Xantrex PROsine 2.0 manual

PROsine 2.0 Inverter/Char g er User’ s Manual[...]

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PROsine 2.0 Inverter/Charger User’s Manual[...]

About Xantrex Xantrex T echnology Inc. is a w orld-leading supplier 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-co nnected and stand-alon e systems. Xan trex products inclu de [...]

445-0089-01-01 iii About This Manual Purpose The purpose of this User ’ s Manual is to provide explanations and procedures for installing, op erating, maintaining, and troubleshooting the PROsine 2 .0 Inverter/ Charger. Scope The Manual provides safety gu idelines, detailed planning and setup information, procedures for installing the inverter , [...]

About T his Manu al iv 445-0089-01-01 Specifications: Appendix A contains sp ecifications and performance graphs for the PROsine and the disp lay panel. System Diagrams: Appendix B illustrates typical designs for PROsine custom- designed systems. Charging Algorithms: Appendix C prov ides information about the char ging algorithms for PROsine 2.0.[...]

About T h is Manual 445-0089-01-01 v Conventions Used The following conv entions are used in this guide. Abbreviations and Acronyms <just the common ones--don’t make the list too long. If there are lots, then create an appendix to contain them> Related Documents PROsine 2.0 Inverter/Char ger Quick Installation Guide Part Number: 445-0099-01[...]

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445-0089-01-01 vii Important Safety Instructions 1. Before installing and using the PROsine 2.0 Inverter/Charger (PROsine), read all instructions and cautiona ry markings on the PROsin e, the batteries, and all appropriate sections of this Manual. 2. Do not expose the PROsine to rain, snow , spray , or bilge water . T o reduce risk of fire hazard, [...]

Safety viii 445-0089-01-01 Explosive gas precautions 1. W orking in the vicinity of lead -ac id ba tteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly be fore installing or using your PROsine. 2. This equipment contains components wh ich tend to pr[...]

Safety 445-0089-01-01 ix 9. If battery acid contacts skin or clothing, wash immediately with soap and water . If acid enters your eye, immediat ely flood it with runn ing cold water for at least twenty minutes and get medi cal attention immediately . 10. If you need to remove a ba ttery , always re move the ground terminal from th e battery first. [...]

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445-0089-01-01 xi Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii 1 Introduction Your PROsine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1– 2 The Heart of a Sophisticated, Independent Power System - - - - [...]

Contents xii 445-0089-01-01 Step 4: Connecting the AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 General AC Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11 AC Input Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -[...]

Contents 445-0089-01-01 xiii 5 Operation Part 1: System Startup Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Part 2: Operating Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Fan Operation - - - - - - - - - - - - - - - - - - - - -[...]

Contents xiv 445-0089-01-01 Installing a Seri es Sys t em - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5 Connecting AC Input Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5 Connecting AC Output Wiring - - - - - - - - - - - - - - - - - - - - - - - -[...]

445-0089-01-01 xv Figure 1-1 PROsine Materials as Shipped- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Figure 2-1 AC End View (Blank Panel Option) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Figure 2-2 Panel Equipped With GFCI and Circ uit Protecto r - - - - - - - - - - - - -[...]

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445-0089-01-01 xvii Table 1-1 PROsine Default Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9 Table 3-1 Required AC Wire Size vs Breaker Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Table 3-2 Required DC Cable and Fuse Size - - - - - - - - - - - - - - - - - - - - - -[...]

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1 Intr oduction Chapter 1 introduces you to the PR Osine, explains the inverting, changing and power system management functions[...]

Introduction 1–2 445-0089-01-01 Y our PROsine Congratulations o n your purchase of the PROsine 2.0 In verter/Charger (PROsine) As part of the PROsine Inverter/Char g er family , the PROsine 2.0 gives yo u quality power , worry-free op eration, and outstanding reliability . Its integrated inverting–char ging functions and numero us power managem[...]

T he Heart of a Sophisticate d, Independent P ower System 445-0089-01-01 1–3 The Heart of a Sophisticated, Independent P ower System Y our PROsine has been designed to be the heart of a sophisticated, independent power system. While the PROsine is an ex tremely “friendly ” p roduct to operate, Xantrex wants to ensure that you get the best per[...]

Introduction 1–4 445-0089-01-01 Remote Shutdown Naturally , when you are not using the PROsine, you will disable the inverter to conserve your battery . The PROsine still draws up to 50mA of battery curren t, however—and this will eventually discharge the battery . So when you don’t need the PROsine for an extended period of tim e, you can re[...]

T he Heart of a Sophisticate d, Independent P ower System 445-0089-01-01 1–5 P ower System Management As we pointed out at the beginning of this introduction, the PROsine is designed to be the heart of your power system. In addition to refined ch ar ging and inverting functions, the PROsine is the control cent er for managing your power system. A[...]

Introduction 1–6 445-0089-01-01 Auto Restart A f ter Errors The PROsine protects itself against nume rous conditions (e.g. AC overload or over temperature) by shut ting down. Y o u can program the PROsine to restart automatically when the cause of th e shutdown has corrected itself. . Run W ithou t Pa nel T he Run W ithout Panel configuration set[...]

Materials List 445-0089-01-01 1–7 If any of these materials are missing or are unsatisfactory in any manner , please contact Cus t om er Ser vice. See page W A–1. Important: p DC W iring Enclosure For residential installati ons, some installation codes may require a wiring enclosure for DC connections and cables. (Installation procedures are sh[...]

