Page 1 Smart choice for power SW 2524 SW 2548 Owner’s Manual Sine Wave Plus Inverter/Charger www.xantrex.com...
Page 3 Sine Wave Plus Inverter/Charger Owner’s Manual...
Page 4: Contact Information
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, micro turbines, 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.
Page 5: About This Manual
About This Manual Purpose The purpose of this Owner’s Manual is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the Sine Wave Plus Inverter/Charger. Scope 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 About this Guide Organization This guide is organized into nine chapters and nine appendices. Chapter 1, “Introduction” explains the basic features of the Sine Wave Plus Inverter/Charger and describes the optional accessories that may or may not be required for the desired installation configuration. Chapter 2, “System Configuration”...
Page 7: Conventions Used
About this Guide Appendix D, “Generators” supplies information about generator starting. Reading this chapter will help you determine what kind of generator to use, if any. Appendix E, “Over-Charge Protection” supplies information about options for over-charge protection. Appendix F, “Multiwire Branch Circuit Wiring” supplies information about Multiwire Branch Circuit Wiring Precautions when using stand- alone 120 Vac inverters or generators.
Page 8 About this Guide Use Important for content which is important that the Important: reader know, but not as serious as a caution or warning. Related Information You can find more information about Xantrex Technology, Inc. as well as its products and services at www.xantrex.com You may also need to reference the following installation guides to assist with this installation.
Page 9: Important Safety Instructions
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, and all appropriate sections of this manual.
Page 10: Explosive Gas Precautions
Important Safety Instructions 9. Do not expose this unit to rain, snow, or liquids of any type. This product is designed only for use indoors. Damp environments will significantly shorten the life of this product and corrosion caused by dampness will not be covered by the product warranty. 10.
Page 11: Table Of Contents
Contents Important Safety Instructions Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii 1 Introduction Basic Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2...
Page 12 Contents Additional/Optional Equipment Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22 AC Conduit Box (ACCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22 DC Conduit Box (DCCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23 Fuse Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24 DC Disconnect Boxes (DC 175/DC250) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24...
Page 13 Contents Battery Bank Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–4 Unpacking and Inspecting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–5 Knockout Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–7 Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8...
Page 14 Contents 5 Navigation Navigating the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 The Inverter Control Module (ICM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Inverter Control Module Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 The display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3...
Page 15 Contents 12D Equalize Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–16 12E Max Charge Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–18 12F Bulk Done Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–19 12G EQ VDC Done Timer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20...
Page 16 Contents 23F RY10 Delay at Engz. Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16 23G RY11 Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16 Generator Starting Scenarios - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–18 Manual Generator Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–19...
Page 17 Contents AC Input Status (Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–5 Charge Status (Yellow and Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6 Operational Status Indication (Red and Yellow) - - - - - - - - - - - - - - - - - - - - - - -8–7 Error LED Reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–8...
Page 18 Contents 05A Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25 05B Transformer Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25 05C Heatsink Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26 05D Low Battery Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26...
Page 19 Contents B Configuration Settings User Menu Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5 Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–7 C Battery Information...
Page 20 Contents E Over-Charge Protection Over-voltage Protection using a Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - E–2 Diversion Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E–3 F Multiwire Branch Circuit Wiring Multiwire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–2 Identifying Multiwire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–4...
Page 21 Figures Figure 1-1 Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-2 The Front Side of the Sine Wave Plus...
Page 22 Figures 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...
Page 23 Figures Figure 7-8 RY7 and RY8 Timing Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29 Figure 7-9 RY7/RY8 Sequence of Events for RN1 or RN2 Selection - - - - - - - - - - - 7–30 Figure 7-10 RY7/RY8 Sequence of Events for GS Selection - - - - - - - - - - - - - - - - - 7–31 Figure 8-1 LED Indicators- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3...
Page 24 xxii...
Page 25 Tables Table 2-1 Recommended Minimum Safety Ground Wire and DC Disconnect Sizes per NEC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Table 2-2 Minimum Required Battery Cable Size Versus Length - - - - - - - - - - - - - 2–14 Table 2-3...
Page 26 xxiv...
Page 27: Introduction
Introduction Chapter 1, “Introduction” explains the basic features of the Sine Wave Plus Inverter/Charger and describes the optional accessories that may or may not be required for the desired installation configuration.
Page 28: Basic Features
Introduction Basic Features Congratulations on your purchase of a Sine Wave Plus Inverter/Charger from Xantrex Technology, Inc. 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: •...
Page 29: Front Panel
Basic Features Figure 1-1 The Sine Wave Plus Front Panel The front of the Sine Wave Plus has the following features: • the Inverter Control Module (ICM) • the AC Access Cover Inverter Control Module AC Access Cover Figure 1-2 The Front Side of the Sine Wave Plus 976-0043-01-01 1–3...
Page 30: Ac Side
Introduction AC Side The AC side of the Sine Wave Plus has the following features: • The Remote Monitor Port for connecting the Inverter Control Module (ICM) or the Inverter Communications Adapter (ICA) • The Stacking Port for connecting two Sine Wave Plus inverters •...
Page 31: Emergency Power Off (Epo) Option
Basic Features Emergency Power Off (EPO) Option Sine Wave Plus offers an 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.
Page 32: Dc Side
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 Negative (–) Positive (+) Battery Terminal Battery Terminal...
Page 33: Battery Temperature Sensor (Bts)
Basic Features Battery Temperature Sensor (BTS) A BTS is provided 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 temperature. Installing a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures.
Page 34: Top
Introduction The top of the unit has the following features: • Circuit Breaker - This circuit breaker protects the unit’s internal wiring while the unit is inverter or charging. It is not used for the pass-through current. This is not a branch-circuit rated breaker. Separate output breakers are still required.
Page 35: System Configuration
System Configuration Chapter 2, “System Configuration” contains information to help you configure the Sine Wave Plus Inverter/Charger off-grid, on-grid, and backup power applications.
Page 36: Types Of Applications
System Configuration Types of Applications Sine Wave Plus Inverter/Charger can be configured for the following applications: • OFF-GRID (stand-alone) applications 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 operate the AC loads when the Utility System (grid) fails, keep the batteries charged, and/or function as an energy management controller.
Page 37 Pre-Configuration Planning ❐ Mounting location for optimal performance and easy access of all Location Considerations components ❐ Ventilation and clearance requirements for all components ❐ Mounting method (wall or shelf) ❐ Additional items/materials required for mounting ❐ Grounding type (i.e., ground bar, ground bus, or ground rod) Grounding Considerations ❐...
Page 38: System Output Requirements
System Configuration System Output Requirements Determine 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 determine continuous power requirements. •...
Page 39: Mounting Considerations
Pre-Configuration Planning WARNING: Explosion and Corrosion Hazards Do not locate the inverter directly above the batteries or in the same compartment as vented batteries. Vented batteries generate hydrogen and oxygen, which if accumulated, can be ignited by an arc caused by connecting the battery cables or switching a relay.
Page 40: Ventilation Requirements
System Configuration Clearance for fire Please keep all readily flammable materials (cloth, paper, straw, plastic safety etc.) at a minimum clearance of 24" (60 cm.) from the top surface (when wall mounted) and 12" (27 cm.) from either side surface and the front of Sine Wave Plus.
Page 41: Inverter Grounding
Pre-Configuration Planning Positive Ground A positive ground is where 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 A negative ground is where the negative conductor from the battery bank is bonded to earth ground.
Page 42: Equipment Or Chassis Grounding
System Configuration Table 2-1 Recommended Minimum Safety Ground Wire and DC Disconnect Sizes per NEC Battery DC Minimum Size of Disconnect Size Copper Ground Wire 30 amp or 60 amp #10 AWG 100 amp #8 AWG 200 amp #6 AWG 300+ amp #2 AWG or greater Field experience has demonstrated that long distances or high...
Page 43: Bonding The Grounding System
Pre-Configuration Planning grounding electrode. The rod should be 5/8 inch (16 mm) round by 8 feet (2 meters) long and driven into the earth. It is also common to use copper wire placed in the concrete foundation of the building as a grounding system.
Page 44: Battery Considerations
System Configuration “serviceable” item that may be removed from the system. In residential systems, it is located at the utility panel, after the power has gone through the kilowatt-hour meter of the utility (if present). Bonding at the AC Renewable energy systems, with no grid connection, can be grounded at Panel the main AC distribution panel.
Page 45: Battery Bank Requirements
Pre-Configuration Planning Accessibility Locate the batteries in an accessible location 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 disconnects. Install the batteries to the right of a wall-mounted inverter for easy access to the DC side of the inverter and shorter cable runs.
Page 46: Battery Cable Requirements
System Configuration Preparing a battery bank includes the following considerations: 1. Determine types of batteries to be used. 2. Determine the number of batteries required for the battery bank. 3. Prepare the battery bank according to type of battery selected and configure the battery bank to optimize voltage output according to system requirements.
Page 47: Figure 2-1 Awg Wire Size Reference Chart
Pre-Configuration Planning fire caused by overheating wires. Any damage to the inverter caused by overheating from undersized wire is NOT covered by the Xantrex warranty. Important: Figure 2-1 is for reference only. Sizes shown are for the conductor. Do not include any insulation when determining your wire size.
Page 48: Table 2-2 Minimum Required Battery Cable Size Versus Length
System Configuration High quality battery cables are available from Xantrex in an assortment of lengths from 1½ to 10 feet in #2/0 AWG and from 1½ to 15 feet in #4/0 AWG sizes. These cables are color-coded with pressure crimped, sealed ring terminals.
Page 49: Battery Requirements For Dual Inverter Systems
Pre-Configuration Planning Table 2-3 Battery Cable to Maximum Breaker/Fuse Size Rating in Maximum Maximum “Free Cable Size Rating in Breaker/ Breaker/ Required Conduit Fuse Size Air” Fuse Size #2/0 (00) AWG 175 Amps 175 Amps 265 Amps 300 Amps #4/0 (0000) AWG 250 Amps 250 Amps 360 Amps...
Page 50: Figure 2-2 Sample Warning Sticker For Backfeed Conditions
System Configuration The negative ends 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 jumpered together so that they are also common with each other. Shunts near the Losses from the cables will cause each inverter to measure slight inverter...
Page 51: Battery Temperature
Pre-Configuration Planning DC disconnects and The size of the bonding jumper must be the same gauge as that of the over-current devices primary battery cable in which the overcurrent device (DC disconnect) is installed, and as always, the overcurrent device must be sized appropriately for all cables attached to it.
Page 52: Wiring Considerations
System Configuration Wiring Considerations Code Compliance Important: Be sure to consult the local and national electrical codes to confirm grounding and bonding requirements specific to the intended system. All wiring and installation methods should conform to applicable electrical codes and building codes. Conduit Boxes For maximum safety and, in some cases, for code-compliance, run the AC and DC cables in conduit(s).
