startup Check

WARNING

Review the “Important Safety Instructions” on page vii before operating the PROsine.

To test the charging and inverting functions:

1. Close the battery disconnect and turn on the PROsine’s ON/OFF/REM switch.

2. To test the inverter, set the INVERTER switch to ENABLE and disconnect the AC input source breaker.

3. Place a load on the inverter (e.g. plug a light into an outlet that the inverter is powering) and make sure it works. The INVERTING LED should come on and the inverter should run the load using battery power.

4. To test the charger, connect the AC input source breaker. Set the display’s CHARGER switch to ENABLE. After a short delay, the CHARGING LED should come on. Any AC loads powered by the inverter will also work at this time.

5. Remove the AC shorepower. The PROsine should transfer to Inverter mode immediately. (The transfer relay will make a clicking sound and the INVERTING uninterrupted.

If any part of this procedure fails, determine the cause before using the PROsine. Consult the Chapter 6, “Troubleshooting”.

LED will come on.) Loads should continue to operate

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Part 2: Operating Considerations

Fan Operation

The internal cooling fan operates for a number of conditions:

• One of the internal operating temperatures is greater than 55°C.

Part 2: Operating Considerations

Important:

ambient temperature.

The fan will continue to run until one minute after the temperature drops to 45°C.

• The AC input or output current is greater than 20A (15A if the internal temperature is greater than 40°C)—even in bypass mode, to keep the relay cool. It will shut off one minute after the current drops below 13A.

This temperature may be caused by heat in the PROsine or by high

ON/OFF/REMote Control of PROsine Operation

The ON/OFF/REM switch is located on the AC end of the PROsine.

• ON: The PROsine operates normally according to the configuration and Display switch settings.

• OFF: The inverter and charger are disabled regardless of configuration or Display switch settings. Shorepower will not be passed to the AC loads. In this state, the battery current is minimal (less than 2mA). This state guarantees that the PROsine does not discharge the battery bank.

• REMote: In this position, the remote control signal that the user provides to the BATTERY TEMP jack turns the PROsine on or off. (For details about the Remote Shutdown switch, see page 3–24.) When this signal is active, the PROsine operates normally according to the configuration and Display switch settings.

Important:

display panel (or if it is configured to run without panel). When the remote control signal is inactive, the PROsine is OFF, as described above.

The PROsine will enter Invert or Charge modes only if enabled from the

Hysteresis

Consider a scenario: the PROsine is operating in charge mode from shorepower. The shorepower voltage falls below the transfer point of 90V. The PROsine transfers to invert mode and the shorepower voltage rises to 95V - but the PROsine does not transfer back to shorepower even though the shorepower voltage is now above the transfer point. In this instance the PROsine applies 10V of "hysteresis" to the transfer voltage before accepting the shorepower again (that is, the PROsine will require 100V on the shorepower before transferring back).

445-0089-01-01 5–3

Operation

Without this hysteresis the PROsine might continually transfer between invert and charge mode as the shorepower voltage goes up and down a small amount. This concept is applied to the following:

• Invert Low Voltage Shutdown Hysteresis: 2.5V, if the unit stopped inverting due to low battery voltage, it will not restart until the battery voltage has increased to 2.5V above the Invert Low Voltage Shutdown level. NOTE, this hysteresis is adjustable, see Chapter 4, “Configuration”

• Over/under Temperature Hysteresis: 10°C, if the unit shuts down due to over or under temperature (at the battery or internal to the unit) then it will not automatically restart until the temperature has decreased or increased by 10°C (that is, moved 10°C into the allowable range).

Note that, in general, the unit will not automatically restart unless the "Restart After Error" option has been configured to YES. Also, the effect of the hysteresis can be cancelled by turning the unit off and back on, if the parameter is within range the unit will restart. For example if the unit transferred (opened the AC input relay) due to the shorepower voltage dropping below 90Vac and then the voltage rises to 95V the unit will not automatically transfer back to shorepower. Turn the unit off briefly and back on and it will accept the 95V shorepower and transfer.

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Part 3: Operation in Inverter Mode

WARNING

Review the “Important Safety Instructions” on page vii before operating the PROsine.

Once the PROsine is installed, you can operate it in Inverter mode.

