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Xantrex SW Plus 2524 Owner's Manual

Manual is about: Sine Wave Plus Inverter/Charger

Summary of SW Plus 2524

  • Page 1

    Sine wave plus inverter/charger owner’s manual sw plus 2524 sw plus 2548 sw plus 4024 sw plus 4048 sw plus 5548.

  • Page 3: Owner’S

    Sine wave plus inverter/charger owner’s manual.

  • Page 4

    About xantrex xantrex technology inc. Is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one mw utility-scale systems for wind, solar, batteries, fuel cells, micro turbines, and backup power applications in both grid-connected and stand-...

  • Page 5: About This

    976-0043-01-02 iii 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 the manual provides safety guidelines, detailed planning and setup informa...

  • Page 6: Organization

    About this guide 976-0043-01-02 iv organization this guide is organized into nine chapters and nine appendices. Chapter 1, “introduction” lists and describes the basic features and parts of the sine wave plus inverter/charger. Chapter 2, “system configuration” contains information to help you plan f...

  • Page 7: Conventions Used

    About this guide v 976-0043-01-02 appendix e, “over-charge protection” supplies information about options for over-charge protection. Appendix f, “multi-wire branch circuit wiring” supplies information about multi-wire branch circuit wiring precautions when using stand- alone 120 vac inverters or ge...

  • Page 8: Related Information

    About this guide 976-0043-01-02 vi 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. These guides (with the except...

  • Page 9

    976-0043-01-02 vii important safety instructions 1. Before using the inverter, read all instructions and cautionary markings on the unit, the batteries, and all appropriate sections of this manual. 2. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk ...

  • Page 10: Explosive Gas Precautions

    Important safety instructions viii 976-0043-01-02 9. Do not expose this unit to rain, snow, or liquids of any type. This product is designed for indoor use only. Damp environments will significantly shorten the life of this product and corrosion caused by dampness will not be covered by the product ...

  • Page 11: Contents

    976-0043-01-02 ix important safety instructions explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii fcc information to the user - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii 1 introduction b...

  • Page 12

    Contents x 976-0043-01-02 generator start types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20 additional/optional equipment considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22 ac conduit box (accb) - - - - - - - - - - - - - - - - - - - -...

  • Page 13

    Contents 976-0043-01-02 xi hardware / materials required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 optional system accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 battery bank preparation - - - - - - - - - - - - - - - - - ...

  • Page 14

    Contents xii 976-0043-01-02 5 navigation navigating the sine wave plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 the inverter control module (icm) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 inverter control module features - - - - ...

  • Page 15

    Contents 976-0043-01-02 xiii 12e max charge amps ac - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–22 12f bulk done amps ac - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–23 12g eq vdc done timer - - - - - - - - - - - - - - - - - - - - - - - - ...

  • Page 16

    Contents xiv 976-0043-01-02 23g ry11 mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–21 generator starting scenarios - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–23 manual generator control - - - - - - - - - - - - - - - - - - ...

  • Page 17

    Contents 976-0043-01-02 xv charge status (yellow and green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6 operational status indication (red and yellow) - - - - - - - - - - - - - - - - - - - - - - -8–7 error led reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 18

    Contents xvi 976-0043-01-02 05b transformer overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25 05c heatsink overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26 05d low battery voltage - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 19

    Contents 976-0043-01-02 xvii b configuration settings user menu settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - b–2 basic setup menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - b–5 advanced set...

  • Page 20

    Contents xviii 976-0043-01-02 f multi-wire branch circuit wiring multi-wire branch circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - f–2 identifying multi-wire branch circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - f–4 corre...

  • Page 21: Figures

    976-0043-01-02 xix figure 1-1 the sine wave plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 figure 1-2 the front side of the sine wave plus - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 figure 1-3 the ac side of the sine wave plus - - - - - - - - - - - - ...

  • Page 22

    Figures xx 976-0043-01-02 figure 3-3 dimensional drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 figure 3-4 wall-mounting method using 2 x 4’s - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 figure 3-5 wall mounting using plywood - - - - - - - - - - - - - -...

  • Page 23

    Figures 976-0043-01-02 xxi figure 5-13 advanced setup menu map part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–12 figure 5-14 advanced setup menu map part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–13 figure 5-15 complete user menu map - - - - - - - - - - - - - - - - - ...

  • Page 24

    Figures xxii 976-0043-01-02 figure a-12 time versus current for the sine wave plus 4048 - - - - - - - - - - - - - - - - a–15 figure a-13 time versus current for the sine wave plus 5548 - - - - - - - - - - - - - - - - a–15 figure c-1 6-volt battery wiring - “series” configuration - - - - - - - - - - ...

  • Page 25: Tables

    976-0043-01-02 xxiii table 2-1 recommended minimum safety ground wire and dc disconnect sizes per nec 2–8 table 2-2 recommendced battery cable size versus length - - - - - - - - - - - - - - - 2–14 table 2-3 battery cable to maximum breaker/fuse size - - - - - - - - - - - - - - - - - - 2–15 table 3-1...

  • Page 26

    Tables xxiv 976-0043-01-02 table b-3 basic setup default and user settings for the sine wave plus 4024 and 4048 models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - b–6 table b-4 basic setup default and user settings for the sine wave plus 5548 model - - - - - - - - - - - - -...

  • Page 27: Introduction

    1 introduction chapter 1, “introduction” lists and describes the basic features and parts of the sine wave plus inverter/charger ..

  • Page 28: Basic Features

    Introduction 1–2 976-0043-01-02 basic features congratulations on your purchase of a sine wave plus inverter/charger from xantrex technology, inc. The sine wave plus is one of the finest inverter/chargers on the market today, incorporating state-of-the-art technology, high reliability, and convenien...

  • Page 29

    Basic features 976-0043-01-02 1–3 front panel the front of the sine wave plus has the following features: • the inverter control module (icm) display • the ac access cover figure 1-1 the sine wave plus figure 1-2 the front side of the sine wave plus ac access cover inverter control module display.

  • Page 30

    Introduction 1–4 976-0043-01-02 ac side the ac side of the sine wave plus has the following features: • the remote monitor port for connecting a remote inverter control module (icm) or the inverter communications adapter (ica) • the stacking port for connecting two sine wave plus inverters • the aux...

  • Page 31

    Basic features 976-0043-01-02 1–5 emergency power off (epo) option the sine wave plus offers an emergency power off (epo) option through the use of the epo port. The epo feature is designed to shut down the inverter from a remote location (or switch). Since the type of the switch will be dependent o...

  • Page 32

    Introduction 1–6 976-0043-01-02 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 figure 1-5 the dc side of the sine wave plus positive (+) batte...

  • Page 33

    Basic features 976-0043-01-02 1–7 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 over...

  • Page 34

    Introduction 1–8 976-0043-01-02 top 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 o...

  • Page 35: System Configuration

    2 system configuration chapter 2, “system configuration” contains information to help you plan for a sine wave plus installation in an off-grid, on-grid, or backup power application..

  • Page 36: Pre-Configuration Planning

    System configuration 2–2 976-0043-01-02 pre-configuration planning importance pre-configuration planning is essential to ensure optimal performance for your system. This section outlines the components of a system and how you can plan for them. Types of applications the sine wave plus inverter/charg...

  • Page 37

    Pre-configuration planning 976-0043-01-02 2–3 ❐ renewable energy systems (e.G., pv arrays, wind turbines etc.) see “system input requirements” on page 2–4 for more information. Location what are the safe, physical environmental requirements for your installation: ❐ mounting location for optimal perf...

  • Page 38

    System configuration 2–4 976-0043-01-02 generator will a generator be used: ❐ voltage output requirements (120 vac only, 120/240 vac, or 240 vac only) ❐ auto-start or manual-start see “generator considerations” on page 2–19 for additional information. Additional equipment what additional equipment i...

  • Page 39

    Pre-configuration planning 976-0043-01-02 2–5 location considerations dry inverters contain sophisticated electronic components and should be located in a well-protected, dry environment away from sources of fluctuating or extreme temperatures and moisture. The better the environment, the longer the...

  • Page 40

    System configuration 2–6 976-0043-01-02 fire safety all sine wave plus inverter/chargers meet ul fire safety standards as outlined in ul 1741. As such, in the event of a failure, the sine wave plus is designed to fail safe. Be sure the specific mounting and ventilation requirements outlined in this ...

  • Page 41

    Pre-configuration planning 976-0043-01-02 2–7 grounding considerations types whether you are installing a new system or integrating new parts into an existing system, the four types of grounding to consider are: • dc system grounding • inverter grounding • chassis grounding • bonding the grounding s...

  • Page 42

    System configuration 2–8 976-0043-01-02 inverter grounding requirement the inverter/charger should be connected to a grounded, permanent wiring system with the ac and dc grounds commonly bonded to each other and should be bonded to the grounding system at only one point in the system. See “bonding t...

  • Page 43

    Pre-configuration planning 976-0043-01-02 2–9 equipment or chassis grounding equipment or chassis grounding connects the metallic chassis of the various enclosures together to have them at the same voltage potential, thus reducing the possibility for electric shock. It also provides a path for fault...

  • Page 44

    System configuration 2–10 976-0043-01-02 wire may be a better grounding electrode than the ground rods. Well casings and water pipes can also be used as grounding electrodes. Under no circumstance should a gas pipe or line be used. Bonding the grounding system definition bonding means connecting one...

