Xantrex Technology PROwatt 600 User Manual

PROwatt™ 600 Inverter

Owner’s Guide

PROwatt 600 Inverter

Owner’s Guide

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utilityscale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.

Trademarks

PROwatt is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex Technology Inc.

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

Disclaimer

While every precaution has been taken to ensure the accuracy of the contents of this guide, Xantrex International assumes no responsibility for errors or omissions. Note as well that specifications and product functionality may change without notice.

Date and Revision

January 2001, Revision 1

Part Number

445-0115-01-01

Contact Information

Web: www.xantrex.com Email: support.prowatt@xantrex.com Phone: 1-800-670-0707 Fax: 1-800-994-7828

About This Guide

Purpose

The PROwatt 600 Owner’s Guide contains information that enables individuals to install, operate, and troubleshoot the PROwatt 600 Inverter.

Scope

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

Audience

The guide is intended for anyone who needs to install and operate the PROwatt™ 600 Inverter.

About This Guide

Organization

This guide has four chapters and four appendixes.

Chapter 1, “Introduction”, outlines the main performance and safety features of the PROwatt 600 Inverter. Reading this chapter will give you a clear understanding of the inverter’s capabilities.

Chapter 2, “Installation”, outlines the inverter’s main physical features. This information will give you a good orientation to the product before you install it. The chapter then goes on to explain how to plan and complete an effective installation.

Chapter 3, “Operation”, provides information about turning on and operating the inverter. Details are provided about how to read the front panel indicators to monitor the system. The chapter also provides information about battery charging and routine maintenance.

Chapter 4, “Troubleshooting”, explains how to identify and solve problems that can occur with the inverter.

Appendix A, “Specifications”, provides the electrical and physical specifications.

Appendix B, “Battery Types and Sizes”, provides background information about battery types as well as information that will allow you to calculate the size and number of batteries your system requires.

Appendix C, “Alternators and Charging Systems”, describes charging system components and explains how to design a charging system for your installation.

Appendix D,“Product and System Information” , contains the product’s warranty, explains how to return a product for service, and describes how to prepare for a call to Xantrex Customer Service.

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in personal injury or loss of life and appear in this form.

CAUTION

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

Note

Notes describe additional information which may

add to your understanding of how to use the inverter.

About This Guide

Related Information

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

www.xantrex.com

Important Safety Information

WARNING

Before installing and using your PROwatt Inverter, read and save these safety instructions.

General Precautions

1. Before installing and using the inverter, read all appropriate sections of this guide and any cautionary markings on the inverter and the batteries.

2. Do not operate the inverter if it has received a sharp blow, been dropped, or otherwise damaged. If the unit is damaged, see “Warranty” on page 42 and “Return

Material Authorization Policy” on page 43.

3. Do not dismantle the inverter; it contains no user serviceable parts. Attempting to service the unit yourself could cause electrical shock or fire.

remain charged after all power is disconnected.

page 43 for instructions on obtaining service.

4. To reduce the risk of electrical shock, disconnect both AC and DC power from the inverter before working on any circuits connected to the inverter. Turning off the front panel On/Off will not reduce this risk.

5. Protect the inverter from rain, snow, spray, and bilge water.

6. To reduce the risk of overheating or fire, keep the ventilation openings clear, and do not install the inverter in a zero-clearance compartment.

Internal capacitors

™

600

See

vii

Explosive Gas Precautions

1. Batteries generate explosive gases during normal operation. Be sure you follow all relevant instructions exactly before installing or using your inverter.

2. This equipment contains components which tend to produce arcs or sparks. To prevent fire or explosion, do not install the inverter in compartments containing batteries or flammable materials or in locations that require ignition-protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system.

Precautions When Working With Batteries

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 battery.

4. Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circuit the battery or other electrical parts and could cause an explosion.

viii

5. Remove metal items like rings, bracelets, and watches when working with lead-acid batteries. These batteries produce a short-circuit current high enough to weld a ring or the like to metal, and thus cause a severe burn.

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

Precautions For Using Rechargeable Appliances

Most battery-operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage output. If the label on the AC adapter or charger states that the adapter or charger produces a low voltage AC or DC output (less than 30 volts), the PROwatt can power this charger or adapter safely.

Some rechargers for small nickel-cadmium batteries can be damaged if connected to the PROwatt 600 Inverter. Do not use the following with the PROwatt 600 Inverter:

• Small battery-operated appliances like flashlights, razors, and night lights that can be plugged directly into an AC receptacle to recharge

• Chargers for battery packs used in hand power tools. These chargers display a warning label stating that dangerous voltages are present at the battery terminals

AC Wiring Warning

Do not connect the PROwatt 600 Inverter to AC distribution wiring.

The PROwatt is designed to be connected directly to standard electrical and electronic equipment. Do not connect it to household or recreational vehicle AC distribution wiring. Do not connect it to any AC load circuit in which the neutral conductor is connected to ground (earth) or to the negative of the DC (battery) source. Doing so will destroy the unit.

