Xantrex Technology RV2012, RV2512, RV3012 User Manual

Xantrex RV Series Inverter/Charger

RV2012 2512 3012

Owner’s Manual

Xantrex RV Series Inverter/Charger Owner’s Manual

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS..............................................................1

THEORY OF INVERTER OPERATION................................................................4

Waveform...................................................................................................................................................4

Regulation ..................................................................................................................................................4

Search Sense Mode Using Optional RC7 Remote...................................................................................5

BATTERY CHARGER ..........................................................................................6

Theory of Operation..................................................................................................................................6

Transfer Switching Speed .........................................................................................................................6

Battery Terminology .................................................................................................................................6

Charger Terminology................................................................................................................................7

Three Stage Battery Charging..................................................................................................................7

BATTERY CHARGER CONTROLS AND LED INDICATOR................................ 8

Charger LED .............................................................................................................................................8

Generator Requirements...........................................................................................................................8

Batteries......................................................................................................................................................9

Selection of Battery Type..........................................................................................................................9

Battery Care and Maintenance ..............................................................................................................10

Battery Installation..................................................................................................................................11

Battery Sizing...........................................................................................................................................12

Battery Hookup Configurations.............................................................................................................13

INSTALLATION..................................................................................................14

Environment.............................................................................................................................................14

AC WIRING ........................................................................................................ 15

Xantrex RV Series Inverter/Charger Owner’s Manual

Overview ..................................................................................................................................................15

AC Connections .......................................................................................................................................15

Important Precautions ............................................................................................................................15

Ground Fault Interrupting Outlets (GFIs)............................................................................................16

DC WIRING ........................................................................................................ 16

Safety Instructions...................................................................................................................................16

DC Over-Current Protection..................................................................................................................16

Connection of Grounding and Battery Systems....................................................................................17

STACKING INVERTERS.................................................................................... 18

Precautions...............................................................................................................................................18

DC Connections for Stacked Inverters ..................................................................................................18

AC Wiring for Stacked Inverters...........................................................................................................19

Operation .................................................................................................................................................19

Theory of Operation................................................................................................................................19

Search Sense Mode Operation with Stacked Pairs...............................................................................20

RC6 REMOTE CONTROL.................................................................................. 21

Installation ...............................................................................................................................................21

RC7 REMOTE CONTROL.................................................................................. 22

Installation ...............................................................................................................................................22

Programming the RC7 ............................................................................................................................22

User Menu ................................................................................................................................................23

Meters Menu ............................................................................................................................................24

Setup Menu ..............................................................................................................................................24

BATTERY CABLE CONNECTION.....................................................................26

Battery Cable Sizing................................................................................................................................26

Installation with External Transfer Relay (120/240 System)...............................................................27

Xantrex RV Series Inverter/Charger Owner’s Manual

Mobile Installation...................................................................................................................................28

TROUBLESHOOTING GUIDE ...........................................................................29

APPLICATIONS .................................................................................................30

Resistive Loads.........................................................................................................................................30

Inductive Loads .......................................................................................................................................30

Problem Loads.........................................................................................................................................30

Typical Battery Draw of Common Appliances .....................................................................................32

English to Metric Wire Conversion .......................................................................................................33

RC7 Menu Map .......................................................................................................................................34

TECHNICAL INFORMATION ............................................................................. 36

RV Series Specifications..........................................................................................................................36

LIMITED WARRANTY........................................................................................37

Notice of Copyright

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision December 2002, Revision 2 Part Number 445-0202-01-01

Contact Information

Web: www.xantrex.com Email: CustomerService@xantrex.com Phone: 1-800-670-0707 (toll free) 1-604-422-2777 (direct) Fax: 1-604-420-2145

iii

Xantrex RV Series Inverter/Charger Owner’s Manual

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS!

This manual contains important safety and operating instructions as prescribed by UL specifications for inverters used in land vehicle applications. This manual covers Xantrex RV Series Inverter/Chargers models RV2012, RV2512, and RV3012.

General Precautions

1. Before using the inverter/charger, read all instructions and cautionary markings on (1) the inverter/charger, (2) the batteries and (3) all appropriate sections of this instruction manual.