  • Page 45

    Pre-configuration planning 976-0043-01-02 2–11 generator if the generator is the main source of power, (that is, no utility grid power) then the neutral and ground connections are bonded at the main ac distribution panel. Utility grid if the utility grid is the main source of power, then the bond sh...

  • Page 46

    System configuration 2–12 976-0043-01-02 more information consult your battery vendor for additional information on battery enclosure requirements. Battery bank requirements determining requirements to determine your battery requirements you need to know what type of batteries to use, the number of ...

  • Page 47

    Pre-configuration planning 976-0043-01-02 2–13 important recommendation follow the battery cable recommendations listed in this guide. It is absolutely imperative that you adhere to the battery cable size (wire gauge) and length recommendations provided in this section. If cables are used that are t...

  • Page 48

    System configuration 2–14 976-0043-01-02 and inverter amperage per nec/cec guidelines. It is recommended that the cable has battery acid resistant insulation and is rated for 90 °c (32 °f) or better. Be sure to check with any local regulatory agencies for additional requirements. Battery cable lugs ...

  • Page 49

    Pre-configuration planning 976-0043-01-02 2–15 inverters to meet nec/cec compliance. Two amperage ratings are available: a dc250 (250 amps) and a dc175 (175 amps) in either single- or double-pole configurations for single or dual inverter installations. See “dc disconnect boxes (dc175/dc250)” on pag...

  • Page 50

    System configuration 2–16 976-0043-01-02 series stacked when inverters are “stacked” they must operate from a common battery bank. In other words, the dc negative of one inverter must be common with the second inverter and likewise for the dc positive. For example: if you have eight 6-volt batteries...

  • Page 51

    Pre-configuration planning 976-0043-01-02 2–17 disconnect switches. A sample of this warning label is provided in figure 2-2 . These labels are not available or provided by xantrex, but may be available from your local electrical warehouse. Dc disconnects and overcurrent devices the size of the bond...

  • Page 52

    System configuration 2–18 976-0043-01-02 see “installing the battery temperature sensor (bts)” on page 3–18 for instructions on installing the battery temperature sensor. Wiring considerations conduit boxes for maximum safety and, in some cases, for code-compliance, run the ac and dc cables in condu...

  • Page 53

    Pre-configuration planning 976-0043-01-02 2–19 wire size for ac connections a minimum of #6 awg thhn wire is recommended for all ac wiring (input and output). Wiring scenarios determine all wire routes both to and from the inverter and which knockouts are best suited for connecting the ac conduits. ...

  • Page 54

    System configuration 2–20 976-0043-01-02 stable voltage the generator should provide a stable voltage and frequency output for the inverter to synchronize with. Ac wind turbines and small scale ac water turbines are not recommended for use as ac power sources as they may not be able to provide a sta...

  • Page 55

    Pre-configuration planning 976-0043-01-02 2–21 manual-start and electric-start generators typically do not have self- protection features to shut down the generator in the event of low oil pressure, over-heating, overcranking, etc., and, therefore, are not designed for unattended starting and operat...

  • Page 56

    System configuration 2–22 976-0043-01-02 see “generator starting scenarios” on page 7–23 of this guide for specific instructions on setting the generator-start/stop conditions. Additional/optional equipment considerations the following components are available for use with the sine wave plus . Some ...

  • Page 57

    Additional/optional equipment considerations 976-0043-01-02 2–23 dc conduit box (dccb) the dc conduit box (dccb) connects to the dc side of the inverter and accepts dc conduit runs. Figure 2-4 dc conduit box figure 2-5 sine wave plus with ac and dc conduit boxes installed.

  • Page 58

    System configuration 2–24 976-0043-01-02 fuse block the xantrex fuse block (tfbxxx) 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....

  • Page 59

    Additional/optional equipment considerations 976-0043-01-02 2–25 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, histor...

  • Page 60

    System configuration 2–26 976-0043-01-02 remote monitors three options are available for remote control and monitoring. • use a remote icm, which is identical to the inverter control module display on the inverter, for distances of 25 or 50 feet (7.5 or 15 meters). • use a personal computer to monit...

  • Page 61

    Additional/optional equipment considerations 976-0043-01-02 2–27 inverter control module (icm) the remote icm allows control, monitoring, and adjustment of all inverter settings from a location other than the icm display on the front of the inverter. The remote icm comes with cables in lengths of 25...

  • Page 62

    System configuration 2–28 976-0043-01-02 generator start module (gsm) the gsm is an accessory that enables the inverter to start and stop generators equipped with auto-start features. See “generator considerations” on page 2–19 , for information on using generators and appendix d, “generators” for a...

  • Page 63

    Additional/optional equipment considerations 976-0043-01-02 2–29 240 vac application requirements there are two options available for creating 240 vac output using a 120 vac inverter: • using an autotransformer to step-up or step-down the voltage, or • stacking two identical inverters. Autotransform...

  • Page 64

    System configuration 2–30 976-0043-01-02 renewable energy dc input sources renewable energy (re) sources (for example, 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...

  • Page 65

    Additional/optional equipment considerations 976-0043-01-02 2–31 pvgfp the pv ground fault protection (pvgfp) is designed to minimize the possibility of a fire resulting from ground faults in a pv array (in accordance with nec/cec for rooftop-mounted pv systems on dwellings). It is not designed or i...

  • Page 66: Off-Grid Applications

    System configuration 2–32 976-0043-01-02 off-grid applications the sine wave plus can be used as a primary source of ac power to support off-grid, stand-alone systems where no utility power is available. Sine wave plus applications in an off-grid situation include: • renewable energy systems (with o...

  • Page 67

    Off-grid applications 976-0043-01-02 2–33 figure 2-17 off-grid application – renewable energy system using a single inverter notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run through the in...

  • Page 68

    System configuration 2–34 976-0043-01-02 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 v...

  • Page 69

    Off-grid applications 976-0043-01-02 2–35 figure 2-18 off-grid application – renewable energy system using dual inverters notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run through the inver...

  • Page 70

    System configuration 2–36 976-0043-01-02 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 genera...

  • Page 71

    Off-grid applications 976-0043-01-02 2–37 figure 2-19 off grid application - generator-only system using a single inverter notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run through the inve...

  • Page 72

    System configuration 2–38 976-0043-01-02 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,...

  • Page 73

    Off-grid applications 976-0043-01-02 2–39 figure 2-20 off grid application – generator-only system using dual inverters, series-stacked notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run thr...

  • Page 74: On-Grid Applications

    System configuration 2–40 976-0043-01-02 on-grid applications the sine wave plus can be combined with utility power to provide backup power in the event of a primary power source failure. It can use utility power to backup renewable energy systems. It can use renewable energy and/or a generator to b...

  • Page 75

    On-grid applications 976-0043-01-02 2–41 figure 2-21 on-grid application – backup system using a single inverter notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run through the inverter. 3. S...

  • Page 76

    System configuration 2–42 976-0043-01-02 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 v...

  • Page 77

    On-grid applications 976-0043-01-02 2–43 figure 2-22 on-grid application – backup system using dual inverters, series-stacked notes: 1. Always refer to your local electric codes for proper wiring instructions. 2. For purposes of this illustration, the ground for the ac generator is run through the i...

  • Page 78

    System configuration 2–44 976-0043-01-02 energy management the 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 so...

  • Page 79

    On-grid applications 976-0043-01-02 2–45 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...

  • Page 80

    System configuration 2–46 976-0043-01-02 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 abl...

  • Page 81

    On-grid applications 976-0043-01-02 2–47 see “21 grid (ac1) usage menu” on page 7–16 for instructions on setting these parameters. Renewable energy with grid backup (bx mode) to have the inverter operate independently of the grid but use the grid in times of low battery voltage, the inverter can be ...

  • Page 82

    2–48.

  • Page 83: Installation

    3 installation chapter 3, “installation” describes how to mount and install the sine wave plus inverter/charger and perform wiring and cabling procedures for various configurations..

  • Page 84: Pre-Installation

    Installation 3–2 976-0043-01-02 pre-installation before installing the sine wave plus , read all instructions and cautionary markings located in this manual. Although the dc electrical system may be “low voltage”, significant hazards may still be present, particularly from short-circuits of the batt...

  • Page 85

    Pre-installation 976-0043-01-02 3–3 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) ❐ conduits and appropriate fittings ...

  • Page 86

    Installation 3–4 976-0043-01-02 remote monitors: ❐ icm/25 (inverter control module with 25 foot cable connection) ❐ 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...

  • Page 87

    Pre-installation 976-0043-01-02 3–5 3. Determine the correct size of battery cables to use. See table 2-2, “recommendced 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. See table ...

  • Page 88

    Installation 3–6 976-0043-01-02 ❐ 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. ❐ record the unit’s model numbe...

  • Page 89

    Pre-installation 976-0043-01-02 3–7 figure 3-2 serial number sticker and knockout locations and sizes knockout preparation remove your choice of knockouts from the chassis to facilitate conduit installation for wire runs. This is much easier to do prior to mounting the inverter. Figure 3-2 shows the...

  • Page 90

    Installation 3–8 976-0043-01-02 mounting the 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. Also make sure the supporting surface is s...

