Xantrex Technology DR1524E manual

DR Inverter/Char g er DR1512 DR2412 DR1524 DR2424 DR3624 DR1512W DR1524W DR1512E DR1524E DR1548E DR2424E Installation and Operations Manual[...]

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DR Inverter/Charger Installation and Operation Manual[...]

About Xantrex Xantrex T echnology Inc . is a worl d-leading supp lier of adva nced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar , batteries, fuel cells , microturbines, and backup power applications in both gri d-connected and stand-alon e systems. Xan trex products include i[...]

975-0012-01-02 Rev A iii About This Manual Purpose The purpose of this Installation and Operation Manual is to provide explanati ons and procedures for installing, operating, maintaining, and tro ubleshooting the DR Inverter/Charger. Scope The Manual provides safety gu idelines, detailed planning and setup information, procedures for installing the[...]

About T his Manu al iv 975-0012-01-02 Rev A Conventions Used The following conventio ns are used in this guide. Abbreviations and Acronyms Related Information Y ou can find more information about Xa ntrex T echnology Inc. as well as its products and services at www .xantrex.com. WA R N I N G W arnings iden tify conditions or practices that coul d r[...]

975-0012-01-02 Rev A v Important Safety Instructions SA VE THESE INSTRUCTIONS This manual contains imp ort ant instructions for all DR Inverter/Char ger models that shall be followed during installation and maintenance of the inverter . General 1. Before installing and using the DR Inve rter/Char ger, read all instructions and cautionary markings o[...]

Safety vi 975-0012-01-02 Rev A W iring Requirements 1. All wiring methods and materials sha ll be in accordance with the National Electrical Code ANSI/NFP A 70 (Current Edition). When sizing conductors and conduits interfacing to the DR Inverter, both shall be in accordance with the National Electric Code ANSI/NFP A 70, as well as all state and loc[...]

Safety 975-0012-01-02 Rev A vii Precautions W hen W orking With Batteries 1. Make sure the area around the battery is well ventilated. 2. Never smoke or allow a spark or fl ame near the engine or batteries. 3. Use caution to reduce the risk or dro ppi ng a metal tool on the battery . It could spark or short circuit the battery or other electrical p[...]

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975-0012-01-02 Rev A ix Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v 1 Introduction Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Features - - - - - - - - - - - - - - - - - - - - - - - -[...]

Contents x 975-0012-01-02 Rev A Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–1 5 Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15 Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - [...]

Contents 975-0012-01-02 Rev A xi Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16 Charger Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1 7 3-Stage Charging Process - - - - - - - - - - - - -[...]

Contents xii 975-0012-01-02 Rev A Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13 Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–13 Equalization Charging - - - - - - - - - - - - - - - - - - - -[...]

975-0012-01-02 Rev A xiii Figure 1-1 Front Panel Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-2 AC Side of the DR Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-3 DC Side of the DR Inverter- - - - - - - - - - - - - - - [...]

F igures xiv 975-0012-01-02 Rev A Figure 3-9 Battery Capacity Potentiometer (new) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12 Figure 3-10 Battery Capacity Potent iomete r (old) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12 Figure 3-11 LED Indicators - - - - - - - - - - - - - - - - - - - -[...]

975-0012-01-02 Rev A xv Table 1-1 Model Identification and Numb ering Conventions - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Table 1-2 Letter Suffix Code Definiti ons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Table 2-1 Peak Input Filtrate versus Ch arging Current - - - - - - - - - - - - - - -[...]

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1 Intr oduction Chapter 1, “Introduction” contains information about the features and functions of the DR Inverter/Charg er.[...]

Introduction 1–2 975-0012-01-02 Rev A Introduction Thank you for p urchasing the DR Inverter/Charg er from Xantrex T echnology Inc. The DR Inverter is one of the finest inverter/chargers on the market today , incorporating state-of-the-art technology and high reliability . The inverter features an AC p ass-through circuit, powering y our home app[...]

Fe a t u r e s 975-0012-01-02 Rev A 1–3 AC S i d e The AC side of the DR Inverter has one 30-amp breaker for pass-thru AC Input, and one 30-amp (20 amp in certain models) breaker for ch arger AC inp ut. Figure 1-1 F ront P anel F eatures DC End Front Panel Controls and Indicators Battery Caps AC End Battery Sens e Port COM Port Figure 1-2 AC Side[...]