2. CAUTION: To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell, absorbed mat, or NiCad/NiFe type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.

3. Do not expose inverter/charger to rain, snow or liquids of any type. The inverter is designed for indoor mounting only. Protect the inverter from splashing when used in vehicle applications. Do not mount the inverter in unventilated enclosures or in the engine compartment.

4. Do not disassemble the inverter/charger; take it to a qualified Xantrex service center when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

5. To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning. Turning off the inverter will not reduce this risk. Solar modules produce power when exposed to light—cover them with opaque material before servicing any connected equipment.

6. WARNING: WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Provide ventilation to outdoors from the battery compartment. The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the compartment. Vent the battery compartment from the highest point.

7. NEVER charge a frozen battery.

8. No terminals or lugs are required for hook-up of the AC wiring. AC wiring must be no less than 10 AWG (5.3 mm

rated for 75 °C or higher and should be no less than #2 AWG (67.4 mm

and sealed copper ring terminal lugs with a 5/16 hole should be used to connect the battery cables to the DC terminals of the inverter/charger. Soldered cable lugs are also acceptable.

9. Torque all AC wiring connections to 20 inch-pounds. Torque all DC cable connections to 12 foot-pounds. Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the batteries or other electrical parts, resulting in sparks that could cause an explosion.

) gauge copper wire and rated for 75 °C or higher. Battery cables must be

) gauge. Crimped

Xantrex RV Series Inverter/Charger Owner’s Manual

10. Symbols used in this manual and on the inverter/charger are:

Chassis Phase AC Output AC Input

1. Tools required to make AC wiring connections: Wire strippers, 1/2" (13 mm) open-end wrench or socket, Phillips screwdriver #2, Slotted screwdriver 1/4" (6 mm) blade.

2. This inverter/charger is intended to be used with a battery supply with a nominal voltage of 12 volts DC.

3. For instructions on shelf mounting, see ”Installation” on page 14. For battery installation and maintenance: read the battery manufacturer's installation and maintenance instructions prior to operating.

4. No AC or DC disconnects are provided as an integral part of this inverter. Both AC and DC disconnects must be provided as part of the system installation. See SYSTEM SAFETY WIRING REQUIREMENTS section of this manual.

5. No over-current protection for the battery supply is provided as an integral part of this inverter. Over-current protection of the battery cables must be provided as part of the system installation. See “DC Over-Current Protection” on page 16.

6. No over-current protection for the AC output wiring is provided as an integral part of this inverter. Over-current protection of the AC output wiring must be provided as part of the system installation. See SYSTEM SAFETY WIRING REQUIREMENTS section of this manual.

7. DC GROUNDING INSTRUCTIONS: This inverter/charger should be connected to a grounded, permanent wiring system. For most installations, the negative battery conductor should be bonded to the grounding system at one (and only one point) in the system. All installations should comply with all national and local codes and ordinances.

8. AC GROUNDING INSTRUCTIONS: This inverter/charger includes neutral ground switching for the AC electrical system. The AC system must have the neutral isolated from the grounding system throughout the load distribution circuits. AC generators must have the neutral bonded to the grounding system when used with this inverter.

Xantrex RV Series Inverter/Charger Owner’s Manual

Personal Precautions

1. Someone should be within range of your voice to come to your aid when you work near batteries.

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

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. Wash your hands when done.

4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cool water for at least 15 minutes and get medical attention immediately.

5. Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the batteries.

6. NEVER smoke or allow a spark or flame in the vicinity of a battery or generator.

7. Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could shortcircuit the batteries or other electrical parts, resulting in a spark that could cause an explosion.

8. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing severe burns.

9. To prevent accidental starting during servicing, disable the automatic starting circuit and/or disconnect the generator from its starting battery if a remote or automatic generator start system is used.

Xantrex RV Series Inverter/Charger Owner’s Manual

Theory of Inverter Operation

Waveform

The output waveform of the inverter is referred to as a modified sine wave. This waveform is suitable for a wide variety of applications—induction motors (such as in refrigerators and drill presses), resistive loads (such as heaters and toasters), universal motors (such as in hand tools and vacuum cleaners) as well as microwave ovens and computers.