  • Page 91

    Pre-installation 976-0043-01-02 3–9 figure 3-3 dimensional drawing 1" ½" 1½" 1½" 1" keyhole slots keyhole slots 21" (533 cm) 16" (406 cm) 6½" (165 cm) 1½" 1" 1½" 14 " 8 3 15 " 1 8 4 (102 cm) 10½" (267 cm) 2½" 17" (432 cm) 8 3 " 18 (467 cm) 8 3 " 20" (508 cm) mounting holes* ***not to scale*** 6½" (1...

  • Page 92

    Installation 3–10 976-0043-01-02 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 using 2 x 4’s the easiest method for...

  • Page 93

    Pre-installation 976-0043-01-02 3–11 figure 3-4 wall-mounting method using 2 x 4’s wall studs 16 inches on center wallboard floor ceiling 14–3/8" c-c se t in v erte r off srch on chg sine wave plus inverter/charger approx. 4–5 ft 2 x 4 mounting supports mounting holes (10) keyhole slots (4).

  • Page 94

    Installation 3–12 976-0043-01-02 wall mounting using plywood alternatively, a half sheet (4 ft x 4 ft) of ¾-inch plywood can also be used as a backing, with the inverter mounted directly to the plywood using ¼-inch diameter lag bolts and washers. The plywood must span three studs for adequate suppor...

  • Page 95

    Pre-installation 976-0043-01-02 3–13 figure 3-5 wall mounting using plywood wall studs 16 inches on center wallboard floor ceiling plywood s et in ve rte r off s rch on chg sine wave plus inverter/charger mounting holes (10) keyhole slots (4).

  • Page 96: Dc Wiring

    Installation 3–14 976-0043-01-02 dc wiring dc wiring includes the following (described in the following locations). ❐ preparing the battery bank - see “preparing the battery bank” on page 3–14 . ❐ preparing grounding - see “grounding the dc system” on page 3– 15 . ❐ connecting dc input sources - see...

  • Page 97

    Dc wiring 976-0043-01-02 3–15 grounding the dc system the inverter’s chassis ground lug (see figure 3-6 ) is used to connect the chassis of the inverter to the dc grounding system. The terminal accepts wires from #14 awg to #2 awg. The xantrex dc175 and dc250 have optional grounding blocks to simpli...

  • Page 98

    Installation 3–16 976-0043-01-02 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...

  • Page 99

    Dc wiring 976-0043-01-02 3–17 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 (–) termin...

  • Page 100

    Installation 3–18 976-0043-01-02 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/...

  • Page 101

    Dc wiring 976-0043-01-02 3–19 figure 3-9 bts (rj11) port location and installation bts (rj11) port dc end of the inverter.

  • Page 102

    Installation 3–20 976-0043-01-02 connecting the batteries to the inverter dc terminal connections are located on the dc end of the inverter. Figure 3-10 shows the locations of the dc connectors. Warning: shock hazard before making any connections, verify that the dc disconnect device is switched off...

  • Page 103

    Dc wiring 976-0043-01-02 3–21 figure 3-11 shows the proper method to attach the cables to the inverter. Figure 3-12 shows the battery terminal covers and associated hardware. Figure 3-11 battery cable connection caution: damage to equipment do not put anything between the battery cable lug and the t...

  • Page 104

    Installation 3–22 976-0043-01-02 procedure for single inverter systems before starting this procedure, please review figure 3-10, “dc terminal connections on the inverter” on page 3–20 and figure 3-11, “battery cable connection” on page 3–21 for the locations of the terminals and details on attachin...

  • Page 105

    Dc wiring 976-0043-01-02 3–23 figure 3-13 dc connections to a single inverter.

  • Page 106

    Installation 3–24 976-0043-01-02 procedure for dual-inverter systems before starting this procedure, please review figure 3-10, “dc terminal connections on the inverter” on page 3–20 and figure 3-11, “battery cable connection” on page 3–21 for the locations of the terminals and details on attaching ...

  • Page 107

    Dc wiring 976-0043-01-02 3–25 figure 3-14 dc connections to dual inverters.

  • Page 108: Ac Wiring

    Installation 3–26 976-0043-01-02 ac wiring this section describes: • “accessing the ac terminal block and ground bar” on page 3–28 , and • “ac wiring for single inverter systems” on page 3–30 . Disregard installation sections and illustrations that do not apply to your configuration (for example, in...

  • Page 109

    Ac wiring 976-0043-01-02 3–27 table 3-1 ac disconnect and wire sizing full pass-through capability maximum fuse/breaker required cable size required in 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 wire...

  • Page 110

    Installation 3–28 976-0043-01-02 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 th...

  • Page 111

    Ac wiring 976-0043-01-02 3–29 figure 3-16 ac input/output wiring terminals ac terminal block ac terminal block enlargement.

  • Page 112

    Installation 3–30 976-0043-01-02 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: 1. “install ac output wiring to the inverter ac distribution panel” on page 3–33 . 2. “in...

  • Page 113

    Ac wiring 976-0043-01-02 3–31 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...

  • Page 114

    Installation 3–32 976-0043-01-02 figure 3-18 ac input and output wiring to a single inverter with an auto-start ac generator.

  • Page 115

    Ac wiring 976-0043-01-02 3–33 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 subpanel. Install the...

  • Page 116

    Installation 3–34 976-0043-01-02 make connections from the inverter to the inverter panel as follows: 1. Connect the ground (green or bare) wire: a) from the inverter ac ground bar b) to the inverter panel ground bar 2. Connect the neutral (white) wire: a) from the inverter neutral out terminal b) t...

  • Page 117

    Ac wiring 976-0043-01-02 3–35 install generator wiring to the inverter generator disconnect switch (if used) having a generator disconnect switch between the inverter and the generator is strongly recommended. This will provide overcurrent protection for the wiring between the inverter and the gener...

  • Page 118

    Installation 3–36 976-0043-01-02 with step-down autotransformer and using a 120/ 240 vac generator the following instructions are illustrated in figure 3-20, “generator input wiring to a single inverter” on page 3–37 . To install the ac wiring from the generator to the inverter: 1. Connect ground (g...

  • Page 119

    Ac wiring 976-0043-01-02 3–37 b) from the neutral in the generator disconnect to the inverter neutral 2 terminal. 3. Connect hot (black) wires: 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 t...

  • Page 120

    Installation 3–38 976-0043-01-02 install utility wiring to the inverter input (on-grid applications only) the following instructions are illustrated in figure 3-21, “utility wiring to the inverter input” on page 3–39 . Install the wiring from the inverter to the utility panel as follows: 1. Feed the...

  • Page 121: Optional Equipment

    Optional equipment 976-0043-01-02 3–39 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 por...

  • Page 122

    Installation 3–40 976-0043-01-02 installing the isc-s cable to install the isc-s cable on the inverters: 1. Connect one end of the isc-s cable to the stacking port on one inverter. 2. Connect the other end of the isc-s cable to the stacking port on the other inverter. The following diagram is for co...

  • Page 123

    Optional equipment 976-0043-01-02 3–41 remote monitoring options the sine wave plus can be controlled remotely by connecting an additional icm or by using an ica connected to a personal computer. The icm operates identically to the icm display on the front of the sine wave plus . See the icm install...

  • Page 124

    Installation 3–42 976-0043-01-02 auxiliary load module (alm) the alm can be used to signal loads to turn on and off based on battery voltage. The alm has a dc voltage controlled relay (switch) that require the sine wave plus in order to operate. The dc voltage set points for energizing and de-energi...

  • Page 125

    Optional equipment 976-0043-01-02 3–43 emergency power off (epo) the 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. Consult your ...

  • Page 126

    3–44.

  • Page 127: Functional Test

    4 functional test chapter 4, “functional test” explains how to conduct a functional test of the inverter..

  • Page 128: Basic Functional Test

    Functional test 4–2 976-0043-01-02 basic functional test the following steps will complete a basic functional test of the sine wave plus . If any test fails, please refer to chapter 9, “troubleshooting” for assistance. Confirm all connections once the ac and dc wiring have been installed and connect...

  • Page 129

    Basic functional test 976-0043-01-02 4–3 turning on the inverter to turn on the inverter: 1. Ensure that the lcd display is as shown in figure 4-1 . 2. Press the red inverter on/off menu switch twice (srch, then on) to turn on the inverter. 3. Monitor the invert (yellow) led to confirm which mode th...

  • Page 130

    Functional test 4–4 976-0043-01-02 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 ...

  • Page 131

    Basic functional test 976-0043-01-02 4–5 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 wil...

  • Page 132

    4–6.

  • Page 133: Navigation

    5 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

    Navigation 5–2 976-0043-01-02 navigating the sine wave plus the sine wave plus is programmed using the inverter control module (icm) to access “user” and “setup” menus. Navigating through the menus requires an understanding of the icm and its features, what menus are required to do specific function...

  • Page 135

    Inverter control module features 976-0043-01-02 5–3 the inverter control module (icm) the icm is located on the front panel of the sine wave plus . It’s used to display status information regarding the operation and performance of the unit. It is also used to access the “basic setup”, “advanced setu...

  • Page 136

    Navigation 5–4 976-0043-01-02 display contrast to change the display contrast, use a small, flat-blade screwdriver in the slot provided to make the adjustment. Push-buttons eight push-buttons enable access to internal software to program user- specific parameters and to monitor the system. These pus...

  • Page 137

    Inverter control module features 976-0043-01-02 5–5 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...

