Xanter 806-1020 User manual

TM
TM
Freedom HF Inverter/Chargers
Installation Guide
Product image shown may vary from actual product. See features for comparisons.
Model Numbers
806-1020, 806-1055,
806-1055-02
806-1840, 806-1840-01,
806-1840-02
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975-0395-01-01 i
InstallationTrademarks
Xantrex and Smart choice for power are trademarks of Schneider Electric,
registered in the United States and other countries. Other trademarks, registered
trademarks, and product names are the property of their respective owners and are
used herein for identification purposes only.
Notice of Copyright
Freedom HF Inverter/Charger Owner’s Guide © 2007, 2011 Xantrex Technology
Inc. All rights reserved. No part of this document may be reproduced in any form or
disclosed to third parties without the express written consent of: Xantrex Technology
Inc., 161-G South Vasco Road, Livermore, California, USA 94551. Xantrex
Technology Inc. reserves the right to revise this document and to periodically make
changes to the content hereof without obligation or organization of such revisions or
changes unless required to do so by prior arrangement.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)
(A)MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(B)ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER’SRISK; AND
(C)REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH,
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE
ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
November 2011 Rev C
To view, download, or print the latest revision, visit the website shown below.
Document Part Number
975-0395-01-01
Product Numbers
1000-watt Models:
806-1020 (Freedom HF 1000),
806-1055 (Freedom HF 1055)
806-1055-02 (Freedom HF 1055 EMS)
1800-watt Models:
806-1840 (Freedom HF 1800),
806-1840-01 (Freedom HF 1800 T),
806-1840-02 (Freedom HF 1800 EMS)
Contact Information
Telephone: [phone] (toll free North America)
1 408 987 6030 (direct)
Web: www.xantrex.com
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ii Freedom HF Installation Guide
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for installing and configuring a Freedom HF Inverter/Charger
for Recreational, Fleet Vehicle, or Marine installations.
Scope
The Guide provides safety guidelines, as well as information about
operating and troubleshooting the installation. It does not provide details
about particular brands of batteries. You need to consult individual battery
manufacturers for this information
Audience
The Guide is primarily intended for qualified installers who need to install
and configure the Freedom HF Inverter/Charger. The installer should have
knowledge and experience in installing electrical equipment, knowledge of
the applicable installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards. A qualified
technician or electrician has this knowledge and experience.
Conventions Used
The following conventions are used in this guide.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions will result in death or serious
injury.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in death or serious
injury.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in minor or moderate
injury.
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975-0395-01-01 iii
Related Information
You can find more information about Xantrex Technology Inc. as well as its
products and services at www.xantrex.com.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
IMPORTANT: These notes describe things which are important for you to
know, however, they are not as serious as a caution or warning.
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iv Freedom HF Installation Guide
Important Safety Instructions
IMPORTANT: READ AND SAVE THIS INSTALLATION GUIDE FOR
FUTURE REFERENCE.
This chapter contains important safety instructions for the Freedom HF
Inverter/Charger (Freedom HF). Each time, before using the Freedom HF,
READ ALL instructions and cautionary markings on or provided with the
inverter/charger, the batteries, and all appropriate sections of this guide.
NOTE: The Freedom HF contains no user-serviceable parts. See “Warranty
and Return Information” on the Owner’s Guide for guidance.
NOTE: Turning off the inverter/charger using the on/off switch on the front
panel will not reduce an electrical shock hazard.
ELECTRICAL SHOCK HAZARD
• Do not expose the Freedom HF to rain, snow, spray, or bilge water.
This inverter/charger is designed for marine applications only when
additional drip protection is installed in certain orientations. See the
installation guide for information.
• Do not operate the inverter/charger if it has received a sharp blow,
been dropped, has cracks or openings in the enclosure including if the
fuse cover has been lost, damaged, or will not close, or otherwise
damaged in any other way.
• Do not disassemble the inverter/charger. Internal capacitors remain
charged after all power is disconnected.