Introduction 1–8 445-0089-01-01 Figure 1-1 PROsine Materials as Shipped U s e r ’ s M a nu a l PROsin e 2.0 Inver ter•Cha rger DC terminal covers Display p anel Communications cable Battery temper ature User’s Manual Quick Installation Guide Quic k Reference C ard ABYC W arning Label sensor Important:: For Marine Installations For marine in[...]

Default Values for the PROsine System 445-0089-01-01 1–9 Default Values for the PROsine System T able 1-1 lists the default settings for the PROsine system. Record your settings in the right-hand colu mn after you have co nfigured the PROsine. This information will be valuable if you need to reconfi gure your system or call Xantrex Customer Servi[...]

Introduction 1–10 445-0089-01-01 Adjustable From the Configur e Battery Menu NOTE Settings below are for Battery T ype = Generic Gel. Battery Size 200Ah ** Default Battery T emperature W arm Battery T ype Generic Gel ** Battery T emp. Coefficient –27mV/°C Bulk Mode Settings: • Max V oltage • Max Current (%C) • Threshold V oltage • Thre[...]

2 Pr oduct Orientation Chapter 2 will familiarize you wi th the following components of a PROsine system: • PROsine features. (S tart on page 2–2.) • Display panel features. (S tart on page 2–6.) • Battery temperature sensor . (See page 2–12.)[...]

Product Orientation 2–2 445-0089-01-01 PROsine F eatures A C End Figure 2-1 AC End V iew (Blank P anel Option) Fea t ur e De sc r ip t io n 1 ON/OFF/REM Switch: ON: Normal operation according to the way the uni t has been configured via the display p anel. OFF: The inverter and charger are of f; sh orepower is not passed through to the loads. The[...]

PROsine F e atures 445-0089-01-01 2–3 A C P a nel Options The PROsine has two AC panel options , each of which includes one 30A hardwire output circu it: • Blank access panel: one hardwire output circuit. See Figure 2-1. • Panel equipped with 15A GFCI receptac le and one hardwire output circuit. See Figure 2-2. Figure 2-2 P anel Equipped With[...]

Product Orientation 2–4 445-0089-01-01 DC End Figure 2-3 DC End Fea t ur e De sc r ip t io n 1 Positive DC cabling terminal, 8 mm stud 2 Negative DC cabling terminal, 8 mm stud 3 Cooling fan. (For details, see “Fan Operation” on page 5–3.) 4 Screw holes for mounting accessory modules 5 Chassis ground lug. Provides a ground path for the PROs[...]

PROsine F e atures 445-0089-01-01 2–5 DC T erminal Covers T wo covers—red for positive and black for negative—are supplied to prevent accidental contact with the cabli ng conn ec tors af ter installation. Figure 2-4 DC T erminal Cover: T op View on Left; Bottom View on Right[...]

Product Orientation 2–6 445-0089-01-01 Display P anel Featur es The display panel lets you monitor and control the PR Osine system. For convenience, the liquid crys tal display (LCD) is back lit and the panel can be configured so an audible tone alerts you to any warnings or system faults that occur . The panel’ s fea tures are described below [...]

Display P anel Features 445-0089-01-01 2–7 DISPLA Y Mode Switch Switch P osition Description ON Puts the unit in Display mo de. Data Display screens are shown so you can monitor sy stem performance. OFF Power continues to be available to the panel so vital dat a like system errors and warning statuses can be checked. CONFIGURE Puts the inverter i[...]

Product Orientation 2–8 445-0089-01-01 INVER TER Switch This switch is active in all Di sp la y mod es : ON , OF F , CONFIGURE. INVER TER LEDs The LEDs are continuously up dated whenev er the Display Mode switch is set to ON or CONFIGURE. Switch P osition Description ENABLE The inverter is enabled and wi ll run if there is no shorepower . ( NOTE:[...]

Display P anel Features 445-0089-01-01 2–9 CHARGER Switch This switch is active in all Di sp la y mod es : ON , OF F , CONFIGURE. CHARGER LEDs The LEDs are continuously up dated whenev er the Display Mode switch is set to ON or CONFIGURE. Switch P o sition Description ENABLE The charger is enabled and wi ll char ge the battery according to the wa[...]

Product Orientation 2–10 445-0089-01-01 LCD Panel The LCD panel lets you mon itor the PROsine system and change its configuration settings. It operates in two basic mo des: Data Displ ay and Configuration. Data Display Mode • In Data Display mode the screens prov ide information abou t PROsine system performance. • Y ou can cycle through them[...]

Display P anel Features 445-0089-01-01 2–11 Menu Navigation and Data Selection Buttons When the DISPLA Y switch is set to CONF IGURE, the menu navigation and data selection buttons operate as follows: Examples of how to change configur ation settings are given on page 4–3. Further information about viewing Displa y mode screens is prov ide d on[...]

Product Orientation 2–12 445-0089-01-01 Battery T emperatur e Sensor The temperature sensor contin uous ly measures the temperature of the battery and adjusts charger output for a more accu rate, temperature-co mpensated charge. Figure 2-6 Battery T emperature Sensor Fea t ur e De sc r ip t io n 1 Mounting plate. Connects to the negative battery [...]

3 Installation Chapter 3 This section gives complete information for installing a PROsine system. Specifically , this section describes: • Safety instructions and installa tion codes that must be observed during instal lation • Installation tools and materials • Appropriate locations and environments for mounting the PROsine, display panel, a[...]