Introduction 1–4 975-0012-01-02 Rev A DC Side The DC side of the DR Inverter has th e equipment ground lug, the positive (+) battery terminal, and the negative (–) battery terminal. Optional Equipment The following options are availabl e for the DR Inverter/Char gers. Remote Control (RC8) The RC8 allows the inverter to be switche d ON or OFF re[...]

Fe a t u r e s 975-0012-01-02 Rev A 1–5 ❐ V erify all of the items listed on the packing material sheet are present. Please call Xantrex Customer Service at (800 ) 670-0707 if any items are missing. ❐ Save your proof-of-purchas e. This is required if the unit should require warranty service. ❐ Save the original shipping carton and packing m[...]

Introduction 1–6 975-0012-01-02 Rev A Regulatory The 120 V ac/60 Hz models of t he DR Series inverter/charger (models DR1512, DR1524, DR2412, DR2424, an d DR3624) are ETL Listed to UL S tandard 1741, (First Edition) Power Conditioning Units for use in Residential and Commer cial Photovoltaic Power Systems . These standards guarantee tha t the DR [...]

2 Installation Chapter 2, “Installation” contains information about how to plan for and install the DR Inverter/Charger.[...]

Installation 2–2 975-0012-01-02 Rev A Pre-installation Planning T ake some time prior to installing the eq uipment to pre-plan the installation. Location, mount ing, and ventilati on should be taking into co nsideration before any cabling can be done. Location Inverters contain sophisticated el ectronic components and should be located in a well [...]

Pre-installation Planning 975-0012-01-02 Rev A 2–3 Mounting The National Building Code requires the in verter be mou nted on a vertical surface (or wall). The keyhole slots must not be used as the onl y method of mounting. The purpose of the wall mounting requirement is to orient the inverter so that its bottom cover , which has no ho les, will n[...]

Installation 2–4 975-0012-01-02 Rev A Hardwar e / Materials Required The following hardware or ma terials may be required to complete this installation. ❐ 4 ft. x 4 ft. sheet of 3/4 " plywood or 2 x 4’ s studding material ❐ #12 wood scr ews (or 1/2" x 1-1/4" lag b olts) ❐ Conduit and approp riate fittings ❐ Wi r e n u t s[...]

Pre-installation Planning 975-0012-01-02 Rev A 2–5 Wi re R o u ti n g Determine all wire routes bo th to and from the inverter and which kn ockouts ar e best suited for connecting the AC condui ts. Possible routing scenarios include: • AC input wiring from the main electrical service panel to the inverter/char ger (if used) • AC input wiring [...]

Installation 2–6 975-0012-01-02 Rev A Battery Location Locate the batteries in an accessible location. T wo feet clearance above the batteries is recommended for access to the battery caps. They s hould be located as close to the inverter as possible wi thout limiting access to the inverter ’ s disconnects. Install the batteries to the le ft of[...]

Pre-installation Planning 975-0012-01-02 Rev A 2–7 Figure 2-1 On-Grid Basic Configuration (Utility Backup) Figure 2-2 Off-Grid Configurat ion (Generator only)[...]

Installation 2–8 975-0012-01-02 Rev A Figure 2-3 On-Grid Configuration - with Renew able Energy Sources[...]

Pre-installation Planning 975-0012-01-02 Rev A 2–9 Figure 2-4 Off-Grid Configuration - with Renewable Energy Sources[...]

Installation 2–10 975-0012-01-02 Rev A Ge nera tors An AC generator can be used as an input source instead of the utility power , or can be connected (using addi tional hardwa re) to power the loads when utility is not present (utility outage), and to char ge the batteries. The generator must be of the permanently installed type and not a portabl[...]

Pre-installation Planning 975-0012-01-02 Rev A 2–11 Inverter Mounting The DR Series inverter can wei gh as much as 45 lb. ( 20.4 kg). W allboard is no t strong enough to support its weight so additional support must b e used or added. The inverter can be mounted directly to the wall studs if the wall studs are 16" apart. If not, then 2x4’ [...]

Installation 2–12 975-0012-01-02 Rev A 3. Secure the 2 x 4 with #10 wood screws (l ength to penetrate 1½ inches into the studs) as shown in Figure 2-7. 4. Measure 7 5/8" from the center of the first 2 x 4 and draw another level line. Place the center of the second 2 x 4 over this line and secure to the wall as described in Step 5. 5. Using [...]

