Xantrex TRACE DR Series Installation & Operator's Manual
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Xantrex TRACE DR Series Installation & Operator's Manual

Inverter/charger
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Summary of Contents for Xantrex TRACE DR Series

  • Page 1 DR Series ™ Inverter/Charger Installation & Operator’s Manual...

  • Page 3: Table Of Contents

    Battery Cable Sizing ............13 DC Disconnect and Over-current Protection ....14 Battery Cable Connections ........... 15 Battery Bank Sizing ............16 Battery Types ..............16 Battery Configuration ............ 16 SERIES ..............16 PARALLEL ............... 16 SERIES-PARALLEL ..........16 ©2000 Xantrex Technology Inc.

  • Page 4: Description Page

    8–NiCad 1 ............39 NiCad 2 .............. 39 SEARCH MODE WATTS Potentiometer ....... 40 Battery Charger Rate ............. 41 Over Discharge Protection/AC Transfer Voltage ..42 Over Discharge Protection (ODP) ......42 AC Transfer Voltage ..........43 ©2000 Xantrex Technology Inc.
  • Page 5 Check Battery State of Charge ........63 Problem Loads ..............64 Multiwire Branch Circuits ............ 66 Identifying Multiwire Branch Circuits ......67 Correcting Multiwire Branch Circuit Wiring ....68 LIMITED WARRANTY ..............69 SERVICE INFORMATION ............71 SPECIFICATIONS ................ 72 ©2000 Xantrex Technology Inc.
  • Page 6 Disclaimer of Liability ©2000 Xantrex Technology Inc.
  • Page 7 IMPORTANT SAFETY INSTRUCTIONS WARNING - AVERTISSEMENT - CAUTION - ATTENTION - NOTE - NOTE - · · · · · · · · SAVE THESE INSTRUCTIONS ©2000 Xantrex Technology Inc.
  • Page 8 BATTERY SAFETY INFORMATION · · · · · · · · · · · · · · · · ©2000 Xantrex Technology Inc.

  • Page 9: 1.0 Introduction

    1.0 INTRODUCTION Figure 1 The DR Series Inverter/Charger ©2000 Xantrex Technology Inc.

  • Page 10: Unpacking And Inspection

    1.0 INTRODUCTION Unpacking and Inspection exactly fit, form or function ©2000 Xantrex Technology Inc.

  • Page 11: Model Identification And Numbering Conventions

    1.0 INTRODUCTION Model Identification and Numbering Conventions Example: DR 1512 E Letter Suffix Output Voltage Output Frequency Figure 2 Product Identification Figure 3 Model/Serial Number Sticker ©2000 Xantrex Technology Inc.

  • Page 12: Certification

    1.0 INTRODUCTION Certification Power Conditioning Units for use in Residential and Commercial Photovoltaic Power Systems Certification Sticker Figure 4 UL/CSA Certification Sticker ©2000 Xantrex Technology Inc.

  • Page 13: 2.0 Installation

    The DRI stacking interface provides 3-wire 120/240 VAC at twice the power using dual DR Series inverters (120 VAC/60 Hz units only). The DRCB conduit box connects to the DC side of the inverter and accepts a DC conduit run. ©2000 Xantrex Technology Inc.

  • Page 14: Pre-Installation

    • The inverter contains an internal fan. Ensure the air vents and intakes are not obstructed in any way. Provide a minimum clearance of 1-1/2 inches around the top and sides of the inverter for ventilation. ©2000 Xantrex Technology Inc.

  • Page 15: Tools Required

    5 feet (one way) in 12 VDC systems; do not exceed 10 feet (one way) in 24 VDC systems. For optimum performance, use pre-assembled battery cables designed specifically for this application (available from Xantrex). •...

  • Page 16: Batteries

    Locate the enclosure where it will be protected from the afternoon sun and provide vents in the top and bottom of the enclosure to provide air flow. High battery temperatures greatly shortens the life of the batteries. ©2000 Xantrex Technology Inc.
  • Page 17 INVERTER/CHARGER DC CHARGE DC CONDUIT AC CONDUIT (if used) CONTROLLER AC CONDUIT TO SUB-PANEL BATTERIES VENT (outlet) DC CONDUIT AC GENERATOR (if used) (externally located) BATTERY ENCLOSURE (if used) VENT GROUND DC GROUND (inlet) WIRE 975-0012-002 ©2000 Xantrex Technology Inc.