  • Page 138

    Navigation 5–6 976-0043-01-02 set point buttons the set point buttons change the value of a parameter or select a mode from the displayed menu. • press the set point button (+) to move the cursor to the right or raise an adjustable value. • press the set point button (–) to move the cursor left or l...

  • Page 139: Menu Map

    Menu map 976-0043-01-02 5–7 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. Each of the menu headings w...

  • Page 140

    Navigation 5–8 976-0043-01-02 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. See “the user menu summary” on page 8–11 for a summary of the default ...

  • Page 141

    Menu map 976-0043-01-02 5–9 figure 5-10 user menu map - part 2.

  • Page 142

    Navigation 5–10 976-0043-01-02 basic setup menu (10-14) the basic setup menu follows the user menu in the menu architecture. This menu allows access to the settings required for system configuration and modes of operation. Establishing these parameters upon initial power-up will be required. See “ba...

  • Page 143

    Menu map 976-0043-01-02 5–11 figure 5-12 basic setup menu map part 2.

  • Page 144

    Navigation 5–12 976-0043-01-02 advanced setup menu (20-27) the advanced setup menu contains specialized configuration settings such as automatic generator starting details, auxiliary load usage, and energy management (grid usage) parameters. See “advanced setup summary” on page 7–2 for a listing of ...

  • Page 145

    Menu map 976-0043-01-02 5–13 figure 5-14 advanced setup menu map part 2.

  • Page 146

    Navigation 5–14 976-0043-01-02 figure 5-15 complete user menu map.

  • Page 147

    Menu map 976-0043-01-02 5–15 figure 5-16 complete basic setup menu map.

  • Page 148

    Navigation 5–16 976-0043-01-02 figure 5-17 complete advanced setup menu map.

  • Page 149: Basic Setup

    6 basic setup programming chapter 6, “basic setup programming” explains how to program the sine wave plus inverter/charger to operate under basic conditions..

  • Page 150: Basic Setup Summary

    Basic setup programming 6–2 976-0043-01-02 basic setup summary check defaults the following tables provides the default settings for the sine wave plus basic setup menu for each model and the cross-reference pages for locating information on each menu item. • table 6-1, “basic setup menu default set...

  • Page 151

    Basic setup summary 976-0043-01-02 6–3 11c low battery cut out vdc 11.0 to 33.9 22.0 32.0 to 67.8 44.0 page 6–13 11d lbco delay minutes 01 to 255 15 01 to 255 15 page 6–13 11e search watts (srch) 00 to 248 08 00 to 248 08 page 6–14 end menu 11 12 battery charging menu see “12 battery charging menu” ...

  • Page 152

    Basic setup programming 6–4 976-0043-01-02 14c push gen for factory defaults push gen for factory defaults page 6–30 end menu 14 end basic setup menu table 6-2 basic setup menu default settings for the sine wave plus 4024 and 4048 models basic setup menus sine wave plus 4024 sine wave plus 4048 see ...

  • Page 153

    Basic setup summary 976-0043-01-02 6–5 12e max charge amps ac 01 to 30 30 01 to 30 30 page 6–22 12f bulk done amps ac 00 to 30 10 00 to 30 10 page 6–23 12g eq vdc done timer 00:00 to 23:50 02:00 00:00 to 23:50 02:00 page 6–24 12h max bulk/eq timer 00:00 to 23:50 05:00 00:00 to 23:50 05:00 page 6–25 ...

  • Page 154

    Basic setup programming 6–6 976-0043-01-02 table 6-3 basic setup menu default settings for the sine wave plus 5548 model basic setup menus sine wave plus 5548 see page range/ display default 10 time of day setup menu see “10 time of day setup menu” on page 6–11 for details. 10a set hour 00:00:00 to ...

  • Page 155

    Basic setup summary 976-0043-01-02 6–7 13 ac inputs menu see “13 ac inputs menu” on page 6–26 for details. 13a grid (ac1) amps ac 00 to 60 60 page 6–27 13b gen (ac2) amps ac 00 to 60 30 page 6–27 13c input upper limit vac 125 to 150 130 page 6–28 13d input lower limit vac 80 to 115 110 page 6–28 end...

  • Page 156

    Basic setup programming 6–8 976-0043-01-02 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 ...

  • Page 157

    Before you begin programming 976-0043-01-02 6–9 basic setup process the basic setup procedure is comprised of the following items: 1. Setting the time of day – this sets the internal clock for all the features requiring time functions. See “10 time of day setup menu” on page 6–11 for instructions on...

  • Page 158

    Basic setup programming 6–10 976-0043-01-02 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. Press and hold down the green gen...

  • Page 159: Menu Item Descriptions

    Menu item descriptions 976-0043-01-02 6–11 menu item descriptions 10 time of day setup menu this menu allows for setting the time of day in hours, minutes, and seconds. The time is displayed in a 24-hour format (i.E., 00:00:00 to 23:59:59 hours). To set the time of day: ◆ when the begin basic setup ...

  • Page 160

    Basic setup programming 6–12 976-0043-01-02 10c set seconds to set the second display: 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 ...

  • Page 161

    Menu item descriptions 976-0043-01-02 6–13 this voltage level is used to indicate that the batteries have a sufficient level of charge for the inverter to start using power from the battery bank. 11c low battery cut out vdc when the batteries discharge to the level set in 11c low battery cut out vdc...

  • Page 162

    Basic setup programming 6–14 976-0043-01-02 11e search watts this menu item sets the inverter’s search sensitivity. Any load that is below this setting does not cause the inverter to produce an ac output voltage when running from batteries. The srch function must be selected in 01a inverter. How doe...

  • Page 163

    Menu item descriptions 976-0043-01-02 6–15 the sensitivity control should be adjusted so that the smallest load being run can "wake" the inverter up and cause it to deliver power to the load. If loads change significantly, then re-tuning of the search sensitivity will be required. It may take severa...

  • Page 164

    Basic setup programming 6–16 976-0043-01-02 multi-stage charging process the charging cycle uses a multi-stage charging process to maintain the batteries. Whenever ac power that is within the range of the inverter’s settings is present at the inverter’s input, it passes power through to the connecte...

  • Page 165

    Menu item descriptions 976-0043-01-02 6–17 absorption stage absorption charge is the second stage of battery charging and provides the batteries a controlled, constant voltage for a set period of time. During this stage, the current supplied to the batteries slowly decreases. When this current decre...

  • Page 166

    Basic setup programming 6–18 976-0043-01-02 equalize charging the batteries many battery manufacturers recommend periodic equalize charging to level out the voltage between individual cells resulting in better battery performance and life. Over time, the battery’s electrolyte can become “stratified”...

  • Page 167

    Menu item descriptions 976-0043-01-02 6–19 12 battery charging menu battery charging parameters are programmed in 12 battery charging menu using the following menu items. Some of the menu items will require making calculations. Others just require making selections between the set points. The voltag...

  • Page 168

    Basic setup programming 6–20 976-0043-01-02 12b bulk volts dc this is the voltage level at which the charger switches to the absorption stage. The charger will use up to the parameter set in 12e max charge amps ac until the parameter set in 12b bulk volts dc is reached. The actual battery charging v...

  • Page 169

    Menu item descriptions 976-0043-01-02 6–21 the following settings ( table 6-5 ) are guidelines only. Refer to your battery vendor for specific settings and battery maintenance guidelines. Table 6-4 battery voltages for setting charging parameters battery type bulk volts float volts equalization char...

  • Page 170

    Basic setup programming 6–22 976-0043-01-02 12e max charge amps ac this is the maximum ac amperage the inverter will provide to the battery charger to get the battery voltage up to the level set in one of the following menu items depending on which mode the battery charger is in as indicated by the ...

  • Page 171

    Menu item descriptions 976-0043-01-02 6–23 12f bulk done amps ac this is the ac current threshold where the battery charger will transfer from absorption charging to finish charging. It is recommended to set this value at 2 to 4% of the battery bank’s total amp-hour capacity. Guidelines for setting ...

  • Page 172

    Basic setup programming 6–24 976-0043-01-02 12g eq vdc done timer this is the maximum time the batteries will be allowed to charge at the equalize voltage level set in 12d equalize volts dc. This setting is limited by 12h max bulk/eq timer h:m, which sets the maximum period for the eq charge stage. ...

  • Page 173

    Menu item descriptions 976-0043-01-02 6–25 12h max bulk/eq timer h:m this is the maximum time the charger is allowed to keep the batteries in the bulk or eq charge stage. This timer starts when either the equalize charge starts or when the bulk charge starts. Ensure this setting doesn't interfere wi...

  • Page 174

    Basic setup programming 6–26 976-0043-01-02 temperature compensation calculations are derived from the following table: temperature compensation is based on battery type: 5 mv/cell for lead acid type batteries and 2 mv/cell for alkaline type batteries (nicad or nife). The default for this menu item ...

  • Page 175

    Menu item descriptions 976-0043-01-02 6–27 13a grid (ac1) amps ac this is the maximum amount of current that can be drawn from the grid (ac1 input) by the loads and battery charger combined. This settings determines the amperage level at which point the inverter starts drawing power from the batteri...

  • Page 176

    Basic setup programming 6–28 976-0043-01-02 13c input upper limit vac this menu item sets the highest voltage at which the inverter is allowed to connect to either ac1 or ac2 inputs. When this voltage is reached the inverter disconnects from the grid or generator and provides power to the loads from...