DC Wiring 975-0012-01-02 Rev A 2–13 DC W iring This section describes the DC wiring requirements and how to make the connections. It provides the required cable and wire si zes, recommended lengths for cables, and disconnect/circuit breaker requirements. DC Circuit Gr ounding Grounding is an important part of the sy stem installation and must be [...]

Installation 2–14 975-0012-01-02 Rev A Figure 2-9 DC Grounding[...]

DC Wiring 975-0012-01-02 Rev A 2–15 Batteries The DR Inverter can support either 12-vo lt battery banks or 24-volt battery banks. Before proceeding, ensure you h ave th e appropriate sized batteries for this inverter . Battery T ypes Batteries are available in different sizes, amp-hou r ratings, voltage, liq uid or gel, vented or non-vented, che [...]

Installation 2–16 975-0012-01-02 Rev A Battery Cable Sizing Proper cable sizing (diameter and length) is critical to the safe and ef ficient operation of an inverter system. Larger diameter cables (smaller A WG number) have less voltage drop and are, therefore, more efficient when transferring power to and from the batteries. If a cable is unders[...]

DC Wiring 975-0012-01-02 Rev A 2–17 DC Disconnect and Over -current Protection For safety and to comply with regulations, battery over -current protection is required. Fuses and disconnects must be si zed to protect the wi ring in the system and are required to open before the wi re reaches its maximum current carrying capability . The National E[...]

Installation 2–18 975-0012-01-02 Rev A Battery Cable Connections Battery cables must have crimped (or pref erably , soldered an d crimpe d) copper compression lugs unless aluminum m echanical lugs are used. Soldered connections alone are not acceptable. High quality , UL-listed battery cables are available from Xantrex in an assortment of lengths[...]

DC Wiring 975-0012-01-02 Rev A 2–19 Connecting the Battery Bank to the Inverter Follow the procedure below to connect the battery bank to the inverter . T o connect the battery bank to the inverter: 1. Determine the correct size batter y cabl e to use for installation from T able 2-3 on page 2–16 . 2. Determine the correct size disconnec t/fuse[...]

Installation 2–20 975-0012-01-02 Rev A 8. Observing battery polarity , connec t the positive battery cable (from the over-current device) to the inverter ’ s positive terminal. 9. Observing battery polarity , connect the ne gative battery cable to the inverter ’ s negative terminal. 10. Use an insulated ½ inch wrench or so cket to tighten th[...]

DC Wiring 975-0012-01-02 Rev A 2–21 Installing a Battery T emperatur e Sensor A battery temperature sensor (BTS) option can easily be installed in the system to ensure proper charging of the batteries based on temperature. Installing a BTS extends battery life by preventing over charging in warm temperatures and undercharging in cold temperatures[...]

Installation 2–22 975-0012-01-02 Rev A AC W i r i n g This section describes the AC wiring requirements and how to make the connections. It provides the required wire sizes, recomme nded lengths for conductors, and disconnect/cir cuit breaker requirements. A C Distribution P anel (Sub-panel ) Mounting and Conduit Installation 1. Determine the loc[...]

AC W ir i ng 975-0012-01-02 Rev A 2–23 Before wiring the input of the inverter , refer to T able 2-5 below for the minimum recommended wire size. Important: The lower AC cover varies dependi ng on the model. DR24XX and DR36XX models are equipped with a conduit bo x and not a plate. The conduit box is required for the larger diameter wire providin[...]

Installation 2–24 975-0012-01-02 Rev A T o connect the AC Input to the Inverter: 1. Disconnect the main breaker at the ma in electrical service panel (if used) or disconnect the AC generator . 2. Install an appropriately sized circuit breaker in th e electrical service panel. This will serve as both an AC disconnect and over -current protection. [...]

AC W ir i ng 975-0012-01-02 Rev A 2–25 A C Output Wiring to the A C Distribution P anel (Sub-panel) T o connect the AC outpu t wiring to the sub-panel: 1. Connect the GROUND wire to the inve rter ’ s AC GROUND chassis terminal. Connect the other end of this wire to the GROUND bus in the sub-panel. 2. Connect the NEUTRAL (white) wire to the inve[...]