To operate in Inverter mode:

1. Place PROsine’s ON/OFF/REM switch in the ON position.

2. Set the INVERTER switch to ENABLE.

3. If AC is present, the STANDBY LED will come on. If AC is present, remove it and the inverter will come on.

Once the INVERTING LED is on, the PROsine is ready to deliver AC power to the loads.

Part 3: Operation in Inverter Mode

Important:

Applications” on page 6–11.

If you are having problems with any of your loads, refer to “Inverter

Load Sensing Mode

The PROsine’s Load Sensing mode reduces power consumption in order to conserve battery capacity.

When the inverter is ENABLED, the PROsine can be configured to search for an acceptable AC load. (It does this when you Enable Load Sensing on the “Configure PROsine—Basic Menu” on page 4–7 and set Load Sensing parameters on the “Configure PROsine—Advanced Menu” on page 4–8.) The unit will “sleep” if it doesn’t detect a load that meets the Load Sense parameters. This “sleep” mode shuts off much of the PROsine’s power control circuitry and thereby reduces the standby current draw considerably. When an acceptable load is detected, full output power is available.

In Load Sense mode, the INVERTING LED flashes approximately once a second.

Operating Limits for Inverter Operation

Power Output

The continuous output rating for the PROsine is 2000 watts or 17 amps @ 120Vac; surge to 4.5kW. It can deliver this power in an ambient (surrounding) temperature that is up to 40°C. Above this temperature, you must reduce the demand or the unit may shut down. (See the chart on page A–6 for details.)

The PROsine should be able to operate all AC loads rated at or below its power rating. Some high horsepower induction motors used in pumps and other motoroperated equipment require very high surge currents to start, and the PROsine may have difficulty starting these loads. (See page 6–11 for more information.) If

445-0089-01-01 5–5

Operation

you have problems starting certain loads, ensure that the battery connections are solid, the DC cabling is short and of sufficient size, the AC wiring is of sufficient size, and the battery is of sufficient capacity and is fully charged.

As with all inverters, the amount of continuous power that the PROsine can deliver without overheating is limited by the ambient air temperature. It will operate and deliver its continuous power rating at higher temperatures, but the ambient temperature as well as the input voltage from the battery limits the extent to which it can do this. Operating the PROsine in conditions outside the power and temperature limits will result in thermal shutdown and/or significantly decreased performance. In addition, operation in this range is outside the ratings covered by the regulatory approvals of the product. (See page A–6.)

Input Voltage

The input voltage limits are shown in Table 5-1

Table 5-1

Operating Condition

Normal 10V–16V

PROsine Operating Voltage Limits

Voltage Range Comment

Peak Performance 12V–16V High Voltage Alarm ≥15.5V Unit Shuts Down ≥16V Protects inverter against excessive input voltage. Low Voltage Alarm ≤10.5V Unit Shuts Down ≤10.0V Protects battery from being over-discharged. Unit Restarts ≥12.5V The PROsine will not restart unless input voltage exceeds 12.5V or the

inverter is turned ON manually with the DISABLE/ENABLE switch. If the inverter is already enabled (ST ANDBY LED is on), move the switch to DISABLE to turn the inverter OFF, and then move it to ENABLE again to restart the inverter (as long as the battery voltage is between 10–16 volts).

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Part 4: Operation in Charger Mode

WARNING: Explosion hazard

Review the “Important Safety Instructions” on page vii before operating the PROsine. During charging, batteries may generate explosive gasses. Thoroughly ventilate the area around the batteries and ensure that there are no sources of flames or sparks in the vicinity . Study all battery manufacturer’s precautions such as removing or not removing cell caps while charging and recommended rates of charge.

To operate the PROsine in Charger mode:

1. Turn on the PROsine’s ON/OFF/REM switch.

2. Connect AC shorepower.

• The batteries are charged according to the three-step algorithm you have

selected.

• The READY LED comes on when the charge cycle is complete.

• You can interrupt the charge cycle any time if you don’t have time to wait

for a full charge.

• To maintain optimal performance in flooded batteries, an occasional

equalize cycle may be required.

3. While the batteries are being charged, you can monitor which stage they are in by viewing PROsine System Mode on the PROsine—Diagnostics menu. See page 4–17.

Part 4: Operation in Charger Mode

Important:

until battery acid reaches the level specified by the manufacturer. This helps prevent overheating and purges excessive gases from the cells. Do not overfill. For a battery without cell caps, follow the manufacturer’s recharging instructions carefully.