Page 53: Wire Routing
Pre-Configuration Planning A fuse without a switchable disconnect alone does not meet Note: NEC code. Wire size for AC #6 AWG THHN wire for all AC wiring (input and output) is Connections recommended. Wire Routing Determine all wire routes both to and from the inverter, and which knockouts are best suited for connecting the AC conduits.
Page 54 System Configuration Purpose An engine generator can be used as follows: • as an input power source instead of (or in conjunction with) the utility power, or • as a backup power source (connected via additional hardware) to automatically power the loads when utility is not present (utility outage), and/or •...
Page 55 Pre-Configuration Planning Manual-start generators are started with a recoil-start pull cord. Electric- start generators are started by turning an ignition/starter key, switch, or similar means. These generators typically do not have self-protection features to shut down the generator in the event of low oil pressure, over-heating, overcranking, etc.
Page 56: Additional/Optional Equipment Considerations
System Configuration If used with an application that includes utility power, the generator will be started only if utility power is not available, as it is not possible to use both generator and utility power at the same time (except for scheduled exercise periods).
Page 57: Dc Conduit Box (Dccb)
Additional/Optional Equipment Considerations DC Conduit Box (DCCB) The DC Conduit Box (DCCB) connects to the DC side of the inverter and accepts DC conduit runs. It can also accommodate a fuse to comply with CSA requirements for Canadian installations. See the Fuse Block section below for additional information.
Page 58: Fuse Block
System Configuration Fuse Block The Trace™ brand fuse block (TFB) protects the power system’s DC wiring should an overcurrent condition occur. The fuse block is placed between the battery’s ungrounded conductor (usually the positive cable) and the DC input terminal of the inverter. The TFBs include a fast acting, current limiting class-T fuse providing extremely fast protection when a short circuit occurs.
Page 59: Battery Status Meter (Tm500A)
Additional/Optional Equipment Considerations Battery Status Meter (TM500A) The TM500A features six data monitoring functions and three indicators including: • State of charge/amp-hour content (full or percent of capacity) • State of charge/voltage (real-time voltage level, historical high and low system voltage) •...
Page 60: Remote Monitors
System Configuration Remote Monitors Three options are available for remote control and monitoring. • Use a remote ICM, which is identical to the inverter control module on the inverter, for distances of 25 or 50 feet (7.5 or 15 meters). •...
Page 61: Inverter Control Module (Icm)
Additional/Optional Equipment Considerations Inverter Control Module (ICM) The ICM allows remote control, monitoring, and adjustment of all inverter settings. The remote ICM comes with cables 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 on the front panel of the unit.
Page 62: Generator Start Module (Gsm)
System Configuration Generator Start Module (GSM) The GSM is an accessory that enables the inverter to start and stop generators equipped with auto-start features. Figure 2-11 Generator Start Module “Generator Considerations” on page 2–19, for information on using generators and Appendix D, “Generators”...
Page 63: Autotransformer For 240 Vac Applications (T240)
Additional/Optional Equipment Considerations 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 “step- down” the voltage to 120 Vac for the single inverter. For step-up and step- down functions, two T240s will be required.
Page 64: Renewable Energy Dc Input Sources
System Configuration Renewable Energy DC Input Sources Renewable energy sources (e.g., photovoltaic (PV) arrays, wind turbines, DC micro-hydro generators) can be used with the inverter to provide power for all applications—off grid and on grid. However, in addition to the actual RE equipment being used, other items may be needed to ensure safety in the overall system.
Page 65: Figure 2-15 Xantrex C-Series Charge Controllers
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 for rooftop-mounted PV systems on dwellings). It is not designed or intended to prevent electrical shock or to be used for PV DC overcurrent.
Page 66: Off-Grid Applications
System Configuration Off-Grid Applications 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 include: • renewable energy systems (with or without generator backup), and •...
Page 67: Figure 2-17 Off-Grid Application - Renewable Energy System Using A Single Inverter
Off-Grid Applications NOTES: Ensure all the DC negatives in the system are bonded to earth ground in only one place (single Always refer to your local electric codes for proper point bond). If you are using a PVGFP, allow this wiring instructions.
Page 68: Dual Inverter Configurations (240 Vac)
System Configuration Dual Inverter Configurations (240 Vac) If 240 Vac 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.
Page 69: Figure 2-18 Off-Grid Application - Renewable Energy System Using Dual Inverters
Off-Grid Applications NOTES: Ensure all the DC negatives in the system are bonded to earth ground in only one place (single Always refer to your local electric codes for proper point bond). If you are using a PVGFP, allow this wiring instructions.
Page 70: Generator-Only Systems
System Configuration Generator-Only Systems In these applications, an AC generator serves as the main AC source when batteries are insufficient to power the loads. Both an AC and a DC generator can provide a power source for the battery charger. With the aid of the Xantrex GSM, the Sine Wave Plus can turn on automatically most...
Page 71: Figure 2-19 Off Grid Generator-Only System Using A Single Inverter
Off-Grid Applications NOTES: If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor from off- Always refer to your local electric codes for proper site, an external modem is required at the inverter wiring instructions.
Page 72: Dual Inverter Configurations
System Configuration Dual Inverter Configurations If 240 Vac 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.
Page 73: Figure 2-20 Off Grid Application - Generator-Only System Using Dual Inverters
Off-Grid Applications NOTES: Ensure all the DC negatives in the system are bonded to earth ground in only one place (single Always refer to your local electric codes for proper point bond). If you are using a PVGFP, allow this wiring instructions.
Page 74: On-Grid Applications
System Configuration On-Grid Applications 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 generator to backup utility grid power.
Page 75: Figure 2-21 On-Grid Application - Backup System Using A Single Inverter
On-Grid Applications NOTES: Ensure all the DC negatives in the system are bonded to earth ground in only one place (single Always refer to your local electric codes for proper point bond). If you are using a PVGFP, allow this wiring instructions.
Page 76: Dual Inverter Configurations (240 Vac)
System Configuration Dual Inverter Configurations (240 Vac) If 240 Vac 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.
Page 77: Figure 2-22 On-Grid Application - Backup System Using Dual Inverters
On-Grid Applications NOTES: Ensure all the DC negatives in the system are bonded to earth ground in only one place (single Always refer to your local electric codes for proper point bond). If you are using a PVGFP, allow this wiring instructions.
Page 78: Energy Management
System Configuration Energy Management Sine Wave Plus can be programmed to control how and when to use utility power. Advanced features allow for peak load management and time-of-use billing. Utility management features also allow the Sine Wave Plus to use renewable energy sources on a first priority basis and use utility power as a last resort.
Page 79: Time-Of-Use (Tou) Metering
On-Grid Applications Time-of-Use (TOU) Metering Utilities use TOU metering to determine utility charges during peak usage hours and to impose a surcharge. The inverter can be configured to overcome these peak charges by using a battery (or battery bank) to store energy during the inexpensive energy hours and consumes the battery energy during expensive energy hours.
Page 80: Ac Load Support
System Configuration When using the system for TOU metering, the system should be designed with a battery capacity large enough to support the load during the entire peak rate period without reaching the 11C Low Battery Cut Out VDC voltage. To further ensure the batteries are able to support the load, an additional source of power (solar, wind or hydroelectric) is recommended.
Page 81: Renewable Energy With Grid Backup (Bx Mode)
On-Grid Applications UTILITY or GENERATOR + INVERTER SUPPORT VOLTAGE (from battery) INVERTER/CHARGER HEAVY Utility Grid or AC LOAD AC Generator BATTERY Figure 2-24 AC Support Mode Running and Start-up (Peak) currents are limited to the Note: maximum current limits of the inverter. In the AC support mode, the BULK or FLOAT charge indicator Note: LEDs may be ON even though the batteries are draining.
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Page 83: Installation
Installation Chapter 3, “Installation” describes how to mount and install Sine Wave Plus Inverter/Charger and perform cabling procedures for various configurations.
Page 84: Pre-Installation
Installation Pre-Installation Before installing the Sine Wave Plus, read all instructions and cautionary markings located in this manual. Installations should meet all local codes and standards and be performed by qualified personnel, such as a licensed electrician. Important: Be sure to obtain the appropriate permits, if necessary, prior to starting this installation.
Page 85: Hardware / Materials Required
Pre-Installation Hardware / Materials Required The following materials may be required 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) ❐...
Page 86: Battery Bank Preparation
Installation ❐ ICM/25 (Inverter Control Module with 25 foot cable connection) Remote Monitors ❐ ICM/50 (Inverter Control Module with 50 foot cable connection) ❐ ICA (Inverter Communications Adapter with 50 foot cable), for use with your computer. Can be used with a modem on site. Modem required for distances greater than 50 feet.
Page 87: Unpacking And Inspecting The Inverter
Pre-Installation 3. Determine the correct size of battery cables to use for installation. Table 2-2, “Minimum Required Battery Cable Size Versus Length” on page 2–14 for additional information and recommended battery cable sizing. 4. Determine the correct size of DC breaker/fuse to use for installation. Table 2-3, “Battery Cable to Maximum Breaker/Fuse Size”...
Page 88: Figure 3-1 Certification Label Location
Installation ❐ Save the original shipping carton and packing materials. If the inverter ever needs to be returned for service, it should be shipped in the original carton. This is also a good way to protect the inverter if it ever needs to be moved.
Page 89: Knockout Preparation
Pre-Installation Important: The exclamation symbol below the CSA logo on the certification label indicates the need to add overcurrent protection. It shall be installed at the battery as part of the installation in accordance with your local electrical code. Table 2-3, “Battery Cable to Maximum Breaker/Fuse Size”...
Page 90: Mounting
Installation Mounting WARNING: Personal Injury Hazard Do not attempt to mount this unit on the wall by yourself. Have additional help available to assist in lifting the unit during installation. Sine Wave Plus can be either shelf-mounted or wall-mounted. Be sure to use appropriate lifting techniques and have extra people available to assist in lifting the inverter into position while it is being secured.
Page 91: Figure 3-3 Dimensional Drawing
Pre-Installation 21" 16" Keyhole slots 1" 1½" 1½" 1" " 6-½" 6½" ½" 1½" 1½" 14 " " Mounting Holes Size = 0.375" diameter Keyhole slots Mounting Holes 1" 2½" 10½" 17" " 20" ***NOT TO SCALE*** Figure 3-3 Dimensional Drawing 976-0043-01-01 3–9...
Page 92: Wall-Mounting
Installation Wall-Mounting Wallboard is not strong enough to support the weight of the inverter, so additional support must 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 The easiest method for securing the inverter to an existing wall is to place using 2 x 4’s...
Page 93: Figure 3-4 Wall-Mounting Method Using 2 X 4'S
Pre-Installation Wall studs 16 inches on center Ceiling Set Inv erter 2 x 4 OFF SRCH ON CHG mounting 14–3/8" supports Sine Wave Plus Inverter/Charger Keyhole Slots Mounting Holes (10) Wallboard Approx. 4–5 ft Floor Figure 3-4 Wall-Mounting Method using 2 x 4’s 976-0043-01-01 3–11...
