Xantrex Technology RS3000 manual

RS3000 Sine W ave Inverter/Charg er Installation Guide RS3000[...]

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RS3000 Sine Wave Inverter/Charger Installation Guide[...]

About Xantrex Xantrex T echnol ogy Inc. is a w orld-leading supplier of ad va nced power electronics and contro ls with prod ucts 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-co nnected and stand-alon e systems. Xan trex products inclu[...]

975-0171-01-01 i About This Guide Purpose The RS 3000 Sine W ave Inverter/ Char ger Installation Guide describes the procedure for installing the RS3000 Sine W ave Inverter/Charger (RS3000). Scope The Installation Guide provides safety guidelines, detaile d planning and setup information, and procedures for installing the inverter/char ger . It doe[...]

About T his Guide ii 975-0171-01-01 Conventions Used The following conv entions are used in this guid e . Symbols Used The following symbols are used on the product labels or in this guide. Abbreviations and Acronyms For a listing of abbreviations an d acronyms, refer to the RS3000 Sine W ave Inverter/Charger Operation Guide . WA R N I N G W arning[...]

About T his Guide iii 975-0171-01-01 Related Information For related materials on this Xanbus -enabled product and its available accessories, see also: RS3000 Sine W ave Inverter/Char ger Operation Guide (975-0170-01-01) Automatic Generator S tart Owner ’ s Guide (975-0082-01-01) System Contr ol Panel Owner ’ s Guide (975-0083-01-01) Xanbus Sys[...]

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975-0171-01-01 v Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS The RS3000 Sine W ave Inverter/Char ger Installation Guide contains important safety instructions. Before you install and use your RS30 00 Sine W ave Inverter/Charger, be sure to read, understand, and save these safety instructions and those in the other product guides.[...]

Safety vi 975-0171-01-01 6. Do not disassemble the inverter/c harger; it does not contain user serviceable parts. T ake it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. For instructions on ob[...]

Safety 975-0171-01-01 vii Explosive Gas Precautions 1. T o reduce the risk of battery expl osion, follow these instructions and those published by the battery manu facturer and the manufacturer of any equipment you intend to use in the vicinity of a battery . Review the cautionary markings on these products and on the engin e. 2. This eq uipment co[...]

Safety viii 975-0171-01-01 7. Remove personal metal items such as rings, bracelets, neckla ces, and watches when working with a lead -acid battery . A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 8. Never char ge a frozen battery . 9. If it is necessary to remove a bat[...]

975-0171-01-01 ix Important Safety Instructions Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii Personal Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - vii FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - -[...]

Contents x 975-0171-01-01 Step 2: Mounting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Step 3: Connecting t he AC Input and AC Output Wi res - - - - - - - - - - - - - - - - - - - - - 2 1 General[...]

975-0171-01-01 xi Figure 1 Typical Xanbus System Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Figure 2 Typical Recreational Vehicle Electrical Sy stem - - - - - - - - - - - - - - - - - - - - - 7 Figure 3 RS3000 Hardware Materials as Shipped - - - - - - - - - - - - - - - - - - - - - - - - - 15 Figure 4 Mounting Orientation[...]

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Installation The Installation Guide provides detail ed information for installing the RS3000 Sine W ave Inverter/Charger and the battery temperature sensor , wiring the inverter/char ger to the AC and DC circuits, and connecting the inverter/charg er to the Xanbus® system. The RS3000 is a Xanbus-enabled device that typically powers the Xanbus syst[...]

Installation 2 975-0171-01-01 Installation Information Before Y ou Begin the Installation Before beginning your i nstallation: • Read the entire Installation Guide so you can plan the installation from beginning to end. •R e a d t h e Xanbus System Installation Guide to plan your network requirements. • Assemble all the tools and material s y[...]

Installation 975-0171-01-01 3 About the Xanbus System The Xanbus system in clud es the RS3000 Sine W ave Inverte r/Charger and other Xanbus-enabled devices, as sh own in Figure 1, “T ypical Xanbus System Diagram”. Each Xanbus-en able d device interacts and communicates with the other devices on the network, creatin g a power system that can be [...]

Installation 4 975-0171-01-01 Xanbus Enabled The Xanbus-enabled designa tion means that this product will work on a Xanbus network. Xanbus-enabled products are: • Easy to use. The Xanbus network simp lifies operation and automates routine tasks. • Reliable. Software control eliminates analog signalling errors. • Accurate. Digital information [...]

Installation 975-0171-01-01 5 Planning the Installation This section provides informa tion to help yo u plan for a basic installation of the RS3000. As your system configu ration is determ ined, record the deta ils in Information About Y our System on page W A-4 of the RS3000 Sine W ave Inverter/Char ger Operation Guide . Two K ey P erformance F ac[...]