• Disconnect both AC and DC power from the inverter/charger before
attempting any maintenance or cleaning or working on any circuits
connected to the inverter/charger. See note below.
• Do not operate the inverter/charger with damaged or substandard
wiring. Make sure that all wiring is in good condition and is not
undersized.
Failure to follow these instructions will result in death or serious
injury.
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975-0395-01-01 v
NOTES:
1. Follow these instructions and those published by the battery
manufacturer and the manufacturer of any equipment you intend to use
in the vicinity of the battery. Review cautionary markings on these
products and on the engine.
2. This inverter/charger contains components which tend to produce arcs
or sparks.
3. Locations include any space containing gasoline-powered machinery,
fuel tanks, as well as joints, fittings, or other connections between
components of the fuel system.
FIRE AND BURN HAZARD
• Do not cover or obstruct the air intake vent openings and/or install in
a zero-clearance compartment.
• Do not use transformerless battery chargers in conjunction with the
inverter/charger due to overheating.
Failure to follow these instructions will result in death or serious
injury.
EXPLOSION HAZARD
• Charge only properly rated (such as 12 volts) lead-acid (GEL, AGM,
Flooded, or lead-calcium) rechargeable batteries because other
battery types may explode.
• Do not work in the vicinity of lead-acid batteries. Batteries generate
explosive gases during normal operation. See note #1.
• Do not install and/or operate in compartments containing flammable
materials or in locations that require ignition-protected equipment.
See notes #2 and #3.
Failure to follow these instructions will result in death or serious
injury.
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vi Freedom HF Installation Guide
Precautions When Working With Batteries
NOTES:
1. Mount and place the Freedom HF Inverter/Charger unit away from
batteries in a well ventilated compartment.
2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
4. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.
5. Use extra caution to reduce the risk or dropping a metal tool on the
battery. It could spark or short circuit the battery or other electrical
parts and could cause an explosion.
6. Batteries can produce a short circuit current high enough to weld a ring
or metal bracelet or the like to the battery terminal, causing a severe
burn.
7. When removing a battery, always remove the negative terminal from
the battery first for systems with grounded negative. If it is grounded
positive, remove the positive terminal first. Make sure all loads
connected to the battery and all accessories are off so you don’t cause
an arc.
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND EXPLO-
SION FROM VENTED GASES HAZARDS
• Always wear proper, non-absorbent gloves, complete eye protection,
and clothing protection. Avoid touching your eyes and wiping your
forehead while working near batteries. See note #4.
• Remove all personal metal items, like rings, bracelets, and watches
when working with batteries. See notes #5 and #6 below.
• Never smoke or allow a spark or flame near the engine or batteries.
• Never charge a frozen battery.
Failure to follow these instructions can result in death or serious
injury.
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975-0395-01-01 vii
Precautions When Preparing to Charge
NOTES:
• Study and follow all of the battery manufacturer's specific precautions,
such as removing or not removing cell caps while charging, whether
equalization is acceptable for your battery, and recommended rates of
charge.
• For flooded non-sealed batteries, add distilled water in each cell until
battery acid reaches the level specified by the battery manufacturer.
This helps to purge excessive gas from cells. Do not overfill. For a
battery without removable cell caps, carefully follow manufacturer's
instructions.
Precautions When Placing the Inverter/Charger
EXPOSURE TO CHEMICALS AND GASES HAZARD
• Make sure the area around the battery is well ventilated.
• Make sure the voltage of the batteries matches the output voltage of
the inverter/charger.
• Be careful to keep corrosion from coming into contact with your eyes
and skin when cleaning battery terminals.
Failure to follow these instructions can result in death or serious
injury.
FIRE HAZARD
Do not install the inverter/charger or any part of its supplied wiring in
engine compartments.
Failure to follow these instructions can result in death or serious
injury.
RISK OF DAMAGE TO THE INVERTER/CHARGER
• Never allow battery acid to drip on the inverter/charger when reading
gravity, or filling battery.
• Never place the Freedom HF Inverter/Charger unit directly above
batteries; gases from a battery will corrode and damage the inverter/
charger.