Page 94 Installation Wall Mounting Alternatively, a half sheet (4 ft x 4 ft) of ¾-inch plywood can also be used using Plywood 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 adequate support.
Page 95: Figure 3-5 Wall Mounting Using Plywood
Pre-Installation Wall studs 16 inches on center Ceiling Se t In v e rte r OFF SRCH ON CHG Sine Wave Plus Inverter/Charger Mounting Keyhole Holes (10) Slots (4) Plywood Wallboard Floor Figure 3-5 Wall Mounting using Plywood 976-0043-01-01 3–13...
Page 96: Dc Wiring
Installation DC Wiring DC wiring includes the following steps (described in the following locations). ❐ “Preparing the Battery Bank” on page 3–14 ❐ “Grounding the DC System” on page 3–15 ❐ “Connecting DC Input Sources – Renewable Energy Configurations” on page 3–18 ❐...
Page 97: Figure 3-6 Chassis Ground Lug Location On Inverter Dc End
DC Wiring WARNING: Fire Hazard Undersized cables can overheat and melt creating a fire hazard when subjected to heavy (peak) loads. Always 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.
Page 98: Figure 3-7 Dc Grounding Of A Single Inverter
Installation Single Inverter To ground a single inverter: 1. Connect the ground bond in the DC disconnect to the primary grounding electrode, in accordance with local and national electrical codes. 2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconnect.
Page 99: Figure 3-8 Dc Grounding Of Dual Inverters
DC Wiring Dual Inverters To ground a dual inverter configuration: 1. Connect the ground bond in the DC disconnect between the inverters and the batteries to the primary grounding electrode, in accordance with local and national electrical codes. 2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconnect.
Page 100 Installation Connecting DC Input Sources – Renewable Energy Configurations Renewable energy sources (e.g., PV arrays, wind turbines etc.) may require additional equipment such as charge controllers, diversion load controllers, PV Ground Fault Protection and additional fuses and/or disconnects. Since every configuration is unique, specific installation instructions can not be provided.
Page 101: Figure 3-9 Bts (Rj11) Port Location And Installation
DC Wiring BTS (RJ11) Port DC End of the Inverter Figure 3-9 BTS (RJ11) Port Location and Installation 976-0043-01-01 3–19...
Page 102: Figure 3-10 Dc Terminal Connections On The Inverter
Installation Connecting the Batteries to the Inverter WARNING: Shock Hazard Before making any connections, verify that the DC disconnect device is switched OFF. DC terminal connections are located on the DC end of the inverter. Figure 3-10 shows the locations of the DC connectors. Positive (+) Red Negative (–) Black DC Terminal...
Page 103: Figure 3-11 Battery Cable Connection
DC Wiring Figure 3-11 shows the proper method to attach the cables to the inverter. Terminal Surface Battery Cable Figure 3-11 Battery Cable Connection CAUTION: Damage to Equipment Do not put anything between the cable ring terminal and the flat metal part of the terminal.
Page 104: Procedure For Single Inverter Systems
Installation Procedure for Single Inverter Systems Before starting this procedure, please review Figure 3-10, “DC Terminal Connections on the Inverter” on page 3–20 Figure 3-11, “Battery Cable Connection” on page 3–21 for the locations of the terminals and details on attaching positive (+) and negative (–) cables to terminals on the inverter DC end.
Page 105: Figure 3-13 Dc Connections To A Single Inverter
DC Wiring Figure 3-13 DC Connections to a Single Inverter 976-0043-01-01 3–23...
Page 106: Procedure For Dual Inverter Systems
Installation Procedure for Dual Inverter Systems Before starting this procedure, please review Figure 3-10, “DC Terminal Connections on the Inverter” on page 3–20 Figure 3-11, “Battery Cable Connection” on page 3–21 for the locations of the terminals and details on attaching positive (+) and negative (–) cables to terminals on the inverter DC end.
Page 107: Figure 3-14 Dc Connections To Dual Inverters
DC Wiring Figure 3-14 DC Connections to Dual Inverters 976-0043-01-01 3–25...
Page 108: Ac Wiring
Installation AC Wiring This section describes: • “Accessing the AC Terminal Block and Ground Bar” on page 3–28 • “AC Wiring for Single Inverter Systems” on page 3–30 Disregard installation sections and illustrations that do not apply to your configuration (for example, installing utility panels in Off-Grid applications or wiring for generators when no generator is used, etc.) Before wiring the input of the inverter, refer to Table 3-1...
Page 109: Table 3-1 Maximum Ac Disconnect And Wire Sizing
AC Wiring Table 3-1 Maximum AC Disconnect and Wire Sizing Full Pass- Maximum Cable Size Through Fuse/Breaker Required in Capability Required Conduit 60 Amps 60 Amps #6 AWG (THHN) WARNING: Fire Hazard There is risk of fire if 120 Vac only sources (such as inverters and generators) are wired incorrectly into 120/240 Vac distribution panels containing multi-wire branch circuits.
Page 110: Accessing The Ac Terminal Block And Ground Bar
Installation Accessing the AC Terminal Block and Ground Bar All AC wiring connects to the AC terminal block located on the left-hand side of the inverter beneath the AC access cover. To remove the AC access cover: 1. Remove the Phillips screw from above the access cover. Place the loose screw somewhere safe where it will not be lost.
Page 111: Figure 3-16 Ac Input/Output Wiring Terminals
AC Wiring AC Terminal Block AC Terminal Block Enlargement Figure 3-16 AC Input/Output Wiring Terminals 976-0043-01-01 3–29...
Page 112: Ac Wiring For Single Inverter Systems
Installation AC Wiring for Single Inverter Systems There are three major steps in the procedure for AC wiring of single inverter systems. They are described in detail on the following pages: “Install AC Output Wiring to the Inverter AC Distribution Panel” on page 3–33 “Install Generator Wiring to the Inverter”...
Page 113 AC Wiring WARNING: Shock Hazard Auto-start generators can start automatically at any time. Affix the warning label (supplied with the GSM) regarding auto-start generators on or near the main AC distribution panel and near the generator. This will remind the operator that AC power may still be supplied from the generator and additional steps may be required to make the panel and the generator safe.
Page 114: Figure 3-18 Ac Input And Output Wiring To A Single Inverter With An Auto-Start
Installation Figure 3-18 AC Input and Output Wiring to a Single Inverter with an Auto-Start AC Generator 3–32 976-0043-01-01...
Page 115: Install Ac Output Wiring To The Inverter Ac Distribution Panel
AC Wiring Install AC Output Wiring to the Inverter AC Distribution Panel An Inverter AC Distribution Panel (referred to here as the inverter panel) and AC conduit must be installed before AC output wiring is connected to the inverter. The inverter panel is a sub-panel. Install the Inverter AC Distribution Panel and conduit as follows: 1.
Page 116: Figure 3-19 Ac Output Wiring To The Inverter Ac Panel
Installation Make connections from the inverter to the inverter panel as follows: 1. Connect the GROUND (green or bare) wire from the inverter AC GROUND bar to the inverter panel GROUND bar. 2. Connect the NEUTRAL (white) wire from the inverter NEUTRAL OUT terminal to the inverter panel NEUTRAL bus.
Page 117: Install Generator Wiring To The Inverter
AC Wiring Install Generator Wiring to the Inverter WARNING: Shock Hazard Before connecting any AC wiring, ensure that there is no DC energy accessible by the inverter by opening the DC disconnect switch. Generator Having a generator disconnect switch between the inverter and the Disconnect Switch generator is strongly recommended.
Page 118 Installation With T240 While performing the following procedure, please refer to Figure 3-20, “Generator Input Wiring to a Single Inverter” on page 3–37. Autotransformer and using a 120/ To install the AC wiring from the generator to the inverter: 240 Vac Generator 1.
Page 119: Figure 3-20 Generator Input Wiring To A Single Inverter
AC Wiring 3. Connect a HOT (black) wire a) from the generator GEN HOT OUT terminal to the circuit breaker in the generator disconnect, and b) from the circuit breaker in the generator disconnect to the inverter AC2 GEN terminal. 4.
Page 120: Install Utility Wiring To The Inverter Input (On-Grid Applications Only)
Installation Install Utility Wiring to the Inverter Input (On-Grid Applications only) CAUTION: Damage to Equipment The inverter’s AC output must never be wired to any AC source voltage such as a generator output or utility panel. This will cause severe damage to the inverter which is not covered under warranty.
Page 121: Optional Equipment
Optional Equipment Figure 3-21 Utility Wiring to the Inverter Input Optional Equipment Stacking Dual Inverter Systems To power 120/240 Vac loads you can link or stack two identical inverters together in series by using the ISC-S cable. The ISC-S cable connects to the stacking ports on the AC end of the Sine Wave Plus.
Page 122: Installing The Isc-S Cable
Installation Installing the ISC-S Cable CAUTION: Equipment Damage Damage can occur if the ISC-S cable is not properly installed. Do NOT use a standard computer cable in place of the ISC-S cable. To install the ISC-S cable on the inverters: 1.
Page 123: Remote Monitoring Options
Optional Equipment Remote Monitoring Options Sine Wave Plus can be controlled remotely by plugging-in an additional ICM or by using an ICA connected to a personal computer. The ICM operates identically to the inverter control module on the front of the Sine Wave Plus.
Page 124: Auxiliary Load Module (Alm)
Installation Auxiliary Load Module (ALM) The ALM can be used to signal loads to turn on and off based on battery voltage. The ALM is a DC voltage controlled relay (switch) that require Sine Wave Plus in order to operate. The DC voltage set points for energizing and de-energizing the relays are adjustable as are the time delays.
Page 125: Emergency Power Off (Epo)
Optional Equipment Emergency Power Off (EPO) Sine Wave Plus has an EPO communications port that is designed to allow a disconnect switch, using an RJ11-type jack, to function as an emergency shutoff switch. Many different switches are available for this purpose.
Page 126 3–44...
Page 127: Functional Test
Functional Test Chapter 4, “Functional Test” explains how to conduct a functional test of the inverter.
Page 128: Basic Functional Test
Functional Test Basic Functional Test The following steps will complete a basic functional test of the Sine Wave Plus. If any area fails, please refer to Chapter 9, “Troubleshooting” assistance. Confirm all Connections Once the AC and DC wiring have been installed and connected, take a moment to go back over all connections and make sure they are secure and have been installed properly.
Page 129: Turning On The Inverter
Basic Functional Test Turning ON the Inverter WARNING Prior to turning on the inverter, ensure that all AC loads are disconnected from the output of the inverter. To turn on the inverter: 1. Ensure that the LCD display is as shown in Figure 4-1.
Page 130: Ac Voltage Check
Functional Test AC Voltage Check To perform an AC voltage check: 1. With the inverter on (INVERT (yellow) LED on solid), verify with a handheld voltmeter the AC voltage from INV HOT to NEU OUT terminals of the inverter and ensure you get the correct AC voltage for your particular unit.