Installation 6 975-0171-01-01 Planning A C , DC, and Network Components For a successful installation, you need to plan for AC, DC, and network components of the power sy stem. The AC and DC comp onents are described in this section and illustrated in Figure 2 on page 7. AC components include: •A C I n p u t •A C L o a d s • AC Disconnect and[...]

Installation 975-0171-01-01 7 Figure 2 T ypical Recreational V ehicle Electrical System Important: Figure 2 does not show all required ground ing or overcurrent protection. Sensing and control Xanbus-enabled Devi ces Gene rat or Isola tor Non-Inverter L oads Automatic Generator St art System Contro l Panel Sine W ave Inve rter/Ch arger Engi ne Batt[...]

Installation 8 975-0171-01-01 A C Components AC Input AC i n put to the RS3 0 00 can b e s u p p lied fr o m a sp l it-p h ase o r d u al- i np u t AC source such as the utility grid (power company), a generator , or the output of a transfer switch. The RS3000 can be oper ated from the foll owing types of 120 volt 60 Hz AC sourc two 120 V A C lines[...]

Installation 975-0171-01-01 9 A C Disconnect and Over -Current Pr otection Device T o meet CSA, UL, and electrical code re quirements, and to protect system wiring, the AC inputs and outputs of the inverter /char ger must be provided with over- current protection on both the AC input and output. This protection may be a circuit breaker or a fuse wi[...]

Installation 10 975-0171-01-01 Te s t e d G F C I s Compliance with UL standards requires th at Xantrex test an d recommend specific GFCIs for use on the output of the invert er . T able 1 lists models that have been tested and will function properly when conn ected to the AC outp ut of the RS3000. Disconnect Devices Each system requires a method o[...]

Installation 975-0171-01-01 11 Size of Input W iring W ire size must be coordinated with the ov ercurrent protection provided ahead of the wire involved, in a ccordance with the electrical codes or regulations applicable to you r installation. Therefore, the wiring used betwee n the AC input circuit breaker and the inverter/ charger input must be s[...]

Installation 12 975-0171-01-01 AC Output Neutral Bonding The AC source must have it s neutral conductor bonded to groun d. Bonding system The RS3000 provides a system that automatically connects the neutral conductor of the inverter ’ s AC output circuit to safety ground (“bonding” it) while the inverter/charger is inverting, and di sconnects[...]

Installation 975-0171-01-01 13 DC Components Batteries The RS3000 system requires a 12 vo lt, lead-acid deep-cycle battery o r group of batteries to provide the DC current that the inverter/charger converts to AC power . The battery may be a floo ded, gel, or AGM type. See “Battery Information” on page 40 for information on: • Estimating the [...]

Installation 14 975-0171-01-01 DC Cabling Definition DC cabling includes all of the cables and connectors between the batteries, the DC disconnect and over -current protection device, and the i nverter/charger. T ype All installations require multi-strand insulated cables. The DC cables must be copper and must be rated 105 °C minimum. Size and Len[...]

Installation 975-0171-01-01 15 Unpacking and Inspecting the Inverter/Charg er Materials List Contents The following material s are in the shipping box: • RS3000 Sine W ave Inverter/Charger • DC terminal covers (one red, one black) and four screws • Bag containing DC terminal hardware: • T wo flat washers • T wo lock washers • T wo 3/8&q[...]

Installation 16 975-0171-01-01 3. Save your purchase receipt to use as pr oof-of-purchase. This is required if the inverter/charger should need warranty service. 4. Save the original shipping carton and packing materials. If the inverter/ charger needs to be returned for service, it should be shipped in the original carton. This is also a good way [...]

Installation 975-0171-01-01 17 Installing the Inverter/Charg er Overview This section provides detailed information on installin g the RS3000. The overall procedure is divided in to eight steps: Step 1: Choosing a Location for the Inverter/Char ger Step 2: Mounting the Inverter/Char ger St ep 3: Connecting the AC Input and AC Output W ires Step 4: [...]

Installation 18 975-0171-01-01 Dry Do not allow water or other fluids to drip or splash on th e inverter . Do not expose to rain, snow or water . Cool Normal air t emperature shoul d be between 32 °F an d 122 °F (0 °C and 50 °C)—the cooler the better within this range. Clearance Allow as much space around the in verter/char ger as possible. X[...]

Installation 975-0171-01-01 19 Step 2: Mounting the Inverter/Charg er Considerations Before mounting the RS3000, take th e following two factors into account. 1. The weight of the inverter/char ger requires two people to install it. 2. Mounting considerations are show n in Figure 4 on page 20. The RS3000 dimens ion s and l ocati on of the moun ting[...]

