Xantrex Technology SW Plus 4048, SW Plus 4024, SW Plus 2548, SW Plus 2524, SW Plus 5548 User Manual

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Sine Wave Plus Inverter/Charger

SW Plus 2524 SW Plus 2548 SW Plus 4024 SW Plus 4048 SW Plus 5548

Owner’s Manual

Sine Wave Plus Inverter/Charger

Owner’s Manual

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobi le units to one MW utility- sc ale systems for wind, solar, batteries, fuel cells, micro turbines, and backup power applications in both grid-co nnected and stand-alon e systems. Xantrex products include inverters, battery chargers, programmable power s upplies, and variable speed drives that convert, supply, control, clean, a nd distribute electri cal power.

Trademarks

Sine Wave Plus Inverter/Char ger is a trademark of Xantrex International. Xantrex is a registered trademark of

Xantrex International. Other trademarks, registered tra demarks, and product names a re the property of their respective owners and are used

herein for identi fication purposes onl y.

Notice of Copyrigh t

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 INFORMAT ION 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.

Due to continuous q uality improvement and product updates, the photographs shown in this manual may not exactly match the unit purchased.

Date and Revision

September 2003, Revision B

Part Number

976-0043-01-02 Rev B3

Contact Inform ation

Telephone: 1-800-670-0707 (toll free in North America) Telephone: 1-360-925-5097 (dir ect) Fax: 1-800-994-7828 (tol l free in North America) Fax: 1-360-925-5143 (direct) Email: customerservice@xantrex.com Web: www.xantrex.com

About This Manual

Purpose

The purpose of this Owner’s Manual is to provide explanations and procedures for insta lling, operating, maintaining, and troubl eshooting the

Sine Wave Plus Inverter/Charger.

Scope

The Manual provides safety guidelines, detaile d 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 batter y manufacturers for this information.

Audience

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

Sine Wave Plus Inverter/Charger. Installers should be certified

technicians or electricians.

976-0043-01-02 iii

About this Guide

Organization

This guide is organized into nine chapters and nine appendices.

Chapter 1, “Introduction” lists and describes the basic features and parts of the Sine Wave Plus Inverter/Charger.

Chapter 2, “System Configuration” contai ns information to help you plan for a Sine Wave Plus installation in an off-grid, on-grid, or backup power application.

Chapter 3, “Installation” describes how to mount and install the Sine Wave Plus Inverter/Charger and perform wiring and cabling procedures for various configurations.

Chapter 4, “Functional Test” explains how to conduct a functional test of the inverter.

Chapter 5, “Navigation” explains how to navi gate through the Sine Wave Plus Inverter/Charger menus using the Control M odule and the menu maps.

Chapter 6, “Basic Setup Progr amming” expla ins how to progra m the Sine Wave Plus Inverter/Charger to operate under basic conditions.

Chapter 7, “Advanced Setup” explains how to program the Sine Wave Plus Inverter/Char ger to operate under speci al, advance d conditions , such as automatic generator starting, energy manage ment and auxiliary load applications.

Chapter 8, “Operation” expla ins how to operate the Sine Wave Plus Inverter/Char ger . It also explains how to read the LED indicators and User Menus to determine system status.

Chapter 9, “Troubleshooting” contai ns inf ormation and procedures for solving possible prob lems with the Sine W ave Plus.

Appendix A, “Inverter Specifications” provides the electrical and environmental spe cifications of this inverter. This section also provide s

information about how an inverter works, as well as efficiency statistics.

Appendix B, “Configuration Settings” provides worksheet s for programming your inver ter/charger for user-specific parameters. Use this

chapter to record the settings specific to your installat ion. This will make programming or reprogramming easier.

Appendix C, “Battery Information” supplies general information about batteries s uch as ba tter y types, ba tter y bank s izing, batte ry confi gurations, and battery care. For detaile d information, see your battery manufacturer or your system designer. Reading this chapter will help you determine the

battery bank specific ations required by your specific system (e. g., types of batteries, size of battery bank, configuration of the battery bank etc.).

Appendix D, “Generators” supplies information about generator starting.

Reading this chapter will he lp you deter mine what kind of generator to use, if any.

976-0043-01-02 iv

Appendix E, “Over-Charge Protection” supplies information about options for over -charge protection.

Appendix F, “Multi-wire Branch Circuit Wir ing” supplies information about Multi-wire Branch Circ uit Wiring Precautions when using standalone 120 Vac inverters or generators. Rea ding this chapter will provide

information regar ding identifying and correcting the potential fire hazard that exists when using inverters in this situation.

Appendix G, “Emergency Power Off Swi tches” supplies information about the requirements for installing an Emergency Power Off Switch.

“Glossary” contai ns a glossary of technical terms used in this manual. The glossary also defines some common electrical terms. It also provides

a list of acronyms used in this manual.

“Warranty and Product Information” Reading this chapter will pr ovide

clarificat ion of the Limited Warranty and instruct ions for obtaining a Return Material Authoriz ation, if the product needs to be returned to Xantrex or one of its authorized service centers.

Conventions Used

The following conventions are used in this guide.

About 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 Sine Wave Plus Inverter/Charger or other equipment.

v 976-0043-01-02

About this Guide

Related Information

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

You may also need to reference the following installat ion guides to assist with this installa tion. These guides (with the exception of the NEC/CEC Reference G uides) are all provide d wi th the speci fic co m p one n ts wh en purchased.

• Generator Star t Module (GSM) Installation Guide

• Auxiliary Load Module (ALM) Instal lation Guide

• Inverter St acking Control – Series (ISC-S) Cable Owner’ s Guide

• Inverter Communicati ons Adapter (ICA) Owner’s Guide

• Inverter Control Module (IC M) Installation Guide

• AC Conduit Box (ACCB) Owner’s Guide

• DC Conduit Box (DCCB) Installation Guide

• AC and/or DC Conduit Installati on Instructions

• T240 Autotransformer Installation Guide

• Manufacturer’s instructions for Electric al Panels (Main, Sub, and generator disconnec t panels)

• Manufacturer’s instructions for battery installation and use

• Manufacturer’s instructions for generator installation and use

• NEC Guide for related electrical, grounding, and bonding information.

• CEC Guide for related electric al, grounding, and bonding information.

976-0043-01-02 vi

Important Safety Instructions

WARNING

This chapter contains important safety and operating instructions as prescribed by UL and CSA standards for inverters used in residential applications. Read and keep this Installation Guide for future reference.

1. Before using the inverter, read all instructions and cautionary markings on the unit, the batteries, a nd all appropriate sections of this manual.

2. Use only attachments recommend ed or sold by the manufa cturer. Doing otherwise may result in a risk of fir e, electric shock, or injury to persons.

3. The inverter is designed to be permanentl y connecte d to your 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 electric al codes applicable in your jurisdiction.

4. T o avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not unde rsized. Do not operate the inverte r with damaged or substandard wiring. See

Appendix, F “Multi-wire Branch Circuit Wiring” for information

about multi-wire branch circuits.

5. Do not operate the inverter if it has been damaged in any way. If the unit is damaged, see the W arranty and Product Infor mation section at the end of this manual.

6. This unit does not have any user -serviceable parts. Do not disassemb le the i nve rt er. See “How do you get service?” on page I–1 for instructions on obtaining service. Atte mpting to service the unit yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.

7. T o reduce the risk of electrical shock, disconnect both AC and DC power from the inverter before attempting any maintenance or cleaning or working on any components con nected to the inverter. Turning off controls will not reduce this risk.

8. The inverter must be provided with an equipm ent-grounding conductor connected to the AC input ground.

976-0043-01-02 vii

Important Safety Instructions

9. Do not expose this unit to rain, snow, or liquids of any type. This product is designed for indo or use only. Damp environments will significantly shor ten the life of this product and corrosion caused by dampness will not be covered by the product warr a nty.

10. T o reduce the chance of short-circuits, always use insulated tools when installing or working with the inverter, the batteries, or the PV arrays.

11. Remove all jewelry while insta lling this system. This will great ly reduce the chance of accidental exposure to live circuits.

Explosive gas precautions

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 inst ructions exactly before installing or using your inverter/charge r.

2. To reduce the risk of battery explosion, follow these instructions and those published by the batter y manufacturer and the manufacturer of the equipment in which the battery is installed.

FCC Information to the User

This equipment ha s been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rule s. These limits are designed to provide reasonable protection against harmf ul interference in a residentia l installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructi ons, may cause harmful interference t o radio communications. However, there is no guarant ee tha t i nterfer ence wil l not occur in a particular installation. If this equipment does cause harmful interference to radio or tele vision reception, which can be deter mined by turning the equipment off and on, the user is encouraged to try to correct the interferenc e by one or more of the followi ng measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment receiver.

• Connect the equipment into an outl et on a circu it different from that to which the receiver is connected.

• Consult the dealer or an experienced ratio/TV technician for help.

viii 976-0043-01-02

Important Safety Instructions

Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii

Introduction

Basic Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2

Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4

Emergency Power Off (EPO) Option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5 Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5

DC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6

Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7

Top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–8

System Configuration

Pre-Configuration Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2

Types of Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2 System Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2 System Output Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4 System Input Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4 Location Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5

Mounting Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6 Ventilation Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6

Grounding Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7

DC System Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7 Inverter Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–8 Equipment or Chassis Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9 Grounding Electrodes/Gr ound Rods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9 Bonding the Grounding System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10

Battery Considerat ions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–11

Battery Bank Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–12 Battery Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–12 Battery Requirements for Dual Inverter Systems - - - - - - - - - - - - - - - - - - - - - -2–15

Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17 Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18 Generator Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–19

Types of Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–20

976-0043-01-02 ix

Contents

Generator start types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20

Additional/Optiona l Equipment Considerati ons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22

AC Conduit Box (ACCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22 DC Conduit Box (DCCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23

Fuse Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24 DC Disconnect Boxes (DC175/DC250) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24 Battery Status Meter (TM500A) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25 Remote Monitors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26

Inverter Control Module (ICM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27

Inverter Communications Adapte r (ICA) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27 Generator Start Module (GSM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28 Auxiliary Load Module (ALM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28 240 Vac Application Requiremen ts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–29 Autotransformer fo r 240 VAC Applications (T240) - - - - - - - - - - - - - - - - - - - - - - 2–29 Inverter Stackin g Control – Series (ISC-S) Cable - - - - - - - - - - - - - - - - - - - - - - - - 2–29 Renewable Energy DC Input Sources - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–30

Off-Grid Applicati ons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–32

Renewable Energy Systems with/ without Generator Backup - - - - - - - - - - - - - - - - 2–32

Single-Inverter Confi gurations (120 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–32

Single-Inverter Confi gurations (120/240 Vac) - - - - - - - - - - - - - - - - - - - - - - - 2–32

Dual-Inverter Configur ations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–34 Generator-Only Syste ms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–36

Single-Inverter Confi gurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–36

Dual-Inverter Configur ations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–38

240 Vac-only Input Source - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–38

On-Grid Application s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40

Backup Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40

Single-Inverter Confi gurations (120 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40

Single-Inverter Confi gurations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40

Dual-Inverter Configur ations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–42 Energy Management - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44

RE Backup with Utility (SB Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44

Peak Load Management - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44

Time-of-Use (TOU) Metering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–45

AC Load Support - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–46

Renewable Energy with Grid Backup (BX Mode) - - - - - - - - - - - - - - - - - - - - 2–47

Installation

Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

x 976-0043-01-02

Contents

Hardware / Materials Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 Optional System Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 Battery Bank Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–4 Unpacking and Inspecting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–5 Knockout Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–7 Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8

Shelf-Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8 Wall-Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10

DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

Preparing the Batter y Bank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14 Grounding the DC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15 Connecting DC Input Sources – Renewable Ener gy Configurations - - - - - - - - - - - - 3–18 Installing the Batte ry Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - 3–18 Connecting the Batteri es to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–20

Procedure for Single Inverte r Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22 Procedure for Dual-Inverte r Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24

AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–26

Accessing the AC Terminal Block and Ground Bar - - - - - - - - - - - - - - - - - - - - - - 3–28 AC Wiring for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–30

Manual and Auto Start Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–30 Install AC Output Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - 3–33 Install Generator Wiring to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35 Install Utility Wiring to the Inverter Input (On-Grid Applicati ons only) - - - - - -3–38

Optional Equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–39

Stacking Dual Inverter Sys tems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–39

Installing the ISC-S Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–40 Remote Monitoring Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–41 Auxiliary Load Module (ALM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–42 Emergency Power Off (EPO) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43 EPO Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43

Functional Test

Basic Functional Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2

Confirm all Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2 Applying Battery Power to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2 Turning ON the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3

AC Voltage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–4

Confirming Battery Charger Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–4

Confirming Inverter Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–5

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Contents

Navigation

Navigating the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2

The Inverter Control Module (ICM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

Inverter Control Module Fea tures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

The display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 The cursor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Display contrast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4

ON/OFF Menu Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Menu Heading Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Menu Item Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Set Point Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6 Reset Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6

Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7

Basic Setup Programming

Basic Setup Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–2 Before You Begin Programming - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–8

DC Amps verses AC Amps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–8

Basic Setup Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–9 Accessing the Basic Setup Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10 Menu Item Descriptions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11

10 Time of Day Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11

10A Set Hour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11 10B Set Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11 10C Set Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12

11 Inverter Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12

11A High Battery Cut Out VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12 11B Low Battery Cut In VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12 11C Low Battery Cut Out VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–13 11D LBCO Delay Minutes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–13 11E Search Watts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–14

Battery Charger Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–15

Multi-Stage Charging Proces s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–16 Equalize Charging the Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–18

12 Battery Charging Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–19

12A Finish Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–19 12B Bulk Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20 12C Float Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20 12D Equalize Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20

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12E Max Charge Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–22 12F Bulk Done Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–23 12G EQ VDC Done Timer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–24 12H Max Bulk/EQ Timer h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–25 12I Temp Comp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–25

13 AC Inputs Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–26

13A Grid (AC1) Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–27 13B Gen (AC2) Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–27 13C Input Upper Limit VAC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–28 13D Input Lower Limit VAC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–28

14 Save/Restore Settings Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–29

14A Push INV now to Save Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–29 14B Push GEN to Restore Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–29 14C Push GEN for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–30

End Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–30

Advanced Setup

Advanced Setup Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–2 Before You Begin Advanced Programming - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–10 Accessing the Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–11 Menu Item Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–13

20 Silent Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–13

20A Refloat High Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–15 20B Refloat Low Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–15 20C Float Done Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–15 20D Must Float Time Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16

21 Grid (AC1) Usage Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16

21A Grid Usage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–17 21B Grid Usage Begin h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–17 21C Grid Usage End H:M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–18

22 Battery Xfer (BX) Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–18

22A High Xfer (HBX) VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–19 22B Low Xfer (LBX) VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–19

23 ALM Relays Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–19

23A RY9 VDC Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20 23B RY9 VDC DeEnergized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20 23C RY9 Delay At DeEngz. Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–20 23D RY10 VDC Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20 23E RY10 Vdc DeEnergized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–21 23F RY10 Delay at Engz. Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–21

Contents

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Contents

23G RY11 Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–21

Generator Starti ng Scenarios - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–23

Manual Generator Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–23 Automatic Generator Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–24

24 Generator Timers Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–26

24A Gen Run Time Start h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27 24B Gen Run Time Stop H:M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27 24C Quiet Time Begin h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27 24D Quiet Time End h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28 24E Gen Exercise Period Days - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28 24F Gen Exercise Timer Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28 24G Gen Cooldown Timer Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28 24H RN2/Max Gen Run h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29

25 Gen Starting Details Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29

Generator Start Module (GSM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29 25A RY7 Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–30 25B Gen Warm-up Seconds/minutes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37 25C Pre Crank Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37 25D Max Cranking Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37 25E Post Crank Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37