  • Page 18: Main Service Panel

    Load circuit wiring rerouted from the main service panel to the sub-panel Check for existing electrical or plumbing prior to making cuts in the walls. Cut holes in the walls at appropriate locations for routing wiring/cables. ©2000 Xantrex Technology Inc.

  • Page 19: Inverter Mounting

    Place a pre-cut 2 x 4 on the marked location and drill pilot holes through the 2 x 4’s and studs. • Secure the 2 x 4 with #10 wood screws (length to penetrate 1-1/2 inches into the studs). • Repeat the procedure for the remaining 2 x 4. ©2000 Xantrex Technology Inc.
  • Page 20 14.00 inches 1.90 inches 35.56 cm 4.83 cm 16.00 inches 40.64 cm 20.175 inches 51.244 cm 975-0012-D-011 7.00 6.970 8.00 16.00 1.00 20.175 7.640 8.370 .281 DIA. 5 PLACES .375 DIA. 2 PLACES 1.900 0.365 975-0012-D-012 ©2000 Xantrex Technology Inc.

  • Page 21: Wiring

    #2/0 AWG (67.4 mm #4/0 AWG (107 mm DR2424 120 A #2/0 AWG (67.4 mm #4/0 AWG (107 mm #4/0 AWG (107 mm DR3624 180 A #4/0 AWG (107 mm #4/0 AWG (107 mm #4/0 AWG (107 mm 975-0012-004 ©2000 Xantrex Technology Inc.

  • Page 22: Dc Disconnect And Over-Current Protection

    Some installations may not require conduit or a disconnect device, although over-current protection is still required. Xantrex offers a fuse block (TFB) providing the code required inverter over-current protection for these applications. Refer to the table below for the proper size disconnect device for specific cable diameters.

  • Page 23: Battery Cable Connections

    Figure 9 illustrates the proper method to connect the battery cables to the DR Series inverter/ charger terminals. Do not place anything between battery cable lug and terminal surface. Assemble exactly as shown. 2/0 Copper Compression Lug 2/0 Aluminum Mechanical Lug POSITIVE (+) RED TERMINAL NEGATIVE (-) BLACK TERMINAL ©2000 Xantrex Technology Inc.