• Do not place a battery on top of the inverter/charger.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
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viii Freedom HF Installation Guide
Precautions for Using Rechargeable Appliances Regulatory
The Freedom HF Inverter/Charger is certified to appropriate US and
Canadian standards. For more information see “Regulatory Approvals” on
page 37.
The Freedom HF Inverter/Charger is intended to be used for mobile or
commercial applications. This inverter/charger is designed for marine
applications only when additional drip protection is installed in certain
orientations. See the installation guide for information.
It is not intended for other applications as it may not comply with the
additional safety code requirements needed for those other applications. See
“Limitations On Use” below.
NOTE: The Freedom HF Inverter/Charger is a modified sine wave inverter/
charger. Please ensure your equipment or devices are compatible with
modified sine wave prior to usage.
RISK OF DAMAGE TO RECHARGEABLE APPLIANCES
Most rechargeable battery-operated equipment uses a separate charger or
transformer that is plugged into an AC receptacle and produces a low
voltage charging output.
Some chargers for small rechargeable batteries can be damaged if
connected to the Freedom HF. Avoid using the following with the
Freedom HF:
• Small battery-operated appliances like flashlights, razors, and night
lights that can be plugged directly into an AC receptacle to recharge.
• Some chargers for battery packs used in power hand tools. These
affected chargers display a warning label stating that dangerous
voltages are present at the battery terminals.
If you are unsure about using your rechargeable appliance with the
Freedom HF, contact the equipment manufacturer to find out if the
appliance is acceptable for use with an inverter that has a modified sine
wave output voltage.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
LIMITATIONS ON USE
Do not use in connection with life support systems.
Failure to follow these instructions can result in death or serious
injury.
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975-0395-01-01 ix
FCC Information to the User
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to
radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
KKK Information to the User
The Freedom HF 1055 EMS and 1800 EMS models are marked “KKK-A-
1822D Ready”. These models are marketed for use in ambulances and
emergency vehicle applications. For information of compliance of the
ambulance as a whole, please refer to specifications as laid out in Federal
Specification for the Star-of-Life Ambulance also known as KKK-A-1822.
Unauthorized changes or modifications to the equipment could void the
user’s authority to operate the equipment.
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Freedom HF Install Guide.book Page x Thursday, November 24, 2011 11:06 AM

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Materials List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
High Level Overview of Installation Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Basic Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Drip Shield Installation (For Marine Installations). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Marine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Contents
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975-0395-01-01 1
This guide for use by qualified installers only.
Materials List
Your Freedom HF Inverter/Charger package includes the items listed
below.
• one Freedom HF unit,
• one set of owner’s and installation guides and a mounting template,
• one display panel with 7-inch (0.17 m) cable,
• one communications cable (25 feet) (7.5 m),
• two DC terminal covers,
• one strain-relief clamp,
• one GFCI cover plate with knockout,
• one display panel blanking plate (not shown),
• one display panel mounting bezel (not shown), and
• one set of lock washers and nuts (not shown).
NOTE: If any of the items are missing, contact Xantrex or any authorized
Xantrex dealer for replacement. See “Contact Information” on page i.
Figure 1 What’s In The Box
Display panel is
attached to the unit.
Freedom HF unit
communications cable
DC terminal covers
GFCI cover plate strain-relief clamp
Owner’sGuide
mountingtemplate
InstallationGuide
Product image shown
may vary from actual
product.See Features
for comparisons.
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2Freedom HF Installation Guide
Safety Instructions
• Before you begin the installation, review the “Important Safety
Instructions” on page iv, and read this entire section so you can plan
your installation from beginning to end.
• Disconnect all AC and DC power sources to prevent accidental shock.
Disable and secure all AC and DC disconnect devices and automatic
generator starting devices.