26 Gen Auto Run Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38

26A Load Start Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38 26B Load Start Delay Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38 26C Load Stop Delay Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38 26D 24 Hr Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38 26E 2 Hr Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38 26F 15 Min Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39 26G Read LBCO 30 Sec Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39

27 Save/Restore Settings Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39

27A Push INV now to Save Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39 27B Push GEN to Restore Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40 27C Push GEN for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40

End Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40

Operation

Operating the Sine Wave Plus- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2 Operational Status Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3

LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3

Inverter Operation Status (Yellow) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–4 AC Input Status (Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–5

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Contents

Charge Status (Yellow and Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6 Operational Status Indication (Red and Yellow) - - - - - - - - - - - - - - - - - - - - - - -8–7 Error LED Reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–8

LED Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–9 The User Menu Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–11 Accessing the User Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–14 User Menu Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–15

01 Inverter ON/OFF Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–15

01A Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–15 01B EQ Charge OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–16 01C Search Watts (SRCH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–16 01D Bypass Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–17

02 Generator ON/OFF Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–17

02A Generator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–18 02B Gen Start Load Amps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19 02C Gen Start Volts/Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–19 02D Gen Start Exercise Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–19 02E Gen Start Run Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–19 02F Days Left To Gen Exercise - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19

03 Time Of Day Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20

03A SW Plus Software Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–20 03B System Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–20 03C Company Name and Address - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–20 03D City, State, and Zip Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20 03E Xantrex Phone Numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–20 Press Reset for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–21

04 Meters Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–22

04A Battery Actual Vdc - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–22 04B Battery Comp Vdc - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23 04C Inverter/Charger Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–23 04D Input Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23 04E Load Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23 04F Inverter Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23 04G Grid (AC1) Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24 04H Gen (AC2) Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–24 04I Frequency Hertz - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24 04J Max Bulk/EQ Time h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–24 04K Battery Temp Degrees C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24 04L Fan Speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–24

05 Error Causes Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–25

05A Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–25

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05B Transformer Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25 05C Heatsink Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26 05D Low Battery Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26 05E High Battery Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27 05F External Err (Stacked) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27 05G Input Relay Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27 05H Gen Failed to Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28 05I Gen Stopped Due to V/F - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28

06 Status Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28

06A Bypass Mode Selected - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29 06B Chr Selected (No Backup) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29 06C Gen Signaled to Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29 06D Gen In Cooldown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29 06E EQ Charge Selected - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30 6F Battery VDC < LBCO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30 6G Battery VDC > HBCO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30 06H EPO Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30

07 GSM/ALM Options Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30

07A RY7 (GSM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30 07B RY8 (GSM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31 07C RY9 (ALM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31 07D RY9 DeEngz. Time Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31 07E RY10 (ALM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31 07F RY10 Engz. Time Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31 07G RY11 Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31

Troubleshooting

Inverter Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–2 Battery Charger Troubl eshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–4 Error Causes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–7

Inverter Specifications

Electrical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4 Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6 Power Versus Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–8 Inverter Capacity versus Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–12 Time versus Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–13

xvi 976-0043-01-02

Configuration Settings

User Menu Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5 Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–10

Battery Information

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2

Deep-cycle Flooded Lead Acid (FLA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2

Sealed Batteries (Gel and AGM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Understanding Battery Capacity Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4 Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Understanding Amp-hour Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5

Calculating Amp Hours - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–6

Amp Hour Example Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–7 Battery bank size worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8

Battery Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–9

Wiring Batteries in Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–9

Wiring Batteries in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–10

Wiring Batteries in Series-Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–11

Battery Connections for Stacked Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–12 Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–13

Battery charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–13

Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–15

General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–16

Contents

Generators

Two-Wire Start Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2 Three-Wire Start Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2

Honda™ 3-Wire Type Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2

Onan™ 3-Wire Type Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–3

3-2 Wire Converters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–3

Over-Charge Protection

Overvoltage Protection using a Charge Controller- - - - - - - - - - - - - - - - - - - - - - - - - - - E–2 Diversion Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E–3

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Contents

Multi-wire Branch Circuit Wiring

Multi-wire Branch Circuits- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–2 Identifying Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–4 Correcting Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–5

Emergency Power Off Switches

The Purpose of an EPO switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -G–2

How to use the EPO Port for an EPO Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - -G–4

Warranty and Product Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–1 Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–3 Out of Warranty Service- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–4 Information About Your System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–5

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Figures

Figure 1-1 The Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 Figure 1-2 The Front Side of the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 Figure 1-3 The AC side of the Sine Wave Plus- - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4 Figure 1-4 Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5 Figure 1-5 The DC side of the Sine Wave Plus- - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6 Figure 1-6 Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7 Figure 1-7 External Output Circuit Breaker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–8

Figure 2-1 AWG Wire Size Reference Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–13 Figure 2-2 Sample Warning Sticker for Backfeed Conditions- - - - - - - - - - - - - - - - -2–17 Figure 2-3 AC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22 Figure 2-4 DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–23 Figure 2-5 Sine Wave Plus with AC and DC Conduit Boxes Installed - - - - - - - - - - -2–23 Figure 2-6 Fuse Blocks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–24 Figure 2-7 DC250 Disconnect Box and TM500A Battery Status Meter - - - - - - - - - -2–25 Figure 2-8 Accessories for Remote Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - -2–26 Figure 2-9 Inverter Control Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27 Figure 2-10 Inverter Communications Adapter - - - - - - - - - - - - - - - - - - - - - - - - - - -2–27 Figure 2-11 Generator Start Module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–28 Figure 2-12 Auxiliary Load Module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–28 Figure 2-13 T240 Autotransformer- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29 Figure 2-14 ISC-S Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29 Figure 2-15 Xantrex C-Series Charge Controllers- - - - - - - - - - - - - - - - - - - - - - - - - -2–31 Figure 2-16 PV Ground Fault Protection (PVGFP)- - - - - - - - - - - - - - - - - - - - - - - - -2–31 Figure 2-17 Off-Grid Application – Renewable Energy System using a Single Inverter 2–33 Figure 2-18 Off-Grid Application – Renewable Energy System using Dual Inverters - -2–35 Figure 2-19 Off Grid Application - Generator-only System using a Single Inverter - - -2–37 Figure 2-20 Off Grid Application – Generator-only Syst em using Dual Inverters,

Series-stacked - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–39 Figure 2-21 On-Grid Application – Backup System using a Single Inverter - - - - - - - -2–41 Figure 2-22 On-Grid Application – Backup System using Dual Inverters,

Series-stacked - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–43 Figure 2-23 Time-of-Use Metering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–45 Figure 2-24 AC Support Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–47

Figure 3-1 Certification Label Location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–6 Figure 3-2 Serial Number Sticker and Knockout Locations and Sizes- - - - - - - - - - - - -3–7

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Figure 3-3 Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Figure 3-4 Wall-Mounting Method using 2 x 4’s - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 Figure 3-5 Wall Mounting using Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13 Figure 3-6 Chassis Ground Lug Location on Inverter DC End - - - - - - - - - - - - - - - - 3–15 Figure 3-7 DC Grounding of a Single Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16 Figure 3-8 DC Grounding of Dual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17 Figure 3-9 BTS (RJ11) Port Location and Installation- - - - - - - - - - - - - - - - - - - - - - 3–19 Figure 3-10 DC Terminal Connections on the Inverter- - - - - - - - - - - - - - - - - - - - - - 3–20 Figure 3-11 Battery Cable Connection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–21 Figure 3-12 Battery Terminal Covers and Associated Hardware - - - - - - - - - - - - - - - 3–21 Figure 3-13 DC Connections to a Single Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - 3–23 Figure 3-14 DC Connections to Dual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25 Figure 3-15 AC Wiring Access Cover Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–28 Figure 3-16 AC Input/Output Wiring Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - 3–29 Figure 3-17 Connecting the GSM Communications Cable to the Sine Wave Plus- - - - 3–31 Figure 3-18 AC Input and Output Wiring to a Single Inverter

with an Auto-Start AC Generator- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–32 Figure 3-19 AC Output Wiring to the Inverter AC Panel - - - - - - - - - - - - - - - - - - - - 3–34 Figure 3-20 Generator Input Wiring to a Single Inverter - - - - - - - - - - - - - - - - - - - - - 3–37 Figure 3-21 Utility Wiring to the Inverter Input- - - - - - - - - - - - - - - - - - - - - - - - - - - 3–39 Figure 3-22 Series-stacked Inve rters with ISC-S Cable- - - - - - - - - - - - - - - - - - - - - - 3–40 Figure 3-23 Remote Monitor Port Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–41 Figure 3-24 Connecting the ALM Communications Cable to the Si ne Wave Plus- - - - 3–42 Figure 3-25 Connecting the EPO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43

Figure 4-1 Power Up Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Figure 5-1 ICM Display Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Figure 5-2 ICM Display and Contrast Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Figure 5-3 ICM ON/OFF Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4 Figure 5-4 ICM Menu Heading Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Figure 5-5 ICM Menu Item Push-uttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5 Figure 5-6 ICM Set Point Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6 Figure 5-7 ICM Reset Defaults button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6 Figure 5-8 Menu Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7 Figure 5-9 User Menu Map - Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8 Figure 5-10 User Menu Map - Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9 Figure 5-11 Basic Setup Menu Map Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10 Figure 5-12 Basic Setup Menu Map Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11

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Figures

Figure 5-13 Advanced Setup Menu Map Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - -5–12 Figure 5-14 Advanced Setup Menu Map Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - -5–13 Figure 5-15 Complete User Menu Map- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14 Figure 5-16 Complete Basic Setup Menu Map- - - - - - - - - - - - - - - - - - - - - - - - - - - -5–15 Figure 5-17 Complete Advanced Setup Menu Map- - - - - - - - - - - - - - - - - - - - - - - - -5–16

Figure 6-1 Accessing the Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10 Figure 6-2 Multi-Stage Battery Charging Process - - - - - - - - - - - - - - - - - - - - - - - - -6–16

Figure 7-1 Accessing the Advanced Setup Menu - Method 1 - - - - - - - - - - - - - - - - -7–11 Figure 7-2 Accessing the Advanced Setup Menu - Method 2 - - - - - - - - - - - - - - - - -7–12 Figure 7-3 Relay 11 Wiring Example to Dual Inverters with Cooldown selecte d - - - - 7–22 Figure 7-4 Generator Control Mode (GS and RN1)- - - - - - - - - - - - - - - - - - - - - - - - 7–29 Figure 7-5 Generator Control Mode (RN2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–30 Figure 7-6 RY7’s COM and N.O. Contacts Close (energize) to Run Generator - - - - -7–31 Figure 7-7 Wiring examples of Honda™ and Onan™ Generators - - - - - - - - - - - - - -7–33 Figure 7-8 RY7 and RY8 Timing Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–34 Figure 7-9 RY7/RY8 Sequence of Events for RN1 or RN2 Selection- - - - - - - - - - - -7–35 Figure 7-10 RY7/RY8 Sequence of Events for GS Selection - - - - - - - - - - - - - - - - - - 7–36

Figure 8-1 LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–3 Figure 8-2 Inverter Operation Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–4 Figure 8-3 AC Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–5 Figure 8-4 Charge Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6 Figure 8-5 Error and Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–7 Figure 8-6 Inverter ON/OFF Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–14 Figure 8-7 Generator ON/OFF Display- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–14 Figure 8-8 Resetting Factory Default Settings - - - - - - - - - - - - - - - - - - - - - - - - - - -8–21

Figure A-1 Sine Wave Plus Simple Block Diagram - - - - - - - - - - - - - - - - - - - - - - - - A–6 Figure A-2 Sine Wave Plus Inverter Output Waveform - - - - - - - - - - - - - - - - - - - - - A–7 Figure A-3 Power Versus Efficiency Curves for All Models - - - - - - - - - - - - - - - - - - A–9 Figure A-4 Sine Wave Plus Efficiency Curve for the SW Plus 2524- - - - - - - - - - - - - A–9 Figure A-5 Sine Wave Plus Efficiency Curve for the SW Plus 2548 - - - - - - - - - - - - A–10 Figure A-6 Sine Wave Plus Efficiency Curve for the SW Plus 4024 - - - - - - - - - - - - A–10 Figure A-7 Sine Wave Plus Efficiency Curve for the SW Plus 4048 - - - - - - - - - - - - A–11 Figure A-8 Sine Wave Plus Efficiency Curve for the SW Plus 5548 - - - - - - - - - - - - A–11 Figure A-9 Time versus Current for the Sine Wave Plus 2524- - - - - - - - - - - - - - - - A–13 Figure A-10 Time versus Current for the Sine Wave Plus 2548- - - - - - - - - - - - - - - - A–14 Figure A-11 Time versus Current for the Sine Wave Plus 4024- - - - - - - - - - - - - - - - A–14

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Figures

Figure A-12 Time versus Current for the Sine Wave Plus 4048 - - - - - - - - - - - - - - - - A–15 Figure A-13 Time versus Current for the Sine Wave Plus 5548 - - - - - - - - - - - - - - - - A–15

Figure C-1 6-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - C–9 Figure C-2 12-volt Ba tter y Wirin g - “Series ” Con fi gu rat io n- - - - - - - - - - - - - - - - - - C–10 Figure C-3 Battery W iring in Par al le l (Exam p l e Only ) - - - - - - - - - - - - - - - - - - - - - C–10 Figure C-4 Step 1 - Wiring Batteries in “Series” - - - - - - - - - - - - - - - - - - - - - - - - - C–11 Figure C-5 Step 2 - Two series strings wiring in “Parallel” - - - - - - - - - - - - - - - - - - C–11 Figure C-6 “Series-Parallel” Configuration Wired to the Inverter - - - - - - - - - - - - - - C–12 Figure C-7 Example of Battery Connections for Stacked Inverte rs (24 Vdc shown) - - C–12

Figure E-1 Overvoltage using a C-Series Charge Controller- - - - - - - - - - - - - - - - - - - E–2 Figure E-2 Diversion Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E–3

Figure F-1 Conventional Home-type Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–2 Figure F-2 Multi-wire Branch Circuit Wiring and Current Flow - - - - - - - - - - - - - - - - F–3 Figure F-3 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit - - - - - - F–3 Figure F-4 Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–4 Figure F-5 Using a Step-down Autotr ansformer in Multi-wire Branch Circuit Wiring - F–6

Figure G-1 Emergency Power OFF Disconnect Switch - - - - - - - - - - - - - - - - - - - - - -G–2 Figure G-2 Modifying a 6-conductor Cable to connect to the EPO Port - - - - - - - - - - -G–4

xxii 976-0043-01-02

Tables

Table 2-1 Recommended Minimum Safety Ground Wire and DC Disconnect

Sizes per NEC 2–8 Table 2-2 Recommendced Battery Cable Size Versus Length - - - - - - - - - - - - - - - 2–14 Table 2-3 Battery Cable to Maximum Breaker/Fuse Size - - - - - - - - - - - - - - - - - - 2–15

Table 3-1 AC Disconnect and Wire Sizing- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–27

Table 6-1 Basic Setup Menu Default Settings for the Sine Wave Plus

2524 and 2548 Models 6–2 Table 6-2 Basic Setup Menu Default Settings for the Sine Wave Plus

4024 and 4048 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–4 Table 6-3 Basic Setup Menu Default Settings for the Sine Wave Plus

5548 Model 6–6 Table 6-4 Battery Voltages For Setting Charging Par amet ers- - - - - - - - - - - - - - - - 6–21 Table 6-5 Battery Charging Current and Timer Default Settings - - - - - - - - - - - - - 6–21 Table 6-6 Calculating the Maximum Charge Amps for a 24-volt,

700 amp-hour Battery 6–22 Table 6-7 Calculating the Maximum Charge Amps for a 48-volt,

350 amp-hour Battery 6–23 Table 6-8 Calculating the Bulk Done Amps for a 24-volt, 700 amp-hour Battery - - 6–24 Table 6-9 Calculating the Bulk Done Amps for a 48-volt, 350 amp-hour Battery - - 6–24 Table 6-10 Inverter Temperature Compensation Calc ulation using the BTS- - - - - - - 6–26

Table 7-1 Advanced Setup Default Settings f or the Sine Wave Plus

2524 and 2548 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2 Table 7-2 Advanced Setup Default Settings f or the Sine Wave Plus

4024 and 4048 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5 Table 7-3 Advanced Setup Default Settings f or the Sine Wave Plus Plus 5548 Models 7–7 Table 7-4 Calculating the Float Done Amps for a 24-volt, 700 amp-hour Battery - - 7–16 Table 7-5 Calculating the Float Done Amps for a 48-volt, 350 amp-hour Battery - - 7–16

Table 8-1 LED Summary Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–9 Table 8-2 User Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–11

Table A-1 Derating from continuous power (VA) at elevated ambient te mperatures- A–12

Table B-1 User Menu Default and User Settings - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Table B-2 Basic Setup Default and User Settings for the Sine Wave Plus

2524 and 2548 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5

976-0043-01-02 xxiii

Tabl es

Table B-3 Basic Setup Default and User Settings for the Sine Wave Plus

4024 and 4048 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6

Table B-4 Basic Setup Default and User Settings for the Sine Wave Plus

5548 Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8

Table B-5 Advanced Setup Default and User Settings for the Sine Wave Plus

2524 and 2548 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–10

Table B-6 Advanced Setup Default and User Settings for the Sine Wave Plus

4024 and 4048 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12

Table B-7 Advanced Setup Default and User Settings for the Sine Wave Plus

5548 Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–14

Table C-1 Determining Average Daily Load in Amp-hours - - - - - - - - - - - - - - - - - C–7 Table C-2 Determining Battery Bank Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8 Table C-3 Typical Appliance Wattage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8 Table C-4 Variances in Charging Voltage based on Battery Temperature - - - - - - - C–14 Table C-5 Temperature Compensation Calculation - - - - - - - - - - - - - - - - - - - - - - C–14 Table C-6 Battery State-of-Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–17

xxiv 976-0043-01-02

Introduction

Chapter 1, “Introduction” lists and describes the basic features

and parts of the Sine Wave Plus Inverter/Charger.