Installation 20 975-0171-01-01 Figure 4 Mounting Orientations Orientation Approved Mo unting Orientation? Commen t Desktop Mount Y es Upside-dow n Mount Maybe Suitable only for app lications with no risk of condensation or drippin g water . W all Mount DC on Left Y es On a vertical surface with DC terminals facing left. W all Mount DC on Right Mayb[...]

Installation 975-0171-01-01 21 Step 3: Connecting the A C Input and AC Output W ires General AC W iring Considerations AC and DC Wiring Separation Do not mix AC and DC wiring in the same conduit or panel. Consult the applicable installation code fo r details about DC wiring and AC wiring in vicinity to eac h other . AC Input and Output Isolation Th[...]

Installation 22 975-0171-01-01 Connecting AC Input Wir es Figure 5 shows the wiring compartment, which contains a grounding bus (used to wire the AC input and output gound wires) and a terminal block (used to wire the AC input and AC o utput connections). When making the AC input and AC outpu t connections, observe the correct color code for the ap[...]

Installation 975-0171-01-01 23 7. Using a 1/4" blade slot screwdriver , loosen the terminal screws on the terminals. Do not remove the screws. 8. Connect the line and neutral wires to th e input terminals (labeled AC Input on the terminal block, Figure 5 on page 22). Connect Line 1 to L1, Neutral to N, Line 2 to L2. 9. T ighten the terminal sc[...]

Installation 24 975-0171-01-01 Connecting the A C Output Wir es T o ma ke the AC output wir ing connec tions: 1. Remove one of the AC knockouts from the front or side o f the unit. Do not leave the knocko ut ins ide the wiring compartment. 2. Install a strain-relief clamp in the AC knoc kout and run the AC wiring through the strain-relief clamp. 3.[...]

Installation 975-0171-01-01 25 Step 4: Connecting the DC Cables DC Connection Precautions Recommended Cable Sizes and Lengths and Fuse Size For recommended DC cable s and fuse size, see T able 3 on pa ge 1 4. Preparing the Cables T o prepare the DC cables: 1. Cut the negative an d p osi tive cables to the required length. Strip off enough insulatio[...]

Installation 26 975-0171-01-01 Guidelines for Routing the DC Cables Follow these guidelines to en sure maximum performance. • Do not attempt to use the chassis in place of the battery negative con nection for grounding. The inverter requires a reliable return path directly to the battery . • T o reduce the chance of radio frequency interference[...]

Installation 975-0171-01-01 27 Connecting the DC Cables to the Inverter/Charg er T o connect the DC cables: 1. Route the DC cables from the battery ba nk to the inverter/char ger . Observe the “Guidelines for Routing the DC Cables” on page 26. 2. Install a DC fuse and disconnect switch or a DC circuit breaker between the inverter/charger and th[...]

Installation 28 975-0171-01-01 7. Before proceeding, check that the cable polarity is correct: POSITIVE (+) on the inverter/charger is connected to the POSITIVE (+) on the battery , and NEGA TIVE (–) ca ble is connected to the NEGA TIVE (–) terminal on the inverter/charger . 8. Connect the other end of the cable to the NEGA TIVE (–) terminal [...]

Installation 975-0171-01-01 29 DC Grounding The Chassis Ground point on the inverter/cha rger is used to connect the chassis of the inverter/charg er to your system’ s DC grounding point, as required by regulations for some installatio ns. Use copper wire that is either bare or provided with green insulation. The grounding gu ideline given below [...]

Installation 30 975-0171-01-01 Step 5: Connecting the Battery T e mperature Sensor (BTS) Installing a battery temperature sensor (BTS) extends t he life of a battery by preventing overcharging in warm temp eratures and undercharging in cold temperatures. W ith a BTS monitoring th e battery temperature, the voltage delivered to the battery is adjust[...]

Installation 975-0171-01-01 31 Mounting to the Negative Battery T erminal T o mount the sensor on the negative battery terminal: See Figure 10. 1. Select the battery to be monitored. The BTS should be connected to the battery bank that is directly co nnected to the inverter/charger . 2. Switch of f all devices operating from the battery , or open t[...]

Installation 32 975-0171-01-01 Figure 11 Connecting the BTS Cable to Battery T emp . jack[...]

Installation 975-0171-01-01 33 Mounting to the Side of the Battery Case T o mount the sensor on the battery case: See Figure 12. 1. Select the battery to be monitored. The BTS should be co nnecte d to the battery bank that is directly connected to the inverter/charger . 2. Sele ct a side suita ble for attaching the sensor . The surface where the se[...]