Installation 3–2 445-0089-01-01 Safety Instructions • Before you begin the i nstallation, review the “Important Safety Instructions” on “Important Safety Instructions ” on page vii, and read the entire “Installation” section so you can plan your installation from beginning to end. • Disconnect all AC and DC power sources to preven[...]

Safety Instructions 445-0089-01-01 3–3 Installation T ools and Materials Y ou will need the following to install th e PROsine, display panel, and battery temperature sensor: p W ire stripper p Mounting screws or bol ts p #2 Phillips screwdriver p W rench for DC terminals (1/2 inch or 13mm or adjustable) p AC cable (i.e. 2-conductor -plus-ground c[...]

Installation 3–4 445-0089-01-01 Step 1: Designing the Installation All types of PROsine installations share common components, and these are briefly described below . Figure 3-1 shows these components and their relations hip to each other in a typical recreational ve hicle or fleet vehicle installation. (For diagrams of typical residential back u[...]

Step 1: Designing the Installation 445-0089-01-01 3–5 AC shorepower A source of 120 volt, 60Hz altern ating current is needed to provide energy for charging batteries and to pass through to AC loads. This source could be the utility grid (power company) or an AC generato r . An automa tic or manual AC source selector swi tch can be us ed to conne[...]

Installation 3–6 445-0089-01-01 AC Distribution Panels Most systems incorporate distribution cente rs both ahead of the PROsine (the AC source panel) and between the PROsine and the loads (the AC load panel). A source panel includes a main circuit breake r, which serves as over-current protection and as a disconnect for the AC shorepower supply l[...]

Step 1: Designing the Installation 445-0089-01-01 3–7 DC Cabling This includes all the cables and connectors between th e batteries, the DC disconnect and over -current protection de vice, and the PROsine. All installations require multi-strand insulated cables as well as disconnect and over-current devices. DC cable sizes are indicated by A WG n[...]

Installation 3–8 445-0089-01-01 Installations in marine an d recreational vehicles may require GFCI protection of branch circu its connected to the AC output of the PROs ine. In addition, electrical codes require GFCI protection of certain receptacles in residential installations. While the true sine wave output of the PROsine is equivalent to t [...]

Step 2: Choosing a Location for the PROsine 445-0089-01-01 3–9 Step 2: Choosing a Location for the PROsine The PROsine should onl y be installed in locations that meet the following requirements: p Dry . Do not allow water or other fluids to drip or splash on the PROsine. Do not mount the PROsine in an ar ea s ubject to splashing water or bilge w[...]

Installation 3–10 445-0089-01-01 Step 3: Mounting the PROsine T o mount the PROsine: 1. Remove the PROsine from its shipping container , verify that all components are present, and record relevant prod uct information on “Information About Y our System” on page W A–4. 2. T urn off the ON/OFF/REM switch on the AC end. 3. Select an appropriat[...]

Step 4: Connecting the AC Input Wires 445-0089-01-01 3–11 Step 4: Connecting the A C Input Wir es General A C Wiring Considerations AC W iring Connectors Connect AC wires with twist-on wire nuts or crimp-on splice conn ec to rs according to the type of installation: • On a boat, use crimp -on sp lice connecto rs to meet the Amer ic a n Boat an [...]

Installation 3–12 445-0089-01-01 A C Input Connections Figure 3-4 is a cutaway top view of th e PROsine wiring compartment. It shows one incoming AC cable and its co nnections to the PROsine wires. T o make the AC input connections: 1. Run 10A WG 2-conduc tor-plus-ground cable through one of the ca ble cla mps on the AC end. 2. Strip about two in[...]

Step 5: Configuring the Ou tput Neutral Bonding System 445-0089-01-01 3–13 Step 5: Configuring the Output Neutral Bonding System A C Output Neutral-to-Ground Bonding System The PROsine provides an installer-defeatab le system that automatically connects the neutral conductor of the inverter AC outpu t circuit to safety ground (“bonding” it) d[...]

Installation 3–14 445-0089-01-01 The PROsine is shippe d with the screw in the position that enables the automatic bonding system. • T o disable the system, move the screw to the other hole. • Do not remove the screw from the pro duct: make sure it is always install ed in one position or the other , as appropriate fo r the configuration of th[...]

Step 6: Connecting the AC Output Wires 445-0089-01-01 3–15 Step 6: Connecting the A C Output W ires T wo options are available for AC output wiring: • Hardwire output. • Single hardwire output plus GFCI recepta cle. Connections for Hardwir e Option T o make the AC output wir i ng connecti on s 1. Run 10A WG 2-conduc tor-plus-ground cable thro[...]

Installation 3–16 445-0089-01-01 Connections for Single Ha rdw i re Ou tp ut With GFC I Figure 3-6 is a cutaway top view of the PROsine wiring compartme nt showing one set of outgo ing AC wi res with the GFCI option. T o ma ke the AC output wiri ng connecti ons 1. Run 10A WG 2-conductor-plus-ground through one of the cable clamps on th e AC end. [...]

Step 7: Connecting the DC Cables 445-0089-01-01 3–17 Step 7: Connecting the DC Cables Follow the procedure given below to connec t the battery leads to the terminals on the DC end. The cables should be as sh ort as possible and large enough to handle the required current, in accordance with the electrical codes or regulations applicable to your i[...]

Installation 3–18 445-0089-01-01 T o make the DC connections Refer to Figure 3-8. 1. Cut the cables to the correct length w ith enough insulation stripped of f so you can properly install the type of terminals you will be using. The terminals on the DC end are designed to fit up to 500MCM crimp-o n ring terminals (either AMP or ILSCO) or box conn[...]