Introduction

Basic Features

Congratulation s on your purchase of a Sine W ave Plus Inverter/Char ger from Xantrex Technology, Inc. The Sine Wave Plus is one of the finest inverter/chargers on the market today, incorporating state-of-the-art technology, high reliability, and convenient control features.

Specific features include:

• FCC Part B comp lian t

• 2.5 kW, 4.0 kW, or 5.5 kW continuous output of sine wave power f or 120 Vac/60 Hz applications (depending on model)

• expandable up to 11 kW for 120/240 Vac/60 Hz applications by combining dual inverters using the Inverter Sta cking Cont rol – Series (ISC-S) cabl e

• 24-volt or 48-volt models

• multi-stage batte ry charging

• battery temperatu re sen sor which provides automatic temperat ure compens ation fo r batter y charg i ng

• push-button control mod ule with a liquid crystal display (LCD) for easy programming a nd troubleshooting

• light emitting diode (LED) display of system operational stat us

• automatic on/off control of electric-start generators (requires additional equipment)

• remote monitoring (requir es additional equipment)

• auxiliary load contr ol (requires additional equipm ent )

• high surge/ current capacity (depending on the unit, it will surge up to

5.9 times the continuous current rating for a minimum of 2 seconds). See Appendix A, “Electrical Specific ations”.

• energy management fea tures control utility and/ or generator usage

• energy eff icient to 95% peak and less than 20 watts of idle current; less than 2 watts in Search Mode

The default settings of the Sine Wave Plus Inverter/Charge r allow the system to perform in many installations without the need for additional setup. However, if additional setup pa rameters are required, the pushbutton featur es on the I nvert er Control Mo dule (ICM) disp la y on the fr ont panel of the unit enables the syst em to be easil y reprogrammed to meet specific custom er configurations.

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Basic Features

Front Panel

Figure 1-1

The Sine Wave Plus

The front of the Sine Wave Plus has the following features:

• the Inverter Control Module (ICM) Display

• the AC Access Cover

Inverter Control Module Display

AC Access Cover

Figure 1-2

976-0043-01-02 1–3

The Front Side of the Sine Wave Plus

Introduction

AC Side

The AC side of the Sine Wave Plus has the following features:

• The Remote Monitor Port for connecti ng a remote Inverter Control Module (ICM) or the Inverter C ommunications Adapter (ICA)

• The Stacking Port for connecting two Sine W ave Plus inverters

• The AUX Port for connecting the Auxiliary Load Module (ALM)

• The GEN Port for connecting the Generator Start Module (GSM)

• The EPO Port for connecting an Emerge ncy Power Off (EPO) switch

• Certification Label

• The Grid Tie Interfa ce Port . Th e G rid Tie featur e is curren t ly not available with the Sine Wave Plus models. However, the port has been included in the even t tha t the feat ure can b e enab l ed wit h an upgrade at a future date. Continue to check our website www .xantrex.com for more inform at ion and future enhancements on the Sine Wave Plus Inverter/Charger.

• The Serial Number Stick er is on the rail as shows in Figure 1-3.

Grid Tie

Interface

Port

(not used)

Figure 1-3

Remote Monitor Port

AUX Port

GEN Port EPO Port

The AC side of the Sine Wave Plus

Stacking Port

Certification Label

Serial Number Sticker

1–4 976-0043-01-02

Emergency Power Off (EPO) Option

The Sine Wave Plus offers an Emergency Power Off (EPO) option through the use of the EPO Port. The EPO feature is designed to shut down the inverter from a remote location (or switch).

Since the type of the switch will be dependent on the installation, EPO switches are not provided with the Sine Wave Plus. However, many commonly availabl e emergency shut off switches will work with the Sine

Wave Plus EPO. Consult your local system designer or qualified

technician for assistance. The EPO is connected to the Sine Wave Plus with a telephone cord

(RJ11type connector) to the dedicated EPO port on the AC (left ) side of the inverter.

See Appendix G, “Emergency Power Off Switches” for additional information about this f eature and how to prepare a cable for it.

Certification Label

The Sine Wave Plus has been tested to nationally r ecognized safety standards and has been found to be free from reasonably foreseeable risk of fire, electric shock, and related hazards when installe d and operate d in accordance with all the instructions provided in this manual and in accordance with all applicable local and national codes.

Basic Features

Please refer to the Certification Label affixed to the AC side of the inverter for specific agency information.

See Figure 1-3, “The AC side of the Sine Wave Plus” on page 1–4 for the location of this information.

Model Number

Certification Statement

Date of Manufacture

Figure 1-4

976-0043-01-02 1–5

Certification Label

Introduction

DC Side

The DC side of the Sine Wave Plus has the following features:

• the positive (+) battery terminal

• the negative (–) battery terminal

• the battery temperature sensor port

• the chassis ground lug

Chassis Ground Lug

Figure 1-5

Positive (+) Battery Terminal

The DC side of the Sine Wave Plus

Negati ve (–) Battery Termin al

Battery Temperature Sensor

1–6 976-0043-01-02

Battery Temperature Sensor (BTS)

A BTS is provide d with each Sine Wave Plus Inverter/Charger. This sensor can easily be installed in the system to ensure proper charging of the batteries based on tempe ratur e. Installing a BTS extends battery life by preventing overchar ging in warm temperatures and undercharging in cold temperatures .

If more tha n one BTS is being used, install them adjacent to each other so that they all detect a common temperature.

Basic Features

Figure 1-6

Battery Temperature Sensor (BTS)

See Table C-4, “Variances in Charging Voltage based on Battery

T emperature” on page C–14 and Table C-5, “Temperature Compensation Calculation” on page C–14 for additional information.

976-0043-01-02 1–7

Introduction

Top

The top of the unit has the following featur e s:

• Circuit Breaker - This circuit breaker protects the unit’s internal wiring while the unit is inverte r or charging. It is not used for the pass-through curr ent. This is not a branch-circuit rated bre aker. Separate output breake rs are still required. If the button is protruding from the chassis as shown in Figure 1-7, it means the circuit breaker has tripped open. Press the break er back in to reset it.

• Warnings Label

• Ratings Label

Top View of Sine Wave Plus Inverter/charger

Circuit Breaker

AC End

Warnings Label

Circuit Breaker Open Circuit Breaker Reset

Ratings Label

DC End

Figure 1-7

1–8 976-0043-01-02

External Output Circuit Breaker

System Configuration

Chapter 2, “System Configuration” contains informat ion to

help you plan for a Sine Wave Plus installation in an off-grid, on-grid, or backup power application.

System Configuration

Pre-Configuration Planning

Importance Pre-configura tion planning is essential to ensure opti mal performance for

your system. This section outlines the components of a system and how you can plan for them.

Types of Applications

The Sine Wave Plus Inverter/Charger can be configured for the following applications:

• OFF-GRID (stand-alone) app lications where no utility power is available.

See Figure 2-17 through Figure 2-20 for illustrations of off-grid applications.

• ON-GRID applications where it can ope rate the AC loads when the Utility System (grid) fails, ke ep the batter ies charge d, and/ or function as an energy management cont roller .

See Figure 2-21 and Figure 2-22 for illustrations of on-grid applications.

Important: Be sure to consult with your local utility company and/or permit

office to ensure that the desired configuration will be code-compliant. Be sure to obtain the proper licenses and permits as required by law.

Important: Installatio ns of this equipment s hould only be performed by skille d

personnel such as qualified electricians and Certi f ied Renewable Ener gy (RE) System Installers. For a list of Xantrex Certified RE dealers, ple ase visit our website at www.XantrexREdealers.com.

System Considerations

You need to consider the following issues as you design your system.

System output How much power will be required and how it will be produced:

❐ Single or dual inverters (based on output voltage and output

watts required)

❐ Output watts required (i.e., continuous capacity and surge capacity) ❐ Output voltage (120 Vac or 240 Vac)

See “System Output Requirements” on page 2–4 fo r more information.

System input What are the sources of power for your system:

❐ Utility power ❐ AC generator (See “Generator Considerations” on page 2–19)

2–2 976-0043-01-02

Pre-Configuration Planning

❐ Renewable energy systems (e.g., PV arrays, wind turbines etc.) See “System Input Requirements” on page 2–4 for more information.

Location What are the safe, physical environmental requirements for your

installation: ❐ Mounting location for optimal performance and easy access of all

components

❐ Ventilation and clearance requirements for all components ❐ Mounting method (wall or shelf) ❐ Additional items/mater ials required for mounting ❐ RFI or EMI considerations

See “Location Considerations” on page 2–5 for additional information.

Grounding What methods of protecti on and grounding are required:

❐ Grounding type (i.e., ground bar, gr ound bus, or ground rod) ❐ Neutral-to-ground bonding requirements ❐ Lightning and surge prote ction

See “Grounding Considerations” on page 2–7 for additional information.

Battery What kind of DC storage will be used:

❐ Battery type and size ❐ Battery cables and sizes ❐ Size of the battery bank and it’s configuration ❐ Location of battery bank to rest of system

See “Battery Considerations” on page 2–11 for additional information.

Wiring What is needed/require d for the AC and DC wiring for this installation:

❐ Types and sizes of wires needed ❐ Types and sizes of conduits needed ❐ Types and sizes of fuses, disconnects and/or circuit breakers ❐ Additional equipment for code complia nce (e.g., service panels,

conduit boxes, emergency shutoff switches e tc.)

❐ Wire routing See “Wiring Considerations” on page 2–18 for additional information.

976-0043-01-02 2–3

System Configuration

Generato r Will a generator be used:

❐ Voltage Output Requirements

(120 Vac only, 120/240 Vac, or 240 Vac only)

❐ Auto-Start or Manual-Start

Important: Auto-start generators require the addition of the GSM to enable

the inverter to control the operati on of the generator.

See “Generator Considerations” on page 2–19 for additional information.

Additional equipment

What additional equipment is needed: ❐ Remote mo ni tor s, interface cables, stack in g cable s , DC ch arge

controllers, a uxiliary load controllers, T240 autotransformers etc.

See “Additional/Optional Equipm ent Considerations” on page 2–22 for additional infor mation.

System Output Requirements

Determination Dete rmine the inverter output size requirements by calculating the

maximum, continuous capacity and surge (inrush current) capacity the system will demand.

• Add all potential loads which would be on at once to determi ne continuous power requir ements.

• Add the surge current of all loads whic h might start at once to determine surge requirements (e.g., washer spinner, waterpump and refrigerator compressor could a ll start at once).

More information See Appendix C, “Understanding Amp-hour Requirements” for

assistance in determ ining the System Output Requirements.

System Input Requirements

Determination Determine the input r equirements based on the output requirements. In

other words, is grid power available or will renewable energy equipment be used? Wil l a gener ator be used to supple ment or back up the othe r input sources?

More information See “Generator Considerations” on page 2–19 and Appendix D,

“Generators” for additional information regarding using generators for

system input.

2–4 976-0043-01-02

Pre-Configuration Planning

Location Considerations

Dry Inverters contain sophisticated electronic components and should be

located in a well-prote cted, dry environment away from sources of fluctuating or extr eme temper atures and moisture.

The better the environment, the longer the inverter will last. Consider installing your inverter in the same type of location in which you would store high quality electronic equipment of equal value.

Avoid saltwater Exposure to saltwater is particularly destructive and potentially

hazardous. Internal corrosi on caused by improper inst allat ion may cause the inverter to prematur ely fail and additionally will void the warranty.

Close to battery bank

Locate the inverter as close to the batteries as possible in order to keep the battery cable length shor t. However, note the following warnings and important notes about inve rter location.

WARNING: Explosion and Corrosion Hazard

Do not loca te the i nve rte r di rec tly above the bat ter ies or i n th e sa me com par tmen t as vented batteries.

Vented batteries generate hydrogen and oxygen, which if accumulated, can be ignited by an arc caused by connecting the battery c ables or switching a relay. Vented batteries also gene rate hydrogen-sulfid e gas, which is corrosive to electroni c equi pment.

Batteries can sometimes re lease explosive ga s, please see the battery manufacturer’s recommendations for ventilation r equirements.

CAUTION: Damage to Inverter

Do not mount the inverter in the same space as the generator. The heat and dust from the generator can damage the inverter.

RFI Interference Inverters can generate radio frequenc y interference (RFI) . Loc ate any

sensitive electronic equipment susceptible to RFI as far away from the inverter as possible . This inc ludes radios and televisions.

Electromagnetic Interference

Inverters can emit strong electromagnetic f ields. This should be considered when choosing an installation location.

See “FCC In fo rm at ion to t he User ” on page viii for additional information regar ding RFI requirements.

976-0043-01-02 2–5

System Configuration

Fire Safety All Sine Wave Plus inverter/chargers meet UL fire safety standards as

outlined in UL 1741. As such, in the eve nt of a fail ure, th e Sine Wave Plus is designed to fail safe. Be sure the spe cific mounting and ventilation requirements outlined in this Owner’s Manual are followed carefully.

Do not locate the inverter near readily flammable materials such as cloth, paper, straw, plastic etc. Flammable materials should be kept a minimum distance of 24 inches (60 cm.) from the top surface (when wall mounted) and 12 inches (27 cm.) from either side surface and the front of the Sine

Wave Plus. Readily flammable materials refers to instantly combustible

substances such as cloth, paper, straw, an d plast ic sheeting.

Mounting Considerations

Method The inverter can be mounted on a ve rtical surface (or wall) or on a shelf.

The advantage of the wall mounting is to provi de easier acces s to the controls and displays.

Securing The mounting surf ace (wall or shelf) must be capable of suppor ting twice

the weight of the inverter. The keyhole slots should not be used as the only method of securing the unit to the mounting surface. Use all ten mounting holes and all four ke yhole slots for securing the unit and use

0.25-inch diameter bolts for mounting.