Installation 2–26 975-0012-01-02 Rev A The following diagrams illustrate the AC wiring for the following basic 120/240 V ac scenarios. Consult your system design for other possible configurations. • On-Grid Application (See Figure 2-18) • On-Grid using with a generator Backu p (See Figure 2-19) • On-Grid Dual-Inverter Application (See Figur[...]

AC W ir i ng 975-0012-01-02 Rev A 2–27 A C Input Wiring using a Generator in an On-Grid Application If a generator is used as a backup for th e utility , then a manual transfer switch must be added to provide a means to switc h the generator power to the inverter ’ s inputs. The generator can be used during extended outages to recharge the batt[...]

Installation 2–28 975-0012-01-02 Rev A A C Input Wiring - Off-Grid Applic ations using a 120 V ac Generator Follow the example below to complete the wiring for an of f-grid application. Figure 2-20 AC Wiring using a 120 V ac Generator - Off-Grid Application[...]

AC W ir i ng 975-0012-01-02 Rev A 2–29 A C Input Wiring - Off-Grid Applicat ions using a 240 V ac Generator for 120 V ac Loads Follow the example below to complete th e wiring for an of f-grid application. Figure 2-21 AC Wiring using a 240 V ac Generator with 120 V ac Loads only- O ff-Grid Application[...]

Installation 2–30 975-0012-01-02 Rev A Series Stacking (120 V ac/60 Hz M odels only) This COM port allows two DR Inverters (120 V ac/60 Hz models only) to be used in the same system in a “SERIES” config uration to operate 240 V ac loads. Series stacking can also be used to connect to 240 V ac on ly power systems providing both 120 and 240 V a[...]

AC W ir i ng 975-0012-01-02 Rev A 2–31 Figure 2-22 AC Wiring for dual-inverters - On-G rid Application (120 V ac models only)[...]

Installation 2–32 975-0012-01-02 Rev A Figure 2-23 Wiring for dual-inverters - On-Gri d Application (120 V ac models only)[...]

3 Oper ation Chapter 3, “Operation” contains info rmation about how to operate the DR Inverter/Charger.[...]

Operation 3–2 975-0012-01-02 Rev A Front P anel Controls and Indicator s All operating controls, indicators and sen se connectors are located on the front panel of the unit. The controls are e asily acces sible, and the LEDs provide inverter/charger status at a glance. PO WER ON/OFF Switch The POWER ON/OFF control is a momentary contact switch th[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–3 P orts There are two ports on the inverter/charger . Both ports are RJ11 type telephone style connectors. One is used for connecting a remote control to the inverter . The other is used for regulating the char ger voltage based on the temperature of the battery bank. B A TTER Y SENSE [...]

Operation 3–4 975-0012-01-02 Rev A • Erratic Blinking (0 to 3 and 2 to 5 flashes @ 2 second intervals) - The inverter has detected an error conditio n caused by overheating, low battery voltage, or high battery vol tage. • OFF - The inverter is OFF . The remote control must be connected prior to switching the inverter ON; otherwise, the micro[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–5 See Important notes that follow . T able 3-1 Battery T ype Selecto r Switch Settings Switch Po si t i o n Description 12-volt Mode ls 24-vo lt Models Charge Function Float V oltage Bulk/ Equalize* V oltage Float V oltage Bulk/ Equalize* V oltage Equalize Charge Rate Equali ze Time 0 E[...]

Operation 3–6 975-0012-01-02 Rev A SEARCH MODE W A TTS P otentiometer The Search Mode W atts potentiometer adju sts the current thre sh old required to bring the inverter out of search mode into full wave operation. W ith search mode enabled, the inverter pul ses the AC output looking for an applied load. W ith no load detected, the inverter goes[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–7 Battery Charge r Rate The Battery Charger Rate potentiometer sets the maximu m char ge current supplied to the battery bank and is also us ed to regulate cons tant current in the Bulk Charge Mode. The level should be adju sted to provide a charge rate less than or equal to the amp-hou[...]

Operation 3–8 975-0012-01-02 Rev A Use T able 3-2 to find the approximate setting of the Battery Charge Rate potentiometer . The settings do not need to be exact, but should be as clos e as possible to the actual value required. Over Discharge Pr otection/AC T ransfer V oltage The Over D ischar g e Protectio n/AC T ransfer V ol tage potentiome te[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–9 Over Discharge Pr otection (ODP) When enabled, ODP shuts down the invert er at a specified voltage (low battery cutoff) to protect the batteries from over dischar ge damage. Th e inverter circuitry calculates the lowest (safe) DC volta ge (leaving approximately 20 % battery capacity) [...]