Installation 34 975-0171-01-01 Step 6: Connecting to the Network For your reference, Figure 13 shows wh ere the network connections are made on the RS3000. T o connect the RS3000 to the Xanbus network: u Plug a netwo rk cable co nnected to the Xa nbus network into either one of the two network jacks on the RS3000. Detailed information on planning a[...]

Installation 975-0171-01-01 35 Step 7: P erforming Checks Prior to Initial Start-Up Before testing your installation, ensure these conditions are met: p Chassis and AC grounds are properly installed. p AC input connections and AC output co nnections are wired correctly on the terminal block and not reversed. p Positive (+) battery cable is connecte[...]

Installation 36 975-0171-01-01 Step 8: Testing Y our Installation There are several tests to be performed for testing your installation. These tests will verify that: • The RS3000 works in invert mode • The RS3000 works in char ge mode • The RS3000 works in AC bypass mode If the test fails at any point, go to “S tep 7: Performing Checks Pri[...]

Installation 975-0171-01-01 37 3. Press the Inverter Enable button. V erify that: • The Inverter Enable button light illuminates • The Invert On light illuminates 4. Connect the RS3000 to the test load by closing the AC breaker that co ntrols the circuit that the test load is connected to. If the light bulb illuminates, the Invert mode is worki[...]

Installation 38 975-0171-01-01 Inverter/Charg er Physical Specifications For complete inverter/char ger specifications, refer to the RS3000 Sine W ave Inverter/Char ger Operation Guide . The physical specifications of the RS3000 a re shown in Figure 1 5 on page 39 and described in T able 4. T able 4 RS3000 Physical Specifications Length 16.19 inche[...]

Installation 975-0171-01-01 39 Figure 15 Inverter/Charger Dimensions 14.2" [361][...]

Installation 40 975-0171-01-01 Battery Information Battery Bank Sizing Battery capacity Battery size or capacity is just as important as the battery type selected for use with the RS3000. The batteries are the most important part of your system, so Xantrex recommends that you purchase as much battery capacity as possible. A large battery will exten[...]

Installation 975-0171-01-01 41 4. Enter this information on the bl ank calculation worksheet (page 42). S tep 2: Calcul ate Battery Size 5. Complete the rest of the worksheet; see T able 1-1, “Battery Sizing Example” on page 41 for an example. Size the batteries at approximately twic e the estimated total amp-hour usage. Doubling the expected a[...]

Installation 42 975-0171-01-01 Battery Banks As your power requirements increase, you may need to us e more than one batte ry to obtain sufficient capacity . Batteries can be connected in parallel, in series, or in series-parallel to create hi gher capacity sy s t em s . See “Cabling and Hook-up Config urations” on page 44 for more inform ation[...]

Installation 975-0171-01-01 43 T able 1-2 Battery Sizing Worksheet Appliance (A) Power Consumption (W atts) (B) Operating Time per Day (Hours) Daily watt-hours neede d for this applianc e (= A × B) W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh T otal daily watt-hours of AC lo ad Wh × Number of days betwee[...]

Installation 44 975-0171-01-01 Cabling and Hook-up Configurations Several smaller batteries can be connected to crea te a battery bank of substantial size. Y ou can connect batteries in three wa ys: in parallel, series, or series-parallel. T o make a larger battery bank, connect in dividual batteries with heavy cables. The actual size of the cable [...]

Installation 975-0171-01-01 45 Series Connection When batteries are connected with the positive terminal of one battery to the negative terminal of the next battery , th ey are connected in series. In a series configuration, the battery ba nk has the sa me Ah rating of a single battery , but an overall voltage equal to the sum of the ind ividual ba[...]

Installation 46 975-0171-01-01 Series-P arallel Connections As the name series-parallel implies, both the series and parallel configurations are used in combination. The result is an incr ease in both the volta ge and the capacity of the total battery bank. This is co mmon with all battery-inverter system voltages. The smaller , lower voltage batte[...]

A AC and DC wiring separation 21 AC input wiring connections 22 AC input, defined 8 AC knockout dimensions 21 AC output neutral bonding 12 AC output wiring connectio ns 24 AC wiring defined 10 size 11 type 10 AC wiring compartment, illustrated 21 AC wiring considerations 21 AC wiring terminal, illustrated 21 B batteries 13 battery temperature senso[...]

Index 48 975-0171-01-01 T tools, installation 16 two key performa nce factors 5 V ventilation openings, recommended clearance 18 X Xanbus-enabled designation, meaning of 3 Xantrex, web site iii[...]

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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 975-0171-01-01 Printed in China[...]