Step 7: Connecting the DC Cables 445-0089-01-01 3–19 DC Grounding T o connect the DC grou nd: The Chassis Ground lug on the DC end of the PROsine is used to connect the chassis of the PROsine 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 insula[...]

Installation 3–20 445-0089-01-01 Step 8: Mounting the Display P anel The communic atio ns cab le supplied with t he display panel is 70 feet long (21 meters). If you want to replace the cable w ith one that is longer or shorter , use a high quality , 6-wire telephone extension cable. Y ou can install the panel up to 100 feet (30 meters) away from[...]

Step 9: Connecting the Battery T emperature Sensor 445-0089-01-01 3–21 Step 9: Connecting the Battery T emperatur e Sensor Mounting Options Y ou can mount the battery temperatur e sensor (BTS) in one of two ways: • Mounting the sensor to th e negative battery post allows the internal battery temperature to be sensed and provides the most accura[...]

Installation 3–22 445-0089-01-01 1. Decide which battery is to be monitored. When all battery banks are located in the same compartment, select the battery that requires the most frequent ch ar ging (in a boat or an R V , this is usually the “house” batte ry). Where a battery is loc ated in a separate compartment from other batteries, and whe[...]

Step 9: Connecting the Battery T emperature Sensor 445-0089-01-01 3–23 Mounting to the Side of the Battery Case T o mount the sensor on the battery case See Figure 3-10. 1. Select the battery to be monitored (s ee step 1 in the preceding procedure). 2. Select a side suitabl e for attaching the sensor . The surface where the sensor is to be mounte[...]

Installation 3–24 445-0089-01-01 Step 10: Connecting the Remote Shutdown Some installations may requ ire remote shutdown capab ility . This feature enables you disable all circuitry in the PROsin e and remove all power from the display panel using a remote shutdown switch (e.g . the ignition switch in a vehicle). This also removes all power (inve[...]

Step 10: Connecting the Remote Shutdown 445-0089-01-01 3–25 Next Steps At this point, you have installed the PROsine system and are now ready to configure it. 1. Read the configuration procedures in Chapter 4, “Configurati on”. 2. Reconnect the AC shorepower supply . 3. Use the display panel to configure the PROsine. Figure 3-11 Cabling Detai[...]

Installation 3–26 445-0089-01-01[...]

4 Configur ation Chapter 4 explains how to configur e the PROsine to best meet your electrical system requirements. It is divided into three parts: • General Configuration Information on page 4–2. T ells you how to enter Configure mode and Installer mode, how to scroll through the configurati on screens, and how to change configuration settings[...]

Configuration 4–2 445-0089-01-01 P art 1: General Configur ation Information All changes to the operation of the PROs ine are m ade via the dis play panel . The unit must be in Configure mod e or Installer -Only mode before you can change system settings. It is essential that you understand the implic ations of changing User and Installer setting[...]

P art 1: General Configuration Information 445-0089-01-01 4–3 Changing Settings T o change system settings: 1. Set the DISPLA Y switch to CONFIGURE . 2. Press Up s MENU or Down t MENU to display the menu you want. 3. Press ENTER once, and then press Up s MENU or Down t MENU until the menu item you want appears. 4. Press Up s DA T A or Down t DA T[...]

Configuration 4–4 445-0089-01-01 Resetting to Factory Defaults T o reset the PROsine to the factory defaults: 1. Disable Invert and Charge mode. 2. Set the DISPLA Y switch to CONFIGUR E . 3. Press Down t MENU until Configur e PROsin e—Advanced Menu appears. 4. Press the ENTER button once. 5. Press Down t MENU until Reset to Dflts appea rs. 6. P[...]

P art 2: Configuration Menus and Screens 445-0089-01-01 4–5 T able 4-1 Menu Structure—Overview Configure PROsine—Basic Configure PROsine—Advanced Configu re Display P anel Configure Battery Diagnostics AC Breaker Size Load Sensing Equalize Load Sensing Load Sense Power Load Sense Interval Low AC T ransfer (V) Low AC T ransfer (Hz) High AC T[...]

Configuration 4–6 445-0089-01-01 P art 3: Configuration Options This section gives you informat ion about the optio ns on each configuration menu. Refer to this section when you are changing system settings. The information in this sec tion is arranged as follows: • Each configuration menu is identified by a heading (e.g. Configure PROsine—Ba[...]

P art 3: Configuration Options 445-0089-01-01 4–7 Configure PROsine—Basic Menu Menu Choices or Information Displayed AC Breaker Size Set the AC breaker size to match the shorepower circuit breaker size to reduce circuit breaker “nuisance” tripping. V alues range from 0–30 amps . Load Sensing Select Enabled if you want the unit to only tur[...]

Configuration 4–8 445-0089-01-01 Configure PROsine—Advanced Menu Menu Choices or Information Displayed Load Sensing Select Enabled if you want the unit to periodica lly search for the presence of an AC load while it is inverting. The unit will “sleep” if the load it detects is less than the Load Sensing setting. Select Disabled if you do no[...]

P art 3: Configuration Options 445-0089-01-01 4–9 Low AC T ransfer (V) This is the voltage below which the unit will no longer recognize AC as “good”, will open the relay , and will attempt to transfer to Invert mode if Invert is Enabled . The range of values is 85–1 10 V ac . Low AC T ransfer (Hz) This the frequency at which the unit will [...]