Operation 3–10 975-0012-01-02 Rev A A C T ransfer V oltage During normal operation, the inverter supplies AC power to the applied loads through the pass-throug h circuit and simult aneously charges the system batteries. Whenever the external AC source drops belo w the AC T ransfer V oltage (set by the potentiometer), the inverter switches to batt[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–11 Figure 3-7 ODP Enabled/Disabled P ositions Important: Most AC appliances will operate properly with an AC pass-through voltage between 95 and 10 5 volts. Setting the AC Transfer V oltage potentiom eter between these values will allow the incoming source volt age to drop to this level[...]

Operation 3–12 975-0012-01-02 Rev A Battery Capacity The Battery Capacity potentio meter is used to set the correct charge profile for the battery capacity (amp-hours) used with the inverter (see illustration below). The setting allows the inverter to calculate over-discharge protection values and also the end of the Bulk/Absorption charge mode, [...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–13 LED Indicators There are four LEDs on the inverter ’ s fr ont panel, indicatin g inverter status, battery condition, o ver temperature/ov erload conditions an d charger status. These LEDs blink or change color depending on the condition or function they are displaying. Inverter Mod[...]

Operation 3–14 975-0012-01-02 Rev A Whenever the battery voltage drops to its lowest (safe) level (as calculated by the ODP), the LED lights green to indicate th e condition. If the c ondition persists, the inverter will shut down until the battery voltage returns to a safe level and then restart. Charg er LED - Orang e / Green The Char ger LED i[...]

F ront P anel Controls and Indicators 975-0012-01-02 Rev A 3–15 Circuit Br eaker s The DR Inverter contains two circuit breaker s located on the right-hand side of the chassis, directly above the AC input term inal block. The pass-through AC input circuit breaker protects the AC wiri ng an d connected load. The char ger AC input circuit breaker p[...]

Operation 3–16 975-0012-01-02 Rev A Start-up Once the inverter is properly connected to the batteries, AC source, and loads (using a sub-panel) the inverter is rea dy for operation. Recheck the controls and ensure they are in the proper position. Re check all wiring and ensure it is correct. S tarting the inverter: 1. Apply DC power to the invert[...]

Charger Mode 975-0012-01-02 Rev A 3–17 Charg er Mode 3-Stage Char ging Process The charging cycle uses a 3-stage chargi ng process to maintain the batteries. Whenever nominal AC is present at the in verter ’ s input, it passes power through to the connected load and begins charging the batteries, indicated by the dual color BA TTER Y CHARGER LE[...]

Operation 3–18 975-0012-01-02 Rev A Equalize Charging Equalize charging is a special mode of battery charging. During use, the batte ry’ s cells can become unequal in the voltage an d current they can deliver . This is due to a buildup of sulfate on the plates as well as stratified electrolyte. Sulfate prevents the cells from receiving or deliv[...]

Charger Mode 975-0012-01-02 Rev A 3–19 4. Set the BA TTER Y TYPE SELECTOR switch to position “0” or “1”. T o start the equalization charging process, cycl e the AC power (i.e., disconnect and then reconn ect the AC source ). A solid orange BA TTER Y CHARGER LED indicates equalize charge. a) Position “0” equalizes the batteries at the [...]

Operation 3–20 975-0012-01-02 Rev A Figure 3-16 Equalize 1 Battery Charger Rate P otentiometer (P osition “1”) See Table 3-1 Sw itch Position “1”. Figure 3-17 Equalize 2 Battery Capacity Rate Potentiometer (P osition “0”) See Table 3 -1 Switch Position “0”.[...]

4 T r oubleshooting Chapter 4, “T roubleshooting” contai ns information about how to troubleshoot possible error condi tions while using the DR Inverter/Charger.[...]

T roubleshooting 4–2 975-0012-01-02 Rev A T roubleshooting the DR Inverter T able 4-1 provides a list of possible erro r conditions that may occur , their possible causes, and possible solutions to resolve the error condition. T able 4-1 T roubleshooting the DR Inverter Error Condition P ossible Cause Solution No AC output voltage and no warning [...]