Ventilation Requirements

Location Install the inverter in a well-ventilated area/enclosure for proper

operation. The inverter’s thermal shutdown point will be reached sooner than normal in a poorly ventilated environment re sulting in reduced peakpower output and surge capa bility as well as shorter inverter lif e.

Requirements Provide a minimum clearance of 6 inches (12 inche s is pref erred) around

the top and 6 inches a t t he AC- and DC -side of the i nve rter for venti lation. A fan-forced, fresh-air vent (on the inverter’s AC side) allows cool air to enter the unit and exit from the DC-end of the inve rter . Ensur e that this vent is not obstructed with for eign objects, such as dirt and dust and that the minimu m clearances are met.

Airflow clearance All air ventilatio n openings should have 6 inches of clearance and there

should be no nearby cover over the top of the unit. This is to preve nt warm, exhausted air from the unit from being drawn back into it. The warm air could cause premature shutdown due to overhe ating.

Screening The unit is equipped with screening to pr ev ent insects and rodents from

entering. This screening needs to be checked and cleaned regularly from the outside to prevent dust buildup.

2–6 976-0043-01-02

Pre-Configuration Planning

Grounding Considerations

Types Whether you are installing a new system or integrating new parts into an

existing system, the four types of grounding to consider are:

• DC system grounding

• Inverter groundin g

• Chassis grounding

• Bonding the grounding system

Important:

All install ations must comply with nat ional and local codes and ordinances. Consult local and/or national codes and the NEC/CEC for specific grounding a nd bonding require ments for the desired installation.

DC System Grounding

Systems The Sine Wave Plus can be used in either a positive or negative grounde d

system. However, unless you are installing the inverter into an existing positive gro unded system (i.e., a telecommunicat ions system), it is highly recommended to use negative grounding.

Positive grou nd In a positive ground, the positive conductor from the battery bank is bonded to earth ground. This arrangement is most often used in telecommunications systems where an isolated ground is a requirement.

The grounding requirements vary by country and by application.

Negative ground In a negative ground, the nega tive c onductor f rom the battery bank is bond ed to earth ground. This is the most common form of grounding methods used for residenti al and commerc ial applic ations. The

Sine Wave Plus meets FCC part 15 Class B regulations in a negative

grounded system. See “FCC Information to the User” on page viii for additional infor mation.

Convention The remainder of this guide will ass ume the negative ground convention.

Important:

applicati ons) to ground can only be in one location in the DC system. This DC ground bond must be made in a non-serviceable item in the DC system. The Xantrex DC175 a nd DC250 can have the optional DC Bonding Block (DCBB) installed to provide the DC system bond. Additionally, the Xant rex PVGFP can also provide this bond a nd comply with NEC/CEC requirements for roof mounted PV arrays installed on dwelling units (homes).

976-0043-01-02 2–7

The bonding of the DC negative (or positive in positi ve ground

System Configuration

Inverter Grounding

WARNING: Shock Hazard

Attach the ground lead BEFORE atta ching any AC or DC power connections.

Requirement The inverter/charger should be connected to a grounded, permanent

wiring system with the AC and DC grounds commonly bonded to each other and should be bonded to the grounding syste m at only one point in the system. See “Bonding the Grounding System” on page 2–10 for additional infor mation.

Conductor size The size for the grounding conductor is usually based on the size of the

circuit breaker in the DC system. Table 2-1 provides battery DC disconnect sizes and minimu m wire sizes of copper ground wires for grounding systems.

It is recommended that the size and gauge of grounding wire should be more than the NEC/CEC minimum requirements when inst alling power sources such as inverter/chargers or generators.

Table 2-1

Recommended Minimum Safety Ground Wire and

DC Disconnect Sizes per NEC

Battery DC Disconnect Size

30 amp or 60 amp #10 AWG 100 amp #8 AWG 200 amp #6 AWG 300+ amp #2 AWG or greater

Minimum Size of Copper Ground Wire

Note: Field experience has demonstrated that long distances or high

impedance grounds can cause equipment malfunc tion or damage.

WARNING: Explosion Hazard

Never use a gas pipe or gas line for grounding purposes. The inverte r is a power source and it is int ended to be grounded at the service/main ground rod.

2–8 976-0043-01-02

Pre-Configuration Planning

Equipment or Chassis Grounding

WARNING: Shock Hazard

Attach the ground lead BEFORE attaching AC or DC power conne ctions.

Equipment or chassis groundi ng connects the metallic chassis of the various enclosure s together to have them at the same voltage potential, thus reducing the possibility for electric shock. It also provide s a path for fault currents to flow thr ough to blow fuses or trip circuit breakers. The size of the connecting conductors should be coordinated with the size of the over- current de vices i nvolve d. Und er some circ umstan ces, t he c onduit and enclosures themselves will provide the current paths.

Grounding Electrodes/Ground Rods

Purpose The purpose of the grounding electrode (often called a ground rod) is to

maintain the potentia l of equipment tie to it at “ground” pote nti al to avoid a shock hazard. It also shunts to ground fault currents and currents due to ground tied filtering.

Size The size for the conductor to the grounding electr ode or grounding system

is usually based on the size of the largest conductor in the system. Most systems use a copper- plated rod as the grounding electrode. The rod should be 5/8 inch (16 mm) round by 8 feet (2 meters) long and driven into th e ear t h. It i s also common to us e co p per wi r e pla ce d i n t he co n cr et e foundation of the building as a grounding system. Either method may be acceptable, but the local code will prevail. Connection to the ground electrode shoul d be done wi th specia l cla mps loca ted above ground where they can be periodicall y inspected.

Note:

system, are subject to severe damage from the effects of lightning. Lightning damage is not covered by your warranty. If your installation is in an area of

high probability for lightning, you should consult with a local lightning expert or your a uthorized Xantrex install er to determi ne what extra precautions should be taken to protect your equipment.

This inverter, along with all other power electronic devices in your

Number of rods Many large systems use multiple ground rods. The most common

example is providing a direct pa th from the solar array to earth near the location of the solar array. Most electrical codes ex pect mul tip le gr o und rods to be connected by a se para te wire with its own set of clamps. If this connection is done, it is a good idea to make the connection with a bare wire located outside of the conduit (if used) in a trench. The run of buried

976-0043-01-02 2–9

System Configuration

wire may be a better grounding electrode than the ground rods. Well casings and water pipes can also be used as grounding electrodes. Unde r no circumstance should a gas pipe or line be used.

Important:

Consult local codes and the NEC/CEC for more information.

Bonding the Grounding System

Definition Bonding means connecting one of the curre nt- carrying conductors

(usually the AC neutral and DC nega tive) to the gr ounding system. When the other ungrounded conductor (the hot or positive) touches the grounding system, current will flow through it to the point of connection to the grounded conductor and back to the source. This will cause the over-current protection to stop the flow of current, protecting the system. This point of connect ion between the grounding system (ground rod), the current carrying grounded conductor (AC neutral and DC negative), and the equipment grounding conductor (green ground wire, equipment ground) is called a “bond”.

Bonding locations Bonding is usually located in the over-current protection device

enclosures (both AC and DC). Residential systems In residentia l systems bonding is located at the

utility panel, after the power has gone through the kilowatt-hour meter of the utility (if prese nt).

Renewabl e en erg y sys te m s Renewable energy system s, with no gr id connection, can be grounded at the main AC distribution panel. Renewable energy systems should be grounded to the same grounding electrode as the AC distribution panel.

Bonding should not be done at the inverte r. Codes do not generally allow it because the inverter is considered a “serviceable” item that may be removed from the sytem, in which case, the bonding would be broke n.

Bonding at one point

Bonding must be done at only one point in an electric al system. Inherently, Xantrex systems have two separate electric systems; a DC system and an AC system. This means t hat two bonding points will occur in all inverter appli cations. The bonding point will also be connecte d to the equipment (chassis) grounding conductors. It is common to have two separate conductor s connect the ground electrode and the two bonding points. Each conductor should use a separate clamp.

Guidelines The ground and neutral must be bonded at one place, and only one

place, in the system. Use the following guideline s for ground and neutral bonding:

2–10 976-0043-01-02

Pre-Configuration Planning

Generator If the generator is the main source of power, (that is, no utility grid power) then the neutral and ground connections are bonded at the main AC distribution panel.

Utility grid If the utili ty grid is t he mai n source of powe r , the n the bond should be at the utility AC distribution panel.

No utility or generator If there is no utility or generator in the system, then the ground/neutra l bond should be in the inverter AC distribution panel.

Battery Considerations

CAUTION: Damage to Equipment

The Sine W ave Plus is intended to operate with batteries as its source of DC power. Do not connect DC chargi ng sou rces , such a s PV arrays, win d turbine s, or micro-hydro turbines, direct ly to the Sine Wave P lus . If DC chargi ng s ources are connected dire ctly to the inverter, the DC rating of the inverter can be exceeded and the inverter can be damaged.

Accessibility Locate the batteries in an accessible loca tion if maintenance is required.

Two feet clearance above the batteries is recommended for access to the battery caps. They should be located as close to the inverter as possible without limiting access to the inverter’s disconne cts. Install the batterie s to the right of a wall-mounted inver te r for easy access to the DC side of the inverter and shorte r cable runs. The battery bank may also be placed on the opposite side of the wall on which the inver ter is mounted.

Vented enclosures For safety and to limit access to the batteries, the batteries should be

housed in an enclosure or dedicat ed room that can be locked or screened, and ventilated. It should be vented to the outside by a 1-inch minimum vent pipe located at the top of the enclosur e . An inta ke vent should be installed at the bott om of the enclosure to promote air circulation.

Important: These vents exhaust corrosive and explosive hydrogen sulfide

gases and must not be overlooked when designing an enclosure.

Enclosure requirements

976-0043-01-02 2–11

The enclosure should be made of an acid resistant material or have a finish that resist s acid to prevent corrosion and must be capable of containing the elect rolyte from at least one battery should a leak occur.

Enclosures located outside must be rainproof and screened to prevent access by rodents or insects and insulated from extreme temperatures.

Batteries will give their best performance and servic e life when operat ing in a 20 to 25 °C ( 6 8 t o 77° F) envir o nment .

System Configuration

More information Consult your battery vendor f or additional information on battery

enclosure requirements.

Battery Bank Requirements

Determining requirements

Note:

battery bank is 100 Ah. T he rec om me nded battery bank size is determined by the battery ba nk works h ee t in Appendix C (Table C-1, “Determining Average

Daily Load in Amp-hours” on page C–7). The inverter is designed to operate

with batterie s and should not be operated wit hout them.

Based on the peak current of the inverter, the minimum allowed

To determine your battery requirements you need to know what type of batteries to use, the number of batt eries for the battery bank, and how to configure the bank to optimize voltage output according to system requirements.

See Appendix C, “Battery Information” for additional information on determining batte ry bank type and configuration.

The DC voltage of your inverter must match the DC voltage of your system and all of its accessori es . If you hav e a 24-volt inverter , the n the battery bank and all other DC devices in the system must be configured for 24 volts.

WARNING: Fire Hazard

Undersized cables ca n overheat and melt, creating a fire hazard when subjected to heavy (peak) loads. Always us e a cable of proper s ize and length, rated for the amperage of the inverter and batteries.

Battery Cable Requirements

Important:

connections. Do not use coarse, strand ed wire, as the lack of flexibility may damage battery and inverter terminals.

Size and length Battery cables must be the correct size and length to optimize

performance and ensure the safety of the system. Larger diameter cables (smaller AWG number) have less voltage drop and are, therefore, more efficient when tr ans ferr ing power to and from the batte ri es. Th e use o f oversized cables ( e. g., 4/0 cables) will allow you to ta ke advantage of the improved surge perf ormance of the Sine W ave Plus inverters.

2–12 976-0043-01-02

Use only fine, stranded copper cables for battery and inverter DC

Important

recommendation

Pre-Configuration Planning

Follow the battery cable recommendations listed in this guide. It is absolutely imperat ive that you adhere to the battery cable size (wire gauge) and length recommendation s prov ided in this sec tion. I f cables are used that are too long or of insuff icient gauge (i.e., the diameter is too small), then inverter performance will be adversely af f ected.

In addition to poor inverte r perfor mance, undersized cables can result in fire caused by overheating wir es. Any damage to the inverter caused by overheating from undersized wire is not covered by the Xantrex war ranty.

Important:

Figure 2-1 is for reference only. Sizes shown are for the

conductor. Do not include any insulation, or shea thing, when determining your wire size. Due to prin ting anomalies, these dimensions may not be to scale.

Size

iameter

Size

Diameter

Size

Diameter

.07210.1158.1466.184

.073

.335

250 MCM

.580

1/0

.380

300 MCM

.635

2/0

.420

350 MCM

.690

.235

3/0

.475

400 MCM

.730

.281

.295

4/0

.530

500 MCM

.820

Figure 2-1

AWG Wire Size Reference Chart

Battery cable length Cable length is another important factor. Runs should be kept as short as

practical. Longer cable runs increase resistance, thus lowering the overall efficiency of the system. This is especially true in lower voltage systems where, depending upon the length of the cable run, it may be necess ary to oversize the diameter of the wire, or pa rallel (double) the cables. Table 2-

2 provides recommended minimum cable sizes for various cable lengths

976-0043-01-02 2–13

System Configuration

and inverter amperage per NEC/CEC guidelines. It is recommended that the cable has battery acid resistant insulation and is rated for 90 °C (32 °F) or better.

Be sure to check with any local regulatory agencies for additional requirements.

Battery cable lugs Battery cabl es must have crimped copper compression lugs or crimped

and soldered copper compression lugs. Soldered connections alone are not acceptab le.

High quality ba ttery c able s are ava ilable f rom Xantrex i n an assor tment of lengths from 1½ to 10 feet in #2/0 AWG and from 1½ to 15 feet in #4/0 AWG sizes. These c ables are color-coded with pressure crimped, sealed ring term ina ls.

Overcurrent protection

For safety and compliance with regulations, battery overcurrent protection is required. Fuses and disconnects must be siz ed to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability.

Table 2-2

Inverter Model

2524 134 167 #2/0 A W G

2548 67 84 #2/0 AWG

4024 214 267 #4/0 A W G

4048 107 134 #2/0 A W G

5548 147 184 #4/0 A W G

Recommendced Battery Cable Size Versus Length

Maximum Continuous

DC amps

a. “Maximum Conti nuou s DC amps ”, as show n in th is table , is bas ed o n low

battery vo ltage with an efficiency of 85%.

b. “NEC amps”, as shown in this table, is based on low battery voltage, and

efficiency of 85%, and a 125 % NEC de rating.

NEC

amps

Up to 5 Feet

One-way

(67.4 mm

(107 mm

(67.4 mm

(107 mm

)

Up to 10 Feet One-way

#4/0 AWG (107 mm2) #4/0 AWG (107 mm2) #4/0 AWG x 2 (107 mm2 x 2) #4/0 AWG (107 mm2) #4/0 AWG x 2 (107 mm2 x 2)

Up to 15 Feet One-way

Not Recommended

#4/0 AWG x 2 (107 mm2 x 2) Not

Recommended Not

Recommended

Xantrex DC175 and DC250

The NEC/CEC requires both overcurre nt protection and a disconnect switch for resi den tia l and commercial electr ic al sys te ms. Th es e item s are not supplied as part of the invert er. However, Xantrex offers a DC circuit breaker disconnect module specifically designed for use with Xantrex

2–14 976-0043-01-02

Pre-Configuration Planning

inverters to meet NEC/CEC compliance. Two amperage ratings are available: a DC250 (250 a mps) and a DC175 (175 amps) in either singleor double-pole config urations for single or dual inverter installations.