Configuration 4–10 445-0089-01-01 Auto Restart A f ter Error If you select Ye s , the PROsine will attempt to rest art (five attempts) after a fault has occurred. If you select No , the PR Osine ceases operation when an error occurs. It then requires that you manually restart the unit by going to the Configuration menu and clearing the error . Ex[...]

P art 3: Configuration Options 445-0089-01-01 4–11 Configure Display P anel Menu Menu Choices or Information Displayed This menu lets you ch ange display pane l settings to suit your preferences and environment. Audible Alarm Select All Faults if you want a beeper to alert you to each W arnin g and Error that occurs. If you prefer , choose Errors[...]

Configuration 4–12 445-0089-01-01 Configure Battery Menu Menu Display (if different from Menu Item) Menu Items Access Battery Size Installer Dflt Batt T emp Default Batt T em p User Battery T ype Installer V iew / Change Battery Details: Batt T e mp Coeff Mode Settings: Bulk Charge • Bulk - Maximum V olt age • Bulk - Maximum Current (%C) a ?[...]

P art 3: Configuration Options 445-0089-01-01 4–13 Menu Choices or Information Displayed The Configure Battery menu lets you read (as a user) and change (installer-only) settings associated with the battery system. The parameters that can be set include battery size, temperature, and type. Battery Size This is the capacity of the battery or batte[...]

Configuration 4–14 445-0089-01-01 Bulk Charge Mode Settings • Max V oltage This is the maximum available charging voltage for the Bulk charging stage. • Max Current (%C) The maximum available charging current (in A) as a percentage of battery capacity (in Ah) for the Bulk char ging stage. • Threshold V oltage and Timeout When the battery vo[...]

P art 3: Configuration Options 445-0089-01-01 4–15 Equalize Mode Settings • Max V oltage This is the maximum available chargi ng vo ltage for the Equalize char ging stage. • Max Current (%C) This is the maximum available charging current (in A) as % of battery capacity in (Ah) for the Equalize charging stage. • Max T imeout This is the maxi[...]

Configuration 4–16 445-0089-01-01 Charger T ype Choose one of the three charger type s listed below . For information about multi- stage charging, see Application Note: Ba ttery Banks for Inverter Systems (976- 01 14-0 1-01). p 3-step The PROsine will perform the Bulk, Absorption/Over charge, and Float steps p 2-step The PROsine will only perform[...]

P art 3: Configuration Options 445-0089-01-01 4–17 Diagnostics Menu Menu Choices or Information Displayed The screen s on the Diagnostics menu are Read-Only . They let you mo nitor and troubleshoot the status of yo ur PROsin e system. For example, if the unit is continually recording W arnings about low battery voltage, you can view the messages [...]

Configuration 4–18 445-0089-01-01 V iew Last 10 Panel Faults The display panel records the last ten fa ults that have occurred in the display panel. Y ou can vie w these for diagnostic and trou bleshooting purpose s. See “Display Panel Faults” on page 6–9. AC Bad Cause If the input AC is not acceptable according to the configuration values [...]

5 Oper ation Chapter 5 begins with a system st artup check that you carry out after installation and configuration to verify that the PROsine is operating correctly . The chapter also provides information that will guide you during routine, ongoing operations. For your convenience, the informat ion is divided into four parts: • System Startup Che[...]

Operation 5–2 445-0089-01-01 P art 1: System Startup Check T o test the charging and inve rting functions: 1. Close the battery disconne ct and turn on the PROsine’ s ON/OFF/REM switch. 2. T o test the inverter , set the INVER TER switch to ENABLE and disconnect the AC input source breaker . 3. Place a load on the inverter (e.g. plug a light in[...]

P art 2: Operating Considerations 445-0089-01-01 5–3 P art 2: Operating Considerations F an Operation The internal cooling fan operat es for a number of conditions: • One of the internal operating temperatures is greater than 55°C. The fan will continue to run until one minute after the temperature drops to 45°C. • The AC input or output cu[...]

Operation 5–4 445-0089-01-01 W ithout this hysteresis the PROsine might continually transfer between invert and charge mode as the shorepower voltage goes up and down a small amount. This concept is applied to the following: • Invert Low V oltage Shutdown Hysteresis: 2.5 V , if the unit stop ped inverting due to low battery voltage, it will no [...]

P art 3: Operation in Inverter Mode 445-0089-01-01 5–5 P art 3: Operation in Inverter Mode Once the PROsine is installed, you can operate it in Inverter mode. T o operate in Inverter mode: 1. Place PROsine’ s ON/OFF/REM switch in the ON position. 2. Set the INVER TER switch to ENABLE. 3. If AC is present, the ST ANDBY LED will come on. If AC is[...]

Operation 5–6 445-0089-01-01 you have problems start ing certain loads, ensure that the battery connections are solid, the DC cabling is short and of suf fic ient size, the AC wiring is of suf ficient size, and the battery is of suf ficient capacity and is fully charged. As with all inverters, the amount of co ntinuous power th at the PROsin e ca[...]

P art 4: Operation in Charger Mode 445-0089-01-01 5–7 P art 4: Operation in Charger Mode T o operate the PROsine in Charger mode: 1. T urn on the PROsine’ s ON/OFF/REM switch. 2. Connect AC shorepower . • The batteries are charged according to the three-step algorithm you hav e selected. • The READY LED comes on when the charge cycle is com[...]

