Related Manuals for Xantrex DR1512W
Summary of Contents for Xantrex DR1512W
- Page 1 DR1512 DR2412 DR1524 DR2424 DR3624 DR1512W DR1524W DR1512E DR1524E DR1548E DR2424E Installation and Operations Manual DR Inverter/Charger...
- Page 3 DR Inverter/Charger Installation and Operation Manual...
- Page 4 About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
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Page 5: Specifications Of The Dr Inverter
About This Manual Purpose The purpose of this Installation and Operation Manual is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the DR Inverter/Charger. Scope The Manual provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the unit. -
Page 6: Conventions Used
Abbreviations and Acronyms DR Inverter PVGFP Related Information You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com. These notes describe things which are important for you to know, but not as Alternating Current... -
Page 7: Save These Instructions
Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions for all DR Inverter/Charger models that shall be followed during installation and maintenance of the inverter. General 1. Before installing and using the DR Inverter/Charger, read all instructions and cautionary markings on the DR Inverter/Charger and all appropriate sections of this guide. -
Page 8: Explosive Gas Precautions
Safety Wiring Requirements 1. All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70 (Current Edition). When sizing conductors and conduits interfacing to the DR Inverter, both shall be in accordance with the National Electric Code ANSI/NFPA 70, as well as all state and local code requirements. -
Page 9: Precautions When Working With Batteries
Precautions When Working With Batteries WARNING: Explosion or Fire Hazard Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed. 1. Make sure the area around the battery is well ventilated. 2. - Page 10 viii...
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Page 11: Table Of Contents
Contents Important Safety Instructions 1 Introduction Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 DC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4... - Page 12 Contents Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Battery Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15...
- Page 13 Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16 Charger Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17 3-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17 Equalize Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–18...
- Page 14 Contents Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13 Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13 Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–15 General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–16...
- Page 15 Figures Figure 1-1 Front Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-2 AC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-3...
- Page 16 Figures Figure 3-9 Battery Capacity Potentiometer (new) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12 Figure 3-10 Battery Capacity Potentiometer (old)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12 Figure 3-11 LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13 Figure 3-12 AC Pass-through and Charger AC Input Circuit Breakers - - - - - - - - - - - - - - - - - - - - -3–15...
- Page 17 Tables Table 1-1 Model Identification and Numbering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Table 1-2 Letter Suffix Code Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Table 2-1 Peak Input Filtrate versus Charging Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Table 2-2...
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Page 19: Introduction
Introduction Chapter 1, “Introduction” contains information about the features and functions of the DR Inverter/Charger. -
Page 20: Features
Introduction Introduction Thank you for purchasing the DR Inverter/Charger from Xantrex Technology Inc. The DR Inverter is one of the finest inverter/chargers on the market today, incorporating state-of-the-art technology and high reliability. The inverter features an AC pass-through circuit, powering your home appliances from utility or generator power while charging the batteries. -
Page 21: Ac Side
DC End COM Port Battery Caps Figure 1-1 Front Panel Features AC Side The AC side of the DR Inverter has one 30-amp breaker for pass-thru AC Input, and one 30-amp (20 amp in certain models) breaker for charger AC input. 30 Amp Breaker for Pass-thru AC Input 20 or 30 Amp Breaker... -
Page 22: Dc Side
Introduction DC Side The DC side of the DR Inverter has the equipment ground lug, the positive (+) battery terminal, and the negative (–) battery terminal. Battery Positive (+) Terminal Ventilation Holes Figure 1-3 DC Side of the DR Inverter Optional Equipment The following options are available for the DR Inverter/Chargers. -
Page 23: Model Identification And Numbering Conventions