Comparison of Output Waveforms

The waveform could be more accurately described as a pulse width modulated square wave. The illustration above shows the relationships between square wave, sine wave and modified sine wave formats.

Regulation

The inverter is RMS voltage regulated. RMS regulation ensures that resistive loads will always have the same amount of power delivered to them as battery voltage changes. Regulation is achieved by varying the width of each pulse. Peak voltage is the product of the battery voltage times the turns ratio of the inverter’s power transformer and is therefore not actively regulated.

Xantrex RV Series Inverter/Charger Owner’s Manual

Search Sense Mode Using Optional RC7 Remote

The SEARCH SENSE menu on the RC7 is used for adjusting the sensitivity of the search mode circuit. The RV inverter’s search sensitivity can only be set using the optional RC7 remote. However, once the mode is set the remote may then be removed and the inverter will retain the settings. The RV Series inverters feature an adjustable search mode circuit. It minimizes power drain by reducing the inverter’s output to small test pulses when there is no load connected. These pulses are used to detect the presence of a load. When a load is detected the inverter’s output goes to full voltage. The sensitivity of the detection threshold is adjustable.

Example: With the SEARCH WATTS control set to detect a 40-watt load, a 50-watt load will bring the unit to full output voltage. However, a 30-watt load will leave the inverter in its energy-saving search mode state. If the sensitivity is increased by setting the control to 10, a 20-watt load will bring the inverter out of the search mode, while a 5-watt load will not.

When in the search mode, the green power LED will blink and the inverter will make a ticking sound. At full output voltage, the green power LED will burn steadily and the inverter will make a steady humming sound. When the inverter is used as an “uninterruptible” power supply the search mode function should be defeated.

A neon-type nightlight can also be used as a good indicator to determine if the inverter is in search mode. Simply plug the light into any AC outlet. When the inverter is in the search mode the light will blink. If the inverter is running a load, the light will be solid.

Exceptions

Example A: If the SEARCH WATTS control is set to detect a 40-watt load and a 30-watt

incandescent light is turned on, the inverter will detect the light. The light is a bigger load than 40 watts when its filaments are cold. When the light gets bright the filaments heat up and the light becomes a 30-watt load. Since this is below the control setting of 40, the inverter will not detect it and the light will go out, beginning the process all over again.

Example B: If the SEARCH WATTS control is set to detect a 30-watt load and a 40-watt fluorescent light is turned on, the inverter will not detect the light. The light presents a smaller load than 30 watts until the gas in the fluorescent tube ionizes.

Example C: There are some appliances that draw power even though they are turned off. TVs with instant-on circuits, microwave ovens with digital displays and VCRs are examples. These loads present a dilemma. If the sensitivity is set higher than the combination of these loads, then an auxiliary load must be used to bring the inverter out of the search mode before the appliances can be turned on. If the sensitivity is set lower than this combination of loads, the loads will be left on and will put an additional drain on the batteries. (Three such 15-watt loads would amount to an additional 90 amp hours per 24 hours in a 12 VDC system.) One solution is to turn these items off at the wall. Use an extension cord with a rocker switch, a switch at the outlet, or the appropriate circuit breaker.

Xantrex RV Series Inverter/Charger Owner’s Manual

Battery Charger

Theory of Operation

Inverter to Charger Transition

The internal battery charger and automatic transfer relay allows operation as either a battery charger or inverter (but not both at the same time). An external source of AC power (such as shorepower or a generator) must be supplied to the inverter AC input in order to allow it to operate as a battery charger. The RV series charger will always charge when there is AC power present, even when the inverter itself is turned off (by the on/off switch). W hen operating as a charger, the AC output is powered by the external source (such as a generator or public power).

The inverter automatically becomes a battery charger whenever AC power is connected to its AC inputs. There is a minimum 20-second time delay from the time the inverter senses that AC is present at the input terminals to when the transfer is made. This delay is built in to provide time for a generator to spin-up to a stable voltage and avoid relay chattering. The inverter will not transfer to generator until it has locked onto the generator’s output. The inverter’s AC input is internally connected to the inverter’s AC output while in the battery charger mode.

Transfer Switching Speed

While this inverter is not designed specifically as an uninterruptible power supply (UPS) system, its transfer time is normally fast enough to hold up most computers. The transfer time is typically 16 milliseconds.