Operation 5–8 445-0089-01-01 Follow the battery manufacturer ’ s recomm endations for equalizing you r batteries. 10 provides some backg r ou nd on different batteries. As a guide, a heavily used flooded battery may need to b e eq ualized once a month an d a battery in light service every two to four months. The PROsine delivers a high quality [...]

P art 4: Operation in Charger Mode 445-0089-01-01 5–9 5. During equalization, measure the S.G . When all cells have an S.G . of approxi mately 1.265, termin ate the char ge by setting the CHARGER switch to DISABLE. As a safety feature, the PROsine will exit Equalize mode after a specified period (depending on battery type). If the S.G . is still [...]

Operation 5–10 445-0089-01-01 P art 5: Display Mode Screens When the DISPLA Y switch is ON, you can view the screens shown below . (The values shown here are examples only .) Dis play Mode scree ns are updated continuously to sh ow current PROsine operating data. Y ou can scroll throug h them by pr essing the Up s and Down t MENU buttons. Screen [...]

6 T r oubleshooting Chapter 6 describes how to troubleshoot the PROsine This section is divided the following parts: • General T roubleshooting Guidelines on page 6–2. • Shutdown / Restart W ithout Error Message on page 6–3. • AC Bad Causes on page 6–3. • W arning Messages on page 6–4. • Error Messages on page 6–6. • Display P[...]

T roubleshooting 6–2 445-0089-01-01 General T r oubleshooting Guidelines This section will help you narrow down the source of an y problem you encounter . Before contracting Xantrex, please work through the steps liste d below: 1. Check for a W arning, Error, or Panel Fa ult message. (See T able 6-2, T able 6-3, and T able 6-4 for descriptions of[...]

General T roubleshooting Guide lines 445-0089-01-01 6–3 Shutdown / Restart W ithout Error Message While inverting, the PROsine could shut down for a few seconds and then restart inverting without reporting an error . This has likely been caused by a reset of the internal microprocessor, which was probably cause d by a discharged and/or w eak batt[...]

T roubleshooting 6–4 445-0089-01-01 W arning Messages W arning messages appear on the display panel LCD to alert you to an impending system change. W arnings do not affect operation. • Y ou can retrieve the previous twenty W arning and/or Error messages by placing the unit in Configur e mode and then selecting V iew Last 20 PROsine Faults from [...]

W arning Messages 445-0089-01-01 6–5 Inv Hi Bat V -W High battery voltage, invert mode. Check for external charging sources and disable if necessary . Chg Hi Bat V -W Battery voltage exceeds 15.5V in charge mode. AC In Rev Pol -W Input AC line and neutral wiring polarity is reserved. Check to see that the Line side of the AC source (shorepower) h[...]

T roubleshooting 6–6 445-0089-01-01 Error Messag es Error messages indicate that there has been a change in system operation due to a detected condition. • Y ou can retrieve the previous twenty Error messages by placing the unit in Configure mode and then selecting V iew Last 20 PROsine Faults from th e Diagnostics menu. • T o clear an Error [...]

Error Messages 445-0089-01-01 6–7 Invert Hi Bat V Inverter battery voltage greater than 16V . Check for external charging sources and disable if necessary . AC Out Overload AC output over load. R educe the AC load so that even for short times, the AC output current does not exceed 26A. Ext Comm T imeout PROsine external communications timeout Che[...]

T roubleshooting 6–8 445-0089-01-01 Chg Bad AC Qlty In Charger or Bypass mode the PROsine is being powered from an incompatible AC so urce, probably a very low qual ity generator . The PROsine is compatible wit h virtually all nominal 120V 6 0Hz AC sources (including Modified Sine W ave) bu t it is possible that a very low quality source may caus[...]

Display P anel F aults 445-0089-01-01 6–9 Display P anel Faults A message is displayed for any fault that is detected in the display panel. If a Panel Fault message appears, you can cl ear it from the screen by pressing any button on the panel. Since this type of fault does not trigger a shutdown, operation of the system after the error oc curs d[...]

T roubleshooting 6–10 445-0089-01-01 Unexplained F aults Sometimes the PROsine may not show a fault at the panel, but may be acting in an unexplained way . T able 6-5 Unexplained F aults Error Details Shorepower is present but the PROsine will not transfer The voltage or frequency of the shorepower is not within th e transfer limits configure in [...]

Inverter Applications 445-0089-01-01 6–11 Inverter Applications The PROsine performs dif feren tly de pend in g on the AC loads connected to it. If you are having p roblems with any of your loads, read this section. Resistive Loads These are the loads that the inverter finds the simplest and most efficient to drive. V o ltage and current are in p[...]

T roubleshooting 6–12 445-0089-01-01 freewheel when power is removed (e.g. a grinder). This long transfer may cause computers or other sensitive equipment to operate incorrectly . If power glitches must be minimized then Xantrex recommen ds that motor loads not be operated when the sensitive equi pment is being used. Problem Loads V ery Small Loa[...]

7 Series Oper ation Chapter 7 provides information a bout installing and operating two PROsines in series: • Designing a series system on page 7–2. • Installing a series system on page 7–5. • Configuring a series system on page 7–9. • Series system startup test on page 7–10. • Series system operation on page 7–1 1.[...]

Series Operation 7–2 445-0089-01-01 Designing a Series System System Overview Series operation refers to a specific wiring configur ation that allows you to connect two PROsines in a way that produces two 120V phases which are synchronized to prod uc e 240V . This is commonly referred to as a “120/240V ac split-phase” supply or “240 V singl[...]