“Information About Your System” on page WA–4. Important: or illustrations used in this manual may not exactly match your unit. Xantrex Technology Inc. reserves the right to update this product without notice or releasing an updated manual when fit, form or function are not affected. -
Page 24: Table 1-2 Letter Suffix Code Definitions
Introduction Table 1-2 Letter Suffix Code Definitions Letter Suffix (no letter) Figure 1-5 Model Number Sticker Regulatory The 120 Vac/60 Hz models of the DR Series inverter/charger (models DR1512, DR1524, DR2412, DR2424, and DR3624) are ETL Listed to UL Standard 1741, (First Edition) Power Conditioning Units for use in Residential and Commercial Photovoltaic Power Systems. -
Page 25: Installation
Installation Chapter 2, “Installation” contains information about how to plan for and install the DR Inverter/Charger. -
Page 26: Pre-Installation Planning
Installation Pre-installation Planning Important: and cautionary markings on the DR Inverter/Charger and all appropriate sections of this guide. Be sure to read all instructions and cautionary markings for any equipment attached to this unit. Take some time prior to installing the equipment to pre-plan the installation. Location, mounting, and ventilation should be taking into consideration before any cabling can be done. -
Page 27: Mounting
Mounting The National Building Code requires the inverter be mounted on a vertical surface (or wall). The keyhole slots must not be used as the only method of mounting. The purpose of the wall mounting requirement is to orient the inverter so that its bottom cover, which has no holes, will not allow burning material to be ejected in the event of an internal fire. -
Page 28: Hardware / Materials Required
Installation Hardware / Materials Required The following hardware or materials may be required to complete this installation. 4 ft. x 4 ft. sheet of 3/4" plywood or 2 x 4’s studding material #12 wood screws (or 1/2" x 1-1/4" lag bolts) Conduit and appropriate fittings Wire nuts Wiring Considerations... -
Page 29: Wire Routing
Wire Routing Determine all wire routes both to and from the inverter and which knockouts are best suited for connecting the AC conduits. Possible routing scenarios include: • AC input wiring from the main electrical service panel to the inverter/charger (if used) •... -
Page 30: Battery Location
Installation Battery Location Locate the batteries in an accessible location. 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 disconnects. -
Page 31: Figure 2-1 On-Grid Basic Configuration (Utility Backup)
Pre-installation Planning Figure 2-1 On-Grid Basic Configuration (Utility Backup) Figure 2-2 Off-Grid Configuration (Generator only) 975-0012-01-02 Rev A 2–7... -
Page 32: Figure 2-3 On-Grid Configuration - With Renewable Energy Sources
Installation Figure 2-3 On-Grid Configuration - with Renewable Energy Sources 2–8 975-0012-01-02 Rev A... -
Page 33: Figure 2-4 Off-Grid Configuration - With Renewable Energy Sources
Pre-installation Planning Figure 2-4 Off-Grid Configuration - with Renewable Energy Sources 975-0012-01-02 Rev A 2–9... -
Page 34: Generators
Installation Generators An AC generator can be used as an input source instead of the utility power, or can be connected (using additional hardware) to power the loads when utility is not present (utility outage), and to charge the batteries. The generator must be of the permanently installed type and not a portable type unit used for emergency power. -
Page 35: Inverter Mounting
Inverter Mounting The DR Series inverter can weigh as much as 45 lb. (20.4 kg). Wallboard is not strong enough to support its weight so additional support must be used or added. The inverter can be mounted directly to the wall studs if the wall studs are 16" apart. -
Page 36: Figure 2-7 Suggested Mounting Method
Installation 3. Secure the 2 x 4 with #10 wood screws (length to penetrate 1½ inches into the studs) as shown in Figure 2-7. 4. Measure 7 5/8" from the center of the first 2 x 4 and draw another level line. Place the center of the second 2 x 4 over this line and secure to the wall as described in Step 5. -
Page 37: Dc Wiring
DC Wiring This section describes the DC wiring requirements and how to make the connections. It provides the required cable and wire sizes, recommended lengths for cables, and disconnect/circuit breaker requirements. DC Circuit Grounding Grounding is an important part of the system installation and must be performed correctly to ensure safe operation of the equipment. -
Page 38: Figure 2-9 Dc Grounding
Installation Figure 2-9 DC Grounding 2–14 975-0012-01-02 Rev A... -
Page 39: Batteries
Batteries The DR Inverter can support either 12-volt battery banks or 24-volt battery banks. Before proceeding, ensure you have the appropriate sized batteries for this inverter. Battery Types Batteries are available in different sizes, amp-hour ratings, voltage, liquid or gel, vented or non-vented, chemistries, etc. -