  • Page 177

    Menu item descriptions 976-0043-01-02 6–29 14 save/restore settings menu this menu provides the means to: • save user programmed settings, • restore previously saved programmed settings, or • restore factory default settings. If dc power is removed from the inverter, all user defined set points will...

  • Page 178

    Basic setup programming 6–30 976-0043-01-02 14c push gen for factory defaults this menu item provides the means to restore the factory default settings. To restore the factory default settings: 1. Press the button until 14c push gen for factory defaults is displayed. 2. Press the green gen button to...

  • Page 179: Advanced Setup

    7 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 180: Advanced Setup Summary

    Advanced setup 7–2 976-0043-01-02 advanced setup summary check defaults the following model-specific tables provide the default settings for the sine wave plus advanced setup menu and cross-reference pages for locating information on each menu item. • table 7-1, “advanced setup default settings for ...

  • Page 181

    Advanced setup summary 976-0043-01-02 7–3 21c grid usage end h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00 page 7–18 end menu 21 22 battery xfer (bx) menu see “22 battery xfer (bx) menu” on page 7–18 for details. 22a high xfer (hbx) vdc 16.1 to 33.9 27.0 32.2 to 67.8 54.0 page 7–19 22b low xfer (lbx...

  • Page 182

    Advanced setup 7–4 976-0043-01-02 25a ry7 mode gs rn1 rn2 gs gs rn1 rn2 gs page 7–30 25b gen warm-up second/minute 0 to 127 /0 to 127 10 seconds 0 to 127 /0 to 127 10 seconds page 7–37 25c pre crank seconds 00 to 255 10 00 to 255 10 page 7–37 25d max cranking seconds 01 to 15 10 01 to 15 10 page 7–3...

  • Page 183

    Advanced setup summary 976-0043-01-02 7–5 table 7-2 advanced setup default settings for the sine wave plus 4024 and 4048 models advanced setup menus sine wave plus 4024 sine wave plus 4048 see page range/display default settings range/display default settings 20 silent setup menu see “20 silent setu...

  • Page 184

    Advanced setup 7–6 976-0043-01-02 24b gen run time stop h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27 24c quiet time begin h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27 24d quiet time end h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–28 24e gen exercise period days 00 to 2...

  • Page 185

    Advanced setup summary 976-0043-01-02 7–7 27a push inv now to save settings push inv now to save settings page 7–39 27b push gen to restore settings push gen to restore settings page 7–40 27c push gen for factory defaults push gen for factory defaults page 7–40 end menu 27 end advanced setup menu ta...

  • Page 186

    Advanced setup 7–8 976-0043-01-02 23 alm relays menu see “23 alm relays menu” on page 7–19 for details. 23a ry9 vdc energized 44.2 to 71.0 52.0 page 7–20 23b ry9 vdc deenergized 40.0 to 71.0 44.0 page 7–20 23c ry9 delay at deengz. Min 00 to 255 10 page 7–20 23d ry10 vdc energized 20.0 to 64.0 57.6 v...

  • Page 187

    Advanced setup summary 976-0043-01-02 7–9 26a load start amps ac 00 to 63 45 page 7–38 26b load start delay min 00.0 to 25.5 05.0 page 7–38 26c load stop delay min 00.0 to 25.5 05.0 page 7–38 26d 24 hr start volts dc 20.0 to 71.0 49.2 page 7–38 26e 2 hr start volts dc 20.0 to 71.0 47.2 page 7–38 26f...

  • Page 188

    Advanced setup 7–10 976-0043-01-02 before you begin advanced programming the 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...

  • Page 189

    Accessing the advanced setup menu 976-0043-01-02 7–11 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. While holdi...

  • Page 190

    Advanced setup 7–12 976-0043-01-02 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 6 and 7. 6. Press and hold down the green gen button. 7. While holding the green gen button down, press th...

  • Page 191: Menu Item Descriptions

    Menu item descriptions 976-0043-01-02 7–13 menu item descriptions 20 silent setup menu this menu is used only when silent is selected in menu 12a finish stage. When the silent modeis selected, the charger is turned off and does not supply any charging current to the batteries until certain condition...

  • Page 192

    Advanced setup 7–14 976-0043-01-02 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 mo...

  • Page 193

    Menu item descriptions 976-0043-01-02 7–15 silent mode terminates based on time 20d must float time min, then amps 20c float done amps. 20a refloat high volts dc this menu item sets the upper battery voltage level that triggers the float charge. When this level is met or exceeded, the unit turns on ...

  • Page 194

    Advanced setup 7–16 976-0043-01-02 20d must float time min this menu item sets the minimum amount of time after the 20a refloat high volts dc and 20b refloat low volts dc settings have been reached that the inverter will maintain the float voltage level on the batteries before it reaches the 20c flo...

  • Page 195

    Menu item descriptions 976-0043-01-02 7–17 21a grid usage this menu item allows you to select between the set points sb and bx as described below. Sb (standby) - utility backup this set point is the first set point selection in the 21a grid usage menu. It sets the inverter to be used as a backup pow...

  • Page 196

    Advanced setup 7–18 976-0043-01-02 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 ...

  • Page 197

    Menu item descriptions 976-0043-01-02 7–19 22a high xfer (hbx) vdc this menu is used to set the voltage transfer point when the inverter turns back on and resumes powering the ac loads from the batteries. When this setting is reached, the inverter transfers from the ac1 input (grid) to the batteries...

  • Page 198

    Advanced setup 7–20 976-0043-01-02 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-stac...

  • Page 199

    Menu item descriptions 976-0043-01-02 7–21 23e ry10 vdc deenergized this menu item sets the trip point where the relay de-energizes. When the voltage, based on the 04b battery comp vdc display, drops to or below this setting, the relay de-energizes and opens the contacts between the n.O. And com ter...

  • Page 200

    Advanced setup 7–22 976-0043-01-02 figure 7-3 relay 11 wiring example to dual inverters with cooldown selected.

  • Page 201

    Menu item descriptions 976-0043-01-02 7–23 generator starting scenarios the 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 gene...

  • Page 202

    Advanced setup 7–24 976-0043-01-02 the generator will continue to run unless one of the following procedures is performed: 1. Manual stop – manually stop the generator by selecting off from the 02a generator menu item. The generator will receive the stop command immediately if manually stopped. 2. A...

  • Page 203

    Menu item descriptions 976-0043-01-02 7–25 if set point rn1 is selected in 25a ry7 mode, the generator will automatically shut off once the bulk and absorption stages of the battery charging have completed or if the 24h rn2/max gen run h:m has elapsed. If rn2 is selected in menu item 25a ry7 mode, t...

  • Page 204

    Advanced setup 7–26 976-0043-01-02 24 generator timers menu this menu heading sets parameters for starting the generator based on time. In this menu, you can set the generator to start and stop at a specified time each day. You can specify a quiet time, an exercise time, and a cooldown period for th...

  • Page 205

    Menu item descriptions 976-0043-01-02 7–27 24a gen run time start h:m this menu item sets the hour and minute for the generator to start. This will occur each day at the same time. The set points for this menu item change in 10-minute increments. 24b gen run time stop h:m this menu item sets the hou...

  • Page 206

    Advanced setup 7–28 976-0043-01-02 24d quiet time end h:m this menu item ends the quiet time, after which the generator can be started if required, if an auto-start condition exists. To completely disable the quiet-time feature, set the start and stop times to the same value. The generator exercise ...

  • Page 207

    Menu item descriptions 976-0043-01-02 7–29 24h rn2/max gen run h:m this menu item sets the limit on how long a generator can run when the ry7 relay is programmed for rn2 under menu item 25a ry7 mode. The set points for this menu item change in 10-minute increments. 25 gen starting details menu menu ...

  • Page 208

    Advanced setup 7–30 976-0043-01-02 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. For battery protection, insure that external charge management equipment is installe...

  • Page 209

    Menu item descriptions 976-0043-01-02 7–31 rn1 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 close...

  • Page 210

    Advanced setup 7–32 976-0043-01-02 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 cran...

  • Page 211

    Menu item descriptions 976-0043-01-02 7–33 figure 7-7 wiring examples of honda™ and onan™ generators generator start module ry7 stop switch contacts onan type generator com n.O. N.C. Ry8 com n.O. N.C. Start switch contacts 5 amp fuse 5 amp fuse ry7 run/stop switch contacts honda type generator com n...

  • Page 212

    Advanced setup 7–34 976-0043-01-02 figure 7-8 ry7 and ry8 timing diagram the generator auto-stop sequence is initiated if: 1) the time set in 24c quiet time begin has been reached or passed. This setting will disable 2, 3, and 4 start-scenarios below. 2) if the battery voltage has been held at the 1...

  • Page 213

    Menu item descriptions 976-0043-01-02 7–35 figure 7-9 ry7/ry8 sequence of events for rn1 or rn2 selection y e l le d r y 7 nc c no g r n l e d r y 8 nc c no y e l le d r y 7 nc c no g r n l e d r y 8 nc c no y e l le d r y 7 nc c no g r n l e d r y 8 nc c no y e l le d r y 7 nc c no g r n l e d r y ...