  • Page 24: Battery Bank Sizing

    Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads. Series-parallel configurations increase both the battery voltage (to match the inverter’s DC requirements) and run-time for operating the AC loads. ©2000 Xantrex Technology Inc.
  • Page 25 12 V 12 V 12 V 12 V 12 V 24 V INVERTER 48 V INVERTER (Total battery capacity = 50 Ah) (Total battery capacity = 50 Ah) Each battery’s amp-hour 3597-F00-D25 3597-F00-D24 rating is 50 Ah ©2000 Xantrex Technology Inc.
  • Page 26 Two identical strings of batteries are now wired in series. – – – – Series String 1 12 V 12 V 12 V 12 V – – – – Series String 2 12 V 12 V 12 V 12 V 3597-F00-D27 ©2000 Xantrex Technology Inc.
  • Page 27 12 V 12 V terminal – – – – 12 V 12 V 12 V 12 V Connection from bank 2 to inverter negative (–) terminal – 48 V INVERTER (Total battery capacity = 100 Ah) 3597-F00-D29 ©2000 Xantrex Technology Inc.
  • Page 28 (not required) (not required) (not required) (not required) (not required) (not required) (not required) – – – – – – – – – Fuse Block 48 V INVERTER Disconnect (Total battery capacity = 200 Ah) 3597-F00-D32 ©2000 Xantrex Technology Inc.
  • Page 29 (not required) (not required) (not required) (not required) (not required) – – – – 12 V 12 V 12 V 12 V Fuse Block Disconnect – 48 V INVERTER (Total battery capacity = 100 Ah) 3597-F00-D30 ©2000 Xantrex Technology Inc.
  • Page 30 • Apply antioxidant paste to the battery and inverter terminals. • Install the battery terminal connection covers (red for positive, black for negative) over the inverter’s DC terminals and secure with the screws and washers provided. ©2000 Xantrex Technology Inc.
  • Page 31 6–8 feet into the earth. This procedure will properly ground the DC circuits. 8uh††v†ÃB…‚ˆq 8v…pˆv‡Ã7…rhxr… ; $ 1 7 5 ; $ 1 7 5 ; $ 1 7 5 *URXQG  ©2000 Xantrex Technology Inc.
  • Page 32 BATTERY SENSE jack located on the front of the inverter. • Secure the sensor to one of the batteries located in the center the battery pack. BATTERY SENSE (RJ11) Jack To BATTERY SENSE jack ) BTS connected to battery ©2000 Xantrex Technology Inc.
  • Page 33 NOTE: The lower AC cover varies depending on the system’s power level. Higher power units are equipped with a conduit box and not a plate. The conduit box is required for the larger diameter wire providing ample bending radius. Screws High Power Conduit Box Standard Cover Plate ©2000 Xantrex Technology Inc.
  • Page 34 #10 AWG #10 AWG #14 AWG DR1524 #8 or 6 AWG #10 AWG #12 AWG #16 AWG DR2424 #8 AWG #10 AWG #10 AWG #14 AWG DR3624 #6 AWG Not Available #8 AWG Not Available 975-0012-007 ©2000 Xantrex Technology Inc.
  • Page 35 Connect the NEUTRAL (white) wire from the main utility panel to the inverter’s NEUTRAL INPUT terminal. • Connect the HOT (black) wire from the main utility panel to the inverter’s AC HOT INPUT terminal. • Torque all connections to 16 inch-pounds. AC CHASSIS GROUND NEUTRAL ©2000 Xantrex Technology Inc.
  • Page 36 Torque all inverter terminal block connections to 16 inch-pounds. Refer to the sub-panel AC CHASSIS manufacturer’s specifications for wire torques. GROUND NEUTRAL NOTE: The two neutral connections (input and output) are common to one another and may be used in any combination. ©2000 Xantrex Technology Inc.
  • Page 37 120 VAC LINE OUT IN MAIN PANEL ONLY! NEUTRAL GROUND EARTH GROUND NOTE: FOR ILLUSTRATIVE PURPOSES ONLY. BREAKER BOXES VARY DEPENDING ON APPLICATION. MAIN PANEL WIRING TO NON-CRITICAL LOADS IS NOT ILLUSTRATED. LINE OUT NEUTRAL GROUND 3597-W00-C06 ©2000 Xantrex Technology Inc.
  • Page 38 57 amps Homelite 2500 DR1512 11 amps Honda 3500 DR1512 39 amps Honda 6000 DR1512 70 amps Honda 1600 DR1524 25 amps Westerbeke 7.0 kW DR1512 Approx. 45 amps Westerbeke 12.5 kW DR1512 Approx. 65 amps 975-0012-013 ©2000 Xantrex Technology Inc.
  • Page 39 Manually start the generator and check for proper operation of the inverter (i.e., the inverter transfers from battery to generator power). 120 VAC INVERTER/ GENERATOR CHARGER Neutral Neutral Neutral/ Ground Ground bond Ground Distribution Panel 120 VAC LOADS 3597-A00-016 ©2000 Xantrex Technology Inc.
  • Page 40 Connect a (black) wire between the inverter’s terminal labeled AC HOT OUTPUT and the SUB-PANEL’s INPUT circuit breaker. • Torque all inverter terminal block connections to 16 inch-pounds. Refer to the sub-panel manufacturer’s specifications for wire torques. • Recheck all connections. Refer to the illustration on the next page. ©2000 Xantrex Technology Inc.
  • Page 41 (to inverter) Ground Switch GENERATOR HOT CONTACT NEUTRAL Isolated Neutral Bus Manual Start Generator AC Input Generator Isolated Power Neutral Bus Inverter AC Output Isolated Main Input Neutral Bus Breaker NEUTRAL To AC Load GROUND Sub-panel 975-0012-008 ©2000 Xantrex Technology Inc.
  • Page 42 The following illustrations provide a general overview of AC and DC wiring configurations and output voltages supplied by stacked inverters. Detailed wiring and operating instructions are provided with the DRI interface kit available from Xantrex Technology Inc. NOTE: Only 120 VAC/60 Hz models can be stacked.
  • Page 43 Inverter 1 (L1) Positive Negative Series Stacking Cable (DRI) Inverter 2 Disconnect (L2) – – 975-0012-009 – – Inverter 1 (L1) Negative Series Stacking Cable (DRI) Disconnect Inverter 2 (L2) – – 975-0012-010 Disconnect – – ©2000 Xantrex Technology Inc.
  • Page 44 3.0 OPERATION Front Panel Controls and Indicators...
  • Page 45 3.0 OPERATION Front Panel Controls and Indicators (continued)