Several PC magazines have run tests indicating a transfer time up to 100 milliseconds will normally hold up the present generation of PCs.

When switching from inverter to charger, the inverter waits a minimum of 20 seconds to ensure the AC source is stable (as the generator gets up to speed).

Battery Terminology

Describing the battery charger’s operation requires the use of terms with which you may not be familiar. The following terms will be referred to in the description of the battery charger operation.

• Electrolyte: Typically a mixture of water and sulfuric acid, it is commonly referred to as

battery acid.

• Plates: Originally made of lead, they are now made of lead oxide. Plates are the part of the

battery that collects current and are connected to the battery terminals. There are several plates in each cell, each insulated from the other by separators.

• Sulphating: As a battery discharges, its plates are progressively covered with lead sulfate.

During recharging, the lead sulfate is removed from the plates and recombines with the electrolyte. If the lead sulfate remains on the plates for an extended period of time (over two months), it hardens, and recharging will not remove it. This reduces effective plate area and the battery capacity is diminished.

• Stratification: Over time the batteries’ electrolyte (liquid) tends to separate. The electrolyte at

the top of the battery becomes watery while at the bottom it becomes more acidic. This effect is corrosive to the plates.

• Deep Cycle: A deep cycle occurs when a battery has been discharged such that less than

20% of its capacity remains (80% discharge).

Xantrex RV Series Inverter/Charger Owner’s Manual

• Temperature Compensation: The optimum voltage is temperature dependent. As

temperature decreases the proper voltage for each charge stage needs to be increased. The optional temperature probe will automatically rescale charge voltage settings for ambient temperature. The compensation slope based on cell voltage is -2.17 mV per degree F per cell.

Charger Terminology

• Bulk Voltage: This is the maximum voltage at which the batteries will be charged during a

normal charging cycle. The normal range is 2.367 to 2.4 volts per cell. For a 12 VDC battery (6 cells) this is 14.1 volts for gel cell type batteries and 14.4 volts for lead acid batteries.

• Float Voltage: This is the voltage at which the batteries will be maintained after they have

been charged. In 12-volt systems 13.4 volts for gel cell batteries and 13.5 volts for lead acid batteries will be maintained by the charger.

• Absorption Stage: During this part of the charge cycle, the batteries are held at the bulk

voltage and accept whatever current is required to maintain this voltage.

• Battery Temperature Compensation: When installed this adjusts the bulk and float voltages

depending on the battery temperature. As battery temperature increases the voltages are reduced, and as temperature decreases the voltages are increased. This is highly recommended for sealed batteries.

Three Stage Battery Charging

The battery charger in standby models normally charges in three stages—bulk, absorption and float—to provide rapid and complete charge cycles without undue battery gassing.

Stage One: Constant Current/Bulk Charge

This stage is initiated when AC is applied to the AC input of the inverter.

Stage one charges the batteries at a constant current. The level of charge for this phase is set using the BATTERY CHARGER RATE control on the front panel. The constant current phase is terminated when the batteries reach the bulk charge voltage. During this stage the Charger LED glows orange.

Stage Two: Constant Voltage/Absorption

Absorption is initiated when the Bulk Voltage setting has been reached. At this point the charge current begins to taper off at whatever rate is required to hold the voltage constant. During this stage the Charger LED blinks orange. The absorption phase is terminated in one of two ways.

1. Normally, as the charge cycle progresses, the current required to hold the battery voltage constant gradually reduces. When this current equals the programmed return amps setting, the voltage is allowed to fall to the FLOAT (float voltage) setting—stage three.

2. If there are DC loads on the batteries, the current may never fall to a level low enough to initiate the float voltage stage. A timer is used to ensure that the battery voltage does not remain indefinitely at the bulk charge voltage. The timing circuit terminates stage two if the charge current does not reach the return amps value setting within 12 hours.

Xantrex RV Series Inverter/Charger Owner’s Manual

Stage Three: Float Voltage

The purpose of stage three is to maintain the batteries at a voltage that will hold full charge but not gas the batteries. The charger remains in the float stage until the AC input is removed. During this stage the status LED will show fast flashing green (four times per second).