Problem Loads 975-0012-01-02 Rev A 4–3 Problem Loads The inverter can drive most loads, howeve r , there are special conditions that can cause a load to behave diff erently than expected. The following describes some of the common proble ms encounte red when using an inverter . Ceiling F ans Most large diameter , slow turning fans ru n correctly [...]

T roubleshooting 4–4 975-0012-01-02 Rev A Clocks The inverter ’ s crystal controlled oscillator keeps the frequency a ccurate to within a few seconds a day; howeve r , external load s in the system may alter the inverter ’ s output waveform causing clocks to run at dif ferent speeds. There may be periods where clocks keep time and then myster[...]

Problem Loads 975-0012-01-02 Rev A 4–5 Printers Most inkjet type printers work well in inverter applications. Laser print ers, however , require high current for their fu sing circuit and a re not recommended for use with an inverter . Recharg eable Devices When first using a rechargeable device, mo nitor its temperature for 10 minutes to ensure [...]

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A Specifications Appendix A, “Specifications” c ontains information about the electrical specifications and environmental specifications of the DR Inverter/Charger.[...]

Specifications A–2 975-0012-01-02 Rev A Specifications of the DR Inverter T able A-1 provides the electrical specifications for the DR Inverter/Charger (120 V ac/60 Hz. models). T able A-2 provides the electrical specifications for the DR Inverter/Charger (220 V ac/60 Hz. models). T able A-3 provides the electrical specifications for the DR Inver[...]

Specifications of the DR Inverter 975-0012-01-02 Rev A A–3 DC Input V oltag e (nominal) c 12.6 Vdc 12.6 Vdc 25.2 Vdc 25.2 Vdc 25.2 Vdc DC Input V oltag e Range 10.8 to 15.5 Vdc 10.8 to 15.5 Vdc 21.6 to 31.0 Vdc 21.6 to 31.0 Vdc 21.6 to 31.0 Vdc Auto Low Battery Protection enabled 1 1 V 1 1 V 22 V 22 V 22 V DC Charger Rate (Adjustable) 0 to 70 amp[...]

Specifications A–4 975-0012-01-02 Rev A T able A-2 Electrical Specifications fo r the DR Inverter/Chargers a - 220 V ac/60 Hz Models Model DR1512W DR2412W AC Input V oltage 220 V ac 220 V ac AC Input Low T ransfer V oltage 80 to 210 V ac 80 to 210 V ac AC Input Current b 45 amps 55 amps Continuous Pow er (@ 25°C ) 1500 V A 2400 V A Continuous Ou[...]

Specifications of the DR Inverter 975-0012-01-02 Rev A A–5 T emperature Comp Probe (BTS) optional Remote Control (RC8) d optio nal a.Specifications subject to change without notice. b.This is the minimum AC current required to obtain full pass-through and maxim um battery charging. c.Product may not meet voltage regulation specificati ons at othe[...]

Specifications A–6 975-0012-01-02 Rev A Auto Low Battery Protection enabled 1 1 V 1 1 V 22 V 22 V DC Char ger Rate (Adjustable) 0 to 70 a mps 0 to 35 am ps 0 to 17.5 amps 0 to 70 am ps Common Specifications: V oltage Regulation (maximum) ± 5% V oltage Regulation (T ypical) ±2. 5% W aveform modified sine wave Load Power Factor (allowed) 0.5 to 1[...]

Specifications of the DR Inverter 975-0012-01-02 Rev A A–7 T able A-4 Environmental Specifications for the DR Inverter/Charger a a.Specifications subject to change without notice. Model DR1512 DR24 12 DR1524 DR2424 DR3624 Dimensio ns b b.Allows for hardware extensions such as mountin g rail s, DC terminals, and front panel controls. 8.5" w x[...]

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B Battery Information Appendix B, “Battery Informati on” supplies gene ral information about batteries such as battery t ypes, battery bank sizing, battery configurations, and battery care. For detailed information, see your battery manufacturer or your system designer .[...]

Battery Information B–2 975-0012-01-02 Rev A Introduction Batteries Batteries are available in different si zes, amp-hour ratings, voltage, liq uid or gel, vented or non-vented, che mistries, etc. They are also available for starting applications (such as an automobile starting battery) and deep discharge applications. Recommendations Consider th[...]