Page 131: Confirming Inverter Operation
Basic Functional Test Confirming Inverter Operation To confirm that the inverter is operating correctly: ◆ Disconnect the AC input power by turning the input AC power breaker off or unplugging the AC power cord. • The inverter should transfer to inverter mode immediately. This will be indicated by the INVERT (yellow) LED illuminating.
Page 132 4–6...
Page 133: Navigation
Navigation Chapter 5, “Navigation” explains how to navigate through the Sine Wave Plus Inverter/Charger menus using the Control Module and the menu maps.
Page 134: Navigating The Sine Wave Plus
Navigation Navigating the Sine Wave Plus Sine Wave Plus is programmed using the control module to access “User” and “Setup” menus. Navigating through the menus requires an understanding of the inverter control module (ICM) and its features and what menus are required to do specific functions and set, or change, parameters.
Page 135: Inverter Control Module Features
Inverter Control Module Features Inverter Control Module Features There are nine push-buttons, eight Light Emitting Diodes (LEDs), one contrast adjustment and one Liquid Crystal Display (LCD) on the front of the ICM. The push-buttons are grouped into sets depending on their function.
Page 136: Menu Heading Buttons
Navigation Menu Heading Buttons The Menu Heading push buttons are used to move either forward or backward through the Menu Heading selections. • Press the Menu Heading button to move forward. • Press the Menu Heading button to move backward. Menu Item Buttons Below the Menu Headings are subdirectories called Menu Items.
Page 137: Menu Map
Menu Map Menu Map Introduction The menu system contains three main menu maps. Each Menu Map is made up of: • Menu Headings, • Menu Items, and • Set points. A set point is selected when the cursor highlights the first letter, or number, of the selection.
Page 138 Navigation User Menu (01-07) The USER MENU allows access to the daily operational functioning of the unit. These Menu Headings do not set configuration parameters, but do provide system performance information. “The User Menu Summary” on page 8–11 for a summary of the default settings and display descriptions.
Page 139 Menu Map Figure 5-4 User Menu Map - Part 2 976-0043-01-01 5–7...
Page 140 Navigation Basic Setup Menu The BASIC SETUP MENU follows the User Menu in the menu architecture. This menu allows access to the settings required for system (10-14) configuration and modes of operation. Establishing these parameters upon initial power-up will be required. “Basic Setup Process”...
Page 141 Menu Map Figure 5-6 Basic Setup Menu Map Part 2 976-0043-01-01 5–9...
Page 142 Navigation Advanced Setup The ADVANCED SETUP MENU contains specialized configuration settings such as automatic generator starting details, auxiliary load usage, Menu (20-27) and energy management (grid usage) parameters. “Advanced Setup Summary” on page 7–2 for a listing of all the default settings for this menu structure.
Page 143 Menu Map 976-0043-01-01 5–11...
Page 144 Navigation 5–12 976-0043-01-01...
Page 145 Menu Map 976-0043-01-01 5–13...
Page 146 Navigation 5–14 976-0043-01-01...
Page 147: Basic Setup Programming
Basic Setup Programming Chapter 6, “Basic Setup Programming” explains how to program the Sine Wave Plus Inverter/Charger to operate under basic conditions.
Page 148: Basic Setup Summary
Basic Setup Programming Basic Setup Summary The following table provides the default settings for the Sine Wave Plus Basic Setup Menu and the cross-reference pages for locating information on each menu item. If your system requires changes to these default settings, record the changes in Table B-2, “Basic Setup Default and User Settings”...
Page 149 Basic Setup Summary Table 6-1 Basic Setup Menu Default Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Range/ Basic Setup Menus Display Default Display Default See Page 12D Equalize Volts DC 20.0 - 32.0 28.8 40.0 - 64.0 57.6 page 6–16 12E Max Charge Amps AC...
Page 150: Before You Begin Programming
Basic Setup Programming Before You Begin Programming Some items must be pre-determined or confirmed before you start programming the inverter/charger for use. These items include the voltage levels to operate the inverter, charging parameters for the battery charger, and AC input amperage limits. DC Amps verses AC Amps Some of the settings in the Basic Setup Menu may require you to convert DC amps to AC amps.
Page 151: Recording Changes
Before You Begin Programming Recording Changes As you determine the required parameters for this section, check your calculations against the default values shown in Table 6-1, “Basic Setup Menu Default Settings” on page 6–2. If your configuration requires making changes to the default settings, write the new settings on Table B-2, “Basic Setup Default and User Settings,”...
Page 152: Accessing The Basic Setup Menu
Basic Setup Programming Accessing the Basic Setup Menu To access the Basic Setup Menu: 1. If you have not already done so, turn on the inverter. 2. Press the button to move forward within the menu headings until the END USER MENU is displayed. 3.
Page 153: Menu Item Descriptions
Menu Item Descriptions Menu Item Descriptions 10 Time of Day Setup Menu This menu allows for setting the time of day in hours, minutes, and 10 Time of Day seconds. The time is displayed in a 24-hour format (i.e., 00:00:00 to Setup Menu 23:59:59 hours).
Page 154: Set Seconds
Basic Setup Programming 10C Set Seconds To set the second display: 10C Set Seconds 1. Press the button to select 10C Set Second. 2. When 10C Set Second is displayed, press the SET POINT buttons (+) or (–) to change the time displayed. The “seconds” section of the display will change in 1-second increments.
Page 155: Low Battery Cut In Vdc
Menu Item Descriptions 11B Low Battery Cut In VDC This menu item sets the battery voltage level that turns the inverter back 11B Low Battery on after being shut down by the LBCO setting. Set this voltage level Cut In VDC lower than the Bulk or Float volts DC setting.
Page 156: Search Watts
Basic Setup Programming 11E Search Watts This menu item sets the inverter’s search sensitivity. Any load that is 11E Search Watts below this setting does not cause the inverter to produce an AC output SRCH voltage when running from batteries. The SRCH function must be selected in 01A Inverter.
Page 157: Battery Charger Functions
Menu Item Descriptions If loads change significantly, then re-tuning of the search sensitivity will be required. It may take several adjustments to tweak the sensitivity to just the right point. If problem loads are in the system such as discussed previously, follow the suggestions given to eliminate the problem.
Page 158: Multi-Stage Charging Process
Basic Setup Programming Important: The default settings of the Sine Wave Plus may or may not work for your specific installation. Take the time to review the default settings to make sure they are appropriate for your installation. If not, you will need to adjust the settings according to the battery manufacturer’s recommendations.
Page 159 Menu Item Descriptions Bulk Stage Bulk charge is the first stage in the charging process and provides the batteries with a controlled, constant current. Once the battery voltage rises to the bulk voltage threshold, the charger switches to the Absorption Stage.
Page 160: Equalize Charging The Batteries
Basic Setup Programming Silent Mode After a bulk and absorption charge cycle is complete, the charger will shut down (go silent). AC voltage on the inverter’s input will pass-through to the loads. The charger continues to monitor the battery voltage in this mode and starts a float charge when certain conditions are met: •...
Page 161: Battery Charging Menu
Menu Item Descriptions WARNING: Explosion Hazard Only flooded or vented batteries should be equalize-charged. Hydrogen and oxygen gases are produced when batteries are equalize-charged. Provide adequate ventilation and remove all sources of ignition to prevent explosion. 12 Battery Charging Menu CAUTION: Damage to DC Loads and Batteries DC loads should be disconnected from the batteries during equalization charging to protect DC loads from high battery...
Page 162: Finish Stage
Basic Setup Programming 12A Finish Stage This menu item determines the Charging Mode (Silent or Float) after the 12A Finish Stage bulk and absorption charge have finished. Select either mode depending Silent Float on your installation. See “Float Mode” on page 6-13 for additional information.
Page 163: Table 6-2 Battery Voltages For Setting Charging Parameters
Menu Item Descriptions Table 6-2 Battery Voltages For Setting Charging Parameters BULK VOLTS FLOAT VOLTS 24-volt 48-volt 24-volt 48-volt Equalization Temp Battery Type models models models models Charge Process Comp Sealed Gel 28.2 Vdc 56.4 Vdc 27.2 Vdc 54.4 Vdc Not recommended - LeadAcid Lead Acid...
Page 164: Max Charge Amps Ac
Basic Setup Programming 12E Max Charge Amps AC This is the maximum AC amperage the inverter will provide to the battery 12E Max Charge charger to get the battery voltage up to the level set in one of the Amps AC following menu items depending on which mode the battery charger is in as indicated by the LEDs on the inverter’s display: •...
Page 165: Bulk Done Amps Ac
Menu Item Descriptions Table 6-5 Calculating the Maximum Charge Amps for a 48-volt, 350 amp-hour Battery Step Instruction Equation Multiply the total battery amp hours by 350 x 10% = 35 (DC Max Charge Rate) Divide the DC Max Charge Rate by 35 ÷...
Page 166: Eq Vdc Done Timer
Basic Setup Programming Table 6-6 Calculating the Bulk Done Amps for a 24-volt, 700 amp-hour Battery Step Instruction Equation Multiply the total battery amp 700 x 2% (3%, 4%) = 14 (21, 28) hours by 2% (3%, 4%) AC Bulk Done Charge Rate) Divide the AC Bulk Done Charge 14 ÷...
Page 167: Max Bulk/Eq Timer H:m
Menu Item Descriptions 12H Max Bulk/EQ Timer h:m This is the maximum time the charger is allowed to keep the batteries in 12H Max Bulk/EQ the Bulk or EQ Charge Stage. This timer starts when either the Equalize Timer h:m Charge starts or when the Bulk Charge starts.
Page 168: Ac Inputs Menu
Basic Setup Programming Temperature compensation calculations are derived from the following table: Table 6-8 Inverter Temperature Compensation Calculation using the Battery Type 24-volt Systems 48-volt Systems Lead Acid 0.060 volts (60 mV) 0.120 Volts (120 mV) per degree Celsius per degree Celsius NiCad 0.040 volts (40 mV) 0.080 volts (80 mV)
Page 169: Grid (Ac1) Amps Ac
Menu Item Descriptions 13A Grid (AC1) Amps AC This is the maximum amount of current that can be drawn from the grid 13A Grid (AC1) (AC1 input) by the loads and battery charger combined. This settings Amps AC determines the amperage level at which point the inverter starts drawing power from the batteries to add to the utility power to meet the demand of the loads.
Page 170: Input Upper Limit Vac
Basic Setup Programming 13C Input Upper Limit VAC This menu item sets the highest voltage at which the inverter is allowed to 13C Input Upper connect to either AC1 or AC2 inputs. When this voltage is reached the Limit VAC inverter disconnects from the grid or generator and provides power to the loads from the batteries as long as the inverter selection in menu 01A Inverter is ON or SRCH.