  • Page 214

    Advanced setup 7–36 976-0043-01-02 figure 7-10 ry7/ry8 sequence of events for gs selection y e l le d r y 7 nc c no g r n l e d r y 8 nc c no y e l le d r y 7 nc c no g r n l e d r y 8 nc c no 80 vac on ac2 input generator off 25c pre-crank seconds 25d max cranking seconds generator run period 1) ma...

  • Page 215

    Menu item descriptions 976-0043-01-02 7–37 25b gen warm-up seconds/minutes this menu item sets the number of seconds or minutes the generator is allowed to warm up before the load is connected and the battery charger started. If the generator is located in a cold location, a longer setting may be re...

  • Page 216

    Advanced setup 7–38 976-0043-01-02 26 gen auto run setup menu menu heading 26 gen auto run setup menu provides the menu items for setting the parameters for starting the generator based on ac current and/or battery voltage. 26a load start amps ac this menu items sets the ac load current that initiat...

  • Page 217

    Menu item descriptions 976-0043-01-02 7–39 26f 15 min start volts dc this menu item sets the battery’s dc voltage level which initiates automatic generator starting whenever the voltage drops below this setting continuously for 15 minutes. This item is not temperature compensated and is defeated dur...

  • Page 218

    Advanced setup 7–40 976-0043-01-02 27b push gen to restore settings this menu item provides the means to restore settings previously set and saved on the inverter. To restore settings previously programmed into the inverter: 1. Press the button to select 27b push gen now to restore settings. 2. Pres...

  • Page 219: Operation

    8 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 220: Operating The

    Operation 8–2 976-0043-01-02 operating the sine wave plus user menu the 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 de...

  • Page 221

    Operational status indicators 976-0043-01-02 8–3 operational status indicators the 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 th...

  • Page 222

    Operation 8–4 976-0043-01-02 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 grid tie led the grid tie feature is not enabled on these models. Therefore, the g...

  • Page 223

    Operational status indicators 976-0043-01-02 8–5 ac input status (green) status leds there are two green leds to indicate ac status conditions. • ac1 led (grid) • ac2 led (generator) ac1 (grid) led the ac1 led indicates power has been applied to the inverter’s ac1 (grid) input terminals. When ac is ...

  • Page 224

    Operation 8–6 976-0043-01-02 charge status (yellow and green) charging indicators there are two leds for battery charging indications. • bulk charge led (yellow) • float charge led (green) bulk charge led (yellow) the bulk charge led indicates if the inverter is in the bulk or absorption charge stag...

  • Page 225

    Operational status indicators 976-0043-01-02 8–7 operational status indication (red and yellow) there are two leds for error and status indications: • error led (red) • status led (yellow) error led (red) the error led indicates an operating error occurred or an error condition exists. Select menu h...

  • Page 226

    Operation 8–8 976-0043-01-02 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 set point buttons. Status led (yellow) the status led illuminates to indicate various conditions of the inv...

  • Page 227

    Operational status indicators 976-0043-01-02 8–9 led summary table 8-1 summarizes the led indicators. Table 8-1 led summary table led name off on flashing grid tie led (yellow) not available invert led (yellow) inverter is off. No power is available from the batteries in case of a power failure. The...

  • Page 228

    Operation 8–10 976-0043-01-02 error led (red) no error has been detected. An inverter error condition has been detected. Use 05 error causes menu to determine the cause of the error. This error led will be on if either an inverter and/or a generator error condition has been detected. A generator err...

  • Page 229: The User Menu Summary

    The user menu summary 976-0043-01-02 8–11 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 invert...

  • Page 230

    Operation 8–12 976-0043-01-02 xantrex tech inc 5916 195th st ne info. Displayed read only info. Displayed read only page 8–20 arlington, wa 98223 usa info. Displayed read only info. Displayed read only page 8–20 ph 1-800-446-6180 www.Xantrex.Com info. Displayed read only info. Displayed read only pa...

  • Page 231

    The user menu summary 976-0043-01-02 8–13 05f external err (stacked) no yes read only no yes read only page 8–27 05g input relay failure no yes read only no yes read only page 8–27 05h gen failed to start no yes read only no yes read only page 8–28 05i gen stopped due to v/f no yes read only no yes ...

  • Page 232: Accessing The User Menu

    Operation 8–14 976-0043-01-02 accessing the user menu to directly access the 01a inverter user menu: ◆ press the red inv button to go directly to 01a inverter. To directly access the 02 generator user menu: ◆ press the green gen button to go directly to 02a generator. Figure 8-6 inverter on/off disp...

  • Page 233: User Menu Description

    User menu description 976-0043-01-02 8–15 user menu description 01 inverter on/off menu the inverter on/off menu heading accesses the startup and shutdown function of the inverter. 01a inverter the 01a inverter menu item has four set points to select from for inverter operation: off, srch, on, and c...

  • Page 234

    Operation 8–16 976-0043-01-02 01b eq charge off on off when off is selected in the menu, the inverter is not set to equalize the batteries. 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 equal...

  • Page 235

    User menu description 976-0043-01-02 8–17 01d bypass mode the bypass modecloses the internal bypass relays and allows the ac connected to the selected input (ac1 or ac2) to pass directly through to the loads without being monitored for ac voltage or frequency quality. Norm when norm is selected in t...

  • Page 236

    Operation 8–18 976-0043-01-02 02a generator the 02a generator menu item provides three set points to choose from for generator control. 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 auto...

  • Page 237

    User menu description 976-0043-01-02 8–19 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 a...

  • Page 238

    Operation 8–20 976-0043-01-02 03 time of day menu menu heading 03 time of day displays information such as the current 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 contac...

  • Page 239

    User menu description 976-0043-01-02 8–21 press reset for factory defaults in addition to providing information, this menu includes a reset function that allows all system settings to be returned to their original default values. Pressing the reset defaults button while this menu item is displayed r...

  • Page 240

    Operation 8–22 976-0043-01-02 04 meters menu the meters menu provides information about system performance. The 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 • 04b battery ...

  • Page 241

    User menu description 976-0043-01-02 8–23 04b battery comp vdc this menu item display shows the battery voltage after it has been compensated based on the battery temperature and the input current. These two compensation values are used by the battery charger for its regulation settings and are only...

  • Page 242

    Operation 8–24 976-0043-01-02 04g grid (ac1) volts ac this menu item displays the ac input voltage connected to the inverter's ac1 terminals. This input voltage display may drift slightly before the inverter has synchronized to the grid. 04h gen (ac2) volts ac this menu item displays the ac input vo...

  • Page 243

    User menu description 976-0043-01-02 8–25 05 error causes menu detected inverter errors cause the red error led to illuminate. These menu items help determine the cause of error conditions. These menu items normally display “no” for all menu items in which no error is detected. The display changes t...

  • Page 244

    Operation 8–26 976-0043-01-02 05c heatsink overtemp if “yes” is visible in this display, the power transistors have exceeded their designed operating temperature and the inverter is shut off. When this error condition occurs, if the unit is operating as a battery charger, the inverter stops charging...

  • Page 245

    User menu description 976-0043-01-02 8–27 05e high battery voltage if “yes” is displayed, the dc battery voltage has increased above the value set in the 11a high battery cut out vdc menu item. This can be caused by a solar array or other charging source not being regulated. Check the operational st...

  • Page 246

    Operation 8–28 976-0043-01-02 05h gen failed to start if “yes” is displayed, the automatic generator-start system did not successfully start the generator. The system completes six start cycles and requires the generator to operate for a minimum of five minutes before the starting attempts counter i...

  • Page 247

    User menu description 976-0043-01-02 8–29 06a bypass mode selected if “yes” is displayed, the bypass mode is selected for either the ac1 or ac2 input. 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 gr...

  • Page 248

    Operation 8–30 976-0043-01-02 06e eq charge selected if “yes” is displayed, the charger is set to run in the equalize charge mode. Be sure to monitor menu items 04i battery temp and 04k read bulk/ eq time when equalize charging the batteries. 6f battery vdc if “yes” is displayed, the battery voltage...

  • Page 249

    User menu description 976-0043-01-02 8–31 07b ry8 (gsm) energized if “yes” is displayed, the inverter has sent out a command to energize the relay (between the n.O. To com connections) in the gsm. This display can be used for troubleshooting purposes by helping to isolate the cause of a generator pr...

  • Page 250

    8–32.

  • Page 251: Troubleshooting

    9 troubleshooting chapter 9, “troubleshooting” contains information and procedures for solving possible problems with the sine wave plus ..

  • Page 252: Inverter Troubleshooting

    Troubleshooting 9–2 976-0043-01-02 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...

  • Page 253

    Inverter troubleshooting 976-0043-01-02 9–3 low ac power output or low surge power invert led is on. Ac inductive loads are not running at full speed. Insufficient dc current being provided to the inverter to operate the ac loads. Check the battery voltage, fuses or breakers and cable connections. E...

  • Page 254

    Troubleshooting 9–4 976-0043-01-02 battery charger troubleshooting if the red error led illuminates on the icm display, 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 le...

  • Page 255

    Battery charger troubleshooting 976-0043-01-02 9–5 charger drops off before full charging has finished (no error comes on). Ac frequency at the ac input terminal may be out-of-tolerance (too high or low) or the ac voltage may be outside the 13c input upper limit vac or 13d input lower limit vac sett...

  • Page 256

    Troubleshooting 9–6 976-0043-01-02 batteries being charged above the bulk/float setting. If bts is installed, it may be in a cold area or have fallen off the batteries. Another dc charging source may be on the batteries. Monitor the 04b battery temp comp vdc while charging. Note: to bring batteries ...