Contents

General Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii

Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - viii

Precautions When Working With Batteries - - - - - - - - - - - - - - viii

Precautions For Using Rechargeable Appliances - - - - - - - - - - - ix

AC Wiring Warning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ix

1Introduction

Quality Power and Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - 2

Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

2 Installation

AC Wiring Warning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

PROwatt 600 Materials- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Front Panel (AC End) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Back Panel (DC End) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - 6

Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Planning Your Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - 7 Choosing a Charging System - - - - - - - - - - - - - - - - - - - - - - - - 7

Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Mounting the Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Contents

Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - 9

Grounding Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Connecting DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Cabling Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 Cabling Procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

3Operation

Turning the Inverter On and Off- - - - - - - - - - - - - - - - - - - - - - - 16

Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - 16

Turning the Inverter Off Between Charges- - - - - - - - - - - - - - - - 16

Reading the Front Panel Indicators - - - - - - - - - - - - - - - - - - - - - 17

Green POWER LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Red FAULT LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Inverter Loads- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Trouble Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Battery Charging Frequency - - - - - - - - - - - - - - - - - - - - - - - - - 20

Routine Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

4 Troubleshooting

Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - 22 Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - 23

Specifications

Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

Battery Types and Sizes

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

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Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - 28 Deep-Cycle Lead-Acid Batteries - - - - - - - - - - - - - - - - - - - - - 29

Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - 31

Battery Sizing Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

Battery Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

Two Batteries Connected In Parallel- - - - - - - - - - - - - - - - - - - - 34

Battery Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Alternators and Charging Systems

Charging System Requirements - - - - - - - - - - - - - - - - - - - - - - - 38

Charging With an Engine Alternator - - - - - - - - - - - - - - - - - - - - 38

Using Your Vehicle’s Standard Engine Alternator - - - - - - - - - 38 Using an Alternator Controller - - - - - - - - - - - - - - - - - - - - - - 39 Using a High-Output Alternator - - - - - - - - - - - - - - - - - - - - - 39

Charging From AC Power- - - - - - - - - - - - - - - - - - - - - - - - - - - 39

Charging From Alternative Energy Sources - - - - - - - - - - - - - - - 40

Product and System Information

Contents

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - 43

Return Material Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 43

Information About Your System - - - - - - - - - - - - - - - - - - - - - - 45

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

xiii

xiv

Introduction

Congratulations on your purchase of the PROwatt™ 600 Inverter! As part of the PROwatt Inverter family, the PROwatt 600 has been designed to give you quality power, ease of use, and outstanding reliability.

Please take a few moments to read this chapter to familiarize yourself with the PROwatt 600’s main performance and protection features.

Quality Power and Ease of Use

The PROwatt 600 Inverter is a professional-quality, midrange inverter designed to handle a variety of household and commercial applications including large screen TVs, VCRs, computer systems, bread makers, blenders, fans, and small power tools.

Superior features and rugged durability have been combined with extreme ease of use:

• The unit is compact, light weight, and easy to install.

• The easy-to-read indicators on the front panel.

• Low standby battery demand means you don’t have to worry about draining your battery if you leave the inverter on for a few days. When the inverter is on but is not powering any loads, the draw on the battery is less than 300mA.

Comprehensive Protection

The PROwatt 600 Inverter comes equipped with numerous protection features to guarantee you safe and worry-free operation:

Low battery alarm

discharged to 10.7V or lower.

Automatic low voltage shutdown feature

from becoming completely discharged if the battery voltage drops below 10V.

High voltage shutdown feature

input voltage rises to 15V or more.

Over temperature shutdown feature

the temperature rises above an acceptable level.

Alerts you if the battery has become

Protects the battery

Protects the inverter if the

Turns the inverter off if

Installation

Chapter 2 explains how to install the

PROwatt 600 Inverter.

Installing the PROwatt 600 is straightforward. Here’s a summary of the five main steps:

• Plan the installation.

• Choose a location.

• Mount the inverter.

• Connect the chassis ground.

• Connect the DC cables.

Remember: the better your planning, the better the performance you will receive from the PROwatt 600 Inverter.

AC Wiring Warning

WARNING

Do not connect the PROwatt 600 Inverter to AC distribution wiring.

Safety Instructions

Before you install the PROwatt 600:

• Review the “Important Safety Information” on page vii.

• Read and follow all Warnings and Cautions in this chapter.

PROwatt 600 Materials

Your PROwatt 600 Inverter package includes:

• 1 PROwatt 600 Inverter

• 1 Owner’s Guide

If either of these items is missing or is unsatisfactory in any way, please contact Xantrex Customer Service:

Phone:

Fax:

Email:

As soon as you unpack your inverter, be sure to record the product information asked for on page 45. Then take a minute to familiarize yourself with the front and back panel features.

1-800-670-0707

1-800-994-7828

support.prowatt@xantrex.com

Front Panel (AC End)

POWER LED

On/Off Switch

POWER

OFF

FAULT LED

FAU LT

Figure 1 Front Panel (AC End)

Back Panel (DC End)

Negative and Positive DC Cabling Terminals

AC Power Receptacles

Chassis Ground

Screw

Ventilation

Openings

OUTPUT

115Vac

60Hz

Ventilation

Openings

Figure 2 Back Panel (DC End)

+ 46 hidden pages