If you are charging a non-sealed battery, add distilled water to each cell

Operation in Equalization Mode

WARNING: Explosion hazard

Equalization generates explosive gases. Ensure adequate ventilation.

CAUTION

Sealed lead-acid batteries and gel batteries must NEVER be equalized or premature battery failure will result. Equalize mode is disabled if you have selected “Gel” as the Battery Type. Only flooded lead-acid batteries shoul d be equ a l ized. As a general rule, do not equalize a battery unless there are provisions to add water to it and the manufacturer recommends equalization.

445-0089-01-01 5–7

Operation

Equalization Procedure

Important:

your batteries. Never equalize a battery more than necessary. Always check electrolyte level before AND after equalization. Fill with distilled water only. Monitor electrolyte specific gravity (S.G.) throughout the equalization phase.

If carried out too frequently or done improperly, equalization can damage

Follow the battery manufacturer’s recommendations for equalizing your batteries. 10 provides some background on different batteries. As a guide, a heavily used flooded battery may need to be equalized once a month and a ba ttery in light service every two to four months.

The PROsine delivers a high quality charge so batteries do not need to be equalized as often as may be necessary when a lower quality charger is used.

To equalize your batteries:

1. Turn off or disconnect all loads on the battery. The voltage applied to the battery during equalization may damage some

electronic equipment. As well, equalization won’t proceed correctly if loads are drawing current from the battery.

2. Check electrolyte level. Fill with distilled water if the electrolyte level is low. Measure the specific

gravity (S.G.) of each cell using a hydrometer. For fully charged lead-acid batteries, the reading should be approximately 1.265. (Consult your battery manufacturer.) Equalization is needed if one or more cells have a substantially lower specific gravity than the others.

3. To request the equalization charge, the charger must already be in operation. Set the CHARGER switch to ENABLE, and then select Equalize on the Configure PROsine—Basic menu (see page 4–7).

Equalization will be carried out after an absorption charge (if the batteries are not fully charged) or right away if fully charged. When equalization has been requested, the CHARGING LED is on and the EQUALIZE LED is flashing. When the system is in equalization, CHARGING is on and EQUALIZE is on.

4. The PROsine will apply a constant low current to the batteries to perform an equalize charge. This current and the maximum voltage values can be configured, see Chapter 4, “Configuration”. The voltage of the batteries will rise as the current is forced into the batteries. When the voltage is rising very slowly (as configured in Chapter 4, “Configuration”) the PROsine will declare an end to the equalize phase. A maximum time in the equalize phase may also be configured. Some users may have trouble with the PROsine not completely equalizing the batteries before exiting this stage. In this case the "Threshold Change" can be configured to 0.0V and the "Threshold Timeout" can be set to a long time (even several hours).

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WARNING: Fire hazard

In this situation it is very important to check the electrolyte level and S.G. in each cell at least once per hour. The char ger should be turned of f and the batteries allowed to rest a few minutes to do this check as the electrolyte will be bubbling if the charger is active. If further equalization is needed the equalize cycle may be restarted.

5. During equalization, measure the S.G. When all cells have an S.G. of approximately 1.265, terminate the charge by

setting the CHARGER switch to DISABLE. As a safety feature, the PROsine will exit Equalize mode after a specified period (depending on battery type). If the S.G. is still rising just before the charger exits equalization, restart the process by requesting an equalization charge.

6. When equalization is finished, check the battery electrolyte level. Top up as necessary with distilled water only.

Operating Limits for Charger Operation

Output Current: The maximum output current for the PROsine is 100 amps.

You can reduce the total output if you change the Battery Size setting on the Configure Battery menu (see page 4–12) or the maximum AC Breaker Size setting on the Configure PROsine— Basic menu (see page 4–7).

Input Voltage: The charger can operate over the range of 90–135Vac. This wide

range allows the PROsine to deliver a maximum current to your batteries even when incoming AC voltage is less than ideal. A built-in surge protector protects the PROsine from surges and spikes on the AC power line.

Part 4: Operation in Charger Mode

Power Share

The PROsine shares power with AC loads. It senses pass-through current going to AC loads and subtracts this current from 80% of the breaker setting. The current that is left over is available for charging the batteries.