See “DC Disconnect Boxes (DC175/DC250)” on page 2–24 for additional infor mation on the Xantrex DC175 and DC250.

After selecti ng battery cables based on the distance from t he battery bank to the inverter, add battery overcurrent protect ion in t he battery c able l ine, based on Table 2-3. This table will help you to determine your maximum breaker/fuse siz e base d on the cable size you selected previously.

Table 2-3

Cable Size Required

#2/0 (00) AWG 175 Amps 175 Amps 265 Amps #4/0 (0000) AWG 250 Amps 250 Amps 360 Amps

Battery Cable to Maximum Breaker/Fuse Size

Maximum Rating in Conduit

a. The term “free air” is defined by the NEC/CEC as cabling that is not

enclosed in a conduit or a raceway. Cables enclosed in conduit or raceways ha ve subs tantial ly lower co ntin uous curre nt carr ying abil ity du e to heating factors.

b. The NEC/CEC allows rounding to the next highest standard fuse size

from the cable rating (i.e., 150 amp cable size rounds up to a standard 175 am p size).

Breaker/Fuse

Size

Rating in “Free Air”

Maximum Breaker/Fuse

Size

300 Amps 400 Amps

Fuse Block (TFB) Some installations may not require condu it(s) or a disconnect device,

however, overcurrent protection is still required. Xantrex offers a fuse block (TFBxxx) providing the cod e-required inverter overcu rre nt protection for these applications. These fuses are available in 110, 200, 300 and 400 amp sizes.

Important: From this point on in this guide, any reference made to a “DC

disconnect” means either a DC breaker or a fuse with a disco nnect switch, which will depend on your specific type of installation.

Battery Requirements for Dual Inverter Systems

The success of “stacked” or “dual” inverter systems is dependent on the quality and maintenance of the DC connections. Stacked inverter se ts are far less forgi ving to long, undersized, uneven, and/or poor connections than are single inverte rs.

Dual inverters (not stacked)

976-0043-01-02 2–15

Dual inverter configurations can be used without using the stacking interface cabl e. In this conf igura tion, two inv erter s separate ly run isol ated loads from the same battery bank or individual battery ba nks.

System Configuration

Series stacked When inverters are “s ta cked ” t hey mu st ope rate fro m a com mo n b at tery

bank. In other words, the DC negative of one inverter must be common with the second inverter and likewise for the DC positive.

For example:

If you have eight 6-volt batteries in a 24-volt configuration, they would be arranged in two rows of four batteries (see Appendix C for diagrams of various arrangements).

The negative e nds of the two “strings” of batteries must be jumpered together to become common with each other.

Likewise, the positive ends of the two “strings” must also be jumpere d together so that they are also common with each other.

Shunts near the inverter

Losses from the cables will cause each inverter to measure slight differenc es in actu al voltage s, in spite of hav ing the batte ry bank common to both inver ters. I t is e asy t o have the DC negative s common c loser to the inverters if an in-line mete ring shunt is installed near the invert ers before the negative cables att ach to the negative battery terminal.

Jumpers The use of optional bonding jumpers can improve how each inverter

measures the DC voltage. These measurements are used to determine when charging amperage s should be reduced as the batteries become charged. The bonding jumpers allow the inverte r s to agree better on what the voltage actuall y is. The longer the DC cables are, the more likely you will need bonding jumpers.

Shunts near the batteries

If a shunt is installed closer to the battery bank than the inverters, a bonding jumper should be in stalled from one inverter’ s negative terminal to the other inverter’s negative terminal. By using a negative bonding jumper and/or a metering shunt near the inve rters, the inverters will have a better zero volt (DC negative) reference to measure the DC voltage.

DC disconnects The DC positive is more dif ficult due to the need to ha ve DC disconnects

in each cable for the inverters. The primary reason for the DC disconnects is for overcurrent protection for the cable it is installe d in. By usin g a positive bonding jumper the inverters will have a more accurate DC positive referenc e to measure the DC voltage.

Bonding Jumpers A bonding jumper may be installed from one inverter’s positive terminal

to the other inverter’s positive if a warning is placed near the DC disconnects. This means that either DC disconnect can energize both inverters whil e the othe r DC di sconnect is not ye t turne d on. This is ca lled “backfeeding” a disconnect or circuit breaker. The 2002 NEC, Section 404.6, C, Exception, allows switches to be backfed if a warning such as the follo wing is permanently ma rked on or ad ja cent to the

2–16 976-0043-01-02

Pre-Configuration Planning

disconnect switc hes. A sample of this warning label is provided in Figure

2-2. These labels are not available or provided by Xantrex, but may be

available from your local electrical warehouse.

DC disconnects and overcurrent devic es

WARNING: Shock Hazard

Load side terminals may be energized by backfeed.

Figure 2-2

Sample Warning Sticker for Backfeed Conditions

The size of the bonding jumper must be the same gauge as that of the primary battery cable in whic h the overcurrent device (DC disconnect) is

Not provided by Xantrex. May be available a t yo ur loca l electrical warehouse.

installed, and as always, the overcurrent device must be sized appropriately fo r all cable s attached to it. If one overcurrent devi ce trips then there will be only half the amount of current available for both inverters to run f rom. If you want to run only one inverter while the othe r is shut down (for example, for maintenance procedures), the positive bonding jumper must be removed or there must be an appropriatel y sized switch installed in the bonding jumper .

Battery Temperature

Cold temperatures Cold temperatures dras tically reduce battery capacity and performance.

Therefore, the batte ry enclosure shoul d provide a fairly st able temperature for the batter ies. If batter ies are in sta lled in a cold environment, insul ation should be installed to protect the batteries from the cold. The insulation will act as a barrier to the cold an d also keep s the heat ge nerat ed by th e batteries inside the enclosure providing a more stable temperature and better system performanc e .

Hot temperatures High battery temperatu res shor ten the life of the batteries. The battery

enclosure should not be insta lled in direct sunlight where the sun can overheat the batteries. Locate the enclosure where it will be protected from the sun and provide vents in the top and bottom of the enclosure to provide air flow throughout the enclosure.

For best performance, locate the batteries where they are in a room temperature of 20 to 25 °C (68 to 77 °F)

Battery temperature sensor

A Battery Temperature Sens or (BT S ) is pr o vided with eac h Sin e Wave

Plus. This sensor can easily be installed in the system to ensure pr oper

charging of the batterie s based on te mperat ure. I nstalli ng a sensor exte nds battery life by prevent ing overcharging in warm temperatures and undercharging in cold temperatures.

976-0043-01-02 2–17

System Configuration

See “Installing the Battery Temperature Sensor (BTS)” on page 3–18 for instructions on installing the Battery Temperature Sensor.

Wiring Considerations

Important:

grounding and bonding requirements specific to the intended system. All wiring and installation methods should conform to applicable ele ctrical codes and building co des .

Be sure to consult the local and national electrical codes to confirm

Conduit boxes For maxim um safety an d, in s ome cas es, for code- compli ance, run the AC

and DC cables in conduit(s) . Pre -plan the wire and conduit runs carefully before installing a ny components.

Main AC distribution pan el (utility fed)

The AC1 input to the inverter requir es a 60-amp breake r maximum be installed into the main AC distribution panel (double-pol ed if stacked) to protect the wiring in accordance with NEC. This breaker supplies utility grid power to the inverter. AC1 is not used in off-grid applications.

Generator disconnect switch

Installing a discon nect switch with an appropriately sized circuit breaker (60 amp maximum) between the generator and inverter provides overcurrent protection f or the wiring between the generator and the inverter’s AC2 terminal. This is also a good safety practice as it also provides a means to prevent the inverter wiring from becoming energized in the event that an electric-start generator starts unexpectedly while the inverter is being serviced.

Subpanel/Inverter Panel

In on-grid applications, loa ds backed up by the inve rter will need to be rerouted from the main AC distribution panel to a subpanel. In off-grid application, the inverter pa nel functions as the main electrical panel. Always use properly rated cir cuit breakers.

WARNING: Fire Hazard

Check existing structure wir ing for “mul ti- branch wiri ng”. For new cons tructi on, do not use “multi-branch wiring”. For both cases refer to Appendix F, “Multi-wire Branch Circuit Wi ring” for addi ti on al info r m a tion.

Fuses and/or DC disconnects

2–18 976-0043-01-02

Install a DC disconnect brea ker or fuse in the positive, ungrounded, battery line. This breaker protects the DC wiring in the event of an acciden tal short. Size the brea k e r in acc o r d a n c e with t h e batt er y c a b l e s . Switch this breaker OFF (or remove the fuse) whenever servicing the batteries or inverte r(s).

Pre-Configuration Planning

Note: A fuse with out a s witchable disconnect alone does not mee t

NEC/CEC code.

Wire size for AC connections

A minimum of #6 AWG THHN wire is recommended for all AC wiring (input and output).

Wiring scenarios Determine all wire r outes both to and from the inverter and which

knockouts are best suite d for connec ting the AC conduits. Possible routing scenarios inc lude the following.

• AC and DC grounds to an external ground rod

• AC input wiring from the main service panel to the inverter/charger (on-grid applica tions only)

• AC input wiring from the generator to the inverter/charger (if used)

• AC output wiring from the inverter /charger to the subpanel

• DC input wiring from the PV array to the controller/batteries

• DC input wiring from the batteries to the inverter/charger

• BTS cable from the batteries to the inverter/charger (ke ep separate from battery cables)

• Remote ICM cab l e to the invert er/ charger (if used)

• Load circuit wiring rer outed from the main service panel to the subpanel (on-grid appl ications only)

Important:

cuts in the walls. Cut holes in the walls at a ppr opriate locations for ro uting wiring/cables.

Check for existing el ectrical wiring or plumbing prior to making

Generator Considerations

Important: The information co ntained in this guide is basi c wiring

information whic h can aid the genera tor manufacturer or electrician in assisting with your installation. Xantrex is not responsible for providing deta iled tech nical support or wiring instructions for generator operation.

Purpose An engine generator can be used as follows:

• as an input power sou rce instea d of (or in conjunc tion with) the util ity power

• as a backup power source (connected with additional hardware) to automatically power the loads when utility is not present (utility outage)

• as a means to charge the batteries.

976-0043-01-02 2–19

System Configuration

Stable Voltage The generator should provide a stable voltage and frequency output for

the inverter to synchroniz e with. AC wind turbines and small scale AC water turbines are not

recommended for use as AC power sources as they may not be able to provide a stable volta ge and frequency as loads and charger requirements change. The only w ay to pr acti cal ly use sources such as these is to tak e the AC power and rectify it into DC. Be sure to include a diversion type controller (e.g., Xantrex C-Series) to protect the batteries from overcharging.

Types of Generators

There are AC generators and DC generators.

AC Generators AC generators can power AC loa ds and charge batteries. An AC

generator is bett er suited for resident ial appl ications, since th e majority of loads require AC power.

DC Generators DC generators can power DC loa ds and charge batteries. In a r esidential

application, DC generators are primarily used to charge the batteries.

Output Requirements

An AC generator can output 120 Vac only, 120 Vac and 240 Vac together, or 240 Vac only depending on the overall needs of the system. The generator must be large e nough to provide adequate power to charge the batteries and support a certain amount of AC loads. I f the generator is not large enough, the amount of time it takes the inve rter to charge the batteries will incr ease.

A DC generator is used primarily to charge the batteries. AC loa ds are only powered by the energy stored in the batteries. The generator must be large enough to provide adequate power to charge the batteries.

Generator start types

Starting type s Generators can either be manually starte d, or when properly equipped,

automatically started. The Sine Wave Plus can operate well with either kind of generator. It is recommended, however, to consult the desired generator’ s manufacturer to ensure the generator of choice is best suited for the desired application.

Manual-start and electric-start generators

When using a manual-start or electric-start generator, the generator is connected to the inverter AC2 input but is not controlled by the inverter. The starting and stopping of the generator occurs at the generator. Manual-start genera tor s are started with a recoil-star t pull cord. Electricstart generators are started by turning an ignition/starter key, switch, or similar means.

2–20 976-0043-01-02

Pre-Configuration Planning

Manual-start and electric-start generators typically do not have selfprotection feat ures to shut down the generator in the event of low oil pressure, over -heating , overcranking, etc. , and, therefore , are not designed for unattended starting and operation.

If using a manual-start or electric start generator, be sure that the generator is located where it can be easily accessed to be started.

Auto-start generators

Starting requirements

When using an auto-start generator, the generator is connected to the inverter AC2 input. The inverter controls the operation of the generator with the assistance of the optional GSM. Auto-start generators are equipped with terminals for signal wires to be routed and connected to a remote switch/r elay (a "dry contact") to signal the generator to run and/or stop.

Auto-start gener ators are equipped with se lf- protect ion feature s to dis able starting and/or to shut down a generator in the event of low oil pressure, over-heati ng, over crankin g, etc. Whe n generator s are equippe d with these protection features, they are designed for unattended starting and operation and may be compatible with the Sine Wave Plus with the optional GSM.

Be sure to locate an auto-s t art g enerator in a place prot ected from extremes of temperatur e so it can successfully start and operate without assistance.

Important:

only function on generator s equippe d with two- or three-wi re auto-sta rt operat ion. Most auto-start gene rators have this feature. Check with your generator suppl ier and make sure this feature is available. Additional hardware may be required.

The automatic generator start feature of the Sine Wave Plus can

The generator can be set to start based on four different, user-specified, scenarios w ith differe nt req u irements for each:

• battery voltage

• inverter load current

• time of day

• exercise time

If used with an application that includes utility powe r, the generator will be started only if utility power is not available, as it is not possible to use both generator and utili ty power at the same time (except for the scheduled exercise time).

It is safe for both the utility an d gener ator inputs to be energized at the same time, although the inverter can only take power from one source at any given time.

976-0043-01-02 2–21

System Configuration

See “Generator Starting Scenarios” on page 7–23 of this guide for specific instructions on setting the generator-start/stop conditions.

Additional/Optional Equipment Considerations

The following components are available for use with the Sine Wa ve Plus. Some of these items may be required depending upon the intended use of the inverter to make the instal la tion code-compliant. These components are not provided with the invert er and must be purchased separately.

Important: Be sure to consult with your local inspe ctor and/or utility

compa n y to en su r e co mplete co mplian ce wi th lo c a l regu lations .

AC Conduit Box (ACCB)

The AC Conduit Box (ACCB) connects to the AC side of the inverte r and accepts AC condui t runs. The AC c onduit box incl udes bypa ss/disc onnec t breakers.

Figure 2-3

2–22 976-0043-01-02

AC Conduit Box

DC Conduit Box (DCCB)

The DC Conduit Box (DCCB) connects to the DC side of the invert er and accepts DC conduit runs.

Additional/Optional Equipment Considerations

Figure 2-4

Figure 2-5

976-0043-01-02 2–23

DC Conduit Box

Sine Wave Plus with AC and DC Conduit Boxes Installed

System Configuration

Fuse Block

The Xantrex fuse block (TFBxxx) pro tects the power system’s DC wiring should an overcurrent cond ition occur. The fuse block is placed between the battery’s ungrounded conductor (usually the positive cable ) and the DC input terminal of the inverte r.

The fuse block includes a fast acting, current limiting class-T fuse providing extremel y fast protec tion when a short circuit oc curs. Whe n the fuse is properly matched to the syst em curr ent, its time delay allows the inverter to surge to f ull power without blowing the fuse. A plastic cover prevents accidental short circuits to the fuse terminals. Fuse sizes include 110, 200, 300, and 400 amps.