Page 171: Save/Restore Settings Menu
Menu Item Descriptions 14 Save/Restore Settings Menu This menu provides the means to: 14 Save/Restore Settings Menu • save user programmed settings, • restore previously saved programmed settings, or • to restore factory default settings. If DC power is removed from the inverter, all user defined setpoints will be intact if they were saved before the power was removed.
Page 172: Push Gen For Factory Defaults
Basic Setup Programming 14C Push GEN for factory defaults This menu item provides the means to restore the factory default settings. 14C Push GEN for factory defaults To restore the factory default settings: 1. Press the button until 14C Push Gen For Factory Defaults is displayed.
Page 173: Advanced Setup
Advanced Setup Chapter 7, “Advanced Setup” explains how to program the Sine Wave Plus Inverter/Charger to operate under special, advanced conditions, such as automatic generator starting, energy management and auxiliary load applications.
Page 174: Advanced Setup Summary
Advanced Setup Advanced Setup Summary The following table provides the default settings for the Sine Wave Plus Advanced Setup Menu and cross-reference pages for locating information on each menu item. If your system requires changes to these default settings, record the changes in Table B-3, “Advanced Setup Default and User Settings”...
Page 175 Advanced Setup Summary Table 7-1 Advanced Setup Menu Headings and Default Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default Advanced Setup Menus Display Settings Display Settings See Page 23C RY9 Delay at DeEngz. Min 00 - 255 00 - 255 page 7–15 23D RY10 VDC Energized...
Page 176 Advanced Setup Table 7-1 Advanced Setup Menu Headings and Default Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default Advanced Setup Menus Display Settings Display Settings See Page 26C Load Stop Delay Min 00.0 - 25.5 05.0 00.0 - 25.5 05.0...
Page 177: Before You Begin Advanced Programming
Before You Begin Advanced Programming Before You Begin Advanced Programming Sine Wave Plus is designed to provide advanced application programming. Advanced applications include: • SILENT SETUP - Sets the parameters for the Silent finish stage of battery charging. This feature is programmed in Menu Heading 20. “20 Silent Setup Menu”...
Page 178: Accessing The Advanced Setup Menu
Advanced Setup Accessing the Advanced Setup Menu To access the Advanced Setup Menu from the User Menu: 1. Press the button to move forward within the Menu Headings until the END USER MENU is displayed. 2. Press and hold down the green GEN button. 3.
Page 179: Figure 7-2 Accessing The Advanced Setup Menu
Accessing the Advanced Setup Menu 5. From here you can, either a) Press the button to move forward within the Menu Headings until the END BASIC SETUP MENU is displayed. b) Or proceed to Steps 5 and 6. 6. Press and hold down the green GEN button. 7.
Page 180: Menu Item Descriptions
Advanced Setup Menu Item Descriptions 20 Silent Setup Menu This menu is used only when SILENT is selected in menu 12A Finish 20 Silent Setup Stage. When the Silent mode is selected, the charger is turned OFF and Menu does not supply any charging current to the batteries until certain conditions based on battery voltage are met.
Page 181 Menu Item Descriptions Silent mode will begin after the charge routine has finished the bulk/ absorption charge and if the silent charge has been selected (from Menu item 12A Finish Stage). After entering the Silent mode, there will be a minimum 60 second delay, then the inverter will monitor the battery voltage to determine if the voltage is at or above the 20A Refloat High Volts DC setting or if the voltage has fallen to or below the 20B Refloat...
Page 182: Refloat High Volts Dc
Advanced Setup This information is provided for guidance only. Variations in Note: battery chemistry, as well as site specific environmental considerations, mean that you should consult your system designer or battery manufacturer for specific recommendations for appropriate battery voltage and current settings. An amp-hour meter (e.g., Xantrex TM500A) would be useful to verify your settings are correct to maintain a proper charge on the batteries.
Page 183: Must Float Time Min
Menu Item Descriptions Table 7-2 Calculating the Float Done Amps for a 24-volt, 700 amp-hour Battery Step Instruction Equation Multiply the total battery amp 700 x 1% = 7 hours by 1% (DC Max Charge Rate) Divide the DC Max Charge Rate 7 ÷...
Page 184: Grid Usage
Advanced Setup 21A Grid Usage This menu item allows you to select between the set points SB and BX as 21A Grid Usage described below. SB BX SB (Standby) - Utility Backup This set point is the first set point selection in the 21A Grid Usage menu.
Page 185: Grid Usage End H:m
Menu Item Descriptions The clock is in a 24 hour format (00:00 to 23:59 hours). Guidelines for setting this menu item: • Ensure the current time is set correctly in menu 10 Time Of Day Setup Menu. • The timer function is deactivated if the 21C Grid Usage Begin h:m is the same as the 21D Grid Usage End h:m time.
Page 186: High Xfer (Hbx) Vdc
Advanced Setup 22A High Xfer (HBX) VDC This menu is used to set the voltage transfer point when the inverter turns 22A High Xfer back on and resumes powering the AC loads from the batteries. When this (HBX) VDC setting is reached, the inverter transfers from the AC1 input (grid) to the batteries to power the loads.
Page 187: Ry9 Vdc Energized
Menu Item Descriptions RY11 RY11, when ERROR is selected, is used as an inverter error detection indicator device to display or sound an alarm when the inverter AC output is lost. If COOLDOWN is selected, this will allow both inverters to have a cooldown period when used in a series-stacked configuration.
Page 188: Ry10 Vdc Deenergized
Advanced Setup 23E RY10 Vdc DeEnergized This menu item sets the trip point where the relay de-energizes. When the 23E RY10 Vdc voltage, based on the 04B Battery Comp VDC display, drops to or below DeEnergized this setting, the relay de-energizes and opens the contacts between the N.O.
Page 189: Figure 7-3 Relay 11 Wiring Example To Dual Inverters With Cooldown Selected
Menu Item Descriptions Figure 7-3 Relay 11 Wiring Example to Dual Inverters with Cooldown selected 976-0043-01-01 7–17...
Page 190: Generator Starting Scenarios
Advanced Setup Generator Starting Scenarios Important: Automatic generator control features require the additional purchase of the Xantrex GSM. Sine Wave Plus can be configured to start and stop a majority of backup generators, either manually or automatically. Automatic operation can be triggered based on time, AC current, battery voltage, or to exercising the generator.
Page 191: Manual Generator Control
Menu Item Descriptions Manual Generator Control The generator equipped for remote starting capabilities can be remotely started by selecting ON from 02A Generator. If the generator started in this manner, the 02C GEN Start Volts/Manual menu item will display YES. The generator will continue to run unless one of the following procedures is performed: 1.
Page 192 Advanced Setup Battery Voltage The generator starts whenever the battery voltage reaches one of the four adjustable low battery voltage levels for the selected delay periods (24 hours, 2 hours, 15 minutes, or 30 seconds). The low battery voltage levels are set under the 26 Gen Auto Run Setup Menu.
Page 193 Menu Item Descriptions Notes: 1. The generator will be prevented from automatically starting when the inverter’s time of day is in the “quiet time” period–between 24C Quiet Time Begin h:m and 24D Quiet Time End h:m. At which time, it will only start if the 11C Set Low Battery Cut Out VDC or 26G Read LBCO 30 Sec Start setting for the LBCO delay period is reached.
Page 194: Generator Timers Menu
Advanced Setup 24 Generator Timers Menu This menu heading sets parameters for starting the generator based on 24 Generator time. In this menu, you can set the generator to start and stop at a Timers Menu specified time each day. You can specify a quiet time, an exercise time, and a cooldown period for the generator.
Page 195: Quiet Time End H:m
Menu Item Descriptions 24D Quiet Time End h:m This menu item ends the quiet time, after which the generator can be 24E Quiet Time started if required, if an auto-start condition exists. End h:m To completely disable the quiet-time feature, set the start and stop times to the same value.
Page 196: Rn2/Max Gen Run H:m
Advanced Setup 24H RN2/Max Gen Run h:m This menu item sets the limit on how long a generator can run when the 24H RN2/Max Gen RY7 Relay is programmed for RN2 under menu item 25A RY7 Mode. Run h:m The set points for this menu item change in 10-minute increments. 25 Gen Starting Details Menu Menu Heading 25 Gen Starting Details provides menu items for setting 25 Gen Starting...
Page 197: Ry7 Mode
Menu Item Descriptions CONTROL INVERTER/ GEN START CHARGER LOADS MODULE CONTROL BATTERY GENERATOR Figure 7-5 Generator Control Mode (RN2) Guidelines for setting this menu item: • When using a DC generator as a charging source, none of the inverter's charge control features (bulk, absorption, float) will be available.
Page 198: Figure 7-6 Ry7'S Com And N.o. Contacts Close (Energize) To Run Generator
Advanced Setup This selection provides a run signal by holding the RY7 relay closed between contacts N.O. and COM. and requires the AC generator output to be monitored by the inverter’s AC2 input. RN2 This selection provides a run signal by holding the RY7 relay closed between contacts N.O.
Page 199 Menu Item Descriptions RY8 Relay (GS and RN1 only) The RY8 is energized (COM and N.O. contacts remain closed) only during the 25D Max Cranking Seconds. This is usually wired to the starter solenoid (relay) of the generator engine. The RY8 Relay energizes after an initial 25C Set Pre Crank Seconds delay period or de-energizes once the inverter senses AC voltage above 80 Vac on its AC2 input terminal.
Page 200: Figure 7-7 Wiring Examples Of Honda™ And Onan™ Generators
Advanced Setup GENERATOR START MODULE HONDA TYPE GENERATOR N.O. RUN/STOP SWITCH CONTACTS N.C. 5 AMP FUSE N.O. START SWITCH CONTACTS N.C. 5 AMP FUSE GENERATOR START MODULE ONAN TYPE GENERATOR N.O. STOP SWITCH CONTACTS N.C. 5 AMP FUSE N.O. START SWITCH CONTACTS N.C.
Page 201: Figure 7-8 Ry7 And Ry8 Timing Diagram
Menu Item Descriptions The Generator auto-start sequence is initiated if: 1) The time set in 24D Quiet Time End has been reached or passed. 2) If the battery voltage remains below the 11C Low Battery Cut Out VDC setting for the required period of time or if below the 26G Read LBCO 30 Sec Start VDC setting for 30 seconds.
Page 202: Figure 7-9 Ry7/Ry8 Sequence Of Events For Rn1 Or Rn2 Selection
Advanced Setup 1) Manual turn OFF. BEGIN 2) Load is reduced. and continue 3) Charger finishes: clockwise a) RN1 finished bulk and absorption charges or reaches 24H RN2 Max Gen Run Time . 1) Manual turn ON. b) RN2 reaches the 24H RN2 MAX 2) Load Start.