In Charge mode, the PROsine operates from a breaker-protected 120Vac circuit. Therefore the total power for AC loads and charger operation is limited to 80% of the breaker rating (80% is the regulatory maximum permitted for continuous loads). In this limited power environment, the PROsine gives priority to userconnected AC loads (pass-through current).

Example A 30 amp circuit breaker is allowed to have a 24 amp continuous load. If you have AC loads of 15 amps, the PROsine will give priority to your loads and

allow the charger to draw up to 9 amps AC.

445-0089-01-01 5–9

Operation

Part 5: Display Mode Screens

When the DISPLAY switch is ON, you can view the screens shown below. (The values shown here are examples only.) Display Mode screens are updated continuously to show current PROsine operating data. You can scroll through them by pressing the Up s

and Down t MENU buttons.

Screen 1

Screen 2

Screen 3

Important:

+ indicates current going into the battery (i.e. + indicates charging). – indicates current coming out of the battery (i.e. – indicates that the battery is supplying

loads or the

PROsine: Battery

12.0V +10A 22

Shows the PROsine’s voltage and current readings from the battery as well as the battery temperature. If the battery temperature sensor is not installed, the screen on the right is displayed.

In the screens below current polarity is indicated as follows:

PROsine is inverting).

PROsine: Battery

°C

12.0V +10A

PROsine: AC In

118.0V 5A 58Hz

Shows the voltage, current, and frequency of the shorepower (i.e. input AC).

PROsine: AC Out

120.0V 10A 60Hz

Shows the voltage, current, and frequency of the output AC.

Screen 4

12.0V –120A 22

120V 10A 60Hz

Combines the battery display (Screen 1) with the AC output display (Screen 3). The left-hand screen appears if the battery temperature sensor is installed. Output AC is shown on the bottom. The PROsine’s voltage and current readings from the battery as well as the battery temperature appear on top. The bottom of the right-hand screen shows the output AC. The top shows battery voltage and current as read by the PROsine. (This is the screen that appears if the battery temperature sensor is not installed.)

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°C

12.0V –120A

120V 10A 60Hz

Troubleshooting

Chapter 6 describes how to troubleshoot the PROsine This section is divided the following parts:

• General Troubleshooting Guidelines on page 6–2.

• Shutdown / Restart Without Error Message on page 6–3.

• AC Bad Causes on page 6–3.

• Warning Messages on page 6–4.

• Error Messages on page 6–6.

• Display Panel Faults on page 6–9.

• Inverter Applications (Loads) on page 6–11.

Troubleshooting

General Troubleshooting Guidelines

WARNING: Shock and Energy hazard

Do not disassemble the PROsine. It does not contain any user-serviceable parts. Attempting to service the unit yourself could result in an electrical shock or burn.

Important:

Before you call Xantrex Customer Service, record the info rmation that is asked for in “Information About Your System” on page WA–4.

This section will help you narrow down the source of any problem you encounter. Before contracting Xantrex, please work through the steps listed below:

1. Check for a Warning, Error, or Panel Fault message. (See Table 6-2, Table 6-3, and Table 6-4 for descriptions of these messages and specific actions to take.) If a message is displayed, record it before doing anything further.

2. As soon as possible, record (on page WA–4) the conditions at the time the problem occurred so you can provide details if you need to contact Xantrex. These details should include the following as well as anything else asked for on page WA–4:

• What loads the PROsine was running or attempting to run

• What the battery condition was at the time (voltage, state of charge, etc.) if

• Recent sequence of events

• Any known unusual AC shorepower factors such as low voltage, unstable

• Whether any extreme ambient conditions existed at the time (temperature,

3. Attempt the solution indicated in Table 6-2, Table 6-3, or Table 6-4.

4. If your PROsine is not displaying a Warning, Error, or Panel Fault message, check the following to make sure the present state of the installation allows proper operation:

• Is the inverter located in a clean, dry, adequately ventilated place?

• Are the battery cables adequately sized and short enough and is the battery

• Are the AC input and output connections and wiring in good condition?

• Are the configuration settings correct for your particular installation?

• Are the display panel and the communications cable properly connected

• Are the battery temperature sensor and its cable properly con nected and

If you need to obtain service, see page WA–1.

known

generator output, etc.

vibrations, moisture, etc.)

in good condition, and are all DC connections tight?

and undamaged?

undamaged?

5. Contact Xantrex for further assistance. Please be prepared to describe details or your system installation and to provide the model and serial number of the unit.