Installation Codes
Governing installation codes vary depending on the specific location and
application of the installation. Some examples include the following:
• The U.S. National Electrical Code (NEC),
• The Canadian Electrical Code (CEC),
• The U.S. Code of Federal Regulations (CFRs),
• Canadian Standards Association (CSA) and the RV Industry
Association (RVIA) for installations in RVs, and
• The American Boating & Yachting Committee (ABYC) for Marine
installations in the U.S.
It is the installer’s responsibility to ensure that all applicable installation
requirements are met.
SHOCK HAZARD
Xantrex Technology recommends that all wiring be done by a certified
technician or electrician to ensure adherence to the applicable electrical
safety wiring regulations.
Failure to follow these instructions can result in death or serious
injury.
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975-0395-01-01 3
This guide for use by qualified installers only.
Installation Tools and Materials
You will need the following to install the Freedom HF:
❐Wire stripper
❐Mounting screws or bolts
❐#2 Phillips screwdriver
❐3.5mm slot long neck screwdriver for WAGO1terminals that are
available in Freedom HF 1000, 1055, and 1800 models.
❐Wrench for DC terminals (1/2 inch or 13mm or adjustable)
❐AC cable (i.e. 2-conductor-plus-ground cable), sized appropriately for
load and application
❐Wire nuts or crimp connectors for AC wire and appropriate tools
❐Two 1/2 inch strain-relief clamps (supplied) for AC cables
❐DC cable, sized appropriately for load and application
❐Lugs for DC cables to fit 8 mm (5/16 in.) DC stud terminals) as well as
appropriate tools (e.g. crimping tool)
❐AC and DC disconnects and over-current protective devices
1. WAGO® manufactures connection devices such as terminal blocks and related accessories.
Many Freedom HF models use WAGO terminal blocks as AC input and output connections.
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4Freedom HF Installation Guide
High Level Overview of Installation Steps
Installing the Freedom HF includes the following steps.
1. Ensure that AC and DC power are both OFF.
2. Mount the inverter securely and permanently in one of the acceptable
orientations.
3. Connect the Equipment Grounding Terminal to the equipment ground
bus.
4. Connect the AC input wiring to the AC source panel.
5. Connect the AC output wiring to the AC load panel.
6. Connect one end of the DC negative cable to the negative of the
battery, and the other to the negative terminal of the unit.
7. Install an appropriately sized fuse and DC disconnect in the positive
cable.
8. Connect the DC positive cable to the positive of the battery, and to the
positive terminal of the unit.
9. Close the DC disconnect switch.
Do not proceed with installation until you have read “Safety Instructions”
on page 2.
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975-0395-01-01 5
This guide for use by qualified installers only.
Basic Installation Procedures
Xantrex recommends that you have your installation performed by a
qualified technician or electrician.
This section provides sample installation information as a guide for your
installation. For your convenience, the overall procedure is divided into ten
main steps:
❐Step 1: Designing an installation. (Start on page 6.)
❐Step 2: Choosing a location for the Freedom HF.
(Start on page 11.)
❐Step 3: Mounting the Freedom HF. (Start on page 12.)
❐Step 4: Connecting the AC input wires. (Start on page 14.)
❐Step 5: Connecting the AC output wires. (Start on page 18.)
❐Step 6: Connecting the DC cables. (Start on page 21.)
❐Step 7: Mounting the display panel. (Start on page 28.)
❐Step 8: Testing your installation. (Start on page 29.)
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6Freedom HF Installation Guide
Basic Installation Procedures
Step 1: Designing the Installation
Most Freedom HF installations share common components, and some of
these are briefly described below. Figure 1 shows some components and
their relationship to each other in a typical recreational vehicle or fleet
vehicle installation. (Also, see “Marine Installation” on page 34.)
Figure 1 Typical Recreational Vehicle and Fleet Vehicle Installation
lto engine
+
–
DC Fuse /
Disconnect or
Circuit Breaker
AC Load Panel
AC Source Panel
Shorepower
Generator
Automatic or Manual AC
Source Select or Switch
FREEDOM
HF| 1000
12V Deep Cycle
Battery
Vehicle Starting
Battery
Equipment Ground
Equipment Ground
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