Page 40: Battery Cable Sizing
Installation Battery Cable Sizing Proper cable sizing (diameter and length) is critical to the safe and efficient operation of an inverter system. Larger diameter cables (smaller AWG number) have less voltage drop and are, therefore, more efficient when transferring power to and from the batteries. -
Page 41: Dc Disconnect And Over-Current Protection
DC Disconnect and Over-current Protection For safety and to comply with regulations, battery over-current protection is required. Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability. -
Page 42: Battery Cable Connections
Installation Battery Cable Connections Battery cables must have crimped (or preferably, soldered and crimped) copper compression lugs unless aluminum mechanical lugs are used. Soldered connections alone are not acceptable. High quality, UL-listed battery cables are available from Xantrex in an assortment of lengths: 1½ to 10 feet, and in #2/0 AWG or #4/0 AWG sizes. -
Page 43: Connecting The Battery Bank To The Inverter
Positive (+) Battery Terminal Torque the Positive (+) Battery terminal to 10-15 ft-lbs (13.6 to 20.3 nm) Torque value for the Ground Lug is 10-15 in-lbs (1.1 to 1.7 nm) Figure 2-11 DC Terminals on the DR Inverter Connecting the Battery Bank to the Inverter Follow the procedure below to connect the battery bank to the inverter. -
Page 44: Figure 2-12 Connecting The Battery Bank To The Dr Inverter/Charger
Installation 8. Observing battery polarity, connect the positive battery cable (from the over-current device) to the inverter’s positive terminal. Important: connecting the cable to the inverter. This is normal, and is caused by the inverter’s capacitors charging up. 9. Observing battery polarity, connect the negative battery cable to the inverter’s negative terminal. -
Page 45: Installing A Battery Temperature Sensor
Installing a Battery Temperature Sensor A battery temperature sensor (BTS) option can easily be installed in the system to ensure proper charging of the batteries based on temperature. Installing a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures. -
Page 46: Ac Wiring
Installation AC Wiring This section describes the AC wiring requirements and how to make the connections. It provides the required wire sizes, recommended lengths for conductors, and disconnect/circuit breaker requirements. Important: qualified person or a licensed electrician following all local and NEC codes. AC Distribution Panel (Sub-panel) Mounting and Conduit Installation WARNING: Shock Hazard Disconnect the power from the utility’s main breaker box before proceeding. -
Page 47: Figure 2-15 Ac Side Cover Panels
Important: DR36XX models are equipped with a conduit box and not a plate. The conduit box is required for the larger diameter wire providing ample bending radius. Standard Cover Plate DR15XX Figure 2-15 AC Side Cover Panels Before wiring the input of the inverter, refer to Table 2-5 below for the minimum recommended wire size. -
Page 48: Figure 2-16 Ac Terminals For Ac Input To The Inverter
Installation Important: NEC and local codes. Conduit fittings can be replaced with strain reliefs where code permits. WARNING: Shock Hazard Disconnect the battery cables from the inverter if they are already connected. To connect the AC Input to the Inverter: 1. -
Page 49: Ac Output Wiring To The Ac Distribution Panel (Sub-Panel)
AC Output Wiring to the AC Distribution Panel (Sub-panel) Important: the system. If the generator is the main source of power, (i.e., no utility grid power) then the neutral and ground connections are bonded at the generator. If the generator is acting as a backup for the utility grid, then the bond should be at the main utility service entrance box. -
Page 50: Ac Input Wiring - On-Grid Applications
Installation The following diagrams illustrate the AC wiring for the following basic 120/240 Vac scenarios. Consult your system design for other possible configurations. • On-Grid Application (See Figure 2-18) • On-Grid using with a generator Backup (See Figure 2-19) • On-Grid Dual-Inverter Application (See Figure 2-20) •... -
Page 51: Ac Input Wiring Using A Generator In An On-Grid Application
AC Input Wiring using a Generator in an On-Grid Application If a generator is used as a backup for the utility, then a manual transfer switch must be added to provide a means to switch the generator power to the inverter’s inputs. -
Page 52: Ac Input Wiring - Off-Grid Applications Using A 120 Vac Generator
Installation AC Input Wiring - Off-Grid Applications using a 120 Vac Generator Follow the example below to complete the wiring for an off-grid application. Figure 2-20 AC Wiring using a 120 Vac Generator - Off-Grid Application 2–28 975-0012-01-02 Rev A... -
Page 53: Figure 2-21 Ac Wiring Using A 240 Vac Generator With 120 Vac Loads Only- Off-Grid Application