Battery T ypes 975-0012-01-02 Rev A B–3 Sealed Batteries (Gel and A GM) Description Gel Cell and absorbed glass mat (AGM) batteries are sealed and do not require the addition of distilled water . Since these ba tteries are valve regulated, over -charging can cause irreversible damage. Attributes Attributes of sealed batteries are: NiCad and NiF e[...]

Battery Information B–4 975-0012-01-02 Rev A Understanding Battery Capacity Ratings Dischar ge rate Deep cycle b atteries have th eir am p-hour rating expressed as “at the x-hour rate”. The hour rating refers to the time it takes to discharge the batteries. A faster hour rate (6 hour rate) means more current is withdrawn from the batteries du[...]

Battery Bank Sizing 975-0012-01-02 Rev A B–5 Back up power systems which use utility power for rechar ging should use the estimated number of days of maximum power outage for determin ing days of autonomy . Understanding Amp-hour Requir ements Amp-hours T o estimate the battery bank requiremen ts, you must first calculate the amount of power you [...]

Battery Information B–6 975-0012-01-02 Rev A Considerations When calculating battery bank size, consider the following: • Motors typically require 3 to 6 times their running current when starting. Check the manufacturer ’ s data sheets fo r their starting current requirements. If you will be starting larg e motors from the inverter , increase[...]

Battery Bank Sizing 975-0012-01-02 Rev A B–7 Battery bank size worksheet Calculation T o calculate the battery bank size, use the average a mp-hours per day that you calculated using T able B-1, then make th e other calculation shown in T able B-2 to calculate the battery bank size you need to support your loads. W orksheets T able B-1 and T able[...]

Battery Information B–8 975-0012-01-02 Rev A Battery Configurations The battery bank must be wired to ma tch the inverter ’ s DC input voltage specifications (12 or 24 Vdc). In additio n, the batteries can be wired to provide additional run time. The variou s wiring configur ations are: Series W iring batteries in series increases the total ban[...]

Battery Configurations 975-0012-01-02 Rev A B–9 W iring Batteries in P arallel Effect W iring the batteries in a parallel conf iguration increases the current of the battery string. The voltage of the battery bank remains the same as an in dividual battery . “Parallel” configurations extend the ru n times of t he AC loads by providing increas[...]

Battery Information B–10 975-0012-01-02 Rev A W iring Batteries in Series-P arallel Effect W iring the batteries in a series-para llel configuration increases the current and voltage of the battery bank. “Series-paralle l” wiring is mo re complicated and ca re should be taken when wiri ng these banks. Steps It is done in three steps; wiring t[...]

Battery Configurations 975-0012-01-02 Rev A B–11 Connect to inverter T o connect to the invert er: 1. Connect a cable from the positive terminal of the first battery string to the inverter ’ s positive DC terminal (via a fused device). 2. Connect the negative terminal of the last battery string to the negative terminal of invert er ’ s DC te [...]

Battery Information B–12 975-0012-01-02 Rev A Battery Connections for Stacked Inverter s When using inverters in a stacked config uration, the same battery bank must be used for both inverters. T o ensure even charging of the batteries, each inverter must be connected to both strings (i.e., positive cable to string two, and negative cable to stri[...]

Battery Maintenance 975-0012-01-02 Rev A B–13 Battery Maintenance Maintenance strategy T o get the best performance from an inve rter system, the batteries must be properly setup and maintained. This includes setting the proper voltages for Bulk and Float charging. See the “CAUTI ONS” in the section on Equalization Charging that follows. In a[...]

Battery Information B–14 975-0012-01-02 Rev A T emperature compensation is b ased 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 calcula tions are derived from T able B-5. T able B-4 V arian ces in Charging V oltage based on Battery T emperature T [...]

Battery Maintenance 975-0012-01-02 Rev A B–15 Equalization Charging Purpose An equalize char ge helps to remove sulfate buildup on the battery plates and balances the charge of individual cells. Effect Equalize c harging also produces gassing which stirs up the electrolyte mixture and helps distribute th e acid more evenly . Non-equalized batteri[...]

Battery Information B–16 975-0012-01-02 Rev A General Maintenance W ater Levels Flooded lead acid batteries require peri odic water refills in e ach battery cell. Only distilled water should be used in a batt ery , as tap or mineral water may contain contaminants which will upset the battery chemistry and may damage the battery . When filling the[...]