There are two types of fuse blocks available. The TFBxxxC fuse block has “set” screw lugs for cables with no termin al connector’s on the ends (known as C-type or s tripped- end batt ery cable s). The TFBxxx f use block has stainless steel bolt connections for cables with ring terminals (known as ring-lugged battery cables). Both fuse blocks include a black poly carbonate, fibe rglass reinforced base and a clear poly carbonate snap-on cover.

Fuse Block for C-type (stripped end) Battery Cables (TFBxxxC)

Figure 2-6

Fuse Blocks

Fuse Block for Ring-l ugged Battery Cabl es (TFBxxx)

DC Disconnect Boxes (DC175/DC250)

Xantrex provides two options for disconnect boxes. The DC175 and DC250 protects your batter ies, inverter, and DC cables from damage caused by short circuits an d overloads through use of a UL listed, high interruption capa city circuit breaker. This breaker is designed to interrupt the tremendous amount of power a batter y can deli ver when short circuited. It is also de signed t o have a long e nough time de lay to allow th e inverter to surge to full power without nuisance tripping of the breaker. If the breaker does trip, it’s easily reset.

2–24 976-0043-01-02

Battery Status Meter (TM500A)

The TM500A features six data monitoring f unctions and three indicators including:

• State-of-charge/amp-hour c ontent (full or percent of capacity)

• State-of- charge/voltag e (real-time voltage level, hist orical high and low system voltage)

• Amps (real-time amps, total charging amps, total load a mps)

• Amp hours removed

• Days since fu lly ch arged

• Cumulative amp hours

• Recharge indicator

• Low-voltage indicator

• Full-charge indicator

The unit is configurable for specific system or application functions such as setting the CHARGED indication para mete rs, battery capacity, charging efficiency, low-battery warning conditions and a recharge reminder. The TM500A can monitor any battery supply from approximately 8 to 65 volts, track energy consumption, and estimate remaining battery life.

Additional/Optional Equipment Considerations

The TM500A operates on 12-, 24-, or 48-volt bat tery systems (48-volt systems require an optiona l shunt board).

DC250

TM500A

Figure 2-7

DC250 Disconnect Box and TM500A Battery Status Meter

976-0043-01-02 2–25

System Configuration

Remote Monitors

Three options are available for remote control and monitoring.

• Use a remote ICM, which is identical to the inverte r control module display on the inverter, for distances of 25 or 50 feet (7.5 or 15 meters).

• Use a personal computer to monitor system status using an optional ICA (for distances up to 50 feet/15 meters). The ICA can be used with cables up to 500 feet (152.4 meters). These longer cables, however, are not provided by Xantrex.

• Use a personal computer off-site to monitor the system using an external modem at the inverte r site and the ICA.

Note: The ICM and the ICA use the s ame input port on the inverter. Both of

these options cannot be used at the same time.

Inverter Communications Adapter (ICA)

(for use with a personal computer

at distances up to 50 feet)

Invert e r Co n t ro l M o dule (ICM) (for distances of 25 or 50 feet)

Note: For distances greater than 500 feet, a modem is required on sit e

Figure 2-8

Accessories for Remote Monitoring

CAUTION: Damage to Equipment

Never connect a gr ounded P C to the Remote Port if the in vert er is conf igur ed i n a positive grou nd arrangement. Connecting a grounded PC to this port (in this configuration) will damage both the PC and the inverter. Xantrex will not c over damages to the PC or honor warrant y cla im s on the inverter under these circumstances.

2–26 976-0043-01-02

Inverter Control Module (ICM)

The remote ICM allows control, monitoring, and adjustment of all inverter sett ings from a locatio n oth er t han the I CM di splay o n the front of the inverter. The remote ICM comes with c ables in lengths of 25 feet (7.5 meters) or 50 feet (15 meters). The remote ICM duplicates all the functions and controls of the ICM display on the front panel of the unit.

For distanc es gre at er tha n 50 feet (15 mete rs ), see the Inverter

Communications Adapter (I CA).

Additional/Optional Equipment Considerations

Figure 2-9

Inverter Control Module

Inverter Communications Adapter (ICA)

The ICA allows the inve rter t o be con n ected dire ct l y to a PC for monitoring and adjustmen t. The ICA comes with a 50-foot cable. The ICA can also be used up to 500 feet away, but additional cabling will be needed and Xantrex does not provide longer c ables at this time. It may also be operated remotely with the addition of a modem at the inverter site.

Figure 2-10

Inverter Communications Adapter

CAUTION: Damage to PC

Do not connect a PC to the invert er when it is configured in a posi tive ground system. Damage t o the PC and t he inve rter may occ ur which i s not c overed und er warranty.

976-0043-01-02 2–27

System Configuration

Generator Start Module (GSM)

The GSM is an accessory that enables the inverter to start and stop generators equipped with a uto-start features.

Figure 2-11

See “Generator Considerations” on page 2–19, for info rm at ion on usin g generators and Appendix D, “Generators” for additional information regarding generator types.

Auxiliary Load Module (ALM)

The ALM is an acce sso ry that enables the inve rt er to sta rt and stop auxiliary loads such as ala rms, water pumps, or ventilation fans.

Figure 2-12

Generator Start Module

Auxiliary Load Module

See “Auxiliary Load Module (ALM)” on page 3–42 for additional information regar ding connecting the Auxiliary Load Module to the inverter.

2–28 976-0043-01-02

Additional/Optional Equipment Considerations

240 Vac Application Requirements

There are two options available for creating 240 Vac output using a 120 Vac inverter:

• using an autotransfor mer to step-up or step-down the voltage, or

• stacking two identical inverters.

Autotransformer for 240 VAC Applications (T240)

The T240 allows a single inverter to increase it’s output voltage from 120 volts to 240 volts or it will take 240 Vac from a generator and “stepdown” the voltage to 120 Va c for the single inverter . For step-up and stepdown functions, two T240s will be required.

A T240 Autotransformer can optimi ze the generator output of smaller generators (<

3.9 kW) and improves charging time.

Figure 2-13

T240 Autotransformer

Inverter Stacking Control – Series (ISC-S) Cable

The ISC-S cable is a special communications cable that allows two Sine

W ave Pl us inver ters to be conne cted tog ether in “seri es” to provide power

to both 120 Vac loads and 240 Vac loa ds. See the ISC-S Owner’s Guide for more information on stacked inverter

applications.

Figure 2-14

976-0043-01-02 2–29

ISC-S Cable

System Configuration

Renewable Energy DC Input Sources

Renewable energ y (RE) sources (for example, photovoltaic (PV) arrays, wind turbines, DC micro-hydro ge nerators) can be used with the inverter to provide power for all applica tions—off grid and on grid. However, in addition to the actual RE equipment be ing used, other items may be needed to ensu re safety in the overall syst em , suc h as charge cont rol l ers, diversion load controllers, and/or PV ground fault protection.

Important: Be sure to consult your authorized dealer and all local/national

electric codes to determine what additional equipment may be req uired for your installation.

Important: Installations of this equipment should only be performed by

skilled per sonnel such as qualified electricians a nd Certified Renewable Ene rgy (RE) System Insta llers. For a li st of Xa ntr ex Certifi ed R E dealer s, plea se visi t our website at www.XantrexREdealers.com.

Note:

connected to either of the AC inputs on the inverter/charger. The Sine Wave

Plus cannot control or regulate DC voltages from DC sources. DC charge

controllers must be used for all DC sources such as PV arrays, wind turbines, and water turbines.

The “charger” built into the Sine Wave Plus is only for AC power

Charge contr oller A charge controller must be used to regulate the charge supplied to the

batteries and prevents over-charging (or high ba ttery conditions). A charge controll er prev e nts the bat te ries from ex ce ed i ng a use r-specifi e d voltage level. This preserves and extends the life of the battery by preventing the damage caused by over-charging. The charge controller can also take over the functions of bulk and equalize charging.

Diversion load control

Wind turbines and hydro-electric generators may be damaged if the DC loads are suddenly removed from them. This can hap pen if the DC disconnect should open (tr ip) or the batteries are fully charged and no other DC loads are connected in the syste m. A diversion load controller prevents damage to the generator system by diverting the power from the generator to a diversio n load devic e. This keeps a load on the generator and controls over- spin if the batteries should be disconnected. Refer to the controller manual for proper types of diversion load devices.

2–30 976-0043-01-02

Additional/Optional Equipment Considerations

Figure 2-15

Xantrex C-Series Charge Controllers

PVGFP The PV Ground Fault Protection (PVGFP) is designed to minimize the

possibility of a fire resulting from ground faults in a PV array (in accordance with NEC/CEC for rooftop-mounted PV syste ms on dwellings). It is not designed or intended to prevent electr ical shock or to be used for PV DC ove rcu rr en t .

Figure 2-16

976-0043-01-02 2–31

PV Ground Fault Protection (PVGFP)

System Configuration

Off-Grid Applications

The Sine Wave Plus can be used as a primary source of AC power to support off-grid, stand-alone systems where no utility power is available.

Sine Wave Plus applications in an off-grid situation includ e:

• renewable ener gy systems (with or without generator backup ), and

• generat or-only s ystems

• inverter only systems (charger in the inverter/charger is not used, but batteries are maintained by an external DC charger).

Renewable Energy Systems with/without Generator Backup

In this configuration, the main power is generated by r enewable energy sources, such as solar, wind, micro-hydro or some other form of a regulated DC charging source, and is stored in a ba ttery bank. The Sine

Wave Plus will operate all AC loads from the power stored in this battery

bank. In the event that renewable energy sources are insuff icient to power the

required loads or keep the batteries charged, a generator can be used to supplement the system.

Single-Inverter Configurations (120 Vac)

If only 120 Vac output is required from the system, a single inverter is adequate to provide the requir ed power, depending on the wattage (output) require ments of the total system.

Single-Inverter Configurations (120/240 Vac)

If 240 Vac output is required from the system and the total of the loads does not exceed the wattage output of the inver ter, a step- up autotrans former can be added to the out pu t of the s ystem to increase the voltage output.

See Appendix F, “Mult i-wire Branch Circuit Wir ing”, for more information on using singl e inverters with multi-wire branch circuits.

See Figure 2-17 for an example of both configurations (120 Vac and 240 Vac output) with all optional equipment. Disregard any part of this illustrati on that does not apply to the components being install ed. For purposes of this publication, the main breaker (utility) panel is referred to as the “inverter AC distribution panel” or simply “inverter pa nel”.

2–32 976-0043-01-02

Off-Grid Applications

NOTES:

1. Always refer to yo ur local electric codes for proper wiring i nstructions.

2. For purposes of this illustration, the ground for the AC generator is run through the inverter.

3. Separate grounding runs are show n in this illustration to demonstrate a single point ground.

4. If using a PC to monitor the system, the Xantrex ICA is requ ired. If using a PC to monitor from offsite, an external modem is required at the inverter site.

5. Ensure all the DC negatives in the system are bonded to ear th ground in only one place (single point bond). If you are using a PVGFP, allow this single “DC Nega tive to earth ground bond” to be provided through the PVGVP.

6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-17

Off-Grid Application – Renewable Energy System using a Single Inverter

976-0043-01-02 2–33

System Configuration

Dual-Inverter Configurations (240 Vac)

If 240 V a c power is required and the wattage required exceeds the wattage output of a single inverter, it may be necessary to add a second inverter. Two inverters can be “series” stacked to provide both 120 Vac and 240 Vac, 60 Hz, power to the AC loads .

Note:

This interface cable is connected to the series stacking port of the inverters (see “Inve r ter Stacking Control – Series (ISC-S) Cable” on

page 2–29).

Series stacking is an excel le nt choice for providing power to multi-wire branch circuits where single (120 Vac) inverters may require extensive rewiring within the buil ding.

See Figure 2-18 for an example of this configuration wit h all options shown. Disregard any part of this illustration that does not apply to the system configuration being installed.

Series-stacking inverters require the use of the ISC-S cable.

2–34 976-0043-01-02

Off-Grid Applications

OTES:

. Always refer to yo ur local electric codes for proper

wiring i nstructions.

. For purposes of this illustration, the ground for the

AC generator is run through the inverter.

. Separ ate grounding runs are shown in this

illustration to demonstrate a single point ground.

. If using a PC to monito r the system, the Xantrex

ICA is requ ired. If using a PC to monitor from offsite, an external modem is require d at the inverter site.

5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single point bond). If you are using a PVGFP, allow this single “DC Nega tive to earth ground bond” to be provided through the PVGVP.

6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-18

Off-Grid Application – Renewable Energy System using Dual Inverters

976-0043-01-02 2–35

System Configuration

Generator-Only Systems

In these applic ati ons, an AC g en era tor serves as the main AC sour ce when batteries are insufficient to power the loads. Both an AC and a DC generator can provide a power source for the battery char ger. With the aid of the Xantrex Generator Start Module (GSM), the Sine Wave Plus can turn on automatically most remote-starting generators, on de mand.

See “Generator Considerations” on page 2–19 and Appendix D,

“Generators” for additional information regarding using generators for

system input.

Single-Inverter Configurations

A single-inverter system is usually adequate to power most 120 Vac loads. If 240 Vac is required from the system and doesn’t exceed the wattage output of a single inver ter, a step-up auto transformer can be added to the output of the system to increase the voltage output.

See Figure 2-19 for an illustration of a 120 Vac generator-only system using a single inverter. Disregard any part of this illustration that does not apply to the system configura tion being installed.

2–36 976-0043-01-02

Off-Grid Applications

NOTES:

1. Always refer to yo ur local electric codes for proper wiring i nstructions.

2. For purposes of this illustration, the ground for the AC generator is run through the inverter.

3. Separate grounding runs are show n in this illustration to demonstrate a single point ground.

4. If using a PC to mo ni to r the syste m, the Xantrex ICA is req uired. If using a PC to monitor from offsite, an external modem is required at the inverter site.

6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-19

Off Grid Application - Generator-only System using a Single Inverter

976-0043-01-02 2–37

System Configuration

Dual-Inverter Configurations

Note:

interface cabl e is connected to the series sta cking port of the inverters (s ee

“Inverter Stacking Control – Series (ISC-S) Cable” on page 2–29).

Series stacking is an excel le nt choice for providing power to multi-wire branch circuits where single (120 Vac) inverters may require extensive rewiring within the buil ding.

See Appendix F, “Mult i-wire Branch Circuit Wir ing” for information on identifying and corr ecting multi-wire branch circuit wiring.

See Figure 2-20 for an illustration of a 240 Vac Generator-Only System using dual inverters

240 Vac-only Input Source

Important:

connection but no neutral ) with a dual-inverter configuration, a neutral connection needs to be provide d from the 240 Vac source to the inverter’s common neutral.

Series-stac king inverters require the use of the ISC-S cable. Thi s

When using a 240 Vac-only input source (with a L1 and L2

2–38 976-0043-01-02

Off-Grid Applications

NOTES:

4. If using a PC to monitor the system, the Xantrex

1. Always refer to your local electric codes for proper wiring in structions.

2. For purposes of this il lustration, the ground for the AC generator is run through the inverter.

3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.

ICA is requ ired. If using a PC to monitor from offsite, an external modem is required at the inverter site.

5. Ensure all the DC negatives in the system are bonded to earth ground in on ly one place (si ngle point bon d). If you are using a PVGFP, allow this single “DC Negative to earth ground bond” to be provided through the PVGVP.

6. If this is not a separ ately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-20

Off Grid Application – Generator-only System using Dual Inverters, Series-stacked

976-0043-01-02 2–39

System Configuration

On-Grid Applications

The Sine Wave Plus can be combined with utility power to provide backup power in the event of a primary power source failure. It can use utility power to backup renewable energy systems. It can use renewable energy and/or a genera tor to backup utility grid power. It can be used as an energy management tool to optimize energy consumption.