AC Wiring AC Input Wiring - Off-Grid Applications using a 240 Vac Generator for 120 Vac Loads Follow the example below to complete the wiring for an off-grid application. Figure 2-21 AC Wiring using a 240 Vac Generator with 120 Vac Loads only- Off-Grid Application 975-0012-01-02 Rev A 2–29... -
Page 54: Series Stacking (120 Vac/60 Hz Models Only)
The following illustrations provide a general overview of AC configurations using stacked inverters. Detailed wiring and operating instructions are provided with the DRI interface kit available from Xantrex Technology Inc. The following diagrams illustrate the AC Wiring for a basic On-Grid and Off-Grid application. -
Page 55: Figure 2-22 Ac Wiring For Dual-Inverters - On-Grid Application (120 Vac Models Only)
AC Wiring Figure 2-22 AC Wiring for dual-inverters - On-Grid Application (120 Vac models only) 975-0012-01-02 Rev A 2–31... -
Page 56: Figure 2-23 Wiring For Dual-Inverters - On-Grid Application (120 Vac Models Only)
Installation Figure 2-23 Wiring for dual-inverters - On-Grid Application (120 Vac models only) 2–32 975-0012-01-02 Rev A... -
Page 57: Operation
Operation Chapter 3, “Operation” contains information about how to operate the DR Inverter/Charger. -
Page 58: Front Panel Controls And Indicators
Operation Front Panel Controls and Indicators All operating controls, indicators and sense connectors are located on the front panel of the unit. The controls are easily accessible, and the LEDs provide inverter/charger status at a glance. Inverter Mode Indicator POWER ON/OFF COM Port Figure 3-1 Front Panel Controls and Indicators POWER ON/OFF Switch... -
Page 59: Ports
Ports There are two ports on the inverter/charger. Both ports are RJ11 type telephone style connectors. One is used for connecting a remote control to the inverter. The other is used for regulating the charger voltage based on the temperature of the battery bank. -
Page 60: Stacking Interface
Operation • Erratic Blinking (0 to 3 and 2 to 5 flashes @ 2 second intervals) - The inverter has detected an error condition caused by overheating, low battery voltage, or high battery voltage. • OFF - The inverter is OFF. The remote control must be connected prior to switching the inverter ON;... -
Page 61: Table 3-1 Battery Type Selector Switch Settings
Table 3-1 Battery Type Selector Switch Settings 12-volt Models Switch Float Description Position Voltage Equalize 1 - 13.2 equalizes at a rate equal to the battery bank capacity (in amp- hours) divided by Equalize 2 - 13.2 charges at a rate set by the BATTERY CHARGER... -
Page 62: Search Mode Watts Potentiometer
Operation Important: 1. Switch positions “0” and “1” are for monthly battery maintenance only. Return the switch to the appropriate position for the system’s batteries when Equalize charging has completed. NEVER EQUALIZE GEL BATTERIES! Use together with BATTERY CHARGER RATE potentiometer (position1) or BATTERY CAPACITY potentiometer (position 0). -
Page 63: Battery Charger Rate
Important: These include: TVs with instant-ON circuits, microwaves with digital displays, VCRs, etc. It is best to operate these devices from another circuit or install a switch to turn these OFF completely or don’t use the Search Mode. Important: 120 Vac loads connected to the “master” inverter will bring the unit out of the search mode. -
Page 64: Over Discharge Protection/Ac Transfer Voltage
Operation Use Table 3-2 to find the approximate setting of the Battery Charge Rate potentiometer. The settings do not need to be exact, but should be as close as possible to the actual value required. Important: small blade screwdriver and rotate the control completely CCW to find the start position. Rotate the potentiometer CW to the desired position (i.e., halfway between the stops for a 50% setting). -
Page 65: Over Discharge Protection (Odp)
Over Discharge Protection (ODP) When enabled, ODP shuts down the inverter at a specified voltage (low battery cutoff) to protect the batteries from over discharge damage. The inverter circuitry calculates the lowest (safe) DC voltage (leaving approximately 20% battery capacity) based on the position the Battery Type Selector switch and the amount of current drawn by the load. -
Page 66: Ac Transfer Voltage
Operation AC Transfer Voltage During normal operation, the inverter supplies AC power to the applied loads through the pass-through circuit and simultaneously charges the system batteries. Whenever the external AC source drops below the AC Transfer Voltage (set by the potentiometer), the inverter switches to battery power in order to maintain the connected load. -
Page 67: Figure 3-7 Odp Enabled/Disabled Positions
AC Transfer Voltage (Adjustable) with ODP Disabled Minimum (45 Vac for 120 Vac models) Figure 3-7 ODP Enabled/Disabled Positions Important: voltage between 95 and 105 volts. Setting the AC Transfer Voltage potentiometer between these values will allow the incoming source voltage to drop to this level and still operate the connected appliances (load). -
Page 68: Battery Capacity