Page 203: Figure 7-10 Ry7/Ry8 Sequence Of Events For Gs Selection
Menu Item Descriptions BEGIN and continue clockwise 1) Manual turn ON. 2) Load Start. 3) Voltage Start. 4) Exercise Start. 5) Gen Run Start Time. Generator OFF Command to Start Gen Stop Command 1) Manual turn OFF. Command 80 Vac on 2) Load is reduced.
Page 204: Gen Warm-Up Seconds/Minutes
Advanced Setup 25B Gen Warm-up Seconds/minutes This menu item sets the number of seconds or minutes the generator is 25B Gen Warm-up allowed to warm up before the load is connected and the battery charger Seconds/Minutes started. If the generator is located in a cold location, a longer setting may be required.
Page 205: Gen Auto Run Setup Menu
Menu Item Descriptions 26 Gen Auto Run Setup Menu Menu Heading 26 Gen Auto Run Setup Menu provides the menu items 26 Gen Auto Run for setting the parameters for starting the generator based on AC current Setup Menu and/or battery voltage. 26A Load Start Amps AC This menu items sets the AC load current that initiates automatic 26A Load Start...
Page 206: 15 Min Start Volts Dc
Advanced Setup 26F 15 Min Start Volts DC This menu item sets the battery’s DC voltage level which initiates 26F 15 Min Start automatic generator starting whenever the voltage drops below this Volts DC setting continuously for 15 minutes. This item is not temperature compensated and is defeated during the quiet time period set in the 24 Generator Timers Menu.
Page 207: Push Gen To Restore Settings
Menu Item Descriptions 27B Push GEN to Restore Settings This menu item provides the means to restore settings previously set and 27B Push GEN to saved on the inverter. Restore Settings To restore settings previously programmed into the inverter: 1. Press the button to select 27B Push Gen Now To Restore Settings.
Page 208 7–36...
Page 209: Operation
Operation Chapter 8, “Operation” explains how to operate the Sine Wave Plus Inverter/Charger. It also explains how to read the LED indicators and User Menus to determine system status.
Page 210: Operating The Sine Wave Plus
Operation Operating the Sine Wave Plus User Menu Sine Wave Plus uses the User Menu architecture to navigate through the operational functions of the inverter/charger. The User Menu contains Operational Menus (01-02) and Operational Status Menus (03-07) to assist the user to determine what the system is doing at any given time. Startup checks When you first power up the system, perform the following system checks.
Page 211: Operational Status Indicators
Operational Status Indicators Operational Status Indicators Sine Wave Plus uses a combination of LED indicators and User Menu Headings (2-7) to display system status. Use both of these features to assess operational status. LED Indicators Eight, colored status LEDs indicate the various operating conditions of the inverter.
Page 212: Inverter Operation Status (Yellow)
Operation Inverter Operation Status (Yellow) There are two yellow LEDs to indicate the following inverter operational modes. • GRID TIE LED - This feature is not available at this time. • INVERT LED Figure 8-2 Inverter Operation Status LEDs GRID TIE LED This feature is not enabled on this model.
Page 213: Ac Input Status (Green)
Operational Status Indicators AC Input Status (Green) Status LEDs There are two green LEDs to indicate AC status conditions. • AC1 LED (grid) • AC2 LED (generator) Figure 8-3 AC Status LEDs AC1 (Grid) The AC1 LED indicates power has been applied to the inverter’s AC1 (grid) input terminals.
Page 214: Charge Status (Yellow And Green)
Operation Charge Status (Yellow and Green) Charging indicators There are two LEDs for battery charging indications. • Bulk Charge LED (yellow) • Float Charge LED (green) Figure 8-4 Charge Status LEDs Bulk Charge LED This LED indicates if the inverter is in the Bulk or Absorption charge (Yellow) stage.
Page 215: Operational Status Indication (Red And Yellow)
Operational Status Indicators Operational Status Indication (Red and Yellow) There are two LEDs for Error and Status Indications: • ERROR LED (red) • STATUS LED (yellow) Figure 8-5 Error and Status LEDs ERROR LED (Red) This LED indicates an operating error occurred or an error condition exists.
Page 216: Error Led Reset
Operation Error LED Reset Reset To reset the inverter after resolving an error condition, press the red INV button (INVERTER ON/OFF Menu) and select OFF and then ON with the SETPOINT BUTTONS. STATUS LED The status LED illuminates to indicate various conditions of the inverter/ (Yellow) charger.
Page 217: Led Summary
Operational Status Indicators LED Summary Table 8-1 summarizes the LED indicators. Table 8-1 LED Summary Table LED Name FLASHING Grid Tie LED Not available (yellow) Invert LED Inverter is OFF. No The inverter is on and is SLOW FLASH (1 blink/4 sec): (yellow) power is available currently providing power from...
Page 218 Operation Table 8-1 LED Summary Table LED Name FLASHING Error LED No error has been An Inverter error condition has A generator error has been (red) detected. been detected. detected. Use 05 Error Causes Menu to Use 05 Error Causes Menu to determine the cause of the error.
Page 219: The User Menu Summary
The User Menu Summary The User Menu Summary The User Menu provides all the controls and settings that may be required on a daily basis such as turning ON the inverter and/or generator, reading the AC and DC meters, checking the possible causes of an error, or adjusting the inverter’s real-time clock.
Page 220 Operation Table 8-2 User Menu Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User Menus Display Settings Display Settings See Page Xantrex Tech Inc Info. Read Only Info. Read Only page 8–20 5916 195th St NE Displayed Displayed Info.
Page 221 The User Menu Summary Table 8-2 User Menu Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User Menus Display Settings Display Settings See Page 05E High Battery Voltage NO YES Read Only NO YES Read Only page 8–27 NO YES Read Only...
Page 222: Accessing The User Menu
Operation Accessing the User Menu To directly access the 01A Inverter User Menu: ◆ Press the red INV button to go directly to 01A Inverter. Figure 8-6 Inverter ON/OFF Display To directly access the 02 Generator User Menu: ◆ Press the green GEN button to go directly to 02A Generator. Figure 8-7 Generator ON/OFF Display 8–14 976-0043-01-01...
Page 223: User Menu Description
User Menu Description User Menu Description 01 Inverter ON/OFF Menu The INVERTER ON/OFF Menu Heading accesses the startup and 01 Inverter ON/ shutdown function of the inverter. 01A Inverter The 01A Inverter menu item has four set points to select from for 01A Inverter inverter operation: OFF, SRCH, ON, and CHR.
Page 224: Eq Charge Off On
Operation 01B EQ Charge OFF ON OFF When OFF is selected in the menu, the inverter is not set to 01B EQ Charge equalize the batteries. OFF ON ON This selection triggers the battery charger to initiate the equalization process. If the AC source is present on the AC1 grid or AC2 GEN terminals, the equalization process will begin.
Page 225: Bypass Mode
User Menu Description 01D Bypass Mode The Bypass Mode closes the internal bypass relays and allows the AC 01D Bypass Mode connected to the selected input (AC1 or AC2) to pass directly through to AC1 NORM AC2 the loads without being monitored for AC voltage or frequency quality. Important: All system functions are disabled in this mode and can only be restored by selecting NORM.
Page 226: Generator
Operation 02A Generator The 02A Generator menu item provides three setpoints to choose from 02A Generator for generator control. OFF AUTO ON OFF This set point disables the auto-start system or immediately turns OFF a generator (without cooldown) started by the inverter. It is also used to reset the automatic generator start system after an ERROR condition occurs.
Page 227: Gen Start Load Amps
User Menu Description Menu items 02B through 02F will indicate “NO” unless the generator- start parameters are met as programmed in the Advanced Setup Menu (Menu items 24, 25, and 26). 02B Gen Start Load Amps A “YES” displayed in this menu item indicates the generator has or is 02B Gen Start about to start and run as the current has maintained the 26A Load Amp Load Amps...
Page 228: Time Of Day Menu
Operation 03 Time Of Day Menu Menu Heading 03 Time Of Day displays information such as the current 03 Time of Day time of day, software revision number, system information (e.g., model type), Xantrex’s mailing address and phone/fax numbers. Use the information contained in this menu when contacting Xantrex for technical assistance or service request.
Page 229: Press Reset For Factory Defaults
User Menu Description Press Reset for Factory Defaults In addition to providing information, this menu includes a reset function PRESS RESET FOR that allows all system settings to be returned to their original default FACTORY DEFAULTS values. Pressing the RESET DEFAULTS button while this menu item is displayed resets the inverter to the factory default settings.
Page 230: Meters Menu
Operation 04 Meters Menu The Meters Menu provides information about system performance. The 04 Meters Menu menus under this heading are read-only. This information includes the following menu items to assist the user in monitoring system performance: • 04A Battery Actual Volts DC •...
Page 231: Battery Comp Vdc
User Menu Description 04B Battery Comp Vdc This menu item display shows the battery voltage after it has been 04B Battery compensated based on the battery temperature and the input current. Comp Vdc These two compensation values are used by the battery charger for its regulation settings and are only used when the inverter is charging.
Page 232: Grid (Ac1) Volts Ac
Operation 04G Grid (AC1) Volts AC This menu item displays the AC input voltage connected to the inverter's 04G Grid (AC1) AC1 terminals. This input voltage display may drift slightly before the Volts AC inverter has synchronized to the grid. 04H Gen (AC2) Volts AC This menu item displays the AC input voltage connected to the inverter's 04H Gen (AC2)
Page 233: Error Causes Menu
User Menu Description 05 Error Causes Menu Detected inverter errors cause the red ERROR LED to illuminate. These 05 Error Causes menu items help determine the cause of error conditions. Menu These menu items normally display “NO” for all menu items in which no error is detected.
Page 234: Heatsink Overtemp
Operation 05C Heatsink Overtemp If “yes” is visible in this display, the power transistors have exceeded their 05C Heatsink designed operating temperature and the inverter is shut off. Overtemp When this error condition occurs, if the unit is operating as a battery charger, the inverter stops charging to prevent further overheating.
Page 235: High Battery Voltage
User Menu Description 05E High Battery Voltage If “Yes” is displayed, the DC battery voltage has increased above the 05E High Battery value set in the 11A High Battery Cut Out VDC menu item. Voltage This can be caused by a solar array or other charging source not being regulated.
Page 236: Gen Failed To Start
Operation 05H Gen Failed to Start If “Yes” is displayed, the automatic generator start system did not 05H Gen Failed to successfully start the generator. Start The system completes six start cycles and requires the generator to operate for a minimum of five minutes before the starting attempts counter is cleared.
Page 237: Bypass Mode Selected
User Menu Description 06A Bypass Mode Selected If “Yes” is displayed, the Bypass Mode is selected for either the AC1 or 06A Bypass Mode AC2 input. Selected When the inverter is setup to operate in the bypass mode it does not check the AC inputs for quality and will allow any anomalies appearing on the grid (AC1) or generator output (AC2) to pass through to the loads.