  • Page 46: Description

    3.0 OPERATION Front Panel Controls and Indicators (continued) 12 Volt Models 24 Volt Models Equalize Switch Description Float Bulk/Equalize* Float Bulk/Equalize* Charge Position Time Voltage Voltage Voltage Voltage Rate Battery Capacity 6 hours minimum Equalize 1 13.2 *15.0 26.4 *30.0 Setting 12 hours maximum (C/40)
  • Page 47 3.0 OPERATION Front Panel Controls and Indicators (continued)

  • Page 48: Inverter Mode Led - Green

    3.0 OPERATION Front Panel Controls and Indicators (continued) INVERTER MODE LED blinks 2-3 times/second Lower wattage device turns ON inverter DEFEAT switches SEARCH MODE OFF Higher wattage device turns ON inverter...
  • Page 49 3.0 OPERATION Front Panel Controls and Indicators (continued) Percent of Potentiometer Rotation (between stops) 100% Model DR1512 DR2424 0 amps 17.5 amps 35 amps 52.5 amps 70 amps DR3624 DR2412 0 amps 30 amps 60 amps 90 amps 120 amps DR1524 0 amps 8.75 amps...
  • Page 50 3.0 OPERATION Front Panel Controls and Indicators (continued)
  • Page 51 3.0 OPERATION Front Panel Controls and Indicators (continued) Approximate Approximate Approximate Approximate Approximate Approximate Approximate Approximate...
  • Page 52 3.0 OPERATION Front Panel Controls and Indicators (continued) Maximum (105 VAC for 120 VAC models) Maximum (105 VAC for 120 VAC models) Minimum ( 45 VAC for 120 VAC models) Minimum ( 45 VAC for 120 VAC models)
  • Page 53 3.0 OPERATION Front Panel Controls and Indicators (continued)
  • Page 54 3.0 OPERATION Front Panel Controls and Indicators (continued)
  • Page 55 3.0 OPERATION Front Panel Controls and Indicators (continued) prolonged...
  • Page 56 3.0 OPERATION Front Panel Controls and Indicators (continued)

  • Page 57: Start-Up

    3.0 OPERATION Start-up...

  • Page 58: Charger Mode

    3.0 OPERATION Charger Mode...
  • Page 59 3.0 OPERATION Charger Mode (continued) equalize 1 Battery...

  • Page 60: Equalize Charging

    3.0 OPERATION Charger Mode (continued) 12 Volt Models 24 Volt Models Equalize Switch Description Float Bulk/Equalize* Float Bulk/Equalize* Charge Position Time Voltage Voltage Voltage Voltage Rate Battery Capacity 6 hours minimum Equalize 1 13.2 *15.0 26.4 *30.0 Setting 12 hours maximum (C/40) Battery Charger...

  • Page 61: 4.0 Troubleshooting

    Check AC wiring connections. Have unit serviced. - is flashing and no AC output. The load is too small for the search Reduce or defeat the AC search watts setting. mode to detect. Increase the AC load. 975-0012-015-A ©2000 Xantrex Technology Inc.
  • Page 62 Charger turns OFF while charging High peak AC input voltages from Load the generator down with a heavy load. from a generator. the generator. Turn the generator output voltage down. 975-0012-015B ©2000 Xantrex Technology Inc.

  • Page 63: 5.0 Appendix

    5.0 APPENDIX Batteries Selection of a Battery Type ©2000 Xantrex Technology Inc.
  • Page 64 5.0 APPENDIX Selection of a Battery Type (continued) ©2000 Xantrex Technology Inc.

  • Page 65: Battery Bank Sizing

    5.0 APPENDIX Battery Bank Sizing ©2000 Xantrex Technology Inc.
  • Page 66 0.25 Television Washer Refrigerator* 480/3 = 160 3840 Vacuum Cleaner 1200 Total Daily Watt-Hours Autonomy Rough Battery Size Safe Battery Size Safe Battery Size Required Battery Size (Watt-Hours) (Watt-Hours) (Amp-Hours) 5,139 15,417 30,834 37,001 1,542 975-0012-016 ©2000 Xantrex Technology Inc.
  • Page 67 Each Week Watt-Hours Required AC Appliance Watts Step 6 Step 7 Step 8 Step 9 Step 10 Total Daily Watt-Hours Autonomy Rough Battery Size Safe Battery Size Safe Battery Size Required Battery Size (Watt-Hours) (Watt-Hours) (Amp-Hours) 975-0012-017 ©2000 Xantrex Technology Inc.