Operation Battery Capacity The Battery Capacity potentiometer is used to set the correct charge profile for the battery capacity (amp-hours) used with the inverter (see illustration below). The setting allows the inverter to calculate over-discharge protection values and also the end of the Bulk/Absorption charge mode, at which point the inverter switches to the Float mode of battery charging. -
Page 69: Led Indicators
LED Indicators There are four LEDs on the inverter’s front panel, indicating inverter status, battery condition, over temperature/overload conditions and charger status. These LEDs blink or change color depending on the condition or function they are displaying. INVERTER MODE Figure 3-11 LED Indicators Inverter Mode LED - Green The green Inverter Mode LED lights (solid) to indicate the inverter is running on batteries (full wave operation). -
Page 70: Charger Led - Orange / Green
Operation Important: controllers must be set to a level below the inverter’s maximum input voltage or the inverter shuts OFF. Whenever the battery voltage drops to its lowest (safe) level (as calculated by the ODP), the LED lights green to indicate the condition. If the condition persists, the inverter will shut down until the battery voltage returns to a safe level and then restart. -
Page 71: Circuit Breakers
Circuit Breakers The DR Inverter contains two circuit breakers located on the right-hand side of the chassis, directly above the AC input terminal block. The pass-through AC input circuit breaker protects the AC wiring and connected load. The charger AC input circuit breaker protects the charger circuit. -
Page 72: Start-Up
Operation Start-up Once the inverter is properly connected to the batteries, AC source, and loads (using a sub-panel) the inverter is ready for operation. Recheck the controls and ensure they are in the proper position. Recheck all wiring and ensure it is correct. Starting the inverter: 1. -
Page 73: Charger Mode
Charger Mode 3-Stage Charging Process The charging cycle uses a 3-stage charging process to maintain the batteries. Whenever nominal AC is present at the inverter’s input, it passes power through to the connected load and begins charging the batteries, indicated by the dual color BATTERY CHARGER LED. -
Page 74: Equalize Charging
Operation Battery Charger LED Solid Orange = Bulk Blinking Orange = Absorption Solid Green = Float Figure 3-14 Charger Controls and Indicators Equalize Charging Equalize charging is a special mode of battery charging. During use, the battery’s cells can become unequal in the voltage and current they can deliver. This is due to a buildup of sulfate on the plates as well as stratified electrolyte. -
Page 75: Figure 3-15 Equalize Positions On Battery Type Selector Switch
Important: 4. Set the BATTERY TYPE SELECTOR switch to position “0” or “1”. To start the equalization charging process, cycle the AC power (i.e., disconnect and then reconnect the AC source). A solid orange BATTERY CHARGER LED indicates equalize charge. a) Position “0”... -
Page 76: Figure 3-16 Equalize 1 Battery Charger Rate Potentiometer (Position "1")
Operation Figure 3-16 Equalize 1 Battery Charger Rate Potentiometer (Position “1”) Figure 3-17 Equalize 2 Battery Capacity Rate Potentiometer (Position “0”) 3–20 See Table 3-1 Switch Position “1”. See Table 3-1 Switch Position “0”. 975-0012-01-02 Rev A... -
Page 77: Troubleshooting
Troubleshooting Chapter 4, “Troubleshooting” contains information about how to troubleshoot possible error conditions while using the DR Inverter/Charger. -
Page 78: Troubleshooting The Dr Inverter
Troubleshooting Troubleshooting the DR Inverter Table 4-1 provides a list of possible error conditions that may occur, their possible causes, and possible solutions to resolve the error condition. Table 4-1 Troubleshooting the DR Inverter Error Condition No AC output voltage and no warning LEDs on ON. -
Page 79: Problem Loads
Table 4-1 Troubleshooting the DR Inverter Error Condition CHARGER LED: - indicates charging, but no charge is going to the batteries. - is ON, but there is no output power. Charger turns OFF while charging from a generator Problem Loads The inverter can drive most loads, however, there are special conditions that can cause a load to behave differently than expected. -
Page 80: Clocks
Troubleshooting Clocks The inverter’s crystal controlled oscillator keeps the frequency accurate to within a few seconds a day; however, external loads in the system may alter the inverter’s output waveform causing clocks to run at different speeds. There may be periods where clocks keep time and then mysteriously do not. -
Page 81: Printers
Printers Most inkjet type printers work well in inverter applications. Laser printers, however, require high current for their fusing circuit and are not recommended for use with an inverter. Rechargeable Devices When first using a rechargeable device, monitor its temperature for 10 minutes to ensure it does not become abnormally hot. - Page 82 4–6...