Page 238: Eq Charge Selected
Operation 06E EQ Charge Selected If “Yes” is displayed, the charger is set to run in the Equalize Charge 06E EQ Charge Mode. Selected Be sure to monitor menu items 04I Battery Temp and 04K Read Bulk/ EQ Time when equalize charging the batteries. 6F Battery VDC <...
Page 239: Ry8 (Gsm) Energized
User Menu Description 07B RY8 (GSM) Energized If “Yes” is displayed, the inverter has sent out a command to energize the 07B RY8 (GSM) relay (between the N.O. to COM connections) in the GSM. Energized This display can be used for troubleshooting purposes by helping to isolate the cause of a generator problem.
Page 240 8–32...
Page 241: Troubleshooting
Troubleshooting Chapter 9 contains information and procedures for troubleshooting the Sine Wave Plus.
Page 242: Inverter Troubleshooting
Troubleshooting Inverter Troubleshooting If the red ERROR LED illuminates on the control module, see “05 Error Causes Menu” on page 8–25 to determine the cause of the error condition then refer to the troubleshooting solutions below to resolve the situation. Problem Possible cause Solution...
Page 243 Inverter Troubleshooting Problem Possible cause Solution Low AC power output Insufficient DC current Check the battery voltage, fuses or breakers and or Low surge power being provided to the cable connections. INVERT LED is on. inverter to operate the AC inductive loads are AC loads.
Page 244: Battery Charger Troubleshooting
Troubleshooting Battery Charger Troubleshooting If the red ERROR LED comes illuminates the control module, see “05 Error Causes Menu” on page 8–25 to determine the cause of the error condition. Then use the solutions below to resolve the situation. Problem Possible Cause Solution AC1 LED is flashing,...
Page 245 Battery Charger Troubleshooting Problem Possible Cause Solution Charger drops off before AC frequency at the AC Check for the correct AC voltage or frequency using full charging has input terminal may be the Control Panel. finished (no ERROR out-of-tolerance (too comes on).
Page 246 Troubleshooting Problem Possible Cause Solution Batteries being charged If BTS is installed, it Monitor the 04B Battery Temp Comp VDC while above the Bulk/Float may be in a cold area or charging. setting. have fallen off the batteries. NOTE: To bring batteries that are cold to the correct state of charge may require charging at a higher Another DC charging voltage.
Page 247: Error Causes
Error Causes Error Causes This table refers to 05 Error Causes Menu messages. Refer to these messages when the ERROR LED is on or flashing. Message Problem Solution 05A Over Current Excessive load on the Reset the inverter by pressing the On/Off switch to AC output.
Page 248 Troubleshooting Message Problem Solution 05G Input Relay The AC transfer relay is Disconnect the inverter’s output wiring. If error Failure bad or an AC source was continues, have unit serviced. wired directly to the AC output. 05H Gen Failed To Indicates that six “auto Reset the auto-generator control system by selecting Start...
Page 249: A Inverter Specifications
Inverter Specifications Appendix A, “Inverter Specifications” provides the electrical and environmental specifications of this inverter.
Page 250: Electrical Specifications
Inverter Specifications Electrical Specifications Sine Wave Plus Sine Wave Plus Electrical Specifications 2524 2548 AC Input Voltage 120 Vac 120 Vac AC Input Voltage Range 80 - 150 Vac 80 - 150 Vac AC Input Current 60 amps AC Pass- 60 amps AC Pass- through/ 20 amps AC through/ 20 amps AC...
Page 251: Mechanical Specifications
Mechanical Specifications Mechanical Specifications Mechanical Sine Wave Plus Sine Wave Plus Specifications 2524 2548 Specified Temperature Range SPECIFIED 32 °F to 77 °F 32 °F to 77 °F (will meet specified (0 °C to 25°C) (0 °C to 25°C) tolerances) ALLOWED -13 °F to 140 °F -13 °F to 140 °F...
Page 252: Theory Of Operation
Inverter Specifications Theory of Operation Sine Wave Plus employs a patented inverter design. This design uses a combination of three transformers, each with its own low frequency switches, coupled in series and driven by separate interconnected micro- controllers. In essence, it is three inverters linked together by their transformers.
Page 253 Theory of Operation The inverter runs in two basic formats: as a stand-alone inverter (converting DC to AC), or as a parallel inverter (with its output synchronized to another AC source). In inverter mode, only 60 Hz waveforms are created. As the battery voltage rises, waveforms with progressively fewer steps are generated.
Page 254: Power Versus Efficiency
Inverter Specifications Power Versus Efficiency There are two primary losses that combine to create the efficiency curve of the Sine Wave Plus. The first is the energy that is required to operate the inverter at full output voltage while delivering no current. This is the no load or idle power.
Page 255: Figure A-3 Sine Wave Plus Efficiency Curves
Theory of Operation SW Plus 2524 Efficiency Curve Measurements made using resistive load bank and Yokogawa WT 2030 Digital Power Meter 100% 1000 1500 2000 2500 Output Power in Watts SW Plus 2548 Efficiency Curve Measurements made using resistive load bank and Yokogawa WT 2030 Digital Power Meter 100% 1000 1500...
Page 256: Inverter Capacity Versus Temperature
Inverter Specifications Inverter Capacity versus Temperature The current protection circuit in the Sine Wave Plus is temperature compensated, therefore the maximum sized load that the inverter can run changes with temperature. As the temperature of the power devices (FETs) increase, the allowable current is reduced. When the available current is reduced, the capacity of the inverter to run loads is reduced.
Page 257: Time Versus Current
Theory of Operation Time versus Current Loads presented to the inverter are seldom constant. Typically, large loads are operated for only short periods of time. In order to provide the maximum utility, Xantrex inverters are allowed to operate at power levels that exceed their continuous power ratings.
Page 258: Figure A-6 Time Versus Current For The Sine Wave Plus 2548
Inverter Specifications Figure A-6 Time versus Current for the Sine Wave Plus 2548 A–10 976-0043-01-01...
Page 259: B Configuration Settings
Configuration Settings Appendix B, “Configuration Settings” provides worksheets for programming your inverter/charger for user-specific parameters.
Page 260: Table B-1 User Menu Default And User Settings
Configuration Settings User Menu Settings Table B-1 provides a list of User Menu headings and menu items, with available setpoints. This table also provides the default settings for each menu item as programmed in the factory. The last column “User Settings” is provided for you to write in the settings specific to your installation.
Page 261: User Menu Settings
User Menu Settings Table B-1 User Menu Default and User Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User User Menus Display Settings Display Settings Settings Press reset for factory defaults Press to refresh the LCD display. 04 Meters Menu “04 Meters Menu”...
Page 262 Configuration Settings Table B-1 User Menu Default and User Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User User Menus Display Settings Display Settings Settings 06 Status Menu “06 Status Menu” on page 8–28 for details. 06A Bypass Mode Selected NO YES Read Only...
Page 263: Basic Setup Menu
Basic Setup Menu Basic Setup Menu Table B-2 provides a list of Basic Setup Menu headings and menu items, with available setpoints. This table also provides the default settings for each menu item as programmed in the factory. The last column “User Settings”...
Page 264 Configuration Settings Table B-2 Basic Setup Default and User Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Range/ User Basic Setup Menus Display Default Display Default Settings 12I Temp Comp LeadAcid LeadAcid LeadAcid LeadAcid NiCad NiCad 13 AC Inputs Menu “13 AC Inputs Menu”...
Page 265: Advanced Setup Menu
Advanced Setup Menu Advanced Setup Menu Table B-3 provides a list of Advanced Setup Menu headings and menu items, with available setpoints. This table also provides the default settings for each menu item as programmed in the factory. The last column “User Settings”...
Page 266 Configuration Settings Table B-3 Advanced Setup Default and User Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User Advanced Setup Menus Display Settings Display Settings Settings 24 Generator Timers Menu “24 Generator Timers Menu” on page 7–22 for details.
Page 267 Advanced Setup Menu Table B-3 Advanced Setup Default and User Settings Sine Wave Plus 2524 Sine Wave Plus 2548 Range/ Default Range/ Default User Advanced Setup Menus Display Settings Display Settings Settings 27 Save/Restore Setup Menu “27 Save/Restore Settings Menu” on page 7–34 for details.
Page 268 B–10...
Page 269: Battery Information
Battery Information Appendix C, “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 270: 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 271: Sealed Batteries (Gel And Agm
Battery Types Types of FLA Batteries Attributes Industrial (electric forklift) • Popular in large inverter systems • Extremely rugged - lasts up to 10 years or more in an inverter system • Typically 2 volt cells (1,000 amp hours or more) Sealed Batteries (Gel and AGM) Description Gel Cell and absorbed glass mat (AGM) batteries are sealed and do not...
Page 272: Understanding Battery Capacity Ratings
Battery Information Other options Another option for 24 volt (only) alkaline battery banks is to use only 19 cells instead of 20. Fewer cells allow the battery charger to operate more closely to the settings used for lead-acid batteries. However, the battery voltage will drop to as low as 18 volts when discharging the batteries.
Page 273: Understanding Amp-Hour Requirements
Battery Bank Sizing Depth of discharge In general, the battery bank should be designed so the batteries do not discharge more than 60% of their capacity on a regular basis. Discharging up to 80% is acceptable on a limited basis, such as a prolonged utility outage.
Page 274: Calculating Amp Hours
Battery Information Time and power The length of time a load is operated will affect the power draw. In some cases, an appliance which draws a large wattage may not consume as many amp hours as a load drawing fewer watts but running for a longer period of time.
Page 275: Amp Hour Example Worksheet
Battery Bank Sizing Amp Hour Example Worksheet Complete the following steps to calculate the amp-hour requirements per day for your system. Use and Table C-2 as examples to complete your own. To calculate amp-hour requirements: 1. Determine the loads the inverter will power and enter their wattage in the watts column.
Page 276: Battery Bank Size Worksheet
Battery Information Battery bank size worksheet Calculation To calculate the battery bank size, use the average amp-hours per day that you calculated using Table C-1, then make the other calculation shown in Table C-2 to calculate the battery bank size you need to support your loads.
Page 277: Battery Configurations
Battery Configurations Battery Configurations The battery bank must be wired to match the inverter’s DC input voltage specifications (24 or 48 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 278: Wiring Batteries In Parallel
Battery Information Each battery's amp-hour rating is 100 Ah. 12 V 12 V SHUNT DC Disconnect (either a circuit breaker or a fuse with a disconnect) 24 V INVERTER (Total battery capacity = 100 Ah) Each battery's amp-hour rating is 100 Ah. 12 V 12 V 12 V...
Page 279: Wiring Batteries In Series-Parallel
Battery Configurations 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 280: Battery Connections For Stacked Inverters
Battery Information 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.
Page 281: Battery Maintenance
Battery Maintenance Battery Maintenance Maintenance To get the best performance from an inverter system, the batteries must be strategy properly set up and maintained. This includes setting the proper voltages for Bulk and Float charging. See the “CAUTIONS” in the section on Equalization Charging below).