  • Page 68: Typical Appliance Wattages

    *Refrigerator (3 cu ft) Vacuum Cleaner 1200 *Refrigerator (12 cu ft) Coffee Maker 1200 * Refrigerators and icemakers typically run only 1/3 of the time, therefore, the running wattage is 1/3 or the total wattage of the appliance. 975-0012-018 ©2000 Xantrex Technology Inc.

  • Page 69: Battery Care And Maintenance

    5.0 APPENDIX Battery Care and Maintenance ©2000 Xantrex Technology Inc.
  • Page 70 5.0 APPENDIX Battery Care and Maintenance (continued) ©2000 Xantrex Technology Inc.
  • Page 71 24.6 49.2 2.05 12.2 24.4 48.8 2.03 12.1 24.2 48.4 2.02 12.0 24.0 48.0 2.00 11.8 23.6 47.2 1.97 11.7 23.4 46.8 1.95 11.6 23.2 46.4 1.93 < 11.6 < 23.2 < 46.4 < 1.93 975-0012-019 ©2000 Xantrex Technology Inc.

  • Page 72: Problem Loads

    5.0 APPENDIX Problem Loads ©2000 Xantrex Technology Inc.
  • Page 73 5.0 APPENDIX Problem Loads (continued) ©2000 Xantrex Technology Inc.

  • Page 74: Multiwire Branch Circuits

    The out-of-phase Bare–Ground Bare–Ground current flows through currents subtract Splice Splice each leg, only the at this point 25 A White–Neutral 25 A White–Neutral difference current Splice flows through the Splice neutral return wire. 062949-002 062949-002a ©2000 Xantrex Technology Inc.
  • Page 75 Single White–Neutral The in-phase currents Bare–Ground Bare–Ground add at this point Splice exceeding wire capacity! 25 A White–Neutral Splice 062949-003 Black From L1 Breaker From L2 To Branch Circuits Breaker Single Neutral White Ground Bare Copper 062949-005 ©2000 Xantrex Technology Inc.
  • Page 76 25 A Ground Breaker Breaker Hot-L2 (Ganged) (Ganged) Hot–L1 25 A Red–Hot White–Neutral 25 A Black–Hot 120 VAC 120 VAC Single White–Neutral The out-of-phase Bare–Ground Bare–Ground currents subtract at this Splice point 25 A White–Neutral Splice 062949-004 ©2000 Xantrex Technology Inc.

  • Page 77: Limited Warranty

    Xantrex agrees to supply all parts and labor to repair or replace defects covered by this warranty with parts or products of original or improved design, at the company's option. Xantrex also reserves the right to improve the design of its products without obligation to modify or upgrade those previously manufactured.
  • Page 78 6.0 WARRANTY Life Support Policy Xantrex does not recommend the use of any of its products in life support applications or direct patient care. This especially applies to situations where the product’s failure or malfunction can be reasonably expected to cause the failure or malfunction of the life support device, or to significantly affect its safety or effectiveness.

  • Page 79: 7.0 Service Information

    7.0 SERVICE INFORMATION Xantrex Technology Inc. takes great pride in its products and makes every effort to ensure your unit fully meets your independent powering needs. If your product needs repair, contact our Service department at: (360) 435-8826 to obtain an RMA# and shipping information;...

  • Page 80: 8.0 Specifications

    21.6 cm W x 18.4 cm H x 54.6 cm D Mounting wall-mount (with 16” mounting centers) shelf-mount Allows for hardware extensions such as mounting rails, DC terminals, and front panel controls. Specifications subject to change without notice. ©2000 Xantrex Technology Inc.
  • Page 84 Xantrex Technology Inc. 5916 195th Northeast Arlington, WA 98223 U.S.A. t: 360/435.8826 © 2000 Xantrex Technology Inc. f: 360/435.3945 www.xantrex.com P/N 975-0012-01-01 Rev. A 12/00 Printed in U.S.A.

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