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Page 83: Specifications
Specifications Appendix A, “Specifications” contains information about the electrical specifications and environmental specifications of the DR Inverter/Charger. -
Page 84: Specifications Of The Dr Inverter
Specifications Specifications of the DR Inverter Table A-1 provides the electrical specifications for the DR Inverter/Charger (120 Vac/60 Hz. models). Table A-2 provides the electrical specifications for the DR Inverter/Charger (220 Vac/60 Hz. models). Table A-3 provides the electrical specifications for the DR Inverter/Charger (230 Vac/50 Hz. - Page 85 Table A-1 Electrical Specifications for the DR Inverter/Charger Model DR1512 DC Input Voltage 12.6 Vdc (nominal) DC Input Voltage 10.8 to 15.5 Vdc Range Auto Low Battery 11 V Protection enabled DC Charger Rate 0 to 70 amps (Adjustable) Common Specifications: Voltage Regulation ±...
- Page 86 Adjustable Load Sensing Range Series Operation Force Air Cooling Automatic Transfer Relay Number of Charging Profiles Three-stage Charging A–4 - 220 Vac/60 Hz Models DR1512W 220 Vac 80 to 210 Vac 45 amps 1500 VA 6.8 amps AC 94% max 220 Vac 20 amps AC 0.045 amps...
- Page 87 DC Input Voltage 12.6 Vdc (nominal) DC Input Voltage 10.9 to 15.5 Vdc Range 975-0012-01-02 Rev A - 220 Vac/60 Hz Models DR1512W optional optional - 230 Vac/50 Hz Models DR1524E DR1548E 230 Vac 230 Vac 80 to 210 Vac...
- Page 88 Specifications Table A-3 Electrical Specifications for the DR Inverter/Charger Model DR1512E Auto Low Battery 11 V Protection enabled DC Charger Rate 0 to 70 amps (Adjustable) Common Specifications: Voltage Regulation ± 5% (maximum) Voltage Regulation ±2. 5% (Typical) Waveform modified sine wave Load Power Factor 0.5 to 1.0 (leading or lagging) (allowed)
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Page 89: Table A-4 Environmental Specifications For The Dr Inverter/Charger
Table A-4 Environmental Specifications for the DR Inverter/Charger Model DR1512 8.5" w x 7.25" H x 21" D (21.6 cm W x 18.4 cm H x 54.6 cm D Dimensions Unit Weight 35 lbs (16 kg) “E” Models 38 lbs (18 kg) Ambient Temp Range (rated 0 to 25 °C): Operating 0 °C to +50 °C Storage -55 °C to +75 °C... - Page 90 A–8...