  • Page 257: Error Causes

    Error causes 976-0043-01-02 9–7 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 ac output. Reset the inverter by pressing the on/off switch to off, then to s...

  • Page 258

    Troubleshooting 9–8 976-0043-01-02 05g input relay failure the ac transfer relay is bad or an ac source was wired directly to the ac output. Disconnect the inverter’s output wiring. If error continues, have unit serviced. 05h gen failed to start indicates that six “auto generator start attempts” hav...

  • Page 259: Inverter

    A inverter specifications appendix a, “inverter specifications” provides the electrical and environmental specifications of this inverter..

  • Page 260: Electrical Specifications

    Inverter specifications a–2 976-0043-01-02 electrical specifications electrical specifications sine wave plus 2524 sine wave plus 2548 ac input voltage (nominal) 120 vac 120 vac ac input voltage range 80 to 150 vac 80 to 150 vac ac input current 60 amps ac pass- through/ 20 amps ac charging 60 amps ...

  • Page 261

    Electrical specifications 976-0043-01-02 a–3 electrical specifications sine wave plus 4024 sine wave plus 4048 sine wave plus 5548 ac input voltage (nominal) 120 vac 120 vac 120 vac ac input voltage range 80 to 150 vac 80 to 150 vac 80 to150 vac ac input current 60 amps ac pass- through/ 30 amps ac ...

  • Page 262: Mechanical Specifications

    Inverter specifications a–4 976-0043-01-02 mechanical specifications mechanical specifications sine wave plus 2524 sine wave plus 2548 operating temperature range specified (will meet specified tolerances) 32 °f to 77 °f (0 °c to 25 °c) 32 °f to 77 °f (0 °c to 25 °c) allowed (may not meet specified ...

  • Page 263

    Mechanical specifications 976-0043-01-02 a–5 mechanical specifications sine wave plus 4024 sine wave plus 4048 sine wave plus 5548 operating temperature range specified (will meet specified tolerances) 32 °f to 77 °f (0 °c to 25 °c) 32 °f to 77 °f (0 °c to 25 °c) 32 °f to 77 °f (0 °c to 25 °c) allow...

  • Page 264: Theory Of Operation

    Inverter specifications a–6 976-0043-01-02 theory of operation the 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...

  • Page 265

    Theory of operation 976-0043-01-02 a–7 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 w...

  • Page 266: Power Versus Efficiency

    Inverter specifications a–8 976-0043-01-02 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...

  • Page 267

    Power versus efficiency 976-0043-01-02 a–9 figure a-4 sine wave plus efficiency curve for the sw plus 2524 figure a-3 power versus efficiency curves for all models sw plus efficiency curves 75% 80% 85% 90% 95% 100% 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 output pow er in watts e ff i...

  • Page 268

    Inverter specifications a–10 976-0043-01-02 figure a-5 sine wave plus efficiency curve for the sw plus 2548 figure a-6 sine wave plus efficiency curve for the sw plus 4024 sw plus 2548 efficiency curve 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 500 1000 1500 2000 2500 output pow er in watts e ff ...

  • Page 269

    Power versus efficiency 976-0043-01-02 a–11 figure a-7 sine wave plus efficiency curve for the sw plus 4048 figure a-8 sine wave plus efficiency curve for the sw plus 5548 sw plus 4048 efficiency curve 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 500 1000 1500 2000 2500 3000 3500 4000 output pow er...

  • Page 270

    Inverter specifications a–12 976-0043-01-02 inverter capacity versus temperature the output power of the inverter diminishes as ambient temperature rises. However, as can be seen below, with the exception of the swp5548, these inverters are sized to be able to run a full rated output power up to 40c...

  • Page 271: Time Versus Current

    Time versus current 976-0043-01-02 a–13 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 con...

  • Page 272

    Inverter specifications a–14 976-0043-01-02 figure a-10 time versus current for the sine wave plus 2548 figure a-11 time versus current for the sine wave plus 4024.

  • Page 273

    Time versus current 976-0043-01-02 a–15 figure a-12 time versus current for the sine wave plus 4048 figure a-13 time versus current for the sine wave plus 5548.

  • Page 274

    A–16.

  • Page 275: Configuration

    B configuration settings appendix b, “configuration settings” provides worksheets for programming your inverter/charger for user-specific parameters..

  • Page 276: User Menu Settings

    Configuration settings b–2 976-0043-01-02 user menu settings table b-1 provides a list of user menu headings and menu items, with available set points. 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 t...

  • Page 277

    User menu settings 976-0043-01-02 b–3 ph 1-800-446-6180 www.Xantrex.Com press reset for factory defaults press to refresh the lcd display. 04 meters menu see “04 meters menu” on page 8–22 for details. 04a battery actual vdc 13.2 to 35.5 read only 20.0 to 71.0 read only 04b battery comp vdc 13.2 to 3...

  • Page 278

    Configuration settings b–4 976-0043-01-02 06 status menu see “06 status menu” on page 8–28 for details. 06a bypass mode selected no yes read only no yes read only 06b chr selected (no backup) no yes read only no yes read only 06c gen signalled to run no yes read only no yes read only 06d gen in cool...

  • Page 279: Basic Setup Menu

    Basic setup menu 976-0043-01-02 b–5 basic setup menu table b-2 provides a list of basic setup menu headings and menu items, with available set points. 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...

  • Page 280

    Configuration settings b–6 976-0043-01-02 12i temp comp leadacid nicad leadacid leadacid nicad leadacid 13 ac inputs menu see “13 ac inputs menu” on page 6–26 for details. 13a grid (ac1) amps ac 00 to 60 60 00 to 60 60 13b gen (ac2) amps ac 00 to 60 30 00 to 60 30 13c input upper limit vac 125 to 15...

  • Page 281

    Basic setup menu 976-0043-01-02 b–7 12 battery charging menu see “12 battery charging menu” on page 6–19 for details. 12a finish stage silent float float silent float float 12b bulk volts dc 20.0 to 32.0 28.8 40.0 to 64.0 57.6 12c float volts dc 20.0 to 32.0 26.8 40.0 to 64.0 53.6 12d equalize volts...

  • Page 282

    Configuration settings b–8 976-0043-01-02 table b-4 basic setup default and user settings for the sine wave plus 5548 model sine wave plus 5548 user settings basic setup menus range/display default 10 time of day setup menu see “10 time of day setup menu” on page 6–11 for details. 10a set hour 00:00...

  • Page 283

    Basic setup menu 976-0043-01-02 b–9 14a push inv now to save settings push inv now to save settings 14b push gen to restore settings push gen to restore settings 14c push gen for factory defaults push gen for factory defaults table b-4 basic setup default and user settings for the sine wave plus 554...

  • Page 284: Advanced Setup Menu

    Configuration settings b–10 976-0043-01-02 advanced setup menu table b-5 provides a list of advanced setup menu headings and menu items, with available set points. This table also provides the default settings for each menu item as programmed in the factory. The last column “user settings” is provid...

  • Page 285

    Advanced setup menu 976-0043-01-02 b–11 24 generator timers menu see “24 generator timers menu” on page 7–26 for details. 24a gen run time start h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 24b gen run time stop h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 24c quiet time begin h:m 00:00 to 23:50 0...

  • Page 286

    Configuration settings b–12 976-0043-01-02 26g read lbco 30 sec start lbco setting (11c) 22.0 lbco setting (11c) 44.0 27 save/restore setup menu see “27 save/restore settings menu” on page 7–39 for details. 27a push inv now to save settings push inv now to save settings 27b push gen to restore setti...

  • Page 287

    Advanced setup menu 976-0043-01-02 b–13 23a ry9 vdc energized 22.1 to 35.5 26.0 44.2 to 71.0 52.0 23b ry9 vdc deenergized 20.0 to 35.5 22.0 40.0 to 71.0 44.0 23c ry9 delay at deengz. Min 00 to 255 10 00 to 255 10 23d ry10 vdc energized 10.0 to 32.0 28.8 20.0 to 64.0 57.6 23e ry10 vdc deenergized 10....

  • Page 288

    Configuration settings b–14 976-0043-01-02 26d 24-hr start volts dc 10.0 to 35.5 24.6 20.0 to 71.0 49.2 26e 2-hr start volts dc 10.0 to 35.5 23.6 20.0 to 71.0 47.2 26f 15-min start volts dc 10.0 to 35.5 22.6 20.0 to 71.0 45.2 26g read lbco 30 sec start lbco setting (11c) 22.0 lbco setting (11c) 44.0...

  • Page 289

    Advanced setup menu 976-0043-01-02 b–15 22b low xfer (lbx) vdc 32.2 to 67.8 46.0 23 alm relays menu see “23 alm relays menu” on page 7–19 for details. 23a ry9 vdc energized 44.2 to 71.0 52.0 23b ry9 vdc deenergized 40.0 to 71.0 44.0 23c ry9 delay at deengz. Min 00 to 255 10 23d ry10 vdc energized 20...

  • Page 290

    Configuration settings b–16 976-0043-01-02 26b load start delay min 00.0 to 25.5 05.0 26c load stop delay min 00.0 to 25.5 05.0 26d 24-hr start volts dc 20.0 to 71.0 49.2 26e 2-hr start volts dc 20.0 to 71.0 47.2 26f 15-min start volts dc 20.0 to 71.0 45.2 26g read lbco 30 sec start lbco setting (11...