Page 282: Table C-4 Variances In Charging Voltage Based On Battery Temperature
Battery Information Table C-4 Variances in Charging Voltage based on Battery Temperature Temperature (around the BTS) 24-volt units 48-volt units Celsius Fahrenheit Lead Acid NiCad Lead Acid NiCad -2.10 -1.40 -4.20 -2.80 -1.80 -1.20 -3.60 -2.40 -1.50 -1.00 -3.00 -2.00 -1.20 -0.80 -2.40...
Page 283: Equalization Charging
Battery Maintenance Note: If the battery temperature is allowed to fall to extremely cold temperatures, the inverter with a BTS may not be able to properly recharge cold batteries due to maximum voltage limits of the inverter. Ensure the batteries are protected from extreme temperatures. Equalization Charging Purpose An equalize-charge helps to remove sulfate buildup on the battery plates...
Page 284 Battery Information Check the water level in the batteries frequently when performing an equalize charge and add water if necessary. Always follow the safety steps covered in the front of the manual. Battery Cables and Battery posts must be clean to reduce the resistance between the battery Posts post and cable connection.
Page 285: Table C-6 Battery State-Of-Charge
Battery Maintenance The voltage should match the following table for the entire battery bank output. These values indicate the overall battery’s state of charge for the entire bank. Individual cell voltages (if available) are also shown as a percentage of charge. The values given are for a temperature of 77 °F (25 °C).
Page 286 C–18...
Page 287 Generators Appendix D, “Generators” supplies information about generator starting. This information is provided for basic reference only. Because of the wide variety of generator circuits available, Xantrex can not be held responsible for the accuracy of the information provided. Always refer to the manufacturer’s recommendation for specific operating instructions.
Page 288: Two-Wire Start Circuits
Generators Two-Wire Start Circuits Two-wire starting generators are the easiest to control and are highly recommended for this type of application. A contact closure starts the generator and opening the contacts stops the generator. These types of generators also provide their own cranking control circuit, possibly oil pressure and overtemp protection circuits, and are designed for unattended operation applications.
Page 289: Wire Converters
Three-Wire Start Circuits system remains energized. To shut down the generator, the switch is held in the “STOP” position until the engine dies. When the switch is released, it returns to the center position. In this system, RY8 duplicates the “START” position and relay RY7 (in the “GS”...
Page 290 D–4...
Page 291: E Over-Charge Protection
Over-Charge Protection Appendix E, “Over-Charge Protection” supplies information about options for over-charge protection. This information is provided for basic reference only. Because of the wide variety of generator circuits available, Xantrex can not be held responsible for the accuracy of the information provided.
Page 292: Over-Voltage Protection Using A Charge Controller
Over-Charge Protection Over-voltage Protection using a Charge Controller When using a renewable energy source to charge the batteries, a charge controller prevents the batteries from exceeding a user-specified voltage level. This preserves and extends the life of the battery by preventing the damage caused by overcharging.
Page 293: Diversion Load Control
Diversion Load Control Diversion Load Control DC generator devices such as wind turbines and hydro-electric generators may be damaged by over-spinning if the DC loads are suddenly removed from them. This can happen if the DC disconnect should open (trip) or the batteries are fully charged and no other DC loads are connected in the system.
Page 294 E–4...
Page 295: F Multiwire Branch Circuit Wiring
Multiwire Branch Circuit Wiring Appendix F, “Multiwire Branch Circuit Wiring” supplies information about Multiwire Branch Circuit Wiring Precautions when using stand-alone 120 Vac inverters or generators. WARNING: Fire Hazard 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 multiwire branch circuits.
Page 296: Multiwire Branch Circuits
Multiwire Branch Circuit Wiring Multiwire Branch Circuits Problem A potential safety problem exists when installing stand-alone 120 Vac inverters into existing 120/240 Vac wired panels where multiwire branch circuit wiring methods were used. Legacy situation Multiwire branch circuits are wired differently from “home run” type wiring (Figure F-1) in that only one neutral wire is used to provide the...
Page 297: Figure F-2 Multiwire Branch Circuit Wiring And Current Flow
Multiwire Branch Circuits Load Center Load Center 240 Vac 240 Vac from Grid from Grid Neutral 15 A 15 A 15 A 15 A Neutral Breaker Breaker Breaker Breaker (Ganged) (Ganged) (Ganged) (Ganged) Ground Ground Red - Hot Red - Hot (Current Flow 15 A) (Current Flow 15 A) Black - Hot...
Page 298: Identifying Multiwire Branch Circuits
Multiwire Branch Circuit Wiring Identifying Multiwire 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 Multiwire branch circuits can be identified by removing the cover on the characteristic load center and inspecting the wiring.
Page 299: Correcting Multiwire Branch Circuit Wiring
Correcting Multiwire Branch Circuit Wiring Correcting Multiwire Branch Circuit Wiring Acceptable options Correcting multiwire branch circuit wiring is not easy. Two options which will correct multi wiring branch circuit wiring are: • Rewire existing multiwire branch circuits to conventional “home run” wiring.
Page 300: Figure F-5 Using A T240 Autotransformer In Multiwire Branch Circuit Wiring
Multiwire Branch Circuit Wiring 120 Vac Inverter or Generator T240 AutoTransformer Load Center HOT - L1 HOT - L2 Neutral 15 A 15 A Breaker Breaker White - Neutral (Ganged) (Ganged) Ground Red - Hot (Current Flow 15 A Black - Hot (Current Flow 15 A) Single White - Neutral 120 Vac...
Page 301: G Emergency Power Off Switches
Emergency Power Off Switches Appendix G, “Emergency Power Off Switches” supplies information about the requirements for installing an Emergency Power Off Switch.
Page 302: The Purpose Of An Epo Switch
Emergency Power Off Switches The Purpose of an EPO switch In the event an emergency situation, the first priority is to remove power from the house by removing the power meter. However, systems with battery backups can run in inverter mode (i.e., no utility power) for hours providing AC output to the household loads.
Page 303 The Purpose of an EPO switch The intent of this feature is to provide three options: • Inverter shutdown using an externally mounted switch as described in the 2002 NEC Article 230-70 (a) (no physical disconnect required), • Inverter shutdown and physical disconnect by using a 2-pole EPO switch, one set of contacts open the AC output breaker, the other set turn off the inverter (Physical shunt trip breaker required), or •...
Page 304: How To Use The Epo Port For An Epo Switch
Emergency Power Off Switches the building at a readily accessible location. The shunt trip switch, when installed should be between six (6) feet and six feet seven inches (6'7") above finish grade. A sign constructed of permanent materials with no less than 1½" high letters designating "Shunt Trip - Main Disconnect"...
Page 305 Glossary “Glossary” contains a glossary of technical terms used in this manual. The glossary also defines some common electrical terms. “Glossary” also defines abbreviations and acronyms associated with the Sine Wave Plus and this manual. Glossary of Terms The second stage of three-stage battery charging. Voltage Absorption remains constant and current tapers as internal battery Charge...
Page 306 A conductive medium in which the flow of electricity takes Electrolyte place; this is the liquid found inside storage batteries. The third stage of three-stage battery charging. After batteries Float Charge reach full charge, charging voltage is reduced to a lower level to reduce gassing (boiling of electrolyte) and prolong battery life.
Page 307: Overcurrent Protection
A voltage drop caused by resistance in wire during Line Loss transmission of electrical power over distance. An electrical system that is connected to a utility distribution Line tie grid. For example, Xantrex SW line tie inverters are designed to connect to and interact with utility power. Any device that consumes electricity in order to operate.
Page 308 A group of electrical devices, such as batteries or PV Series modules, wired together to increase voltage, while ampacity Wiring remains constant. Two 100 amp hour 12 Vdc batteries wired in series form a 100 amp hour 24 Vdc battery bank. Sine Wave The output wave form of an electric generator or utility.
Page 309 Abbreviations and Acronyms Acronym or Abbreviation Definition Alternating Current ACCB AC Conduit Box amp hour Auxiliary Load Module Authorized Service Center Auxiliary American Wire Gauge Battery Temperature Sensor Battery Transfer Canadian Standards Association Direct Current DCCB DC Conduit Box Electro-Magnetic Interference Emergency Power Off Float (relates to battery charging) Federal Communications Commission...
Page 310 Acronym or Abbreviation Definition Liquid Crystal Display Light Emitting Diode National Electric Code Neutral Original Equipment Manufacturer Personal Computer Photovoltaic (solar electric panels) PVGFP PV Ground Fault Protection Renewable Energy Radio Frequency Interference Return Material Authorization Stand By Silent (relates to battery charging) Trace Fuse Block Time Of Use Underwriters Laboratory...
Page 311: Warranty
Warranty and Product Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your Sine Wave Plus Inverter/ Charger. This warranty lasts for a Warranty Period of Warranty period from the date of purchase at point of sale to you, the original end user customer.
Page 312 Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired at one of these facilities.
Page 313: Return Material Authorization Policy
Return Material Authorization Policy MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY. IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY...
Page 314: Return Procedure
Return Procedure 1. Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging. 2.
Page 315: Information About Your System
Information About Your System Information About Your System As soon as you open your Sine Wave Plus Inverter/Charger package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number ______________________________ ❐ Purchased From ______________________________ ❐...
Page 316 I–6...
Page 317 Index Numerics 2–30 Charge Controller 1–6 chassis ground lug D–3 3-to-2 Wire Converters 2–8 Chassis Grounding 1–8 Circuit Breaker Conduit Boxes 3–26 2–22 AC Conduit Boxes 2–2 ACCB 2–22 AC loads Accessing the AC Terminal Block and Ground Bar 2–23 DC Conduit Boxes 3–26 DCCB 2–23...
Page 318 Index 3–3 2–44 Hardware Peak Load Management D–2 2–7 Honda 3-Wire Type Generators Positive Ground A–6 Power Vs. Efficiency 3–4 Prepare I–5 proof of purchase 2–27 I–5 purchase date I–5 Information about Your System form 2–31 PVGFP 3–38 Install inverter I–5 purchase date I–5...
Page 319 Index 976-0043-01-01 IX–3...
Page 320 Index IX–4 976-0043-01-01...
Page 322 Xantrex Technology Inc. 8999 Nelson Way Burnaby, British Columbia Canada V5A 4B5 360 435 8826 360 925 5143 800 446 6180 Toll Free customerservice@xantrex.com www.xantrex.com 976-0043-01-01 Rev A Printed in the USA...

This manual is also suitable for:

Sw 2548 - rev a Sw 2524 Sw 2548

Xantrex SW 2524 - REV A Owner's Manual

Important Safety Instructions

Introduction

System Configuration

Installation

Functional Test

Navigation

Basic Setup Programming

Advanced Setup

Quick Links

Troubleshooting

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Summary of Contents for Xantrex SW 2524 - REV A