Backup Systems

Renewable Energy Backup (BX Mode)

Utility Backup (SB Mode)

This config urat ion u se s rene w abl e en ergy sour ces as the prim ary s our ce of power to operate the AC loads and grid power as an automatic backup source.

In this configuration, the utility grid is the main source of power. The energy stor ed in the batter ies only provide bac kup power in the e vent of a grid failure. Batteries can be charged by the utility grid when available, RE sources, or with a backup generator.

Single-Inverter Configurations (120 Vac)

If only 120 Vac output is required from the system, a single inverter is adequate to provide the requir ed power, depending on the wattage requirements of the total system.

See Appendix F, “Mult i-wire Branch Circuit Wir ing”, for information on multi-wir e bran ch circu i ts.

Single-Inverter Configurations (240 Vac)

See Figure 2-21 for an example of a single inverter configuration for either 120 Vac or 120/240 Vac output. Disregard any part of this illustrati on that does not apply to the system configur ation being installed.

2–40 976-0043-01-02

On-Grid Applications

NOTES:

5. Ensure all the DC negatives in the system are

1. Always refer to yo ur local electric codes for proper wiring i nstructions.

2. For purposes of this illustration, the ground for the AC generator is run through the inverter.

3. Separate grounding runs are show n in this illustration to demonstrate a single point ground.

4. If using a PC to monitor the system, the Xantrex ICA is requ ired. If using a PC to monitor from offsite, an external modem is required at the inverter site.

bonded to ear th ground in only one place (single point bond). If you are using a PVGFP, allow this single “DC Nega tive to earth ground bond” to be provided through the PVGVP.

6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-21

On-Grid Application – Backup System using a Single Inverter

976-0043-01-02 2–41

System Configuration

Dual-Inverter Configurations (240 Vac)

Note:

interface cabl e is connected to the series sta cking port of the inverters (s ee

“Inverter Stacking Control – Series (ISC-S) Cable” on page 2–29).

Series-stac king inverters require the use of the ISC-S cable. Thi s

Series stacking is an excel lent choice for providing power to multi-wire branch circuits where sta nd-alone (120 Vac) inverters may require extensive rewiri ng within the building.

See Appendix F, “Mult i-wire Branch Circuit Wir ing” regarding multi- wire branch ci rcui t s.

See Figure 2-22 for an example of this configuration showing all the optional equipment. Disregard any part of this illustration that does not apply to the system configura tion being installed.

2–42 976-0043-01-02

On-Grid Applications

NOTES:

5. Ensure all the DC negatives in the system are

1. Always refer to yo ur local electric codes for proper wiring i nstructions.

2. For purposes of this illustration, the ground for the AC generator is run through the inverter.

3. Separate grounding runs are show n in this illustration to demonstrate a single point ground.

4. If using a PC to monitor the system, the Xantrex ICA is requ ired. If using a PC to monitor from offsite, an external modem is required at the inverter site.

bonded to ear th ground in only one place (single point bond). If you are using a PVGFP, allow this single “DC Nega tive to earth ground bond” to be provided through the PVGVP.

6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to earth ground in only one place.

Figure 2-22

On-Grid Application – Backup System using Dual Inverters, Series-stacked

976-0043-01-02 2–43

System Configuration

Energy Management

The Sine Wave Plus can be programmed to contr ol how and when to use utility power. Adva nced features allow for peak load management and time-of-use bill ing. Utility management features also allow the Sine W ave

Plus to use renewable energy sources on a first priority basis and only use

utility power if renewable e nergy is insufficient or unavailable to power the loads.

See “21 Grid (AC1) Usage Menu” on page 7–16 for more information about programming these applic ations.

RE Backup with Utility (SB Mode)

In Standby (SB) Mode, the Sine Wave Plus will automatically use power from the DC source, generated by the RE source, over grid power even when the inverter shows it is “char ging” from the grid. When there is excess DC po wer fro m the RE source, the inverter wi ll aut omat i call y reduce the current draw from the grid and power the loads from RE generated power. During a time wh en load s exceed what the RE can provide, the inverter will automatically bring in enough AC power from the grid to power the loads.

See “SB (Standby) - Utility Backup” on page 7–17 for instructions for setting these paramet ers.

Peak Load Management

Many utilities impose a surch arge on their customers based on the peak load used by a facility . To reduce utility peak demand charges, the inverte r can be configured to limit the maximum draw the AC loads place on the utility. The inverter can be programmed to provide power above a specified level, eliminating the surcharge. When the utility current draw reaches the maximum level, the inver ter assists by providing batter y powered AC to the loads.

See “13A Grid (AC1) Amps AC” on page 6–27 for instructions for setting these paramet ers.

For Peak Load Shavi ng to be effective, all loads must be connected to the inverter. For large loads, multiple (or stacked) inver ters may be required.

To further ensure the batteries are able to supplement the power requirements of the connected load, an additional source of power (solar, wind or hydroelectric) is recommended.

Peak Load Shaving can also be used in addition to the Time-of-Use (TOU) metering.

2–44 976-0043-01-02

Time-of-Use (TOU) Metering

Utilities use TOU mete ring t o dete rmine uti lity char ges dur ing peak us age hours and to impose a surcharge . The inverter can be configured to overcome these peak charges by using a battery (or battery bank) to stor e energy during the inexpensive energy hours and consumes the battery energy during expensive energy hours.

When in this mode, the inverter is programmed to only use utility power during user- specified times during the day. This helps the consumer take advantage of lower utility rates by using power from the battery bank during times that utili ty power is most expensive.

See “21 Grid (AC1) Usage Menu” on page 7–16 for instructions for setting these paramet ers.

Energy management determines when utility power is used. Start and Stop times are progr ammed into Menu Items 21B and 21C depending on when you want the inverter to use utili ty power.

In the example below , Figur e 2-23 shows the inverter disconnects from the utility gri d at 6:00 PM and supports the connect ed load from batte ries. It continues to run until 9:00 PM. It then rec onnects to the utility grid, passing AC through to the connected load, and begins mainta ining the batteries based on the batt ery ch arger settings in the Basic Setup Menu (Float or Silent).

On-Grid Applications

Figure 2-23

GRID USAGE BEGIN

TIME 21:00 (9 PM)

OPERATING

FROM INVERTER

DURING PEAK

UTILITY PERIOD

GRID USAGE END

TIME 18:00 (6 PM)

Time-of-Use Metering

OPERATING FROM

UTILITY GRID AND

BATTERY CHARGING

976-0043-01-02 2–45

System Configuration

AC Load Support

When using the system for TOU metering, the system shoul d be designed with a battery capacity large enough to support the load during the entir e peak rate period without reaching the 11C Low Ba tt ery Cut Ou t VDC voltage.

To further ensure the batteries are able to support the load, an additional source of power (solar, wind or hydroelectric) is recommended. Depending upon the capacity of the syste m, cer tain heavy loads should only be run during non-peak pe riods.

Note: In the event the batteries re ach their 11C Low Battery Cut Out VDC

voltage, the inverter wi ll automatically reconnect to the utility grid to ma intain the connected load.

Note: TOU Mode is usually used in conjunction with a renewable ener gy

system. Often these systems will provide their peak output at the high billing times. Batt ery power used to supplemen t the renewable ener gy used during peak times is replenished during non-peak times.

This feature allows power to be automatically drawn from the batteries to assist either the utility grid or an AC generator support heavy load s (i.e., l oad s th at exc eed the available curre n t from eith er the gene rat or or the utility grid). When the grid or generator requires additional AC current to support the loads, current is drawn from the batteries.

Generators have a limited output curr ent and it is possible to reach this limit when operating heavy loa ds. The Sine Wave Plus is designed to assist the genera tor when heavy c urrent demands lo ad down t he generato r by supplying additiona l power from the batteries. In this way, the generator can ope rate loads heavier than it would othe rwise be capable of running. When the inverter is in this mode, the batteries are not char ging even though the LED indicators on the inverter may indicate the charge mode is on.

In addition, the battery charger can back off its charging current to the batteries so the combined load of the charger and load support does not load down the generator or trip its output breakers or fuses.

AC support paramete rs are controlled by th e 13A Gri d (AC1) Amps AC and or 13B Gen (AC2) Amps AC depending on the application.

2–46 976-0043-01-02

UTIL IT Y o r GENERATOR + INVERTER

SUPPORT VOLTAGE (fro m battery)

On-Grid Applications

Utility Grid or

AC Generator

Figure 2-24

INVERTER/CHARGER

AC Support Mode

BATTERY

HEAVY

AC LOAD

Note: Runnin g and Start-up (Peak) cu rrents are limited to the maxim um

current limits of the inverter.

Note: In the AC support ModeMode, the BULK or FLOAT charge indicator

LEDs may be ON even though the batteries are draining. Use the 04 Me ters Menu heading and 04C INV/CHR Amps AC menu item to vi ew the actual

amperage. A negative reading indicates the inverter is supporting the generator from the batteries.

See “21 Grid (AC1) Usage Menu” on page 7–16 for instructions on setting these paramet ers.

Renewable Energy with Grid Backup (BX Mode)

T o have the inverter operate independently of the grid but use the grid in times of low battery voltage, the inver ter can be set up in the "BX" Mode.

In this mode, the inverter powers the AC loads using the RE sources and only uses AC power from the grid to run the loads when the battery voltage drops below user -specified levels.

When the batteries have recharged to a specified voltage by the renewable energy source s, the inverter transfers from the utility grid to inverter supplied AC power.

See “22 Battery Xfer (BX) Menu” on page 7–18 for instruct ions fo r setting these paramet ers.

976-0043-01-02 2–47

2–48

Installation

Chapter 3, “Installation” describes how to mount and install

the Sine Wave Plus Inverter/Charger and perform wiring and cabling procedures for various configurations.

Installation

Pre-Installation

Before installing the Sine Wave Plus, read all instructions and cautionary markings located in this manual.

Tools Require d

Important:

starting this installation.

Important:

Installations of this equipm ent should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System Installers. For a list of Xantrex Certified RE dealers, please visit our website at www.XantrexREdealers.com.

Be sure to obtain the appropriate permits, if ne cessary, prior to

Installations should meet all local codes and standards.

WARNING: Personal Injury

The Sine W ave Plus is can weight up to 145 lbs. Always use proper lifting techniques and have someone available to ass is t with lifting it during installation to pre v en t p er s o n al injur y.

Although the DC electrical system may be “low voltage”, significant hazards may still be prese nt, parti cularly from short-c irc uits of the bat tery system. Inverter systems, by their nature, involve power from multiple sources (inverter, generator, utility, batteries, solar arrays, etc.) that add hazards and complexity that c an be very challe nging.

The following tools may be required fo r installing this equipment:

❐ Assorted Phillips screw dri vers ❐ Level, pencil, and utility knife ❐ Slotted screw driver ❐ Wire strippers ❐ Assorted open-end wre nches ❐ Torque wrench ❐ Socket wrench and sockets ❐ Electrical tape ❐ Multi-meter (AC/DC volts)

3–2 976-0043-01-02

Hardware / Materials Required

The following materials may be requ ir ed for completing this installation.

❐ 4' x 8' sheet of ¾" plywood for mounting ❐ 2 x 4 boards for mounting ❐ #10 and/or #12 wood screws (or ½" x 1¼" lag bolts) ❐ Conduits and appropriate fittings for wire runs (e.g., wire nuts) ❐ Electrical wire of appropriate size and length ❐ Battery cable lugs (depending on type s of batte ry cables used) ❐ Breaker panels ❐ Ground busses, bars, bonding blocks, and/or rods

Optional System Accessories

The following optional syste m accessories can be used in the installation of the Sine Wave Plus. These accessories are available from any authorized Xantrex dealer. Consult with your local system designer to determine what optional eq uipment will be needed for your specific installation.

Pre-Installation

Conduit boxes:

❐ ACCB with input/output/bypass breakers ❐ DCCB

Battery cables:

❐ BC1.5 (Single) Battery Interconnects ❐ BC2/0 AWG (Pair), available in 5 and 10 foot lengths ❐ BC4/0 AWG (Pair), available in 5, 10, and 15 foot lengths

DC disconnects and fuses:

❐ DC175 (175 Amp DC Disconnect with Bonding Bar) ❐ DC250 (250 Amp DC Disconnect with Bonding Bar) ❐ TFB 200 (200 Amp Class-T Fuse) ❐ TFB 300 (300 Amp Class-T Fuse) ❐ TFB 400 (400 Amp Class-T Fuse) ❐ PV Ground Fault Projection (PVGFP1, PVGFP2, PVGFP3,

PVGFP4)

976-0043-01-02 3–3

Installation

Remote mon i tor s:

❐ ICM/25 (Inverter Control Module wit h 25 foot cable co nnection) ❐ ICM/50 (Inverter Control Module wit h 50 foot cable co nnection) ❐ ICA (Inverter Communications Adapter with 50 foot cable), for use

with your compute r. (Can be used with a modem on site. A modem i s required for dis tan ce s grea te r than 50 fee t .)

Other accessories which might be required:

❐ Generator Start Modul e (GSM) ❐ Auxiliary Load Module (ALM) ❐ C-Series Charge Controllers (C35, C40, C60) ❐ TM500A Battery Sta tus Meter ❐ ISC-S Cable

Battery Bank Preparation

Important:

polarity on the DC input connections will cause permanent damage to the inv erter which is not covered und er warra nty. Always check polarit y BEFORE making connections to the inverter

The inverter is not reverse pol arity prote cted. Reversin g the batter y

Be sure to have read the section titled “Battery Considerations” on

page 2–11 in the pr evious chapter b efor e star ting this pr ocedure. For more

information, see Appendix C, “Battery Information”.

Prepare the battery bank as follows:

1. Determine the type of batteries to be used. See “Battery Types” on page C–2 in Appendix C for information on

types of batteries and their applications.

2. Determine the appropria te battery bank size and battery configuration.

See “Battery Requirements for Dual Inverter Systems” on page 2–15 for information on stacked ( dual ) inverter systems.

See “Battery Bank Sizing” on page C–4 for additional information on calculating batte ry bank size and “Battery Configurations” on

page C–9 for information about how to wire the selected bat tery

configuration.

3–4 976-0043-01-02

Pre-Installation

3. Determine the correct size of battery cables to use. See Table 2-2, “Recomme n dc ed Bat t ery Cable Size Ver s us L eng th ”

on page 2–14 for additional information and recommended battery

cable sizing.

4. Determine the correct size of DC breaker/fuse to use. See Table 2-3, “Battery Cab le to Maximum Break er /F u se Siz e” o n

page 2–15 for additiona l information and recommended DC breaker/

fuse sizing.

5. Color code the cables with tape or heat shr ink tubing. The standard colors for DC cables are red for positive (+) and black for negative ( –).

Important:

inverter. To determine the correct voltage for the system, check the last two digits on the inve rter’s model number. For example, the Sine Wave Plus 2524 is a 24-volt inverter and requires a 24 Vdc battery system.

The battery voltage MUST match the voltage requirements of the

Unpacking and Inspecting the Inverter

WARNING: Personal Injury

Do not attempt to mo unt this unit on the wall by yourself as the unit is too heavy for one person. Have additional help available to assist in lift ing the unit during installation.

Before installin g your Sine Wave Plus Inverter/Charger, perform the following.

❐ Carefully unpack the Sine Wave Plus from its shipping carton. ❐ Inspect for shipping damage and contac t the shipping company if

there is damage.

❐ Verify that all of the following items are present. Plea se call your

authorized Xantrex deale r if any items are missing.

•The Sine Wave Plus Inverter/Cha rger

•The Sine Wave Plus Inverter/Cha rger Owner’s Guide

• The Battery Temperature Sensor

• Battery T erminal Covers (with associated hardware)

❐ Save your proof-of-purchase. This is required if the unit should need

warranty serv ice.