  • Page 291: Battery Information

    C 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 292: Introduction

    Battery information c–2 976-0043-01-02 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 ap...

  • Page 293

    Battery types 976-0043-01-02 c–3 sealed batteries (gel and agm) description gel cell and absorbed glass mat (agm) batteries are sealed and do not require the addition of distilled water. Since these batteries are valve regulated, over-charging can cause irreversible damage. Attributes attributes of ...

  • Page 294: Battery Bank Sizing

    Battery information c–4 976-0043-01-02 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 a...

  • Page 295

    Battery bank sizing 976-0043-01-02 c–5 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. Totally discharg...

  • Page 296

    Battery information c–6 976-0043-01-02 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. For example: a circ...

  • Page 297

    Battery bank sizing 976-0043-01-02 c–7 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 en...

  • Page 298

    Battery information c–8 976-0043-01-02 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 lo...

  • Page 299: Battery Configurations

    Battery configurations 976-0043-01-02 c–9 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 batteri...

  • Page 300

    Battery information c–10 976-0043-01-02 wiring batteries in parallel effect wiring the batteries in a parallel configuration increases the current of the battery string. The voltage of the battery bank remains the same as an individual battery. “parallel” configurations extend the run times of the a...

  • Page 301

    Battery configurations 976-0043-01-02 c–11 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...

  • Page 302

    Battery information c–12 976-0043-01-02 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 t...

  • Page 303: Battery Maintenance

    Battery maintenance 976-0043-01-02 c–13 battery maintenance maintenance strategy to get the best performance from an inverter system, the batteries must be properly setup and maintained. This includes setting the proper voltages for bulk and float charging. See the “cautions” in the section on equal...

  • Page 304

    Battery information c–14 976-0043-01-02 temperature compensation is based on battery type—5 mv/cell for lead acid type batteries and 2 mv/cell for alkaline type batteries (nicad or nife). The temperature compensation calculations are derived from table c-5 . Table c-4 variances in charging voltage b...

  • Page 305

    Battery maintenance 976-0043-01-02 c–15 equalization charging purpose an equalize charge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells. Effect equalize charging also produces gassing which stirs up the electrolyte mixture and helps distribute the a...

  • Page 306

    Battery information c–16 976-0043-01-02 general maintenance water levels flooded lead acid batteries require periodic water refills in each battery cell. Only distilled water should be used in a battery, as tap or mineral water may contain contaminants which will upset the battery chemistry and may ...

  • Page 307

    Battery maintenance 976-0043-01-02 c–17 state of charge the battery’s state-of-charge should be checked often and only when the battery at a state of rest (when the battery is not powering loads or actively being charged). First thing in the morning is usually the best time to check the state of cha...

  • Page 308

    C–18.

  • Page 309: Generators

    D 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 cannot be held responsible for the accuracy of the information provided. Always refer to th...

  • Page 310: Two-Wire Start Circuits

    Generators d–2 976-0043-01-02 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...

  • Page 311

    Three-wire start circuits 976-0043-01-02 d–3 onan™ 3-wire type generators most onan 3-wire type generators use a three-position, momentary type switch to control their operation. To start the generator, the switch is held in the “start” position, energizing the ignition system and cranking the start...

  • Page 312

    D–4.

  • Page 313: Over-Charge

    E 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 over-charge protection available, xantrex cannot be held responsible for the accuracy of ...

  • Page 314

    Over-charge protection e–2 976-0043-01-02 overvoltage 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 pre...

  • Page 315: Diversion Load Control

    Diversion load control 976-0043-01-02 e–3 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 ful...

  • Page 316

    E–4.

  • Page 317: Multi-Wire Branch

    F multi-wire branch circuit wiring appendix f, “multi-wire branch circuit wiring” supplies information about multi-wire branch circuit wiring precautions when using stand-alone 120 vac inverters or generators. Warning a possible fire hazard can exist if 120 vac only sources (such as inverters and ge...

  • Page 318: Multi-Wire Branch Circuits

    Multi-wire branch circuit wiring f–2 976-0043-01-02 multi-wire branch circuits problem a potential safety problem exists when installing stand-alone 120 vac inverters into existing 120/240 vac wired panels where multi-wire branch circuit wiring methods were used. Legacy situation multi-wire branch c...

  • Page 319

    Multi-wire branch circuits 976-0043-01-02 f–3 figure f-2 multi-wire branch circuit wiring and current flow figure f-3 120 vac inverter incorrectly wired in a multi-wire branch circuit load center l1 l2 neutral ground 120 vac 120 vac 15 a breaker (ganged) 240 vac from grid bare - ground single white ...

  • Page 320

    Multi-wire branch circuit wiring f–4 976-0043-01-02 identifying multi-wire branch circuits identifying characteristic multi-wire branch circuits can be identified by removing the cover on the load center and inspecting the wiring. Conventional 120 vac circuits are identified by a 2-wire-plus-ground ...

  • Page 321

    Correcting multi-wire branch circuit wiring 976-0043-01-02 f–5 correcting multi-wire branch circuit wiring acceptable options correcting multi-wire branch circuit wiring is not easy. Two options which will correct multi wiring branch circuit wiring are: • rewire existing multi-wire branch circuits t...

  • Page 322

    Multi-wire branch circuit wiring f–6 976-0043-01-02 figure f-5 using a step-down autotransformer in multi-wire branch circuit wiring load center l1 l2 neutral ground 120 vac 120 vac 15 a breaker (ganged) bare - ground single white - neutral (current flow 0 a) black - hot (current flow 15 a) red - ho...

  • Page 323: Emergency Power Off

    G emergency power off switches appendix g, “emergency power off switches” supplies information about the requirements for installing an emergency power off switch..

  • Page 324

    Emergency power off switches g–2 976-0043-01-02 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 provid...

  • Page 325

    The purpose of an epo switch 976-0043-01-02 g–3 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-p...

  • Page 326

    Emergency power off switches g–4 976-0043-01-02 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 design...

  • Page 327: Glossary

    976-0043-01-02 h–1 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 absorption charge the se...

  • Page 328

    H–2 976-0043-01-02 electrolyte a conductive medium in which the flow of electricity takes place; this is the liquid found inside storage batteries. Float charge the third stage of three-stage battery charging. After batteries reach full charge, charging voltage is reduced to a lower level to reduce ...

  • Page 329

    976-0043-01-02 h–3 line loss a voltage drop caused by resistance in wire during transmission of electrical power over distance. Line tie an electrical system that is connected to a utility distribution grid. For example, xantrex sw line tie inverters are designed to connect to and interact with util...

  • Page 330

    H–4 976-0043-01-02 series wiring a group of electrical devices, such as batteries or pv modules, wired together to increase voltage, while ampacity 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 electr...

  • Page 331: Abbreviations And Acronyms

    976-0043-01-02 h–5 abbreviations and acronyms acronym or abbreviation definition ac alternating current accb ac conduit box ah amp hour alm auxiliary load module asc authorized service center aux auxiliary awg american wire gauge bts battery temperature sensor bx battery transfer csa canadian standa...

  • Page 332

    H–6 976-0043-01-02 lcd liquid crystal display led light emitting diode nec national electric code neu neutral oem original equipment manufacturer pc personal computer pv photovoltaic (solar electric panels) pvgfp pv ground fault protection re renewable energy rfi radio frequency interference rma ret...

  • Page 333: Warranty and Product

    976-0043-01-02 i–1 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 o...

  • Page 334: Disclaimer

    I–2 976-0043-01-02 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 re...

  • Page 335

    Return material authorization policy 976-0043-01-02 i–3 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 stip...

  • Page 336: Return Procedure

    I–4 976-0043-01-02 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 packagi...

  • Page 337

    Information about your system 976-0043-01-02 i–5 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. If you need to contact customer service, please record the following details b...

  • Page 338

    I–6.

  • Page 339

    Index 976-0043-01-02 ix–1 numerics 3-to-2 wire converters d–3 a ac 3–26 ac output requirements, determining 2–4 ac side feature 1–4 accb, purpose of 2–22 accessing the ac terminal block and ground bar 3–26 alm, purpose of 2–28 automatic generator control mode generator exercising 7–25 generator star...

  • Page 340

    Index ix–2 976-0043-01-02 g generator exercising 7–25 generator start module see gsm generator start types 2–20 generator, as only source of ac power 2–36 generator, starting requirements 2–21 ground and neutral bonding guidelines 2–10 ground rod purpose 2–9 size 2–9 grounding 3–15 grounding electro...

  • Page 341

    Index 976-0043-01-02 ix–3 s safety instructions ii–vii–?? Serial number i–5 series stacking, operation requirements 2–16 stacking, considerations for 2–15 system input requirements 2–4 system output requirements 2–4 t t240 autotransformer, purpose of 2–29 telephone number for customer service i–1 te...

  • Page 342

    Index ix–4 976-0043-01-02.

  • Page 344

    Xantrex technology inc. 8999 nelson way burnaby, british columbia canada v5a 4b5 800 670 0707 tel toll free in north america 360 925 5097 tel direct 800 994 7828 fax toll free in north america 360 925 5143 fax direct customerservice@xantrex.Com www.Xantrex.Com 976-0043-01-02 rev b pc printed in usa.