Note: When DC loads are placed on the battery, the charger will deliver currents up to the

Maximum Charge Rate setting while maintaining the float voltage.

Battery Charger Controls and LED Indicator

A three-color LED reports on the activity of the battery charger. The optional RC7 remote allows custom control over the charger section of the inverter, including battery type.

Charger LED

The LED indicates charge status as follows:

• Solid Green: this indicates that the unit is inverting

• Slow flashing Green: Search Mode

• Solid Orange: this indicates that the charger is in the bulk-charging mode.

• Blinking Orange: this indicates that the charger is in the absorption stage.

• Fast Flashing Green (four times per second): Float charge mode

• Solid Red: Over current

• Flashing Red: An error has occurred. The number of flashes before a five-second rest

period indicates one of the error conditions listed below.

1 2 3 4 5 6 7 or more

Low battery voltage

Generator Requirements

The maximum charge rate of the battery charger is dependent upon the peak AC voltage available. Because this type of battery charger uses only the peak part of the input sine wave, small variations in peak voltage result in large variations in the amount of energy available to the charger. The charger’s output is rated on the basis of typical public power input, which has a peak voltage of approximately 164 V.

It takes a powerful AC generator set to maintain the full 164-volt peak while delivering the current necessary to operate the charger at its maximum rate (typically 5 kW for 2500-watt models and

2.5 kW for 1500-watt models). Smaller generators will have the tops of their waveform clipped

under such loads. Running at these reduced peak voltages will not harm the charger, but it will limit the maximum charge rate. Large auxiliary AC loads may exacerbate this problem. See the appendix for specific generator types and peak voltage vs. maximum charge amps information.

High battery voltage

Inverter over temp

Charger fault PV controller

fault

Generator start fault

Consult Xantrex support

Xantrex RV Series Inverter/Charger Owner’s Manual

Batteries

Batteries come in different sizes, types, chemistries, amp hours, and voltages. There are nearly as many descriptions of how batteries should be used as there are people willing to offer explanations. It is not possible here to discuss all aspects in detail. However, there are basic guidelines you can follow that will help in battery selection and ensure that your batteries are well maintained.

Selection of Battery Type

Starting Batteries

Starting batteries are not recommended for your inverter/charger. They are designed for high cranking power, but not deep cycling. They do not hurt the inverter, but will not last long in a deepcycle application. The way they are rated should give a good indication of their intended use— "cold cranking amps," a measure of the amperage output that can be sustained for 30 seconds. Starting batteries use lots of thin plates to maximize the surface area of the battery. This allows very high starting current but lets the plates warp when the battery is cycled.

Deep-Cycle Batteries

This type of battery is best suited for use with inverter/chargers. They are designed to have the majority of their capacity used before being recharged. They are available in many sizes and types. The most common type is the non-sealed, liquid electrolyte battery. Non-sealed types have battery caps. The caps should be removed periodically to check the level of electrolyte. When a cell is low, distilled water should be added. The electrolyte level should be checked monthly and topped up if needed after recharging.

Group 27 Batteries The most common deep-cycle battery is the type used with boats and motor homes. They typically are called “Group 27” batteries and are similar in size to a large truck battery. They are 12-volt batteries rated at 80 to 100 amp hours. Often the deep cycle claim is overstated. They do work better than a car battery, but are not recommended for anything but the smallest systems.

Golf Cart Batteries

Another popular and inexpensive battery of this type is the "golf cart" battery. It is a 6-volt battery rated at 220 amp hours. They can be cycled repeatedly to 80% of their capacity without being damaged. This is the minimum quality of battery that should be used with the RV Series inverter in normal applications.

L16-type Batteries

Some systems use the L16 type of battery. These are 6-volt batteries rated at 350 amp hours and are available from a number of manufacturers. They are 17 inches in height and weigh up to 130 pounds each, which may be troublesome in RV or marine installations.

Type 8D Batteries

Type 8D batteries are available with either cranking or deep-cycle construction. The deep-cycle versions are 12-volt batteries rated at about 200 amp hours. Since they are most commonly used to start truck engines, you should make sure you purchase the deep-cycle version. Type 4D batteries are very similar in construction.

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