976-0043-01-02 3–5

Installation

❐ Save the original shipping cart on and packing materials. If the

inverter ever needs to be returned for service, it should be shipped in the original c arton. This is also a good way to protec t the inverter if it ever needs to be moved.

❐ Record the unit’s model number, seria l number, and date-of-purchase

in the appropriate locat ions provided on page I–5 in the Warranty and Product Information section at the back of this manual.

• Model Number information can be f ound on the Certification Label located on the AC end of the unit. See Figure 3-1 for the location of the this label.

• Serial Number information c an be found on the Serial Number Sticker located on the inverter rail adjacent to the AC side dual knockouts and terminal acce ss cov er. See Figure 3-2, “Serial

Number Sticke r and Knockout Locations and S izes” on page 3–7

for the location of this sticker.

Serial Number (on rail)

AC End of the Inverter

Figure 3-1

3–6 976-0043-01-02

Certification Label Location

Pre-Installation

Important: The exclamation symbol below the CSA logo on the certification

label indicates the need to add overcurrent protection. It shall be instal led at the battery as part of the installation in accordance with your local electrical code.

Table 2-3, “Batt ery Cable to Maximum Breaker/Fus e Size” on page 2–15

specifies the type and rating of the overcurrent protection needed .

Figure 3-2

Serial Number Sticker and Knockout Locations and Sizes

Knockout Preparation

Remove your choice of knockouts from the chassis to facilitate conduit installati on for wire runs. This is much easier to do prior to mounting the inverter. Figure 3-2 shows the locations and sizes of chassis knocko uts.

Important:

removing the knockouts. Be sure to install bushings or conduits in the knockout holes to protect the wires from damage.

3/4 and 1” Dual-knockouts

Ensure there are no metal shavings left in the inverter after

Serial Number Sticker

3/4 and 1” Dual-knockouts

976-0043-01-02 3–7

Installation

Mounting

Shelf-Mounting

WARNING: Personal Injury Hazard

Do not atte mpt to mount this unit on the wall by yourself. Have additional help available to assist in lifting the unit durin g in stallation.

The Sine Wave Plus can be either she lf-mounted or wall-mounted. Be sure to use appropriate lifting techniques and have extra people available to assist in lif ting the inverter into position whil e it is being secured. Also make sure the supporting surfa ce is strong enough to support the weight of the inverter.

Refer to “Location Considerations” on page 2–5 for information on proper location of the Sine Wave Plus.

Be sure to use all ten mounting holes in a ddition to the four keyhole slots provided for mounting. Just using the keyhole slots will not be suff icient to safely mount the inverter.

T o mount the Sine Wave Plus on a shelf, follow the instructions below.

1. Ensure that the desired shelf location is strong enough to support the inverter weight and allows ad equ ate clearance for ventilati on and access to the indicators and controls.

2. Drill mounting holes in the shelf by one of the followin g methods. Be sure to use all of the inverter mounting holes and keyhole slots for mounting.

a) Using the measurements from Figure 3-3 drill out the mounting

hole locations for the inverter.

b) Create a cardboard template by tracing around the inverter and

marking the mounting holes and keyhol e slots on the cardboard. Use the cardboa rd template t o locate and dri ll the mounting holes.

3. With assistance, lift the inverter into position and install it onto the shelf, using a ppropriately sized lag bolts and washers.

3–8 976-0043-01-02

(10 cm)

1½"

(25 cm) (38 cm)

6½" (165 cm)

21" (533 cm)

16" (406 cm)

Keyhole slots

6½" (165 cm)

1" 1½"

(38 cm) (25 cm)

Pre-Installation

½"

(13 cm)

15 "

(384 cm)

1½"

(38 cm)

Mounting Holes*

*Size = 3/8" (10 cm) Diameter

1½"

(38 cm)

14 "

(365 cm)

Keyhole slots

Mounting Holes*

(25 cm)

2½"

(64 cm)

4 (102 cm)

10½" (267 cm)

17" (432 cm)

18 (467 cm)83"

20" (508 cm)

***NOT TO S C A LE ***

Figure 3-3

976-0043-01-02 3–9

Dimensional Drawing

Installation

Wall-Mounting

Wallboard is not strong enough to support the weight of the inverter, so additional support mus t be added. This can be in the form of reinforcing 2 x 4’s or a half sheet (4 ft x 4 ft) of ¾-inch plywood.

Wall Mounting using 2 x 4’s

The easiest method for securing the inverter to an existing wall is to place two 2 x 4’s horizontally on the wall (spanning at least three studs) and securing the inverter to the 2 x 4’s.

To mount the Sine Wave Plus on a wall, follow the instructions below.

1. Locate the studs and mark their location on the wall.

2. Measure the desired height from the floor for the inverter to be mounted. The height should pla ce the inve rter’ s contr ol module at the operator’s e ye level for easy viewing and setting.

3. Using a level, run a horizontal line. The length of the line must span at least 3 studs.

4. Place a pre-cut 2 x 4 on the marked location and drill pilot holes through the 2 x 4’s and studs.

5. Secure the 2 x 4 with #10 wood screws (length to pe netrat e 1½ inches or more into the studs).

6. Repeat the procedure for the remaining 2 x 4 (paint the 2 x 4’s, if desired, to match the surrounding wall).

7. Drill mounting holes in the 2 x 4 mounting rails by one of the following methods. Be sure to use all of the inver ter mounting holes and keyhole slots for mounting .

a) Using the measurements from Figure 3-3 drill out the mounting

hole locations for the inverter.

b) Create a cardboard template by tracing around the inverter and

marking the mounting holes and keyhol e slots on the cardboard. Use the cardboa rd template t o locate and dri ll the mounting holes.

8. Ensur e that the 2 x 4’s are securely fas ten ed to the wa ll befo re mounting the inverter to them.

9. With assistance, lift the inverter into position and install it onto the 2 x 4’s using ¼ x 1½-inch lag bolts and washers.

3–10 976-0043-01-02

Ceiling

14–3/8"

c-c

Wall studs 16 inche s

on center

Sine Wave Plus

Inverter /Charger

Set Inverter OFF SRCH ON CHG

Pre-Installation

2 x 4

mounting

supports

Figure 3-4

M ounting

Holes (10)

Approx.

4–5 f t

Wall-Mounting Method using 2 x 4’s

Keyhol e Slots

(4)

Wallboard

Floor

976-0043-01-02 3–11

Installation

Wall Mounting using Plywood

Alternativel y, a half sheet (4 ft x 4 ft) of ¾-inch plywood can also be used as a backing, with the inverter mounted directly to the plywood using ¼-inch diameter lag bolts and washers. The plywood must span three studs for adequat e support.

1. Drill the mounting hol es in the plywood sheet by one o f the foll owing methods. Be sure to use all the mounting holes and keyhole slots for mounting.

a) Using the measurements from Figure 3-3 drill out the mounting

hole locations for the inverter.

b) Create a cardboard template by tracing around the inverter and

marking the mounting holes and keyhol e slots on the cardboard. Use the cardboa rd template t o locate and dri ll the mounting holes.

2. Ensure the plywood is securely fastened to the wall before mounting the inverter on it.

3. With assistance, lift the inverter into position and install it onto the plywood using ¼ x ¼-inch lag bolts and washers.

3–12 976-0043-01-02

Ceiling

Wall studs 16 inches

on ce nter

Sine Wave Plu s

Inverter/Charger

Set Inverte r OFF SRCH ON CHG

Pre-Installation

Figure 3-5

Mounting Holes (10)

Wallboard

Wall Mounting using Plywood

Keyhole

Slots (4)

Plywood

Floor

976-0043-01-02 3–13

Installation

DC Wiring

DC wiring includes the following (described in the following locations). ❐ Preparing the Battery bank - See “Preparing the Battery Bank” on

page 3–14.

❐ Preparing Grounding - See “Grounding the DC System” on page 3–

15.

❐ Connecting DC Input Sources - See “Connecting DC Input Sources –

Renewable Energy Configurations” on page 3–18.

❐ Providing over- charge protection. See “Overvoltage Protection using

a Charge Controlle r” on page E-2.

❐ Providing diversion loa ds if necessa ry. See “Diversion Load Control”

on page E-3.

❐ Connecting the Battery Temperature Sensor - See “Installing the

Battery Temperature Sensor (BTS)” on page 3–18.

❐ Connecting “Connecting the Batteries to the Inverter” on page 3–20.

WARNING: Shock Hazard

Ensure that al l AC and DC breakers a re switched OFF before connecting or disconnecting the battery cables and that all sources of power (both AC and DC) are disconnected from the inverter’s inputs.

Preparing the Battery Bank

Prepare the battery bank acc ording to type of battery selected and configure the bat tery bank to optimize volt age out put according t o syste m requirements. See your battery manufacturer’s installation guide for recommendations.

See Appendix C, “Battery Information” for additional information on determining batte ry bank type and configuration.

Run the positive and negative bat tery cables as close to each other as possible by taping them togethe r after all the connections are made. This reduces the eff ects of inductance, improves surge capacity, and reduces RFI and EMI emissions.

Install a DC disconnect between the battery bank and the inverter. Following the manufacturer’s installation instructions.

3–14 976-0043-01-02

WARNING: Fire Hazard

Undersized cab les can ove rheat and melt cr eatin g a fir e hazard when subj ecte d to heavy (peak) loads . Alwa ys use a properly sized cable and length rated for the amperage of the inverter and batteries.

Grounding the DC System

WARNING: Shock Hazard

Always attach ground leads before attaching AC or DC power connections.

The inverter’s chassis ground lug (see Figure 3-6) is used to connect the chassis of the inverter to the DC grounding system. The terminal accepts wires from #14 AWG to #2 AWG.

DC Wiring

Chassis Ground Lug

DC End of Inverter

Figure 3-6

Chassis Ground Lug Location on Inverter DC End

The Xantrex DC175 and DC250 have optional grounding bloc ks to simplify grounding proce dures and can be used as the DC disconnect as shown in Figur e 3-7 on page 3–16.

976-0043-01-02 3–15

Installation

Single Inverter To ground a single inverter:

1. Connect the ground bond in the DC disconnect to the pri mary grounding electrode , in a ccor dance with local and national electric al codes.

2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconnect.

3. Connect an appropriately sized GROUND wire from the Chassis Bonding Lug on the inverter DC end to the ground bond inside the DC disconnect.

Figure 3-7

3–16 976-0043-01-02

DC Grounding of a Single Inverter

Dual Inverters To ground a dual-inverter configura ti on:

1. Connect the ground bond in the DC disconnect between the inverters and the batteries to the primary grounding electrode, in accord ance with local and na tion al el ect rical codes.

2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconnect.

3. Connect an appropriately sized GROUND wire from the Chassis Bonding Lug on the L1 inver ter DC end to the ground bon d inside the DC disconnect.

4. Connect a second appropriat ely sized GROUND wire from the Chassis Bonding Lug on the L2 inverter DC end to a diffe rent terminal in the ground bond insid e the DC disconnect.

DC Wiring

Figure 3-8

976-0043-01-02 3–17

DC Grounding of Dual Inverters

Installation

Connecting DC Input Sources – Renewable Energy Configurations

Renewabl e energy s o urces (e. g., PV arr ay s, w ind turb in es etc.) m ay require additiona l equipment such as charge controllers, diversion load controllers, PV Ground Fault Protection, and additional fuses and/or disconnects. Since every configuration is unique, spec ific installation instructions cannot be provided. Follow your m anufacturer’s instructions for installation of these components.

Be sure to consult your loc al aut hority to ensure code compliance for your configuration.

Installing the Battery Temperature Sensor (BTS)

Install the sensor on the side of the batte ry below the electrolyte level so as to measure the average battery temperature. If using multiple charging devices (invert ers and charge controlle rs) , instal l all sensors together with each other so they all measure the same temperature. It is best to mount the sensor(s) between the batte ries in an insulated box to reduce the influence of the ambi en t te mperature outsi de the b atte ry enclos u re . Ventilate the battery box at the highest point to prevent hydrogen accumulation.

To install the BTS, follow the steps below.

1. Run the BTS wire in the DC conduit (if used) and route the RJ1 1 connector end (via one of the knockouts) to the BTS port located on the DC end of the inverter.

2. Secure the sensor to one of the batteries located in the center of the battery pack.

3. If other devices are using battery temperature sensors, place al l of them on the same battery so that they all measure the same temperature.

3–18 976-0043-01-02

Xantrex Technology SW Plus 4048, SW Plus 4024, SW Plus 2548, SW Plus 2524, SW Plus 5548 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Sine Wave Plus Inverter/Charger

About This Manual

Purpose

Scope

Audience

Organization

Conventions Used

CAUTION

Related Information

Important Safety Instructions

Explosive gas precautions

FCC Information to the User

Contents

Figures

Tables

Introduction

Basic Features

Front Panel

AC Side

Emergency Power Off (EPO) Option

Certification Label

DC Side

Battery Temperature Sensor (BTS)

System Configuration

Pre-Configuration Planning

Importance Pre-configura tion planning is essential to ensure opti mal performance for

Types of Applications

Important: Be sure to consult with your local utility company and/or permit

Important: Installatio ns of this equipment s hould only be performed by skille d

System Considerations

System output How much power will be required and how it will be produced:

System input What are the sources of power for your system:

Location What are the safe, physical environmental requirements for your

Grounding What methods of protecti on and grounding are required:

Battery What kind of DC storage will be used:

Wiring What is needed/require d for the AC and DC wiring for this installation:

Generato r Will a generator be used:

Important: Auto-start generators require the addition of the GSM to enable

Additional equipment

System Output Requirements

Determination Dete rmine the inverter output size requirements by calculating the

More information See Appendix C, “Understanding Amp-hour Requirements” for

System Input Requirements

Determination Determine the input r equirements based on the output requirements. In

More information See “Generator Considerations” on page 2–19 and Appendix D,

Location Considerations

Avoid saltwater Exposure to saltwater is particularly destructive and potentially

Close to battery bank

CAUTION: Damage to Inverter

RFI Interference Inverters can generate radio frequenc y interference (RFI) . Loc ate any

Electromagnetic Interference

Fire Safety All Sine Wave Plus inverter/chargers meet UL fire safety standards as

Mounting Considerations

Method The inverter can be mounted on a ve rtical surface (or wall) or on a shelf.

Securing The mounting surf ace (wall or shelf) must be capable of suppor ting twice

Ventilation Requirements

Location Install the inverter in a well-ventilated area/enclosure for proper

Requirements Provide a minimum clearance of 6 inches (12 inche s is pref erred) around

Airflow clearance All air ventilatio n openings should have 6 inches of clearance and there

Screening The unit is equipped with screening to pr ev ent insects and rodents from

Grounding Considerations

Types Whether you are installing a new system or integrating new parts into an

Important:

DC System Grounding

Systems The Sine Wave Plus can be used in either a positive or negative grounde d

Positive grou nd In a positive ground, the positive conductor from the battery bank is bonded to earth ground. This arrangement is most often used in telecommunications systems where an isolated ground is a requirement.

Negative ground In a negative ground, the nega tive c onductor f rom the battery bank is bond ed to earth ground. This is the most common form of grounding methods used for residenti al and commerc ial applic ations. The

Convention The remainder of this guide will ass ume the negative ground convention.

Important:

Inverter Grounding

Requirement The inverter/charger should be connected to a grounded, permanent

Conductor size The size for the grounding conductor is usually based on the size of the

Equipment or Chassis Grounding

Grounding Electrodes/Ground Rods

Purpose The purpose of the grounding electrode (often called a ground rod) is to

Size The size for the conductor to the grounding electr ode or grounding system