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Page 91: Battery Information
Battery Information Appendix B, “Battery Information” supplies general information about batteries such as battery types, battery bank sizing, battery configurations, and battery care. For detailed information, see your battery manufacturer or your system designer. -
Page 92: Introduction
Battery Information Introduction Batteries Batteries are available in different sizes, amp-hour ratings, voltage, liquid or gel, vented or non-vented, chemistries, etc. They are also available for starting applications (such as an automobile starting battery) and deep discharge applications. Recommendations Consider the following recommendations for battery use. •... -
Page 93: Sealed Batteries (Gel And Agm
Sealed Batteries (Gel and AGM) Description Gel Cell and absorbed glass mat (AGM) batteries are sealed and do not require the addition of distilled water. Since these batteries are valve regulated, over-charging can cause irreversible damage. Attributes Attributes of sealed batteries are: NiCad and NiFe Batteries Disadvantages These types of batteries can be used but are not optimized for the DR Inverter for... -
Page 94: Understanding Battery Capacity Ratings
Battery Information Understanding Battery Capacity Ratings Discharge rate Deep cycle batteries have their amp-hour rating expressed as “at the x-hour rate”. The hour rating refers to the time it takes to discharge the batteries. A faster hour rate (6 hour rate) means more current is withdrawn from the batteries during their discharge period. -
Page 95: Understanding Amp-Hour Requirements
Back up power systems which use utility power for recharging should use the estimated number of days of maximum power outage for determining days of autonomy. Understanding Amp-hour Requirements Amp-hours To estimate the battery bank requirements, you must first calculate the amount of power you will draw from the batteries during your period of autonomy. -
Page 96: Amp Hour Example Worksheet
Battery Information Considerations When calculating battery bank size, consider the following: • Motors typically require 3 to 6 times their running current when starting. Check the manufacturer’s data sheets for their starting current requirements. If you will be starting large motors from the inverter, increase the battery bank size to allow for the higher start-up current. -
Page 97: Battery Bank Size Worksheet
Battery bank size worksheet Calculation To calculate the battery bank size, use the average amp-hours per day that you calculated using Table B-1, then make the other calculation shown in Table B-2 to calculate the battery bank size you need to support your loads. Table B-2 Determining Battery Bank Size Average amp hours per day Divided by inverter efficiency (90%) for DR Inverter... -
Page 98: Battery Configurations
Battery Information Battery Configurations The battery bank must be wired to match the inverter’s DC input voltage specifications (12 or 24 Vdc). In addition, the batteries can be wired to provide additional run time. The various wiring configurations are: Series Wiring batteries in series increases the total bank output voltage. -
Page 99: Wiring Batteries In Parallel
DC Disconnect (either a circuit breaker or a fuse with a disconnect) Figure B-2 12-volt Battery Wiring - “Series” Configuration Wiring Batteries in Parallel Effect Wiring the batteries in a parallel configuration increases the current of the battery string. The voltage of the battery bank remains the same as an individual battery. “Parallel”... -
Page 100: Wiring Batteries In Series-Parallel
Battery Information Wiring Batteries in Series-Parallel Effect Wiring the batteries in a series-parallel configuration increases the current and voltage of the battery bank. “Series-parallel” wiring is more complicated and care should be taken when wiring these banks. Steps It is done in three steps; wiring the batteries in series, wiring them in parallel, then wiring the string to the inverter. - Page 101 Connect to inverter To connect to the inverter: 1. Connect a cable from the positive terminal of the first battery string to the inverter’s positive DC terminal (via a fused device). 2. Connect the negative terminal of the last battery string to the negative terminal of inverter’s DC terminal.
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Page 102: Battery Connections For Stacked Inverters
Battery Information Battery Connections for Stacked Inverters When using inverters in a stacked configuration, the same battery bank must be used for both inverters. To ensure even charging of the batteries, each inverter must be connected to both strings (i.e., positive cable to string two, and negative cable to string one for inverter 1, and positive cable to string one and negative cable to string two for inverter 2) as shown in the diagram below. -
Page 103: Battery Maintenance
Battery Maintenance Maintenance To get the best performance from an inverter system, the batteries must be strategy properly setup and maintained. This includes setting the proper voltages for Bulk and Float charging. See the “CAUTIONS” in the section on Equalization Charging that follows. -
Page 104: Table B-4 Variances In Charging Voltage Based On Battery Temperature
Battery Information Table B-4 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) 12-volt units Lead Acid Celsius Fahrenheit (6 cells) -1.05 -0.90 -0.75 -0.60 -0.45 -0.30 -0.15 0.00 0.15 0.30 0.45 0.90 0.75 0.90 1.05 1.20 1.35 1.50 1.65... -
Page 105: Equalization Charging
Equalization Charging Purpose An equalize charge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells. Effect Equalize charging also produces gassing which stirs up the electrolyte mixture and helps distribute the acid more evenly. Non-equalized Batteries that are not equalize charged can be damaged by sulfate accumulation, batteries... -
Page 106: General Maintenance
Battery Information General Maintenance Water Levels Flooded lead acid batteries require periodic water refills in each battery cell. Only distilled water should be used in a battery, as tap or mineral water may contain contaminants which will upset the battery chemistry and may damage the battery. When filling the battery, clean the surface first to prevent dirt from entering the cell. -
Page 107: Table B-6 Battery State-Of-Charge
State of Charge The battery’s state-of-charge should be checked often and only when the battery at a state of rest (when the battery is not powering loads or actively being charged). First thing in the morning is usually the best time to check the state of charge. If the batteries are readily accessible, measure the voltage across the individual battery terminals. - Page 108 B–18...