Battery Maintenance 975-0012-01-02 Rev A B–17 State of Charge The battery’ s state-o f-charge should be checked often and only whe n the battery at a state of rest (when the battery is not powering loads or actively being charged). First thing in the morning is usually the best time to check the state of charge. If the batteries are readily acc[...]

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C Multi-wir e Br anch Circuit Wi r i n g Appendix C, “Multi-wire Bran ch Circuit W iring” supplies information about Multi-wire Br anch Circuit W iring Precautions when using stand-alone 120 V ac inverters or generators. WA R N I N G A possible fire hazard can exist if 120 V ac only sources (such as inverters and generators) are wired incorrect[...]

Multi-wire Branch Circ uit Wiring C–2 975-0012-01-02 Rev A Multi-wire Br anch Circuits Problem A potential safety problem exists wh en installing stand-alone 120 V ac inverters into existing 120/240 V ac wired panels where multi-wire branch circuit wiring methods were used. Legacy situation Multi-wire bran ch circuits are wired dif feren tly from[...]

Multi-wire Branch Circuits 975-0012-01-02 Rev A C –3 Figure C-2 Multi-wire Branch Circuit Wiring and Current Flow Figure C-3 120 V ac 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 f rom Grid Bare - Ground Single White - Neutral (Current Flow 0 A) Black - Ho[...]

Multi-wire Branch Circ uit Wiring C–4 975-0012-01-02 Rev A Identifying Multi-wire Br anch Circuits Identifying characteristic Multi-wire branch circuits can be identif ied by removing the cover on the load center and inspecting the wiri ng. Conventional 120 V ac circuits are identified by a 2-wire-plus-ground (black, white, a nd copper) “romex?[...]

Correcting Multi-wire Branch Circuit Wiring 975-0012-01-02 Rev A C –5 Correcting Multi-wir e Branch Cir cuit Wiring Acceptable options Correcting multi-wire branch circ uit wiring is not easy . T wo options which will correct multi wiring branch circuit wiring are: • Rewire existing multi-wire branch ci rcuits to conven tional “home run” wi[...]

Multi-wire Branch Circ uit Wiring C–6 975-0012-01-02 Rev A Figure C-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring Load C ente r L1 L2 Neutral Grou nd 120 Vac 120 Vac 15 A Breaker (Gang ed) Bare - Ground Single White - Neutral (Current Flow 0 A) Black - H ot (Current Flow 15 A) Red - Hot (Current Flow 15 A White - Neutral[...]

975-0012-01-02 Rev A WA–1 W arranty and Return Information Wa r r a n t y What does this warranty cover? This Limited W a rranty is provided by Xantrex T echnology , Inc. ("Xantrex") and covers defects in workmanshi p and materials in your D R Inverter/Charger. This warranty period lasts for W arranty period from the date of purch ase a[...]

W arranty and Return WA–2 975-0012-01-02 Rev A What does this warranty not cover? This Limited W arranty does not c over normal wear and tear of the product or costs related to the removal, installat ion, or tr oubleshooting of the custom er's electrical systems. This warranty does not apply to and Xant rex will no t be respon sible for any [...]

W arranty and Return 975-0012-01-02 Rev A WA–3 Return Material Authorization P olicy Before returning a product direct ly to Xantrex you must obtain a Return Material Au thorization (RMA) number and the correct factory "Ship T o" address. Product s must also be shipped prepaid. Product shipments will be refused and returned at your expe[...]

W arranty and Return WA–4 975-0012-01-02 Rev A Information About Y our System As soon as you open your DR Inverter/Charger package, record the following informat ion and be sure to keep your proof of purchase. If you need to contact Custo mer Servi ce, please record the following details be fore calling. This information will help our representat[...]

A AM radios 4–3 AW G 2–4 B Batteries Battery Care and Maintenance Equalization Charging B–15 Temperature Compensation B–13 Battery T ypes Absorbed Glass Mat B–3 Flooded Lead Acid (FLA) B–2 Gel Cell B–3 Golf Cart B–2 Industrial (electric forklift) B–2 NiCad and NiFe B–3 Charging Bulk Voltage B–13 Charge Rates B–13 Float Volta[...]

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Xantrex Technology Inc. 1 800 670 0707 Tel. toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice@xantrex.c om www.xantrex.com 975-0012-01-02 Rev A PC Printed in the DR[...]