Designing a Series System 445-0089-01-01 7–3 Figure 7-1 T wo PROsine Series Operat ion System * Ground * Ground Battery 1 Battery 2 DC Fuse / disconnect or circuit breaker DC Fuse / disconnect or circuit breaker Solid lines: 2 bank system Dashed lines: add cross- tie jumpers t o create a single bank system. Connect these points to the system grou[...]

Series Operation 7–4 445-0089-01-01 AC I n p u t The AC input (shore power) supply to the system must be a 120/240V ac split- phase system that provides two line conductors (referred to as L1 and L2), a neutral, and ground. Each PROsine requires a line, neutral, and ground run to it, so 2-conductor -p lus-g rou nd cab le is need ed with a 30A max[...]

Installing a Series Syst em 445-0089-01-01 7–5 Installing a Series System • Xantrex recommends that you ha ve an electrician set up the two PROsines because knowledge of the electrical co de, split-phase systems, and load balancing is required. • See page 3–3 for a list of tools and materials required for installation. • See “Step 1: De[...]

Series Operation 7–6 445-0089-01-01 Connecting A C Output Wiring T o connect each PROsine to the load panel: 1. Connect 2-conductor -plus-ground cable to the Line 1 PROsine’ s AC Output line and neutral conducto rs, and connect the cable’ s ground wire to one o f the output ground screws on the PROsine. 2. Run the 2-con ductor-plus-g round ca[...]

Installing a Series Syst em 445-0089-01-01 7–7 The system can be run from a single battery bank or from two separate banks. A large single bank provides better sur ge ca pability for 120V load s and ensures that unbalanced 120V load s do n’t run down the battery on one inverter before the other . The two PR Osines charge the sing le battery ban[...]

Series Operation 7–8 445-0089-01-01 • Single Bank : If yo ur system has a single bank , install bo th se nsors on the battery (or batteries) which will be the hottest. • T wo Separate Banks: If your system has two separate battery banks, connect one sensor to either PROsine and then to the battery it is charging; connect the second sensor to [...]

Configuring a Series Syst em 445-0089-01-01 7–9 Configuring a Series System Configure each PROsine through its display panel. Refer to “Part 2: Configuration Menus and Screens” on page 4–4 for an overview of configuration options. Refer to “Part 3: Configuration Options” on page 4–6 for specific configuration items. T o configure the [...]

Series Operation 7–10 445-0089-01-01 Series System Startup T est T o test the system’s inverting and charging functions 1. Apply DC to both PROsines by closin g the battery disconnect(s). Remove AC by opening the AC input source breaker . On both PROsines , set the ON/OFF/ REM switch to On. 2. Set the INVER TER switch on one display to ENABLE. [...]

Series System Operation 445-0089-01-01 7–11 Series System Operation Invert Mode The two PROsines will operate strictly as a pair in Invert mode. Before each cycle of AC output, the two units confer over th e sync cable to verify that the other unit has no errors and is ready to put out th e next cycle. A number of conditions must be met for the p[...]

Series Operation 7–12 445-0089-01-01[...]

A Specifications Appendix A contains spec ifications and perfor mance graphs for the PROsine and the display panel. Specifications subject to change without notice.[...]

Specifications A–2 445-0089-01-01 Electrical Specifications: Invert Mode DC Inpu t Operatin g vo l tage range 10.0V–16. 0V Safe non-operating voltage range 0–18Vdc Nominal current at full load 200A AC O u t p u t Output voltage 117V ac Continuous power 2.0kW , 2.0kV A to 40°C max. ambient Surge power 4.5kW for 5s Max short-circuit cu rrent 5[...]

Electrical Specifications: Charge Mode 445-0089-01-01 A–3 Electrical Specifications: Charg e Mode A C Input Operating voltage range 90–135V ac Nominal current 15Aac at 100A charge, 120V ac in Power factor (100A charge, 120V ac in) ≥ 0.98 on sine input Nominal frequency 60Hz DC Outp ut Nominal voltage 12.0Vdc Min battery voltage for charging 0[...]

Specifications A–4 445-0089-01-01 Environmental Specifications System Regulatory Approvals Ambient T emperature: Operating T emperature Range Storage T emperature Range –20–60ºC, with output derated above 40 ° C –40–70ºC Humidity: Operation/Storage 5–95% RH, non-condensing T ransfer relay rating 30A, 1.5hp T ransfer time 16ms T ransf[...]

Inverter Overload Operation 445-0089-01-01 A–5 Inverter Overload Operation This graph shows how long the P ROsine will operate fo r given output current. T ypical Inverter Efficiency Ti m e t o Shut down vs. Cur r ent 0.01 0.10 1.00 10.00 100.00 1000.00 10000.00 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 AC O utput C ur re nt (A r m s ) T[...]

Specifications A–6 445-0089-01-01 Invert P ower Derating vs . Ambient T emperatur e If the unit is in elevated ambient temper ature above 40°C, you are required to reduce power draw according to the fo llowing chart to main tain regulatory compliance and to a vo id ov er-temperature shutdown. PROsine Charg er Output Current vs . A C Input V olta[...]

PROsine Dimensions 445-0089-01-01 A–7 PROsine Dimensions Figure A-1 PROsine Dimensions (450mm (17.7”) 10 1/2” (267mm ) 11 3/8” ( 289mm) 5 3/4” (146mm ) 17 3/4” (4 50mm) 1 1/2” (38 mm) 4 3/8” (111 mm) 7 3/16” (183mm) 10 1/16” (256m m) 11 1/16” (281mm)[...]

A–8[...]