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Shutdown / Restart Without Error Message

While inverting, the PROsine could shut down for a few seconds and then restart inverting without reporting an error.

This has likely been caused by a reset of the internal microprocessor, which was probably caused by a discharged and/or weak battery. In particular , this may occur when the battery is weak and the unit is starting loads which demand a high surge (e.g. air compressor, air conditioner, fridge).

You can try recharging the battery bank. If the problem persists, an equalize cycle (only on batteries which permit equalization) may help. If this does not correct the situation, the battery bank may require upgrading or replacement.

Resetting PROsine Operation

If the PROsine does not appear to be operating correctly it may require a system reset to properly restart, this will clear any hysteresis (Chapter 5, “Operation”), most errors and warnings (but these may recur if the condition that caused them persists). Note that this will not change any configuration settings within the unit. Locate the ON/OFF/REM switch on the PROsine, just below the connector for the display panel. Set the switch to OFF for 5 seconds and then back to ON (or REM if you are using a remote switch with the PROsine).

General T r oubleshooting Guidelines

AC Bad Causes

If the input AC is not acceptable according to the configuration values you have set, the AC Bad Cause screen in the Diagnostics menu indicates why. Specific causes are listed in Table 6-1. You have the option of leaving the values or changing them depending on your circumstances. If you want to change configuration settings, see Configure PROsine—Advanced Menu on page 4–8.

Table 6-1

AC Bad Cause Details

None There is no problem with the AC input. Low Cycle V In The rms voltage as calculated over one cycle (0.016s) was less

High Cycle V In The rms voltage as calculated over one cycle (0.016s) was

Low Average V In The rms voltage as calculated over 16 cycles (0.25s) was less

Hi Average V In The rms voltage as calculated over 16 cycles (0.25s) was greater

Low Frequency The frequency was less than the user-set minimum acceptable

High Frequency The frequency was greater than the user-set maximum

AC Bad Causes

than the user-set minimum acceptable operating voltage.

greater than the user-set maximum acceptable operating voltage.

than the user-set minimum acceptable operating voltage.

than the user-set maximum acceptable operating voltage.

operating frequency.

acceptable operating frequency .

445-0089-01-01 6–3

Troubleshooting

Warning Messages

Warning messages appear on the display panel LCD to alert you to an impending system change. Warnings do not affect operation.

• You can retrieve the previous twenty Warning and/or Error messages by

placing the unit in Configure mode and then selecting View Last 20 PROsine

Faults from the Diagnostics menu. Warnings end with the characters -W (e.g. Batt too hot -W).

• To clear a Warning message, press the ESCAPE key.

• If the audible alarm is enabled, press ESCAPE twice. The first key press deactivates the alarm and the second removes the message from the screen. (The warning is not cleared from the system, however.)

Warnings are listed in Table 6-2. The text in the Warning Message column appears as the second line on the LCD; the first line displays the text: PROsine

Warning.

Table 6-2

Warning Message Details Action

Batt Too Hot -W PROsine battery temperature too high. Check the tightness of all connections.

Batt Too Cold -W PROsine battery temperature too low. Extreme cold may require a battery heater. If the

Temp1 Too Hot -W PROsine internal temperature 1 too

Temp2 Too Hot -W PROsine internal temperature 2 too

Temp1 Too Cold -W

Warning Messages

high. Reduce loads on the system.

high.

PROsine internal temperature 1 too

Check electrolyte level. Check charger and battery settings.

battery is frozen, thaw it gradually to avoid damage.

Ensure that the PROsine is being adequately ventilated.

low.

Temp2 Too Cold -W PROsine internal temperature 2 too low. T e mp1 Short -W Temp1 Open-W T e mp2 Short -W Temp2 Open -W

These warnings indicate a problem with an internal temperature sensor but may also be caused by excessive cold or heat

Raise the ambient temperature.

See if the warning persists when the PROsine is in a normal temperature environment of 32°F to 104°F (0°C to 40°C). The internal temperatures can also be checked on the display panel (in Configuration Mode) in the Diagnostic Menu (see page 4–17). If the problem persists contact Xantrex.

Inv Lo Bat V - W Low battery voltage, invert mode. Check battery state of charge and re-charge if

necessary. Check for proper DC cable size. Check all connections for tightness.

6–4 445-0089-01-01

Xantrex Technology PROsine 2.0 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual