Xantrex Technology RS3000 User Manual

RS3000 Sine Wave Inverter/Charger
RS3000
Installation Guide
RS3000 Sine Wave Inverter/Charger
Installation 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 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
RS3000 Sine Wave Inverter/Charger is a trademark of Xantrex International. Xantrex and Xanbus are registered trademarks 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
RS3000 Sine W a ve Inverter/Charger Installation Guide © December 2004 Xantrex International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”) (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION. (b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
December 2004 Rev B
Part Number
975-0171-01-01
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 Guide

Purpose
The RS3000 Sine Wave Inverter/Charger Installation Guide describes the procedure for installing the RS3000 Sine Wave Inverter/Charger (RS3000).
Scope
The Installation Guide provides safety guidelines, detailed planning and setup information, and procedures for installing the inverter/charger. It does not provide information on operation, configuration, troubleshooting, and warranty and product information. Refer to the RS3000 Sine Wave Inverter/Charger Operation Guide.
This guide does not provide details about particular brands of batteries. You need to consult individual battery manufacturers for this information.
Audience
The Installation Guide is intended for qualified installers who need to install the RS3000. Installers should be certified technicians or electricians.
975-0171-01-01 i
About This Guide
Conventions Used
The following conventions are used in this guide.
WARNING
Warnings identify conditions or practices that could result in personal injury or loss of life.
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other equipment.
Symbols Used
Important:
know. They are not as critical as Cautions or Wa rnin gs.
The following symbols are used on the product labels or in this guide.
!
" #
$
%
&
'
Important notes provide information that is important for you to
In this guide: Important information, warnings or cautions. On the product: Important information, warnings or cautions with further explanation in the product guides.
AC – Alternating current
DC – Direct current
Warning: Hot surface. Do not touch.
DC ground connection point
AC safety ground connection point from incoming AC source
AC safety ground connection point for AC output (to AC loads)
Abbreviations and Acronyms
For a listing of abbreviations and acronyms, refer to the RS3000 Sine Wave Inverter/Charger Operation Guide.
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Related Information
For related materials on this Xanbus-enabled product and its available accessories, see also:
RS3000 Sine Wave Inverter/Charger Operation Guide (975-0170-01-01) Automatic Generator Start Owner’s Guide (975-0082-01-01) System Control Panel Owner’s Guide (975-0083-01-01) Xanbus System Installation Guide (975-0136-01-01)
More information about Xantrex Technology Inc. as well as its products and services, including a complete list of Xanbus­available at www.xantrex.com
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
Fax: 1 800 994 7828 (toll free North America)
Email: customerservice@xantrex.com
1 360 925 5097 (direct)
1 360 925 5143 (direct)
About This Guide
enabled devices, is
Web: www.xantrex.com
iii 975-0171-01-01
iv 975-0171-01-01

Important Safety Instructions

READ AND SAVE THESE INSTRUCTIONS
The RS3000 Sine Wave Inverter/Charger Installation Guide contains important safety instructions.
Before you install and use your RS3000 Sine Wave Inverter/Charger, be sure to read, understand, and save these safety instructions and those in the other product guides.
Read all cautionary markings on the inverter/charger, the batteries, and all appropriate sections of this guide.
WARNING: Risk of injury or loss of life
The RS3000 Sine W ave Inverter/Charger shall not be used in connection with life support systems or other medical equipment or devices.
WARNING
The following warnings identify conditions or practices that could result in personal injury or loss of life.
1. Use of accessories not recommended or sold by Xantrex Technology, Inc. may result in a risk of fire, electric shock, or injury to persons.
2. The inverter/charger is designed to be permanently connected to y our AC and DC electrical systems. Xantrex recommends that all wiring be done by a certified technician or electrician to ensure adherence to the local and national electrical codes applicable in your application.
3. To avoid a risk of fire and electric shock, make sure that the existing wiring is in good condition and that the wire is not undersized. Do not operate the inverter/charger with damaged or substandard wiring.
4. To reduce risk of damage and injury, charge only rechargeable lead-acid batteries (flooded, gel, or absorbed glass mat (AGM) types). Other types of batteries may burst causing personal injury and damage.
5. Do not operate the inverter/charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the unit is damaged, see the Warranty and Product Information section in the RS3000 Sine Wave Inverter/Charger Operation Guide.
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Safety
6. Do not disassemble the inverter/charger; it does not contain user serviceable parts. Take it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. For instructions on obtaining service, see the section in the RS3000 Sine Wave Inverter/Charger Operation Guide.
7. Do not expose the inverter/charger to rain, snow, or water.
8. To reduce the risk of electric shock, disconnect all sources of AC and DC power from the Inverter/Charger before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
9. The inverter/charger must be provided with equipment grounding conductors connected to the AC input ground and chassis ground terminals.
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other equipment.
T o reduce the risk of overheating, keep the ventilation openings clear and do not install the inverter/charger in a compartment with limited airflow or inadequate clearances around the unit. The minimum recommended clearance is 3 inches (76 mm).
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Explosive Gas Precautions
WARNING: Risk of explosive gases
Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation. For this reason, it is of utmost importance that each time before servicing equipment in the vicinity of the battery, you must read this guide and follow the instructions closely.
1. To reduce the ris k of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Review the cautionary markings on these products and on the engine.
2. This equipment contains components which tend to produce arcs or sparks. T o prevent fire or explosion, do not install the inverter/charger in compartments containing batteries or flammable materials or in locations that require ignition-protected equipment. This includes any space containing gasoline-power machinery, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system.
Safety
Personal Precautions When Working With Batteries
1. Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts your skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries.
4. If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood the eye with running cold water for at least ten minutes and get medical attention immediately.
5. Never smoke or allow a spark or flame in the vicinity of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto a battery. It might spark or short-circuit the battery or other electrical parts that may cause an explosion.
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Safety
7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead- acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
8. Never charge a frozen battery.
9. If it is necessary to remove a battery, always remove the grounded terminal from the battery first. Make sure all the accessories are off, so as not to cause an arc.
10. Be sure the area around the battery is well ventilated.
11. Clean the battery terminals. Be careful to keep corrosion from coming in contact with your eyes.
12. Study all battery manufacturer’s specific precautions such as removing or not removing the cell caps while charging and the recommended rates of charge.
13. For refillable (flooded) batteries, add distilled water in each cell until the battery acid reaches the level specified by the battery manufacturer. This helps to purge excessive gas from cells. Do not overfill. Carefully follow the manufacturer’s recharging instructions.
FCC Information to the User
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction guide, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and the receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.
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Contents

Important Safety Instructions
Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii Personal Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - vii FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
Installation
Installation Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Before You Begin the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
About the Xanbus System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Xanbus Enabled - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 System Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Planning the Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Two Key Performance Factors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Size and Length of DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 Mounting Location of the RS3000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
AC, DC, and Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 AC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
AC Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 AC Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 AC Disconnect and Over-Current Protection Device - - - - - - - - - - - - - - - - - - - - - 9 Distribution Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10 AC Output Neutral Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
DC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 DC Disconnects and Over-Current Devices - - - - - - - - - - - - - - - - - - - - - - - - - - 13 DC Cabling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 Unpacking and Inspecting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - 15 Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15 Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
Installing the Inverter/Charger- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Step 1: Choosing a Location for the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - 17
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Contents
Step 2: Mounting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Step 3: Connecting the AC Input and AC Output Wires - - - - - - - - - - - - - - - - - - - - - 21
General AC Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21 Connecting AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Connecting the AC Output Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
Step 4: Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
DC Connection Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Recommended Cable Sizes and Lengths and Fuse Size - - - - - - - - - - - - - - - - - - - 25 Preparing the Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Guidelines for Routing the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Connecting the DC Cables to the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - 27 DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
Step 5: Connecting the Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - 30
Mounting Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 Mounting to the Negative Battery Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
Mounting to the Side of the Battery Case - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Step 6: Connecting to the Network - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Step 7: Performing Checks Prior to Initial Start-Up - - - - - - - - - - - - - - - - - - - - - - - - 35 Step 8: Testing Your Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
Testing in Invert Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36
Testing in Charge Mode and AC Bypass Mode - - - - - - - - - - - - - - - - - - - - - - - - 37
Installation Complete - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
Inverter/Charger Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 Battery Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40 Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Calculating Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Battery Banks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
Battery Bank Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42 Restrictions on Motor Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
Cabling and Hook-up Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
Parallel Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
Series Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
Series-Parallel Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
Index
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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
Figures
Figure 1 Typical Xanbus System Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Figure 2 Typical Recreational Vehicle Electrical System - - - - - - - - - - - - - - - - - - - - - 7 Figure 3 RS3000 Hardware Materials as Shipped - - - - - - - - - - - - - - - - - - - - - - - - - 15 Figure 4 Mounting Orientations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 Figure 5 AC Wiring Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Figure 6 DC Cable Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 Figure 7 DC Terminal Covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 Figure 8 Completed DC Wiring and DC Grounding - - - - - - - - - - - - - - - - - - - - - - - 29 Figure 9 BTS with Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 Figure 10 BTS Mounted on the Negative Battery Terminal - - - - - - - - - - - - - - - - - - - 31 Figure 11 Connecting the BTS Cable to Battery Temp. jack- - - - - - - - - - - - - - - - - - - 32 Figure 12 BTS Mounted on the Battery Case- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Figure 13 Connecting to a Network Jack- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Figure 14 RS3000 Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36 Figure 15 Inverter/Charger Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 Figure 16 Batteries Connected in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44 Figure 17 Batteries Connected in Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45 Figure 18 Batteries in Series-Parallel Connections - - - - - - - - - - - - - - - - - - - - - - - - - 46
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xii

Installation

The Installation Guide provides detailed information for installing the RS3000 Sine Wave Inverter/Charger and the battery temperature sensor, wiring the inverter/charger to the AC and DC circuits, and connecting the inverter/charger to the Xanbus® system.
The RS3000 is a Xanbus-enabled device that typically powers the Xanbus system. For information on installing the Xanbus system, see the Xanbus System Installation Guide which is available for download at www.xantrex.com
This Installation Guide provides:
safety instructions that must be observed during installation
a typical Xanbus system diagram
information on additional AC and DC components required
a list of installation tools and materials
detailed procedures for a typical installation
installation testing procedures
battery information For information on operating the RS3000, see the RS3000 Sine Wave
Inverter/Charger Operation Guide.
Installation

Installation Information

Before You Begin the Installation

Before beginning your installation:
Read the entire Installation Guide so you can plan the installation from beginning to end.
•Read the Xanbus System Installation Guide to plan your network requirements.
Assemble all the tools and materials you require for the installation.
Review the Important Safety Instructions on page v.
Be aware of all safety and electrical codes which must be met.
WARNING: Electrical shock and fire hazar d s
Xantrex® recommends all wiring be done by qualified personnel. 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

It is the installer’s responsibility to ensure compliance with all applicable installation codes and regulations.
Applicable installation codes vary depending on the specific location and application of the installation. Some examples are:
The U.S. National Electrical Code (NEC)
The Canadian Electrical Code (CEC)
Canadian Standards Association (CSA) and RV Industry Association (RVIA) for installation in RVs.
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About the Xanbus System

The Xanbus system includes the RS3000 Sine Wave Inverter/Charger and other Xanbus-enabled devices, as shown in Figure 1, “Typical Xanbus System Diagram”. Each Xanbus-enabled device interacts and communicates with the other devices on the network, creating a power system that can be precisely configured to your needs.
The RS3000 is the device that typically provides power in a Xanbus system. The System Control Panel provides configuration and monitoring capability for each device connected to the Xanbus system, such as the Automatic Generator Start and the RS3000.
In Figure 1, network connections are represented by dotted lines and conventional electrical connections are represented by solid lines. Your system requirements may be more complex than the basic installation shown in Figure 1. Xantrex recommends that you consult a qualified installer or electrican to customize your installation to meet your requirements.
Installation
Figure 1
AC Out
AC In
Typical Xanbus System Diagram
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Installation

Xanbus Enabled

System Accessories

The Xanbus-enabled designation means that this product will work on a Xanbus network. Xanbus-enabled products are:
Easy to use. The Xanbus network simplifies operation and automates routine tasks.
Reliable. Software control eliminates analog signalling errors.
Accurate. Digital information is less susceptible to interference and line loss.
Upgradeable. Firmware upgrades mean your purchase will remain up to date.
For detailed instructions and a complete list of Xanbus-enabled devices, visit the website at www.xantrex.com.
System accessories currently available which are Xanbus-enabled include the System Control Panel and Automatic Generator Start. These system accessories are available from any authorized Xantrex dealer or at www.xantrex.com. Please provide the part number of the accessory to the dealer.
Other Xanbus-enabled devices will become available in the future.
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