B System Diagr ams Appendix B illustrates typical desi gns for PROsine custom-designed systems. • Residential backup. (See page B–2.) • Marine installations. (See page B–3.) For a typical R V or Fleet V ehicle installation, see Figure 3-1 on page 3–4.[...]

System Diagrams B–2 445-0089-01-01 Residential Backup System Figure B-1 illustrates a typi cal residential backup sy stem with the following features: 1. AC power supplied by a utility system 2. DC power supplied by a batte ry bank and protec ted by a DC fuse in the positive cable 3. An AC source panel that includes a Ma x 30A circuit breaker tha[...]

Marine System 445-0089-01-01 B–3 Marine System Figure B-2 illustrates a typical marine system with the following components: 1. AC power supp lied from a shorepower connector 2. An AC source panel that includes a Ma x 30A circuit breaker that supplies the PROsine 3. An AC load pane l with br anch circuit breakers that supply only loads that run o[...]

B–4[...]

C Char ging Algorithms Appendix C provides information a bout the char ging algorithms for PROsine 2.0. • Charg e Algorithms. (See page C–2.) • Battery T ype—Charge Algorithm Guide. (See page C–3.)[...]

Charging Algorithms C–2 445-0089-01-01 Charge Algorithms T able C-1 summarizes the voltage and current setpo ints for the char ging algorithms. These voltage set points are applied for a battery temperature of 20°C. T o determine the voltage setpoints at ot her temperatures, apply the temperature coefficient as follows: For example, generic gel [...]

Battery T y pe—Charge Algorithm Guide 445-0089-01-01 C–3 Battery T ype—Charg e Algorithm Guide Use the information in T able C-2 to match your battery type with the appropriate Charge Algorithm and Char ge r T ype. Different battery manufacturers suggest di f ferent battery char ging algorithms. The following information has been provided to [...]

Charging Algorithms C–4 445-0089-01-01 Johnson Controls Fl ooded - Starting/Deep Cycle 12 3 Step Keystone Solid Energy (Flooded) 16 3 Step Keystone Solid Energy (Gel) 15 3 Step Metra Electronic - T sunami, Normal 19 3 Step Optima Blue T o p 19 3 Step Optima Red T op 19 3 Step Optima Y el low T op 19 3 Step Rolls Deep Cycle by Surrette 18 3 Step S[...]

445-0089-01-01 WA–1 W arranty and Return Information Wa r r a n t y What does this warranty cover? This Limited W arranty is provided by Xantrex T echnology In c. ("Xantrex") and covers defects in workmanshi p and mat erials in your PROsine 2.0 Inverter/Charger. This warranty period last s for 2 years (24 months) from the date of purcha[...]

W arranty and Return WA–2 445-0089-01-01 What does this warranty not cover? This Li mi ted 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 customer's electri cal systems. This warranty does not apply to and Xant rex will no t be respon sible for any def[...]

W arranty and Return 445-0089-01-01 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. Products must also be shipped prep aid. Product shipments will be refused and returned at your expense if[...]

W arranty and Return WA–4 445-0089-01-01 Information About Y our System As soon as you open your PROsine 2.0 Inverter/Charger pack age, record the following inform ation 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 represe[...]

445-0089-01-01 IX-1 A Abbreviations and Acronyms v ABYC compliance A–4 ABYC W arning label 1–8, B–3 AC Bad Cause 4–18, 6–3 AC Breaker Size 3–6, 4–5, 4–7 AC cabling 3–6 AC circuit breaker 3–5 AC disconnect devices 3–5 AC distribution center . See AC source panel and AC load panel. AC fuses 3–5 AC input wiring connections 3–[...]

Index IX–2 445-0089-01-01 general configuration information 4–2 how to change settings 4–3 minimum setting s after installation 1–9, 4–5 overview of menu struct ure 4–5 series systems 7–9 Configuration mode 2–10 Configure Battery menu 4–12 Configure Display Panel menu 4–11 Configure mode, entering 4–2 Configure PROsine—Advan[...]

Index 445-0089-01-01 IX–3 frozen batteries 6–4 fuse sizes AC 3–5 DC 3–7 G gases, battery precautions 5–7, 7–8 venting 3–22 generators 3–5 GFCI 2–3, 3–7, 3 –16 GFCI models, tested 3–8 I incandescent lights 6–12 induction motors 6–11 Information about Y our System form WA–4 input voltage range 5–6 installation battery [...]

Index IX–4 445-0089-01-01 Menu Up button 2–11 menus Configure Battery 4–12 Configure Display Panel 4– 11 Configure PROsine—Advanced 4–8 Configure PROsine—Basic 4–7 Diagnostics 4–17 navigating 2–11 selecting data 2–11 microwave 1–2 motor loads 6–11 motors capacitor start 6–11 induction 6–11 universal 6–11 mounting env[...]

Index 445-0089-01-01 IX–5 running current 6–11 R V system, illu strat ed 3–4 S safety instructions viii search mode. See Lo ad Sensing mode. serial number WA–4 series operation Charge mode 7–1 1 Invert mode 7–11 series sync cable installing 7–8 to order 1–7 series sync connection 7–4 series system battery bank(s) 7–7 battery tem[...]

Index IX–6 445-0089-01-01 warranty out of warranty service WA–3 terms and conditions WA–1 wire sizes, AC 3–6 wiring enclosure, DC 3–3, 3–18 wiring, separation of AC and DC 3–11 X Xantrex web site v[...]

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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 445-0089-01-01 Printed in China[...]