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Page 109: C Multi-Wire Branch Circuit Wiring
Multi-wire Branch Circuit Wiring Appendix C, “Multi-wire Branch Circuit Wiring” supplies information about Multi-wire Branch Circuit Wiring Precautions when using stand-alone 120 Vac inverters or generators. WARNING A possible fire hazard can exist if 120 Vac only sources (such as inverters and generators) are wired incorrectly into 120/240 Vac panels containing multi-wire branch circuits. -
Page 110: Multi-Wire Branch Circuits
Multi-wire Branch Circuit Wiring Multi-wire Branch Circuits Problem A potential safety problem exists when installing stand-alone 120 Vac inverters into existing 120/240 Vac wired panels where multi-wire branch circuit wiring methods were used. Legacy situation Multi-wire branch circuits are wired differently from “home run” type wiring (Figure C-1) in that only one neutral wire is used to provide the neutral-return path for each circuit connected to both phases of the AC grid. -
Page 111: Figure C-2 Multi-Wire Branch Circuit Wiring And Current Flow
Load Center 240 Vac from Grid Neutral Ground Single White - Neutral (Current Flow 0 A) Bare - Ground Out-of-Phase current subtract at this point (Current Flow 0 A) Figure C-2 Multi-wire Branch Circuit Wiring and Current Flow 120 Vac Inverter or Generator WARNING: FIRE HAZARD The in-phase currents ADDS... -
Page 112: Identifying Multi-Wire Branch Circuits
Multi-wire Branch Circuit Wiring Identifying Multi-wire Branch Circuits WARNING: Shock Hazard The next step involves opening the load center, exposing live circuits. This procedure should only be performed by qualified persons or electricians. Identifying Multi-wire branch circuits can be identified by removing the cover on the load characteristic center and inspecting the wiring. -
Page 113: Correcting Multi-Wire Branch Circuit Wiring
Correcting Multi-wire Branch Circuit Wiring Acceptable options Correcting multi-wire branch circuit wiring is not easy. Two options which will correct multi wiring branch circuit wiring are: • Rewire existing multi-wire branch circuits to conventional “home run” wiring. This requires a qualified electrician (knowledgeable about multi-wire branch circuit wiring) and is expensive. -
Page 114: Figure C-5 Using A Step-Down Autotransformer In Multi-Wire Branch Circuit Wiring
Multi-wire Branch Circuit Wiring 120 Vac Inverter or Generator T240 AutoTransformer HOT - L1 HOT - L2 White - Neutral Figure C-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring C–6 Load Center Neutral 15 A Breaker (Ganged) Ground Black - Hot (Current Flow 15 A) Single White - Neutral... -
Page 115: Warranty And Return Information
The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status, or • The dated invoice or purchase receipt showing the product exchanged under warranty 975-0012-01-02 Rev A This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") In any warranty claim, dated proof of purchase must accompany the WA–1... - Page 116 Warranty and Return What does this warranty not cover? product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to: a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either inter- nally or externally, or damaged from improper use or use in an unsuitable environment;...
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Page 117: Return Material Authorization Policy
Include the following: • The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the box. • A return address where the unit can be shipped. Post office boxes are not acceptable. -
Page 118: Information About Your System
Warranty and Return Information About Your System As soon as you open your DR Inverter/Charger package, record the following information and be sure to keep your proof of purchase. Serial Number Purchased From Purchase Date If you need to contact Customer Service, please record the following details before calling. This information will help our representatives give you better service. -
Page 119: Index
Index 4–3 AM radios 2–4 Batteries Battery Care and Maintenance B–15 Equalization Charging Temperature Compensation Battery Types B–3 Absorbed Glass Mat Flooded Lead Acid (FLA) B–3 Gel Cell B–2 Golf Cart Industrial (electric forklift) B–3 NiCad and NiFe Charging B–13 Bulk Voltage B–13 Charge Rates... - Page 120 IX-2...
- Page 122 Xantrex Technology Inc. 1 800 670 0707 Tel. toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.com 975-0012-01-02 Rev A PC Printed in the DR...
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