Xantrex ALM - REV A User manual

Owner’s Manual
Auxiliary Load Module

©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to 1 MW utility-
scale systems for wind solar batteries fuel cells microturbines and backup power
applications in both grid-connected and stand-alone systems. Xantrex products
include inverters battery chargers programmable power supplies and variable
speed drives that convert supply control clean and distribute electrical power.
Trademarks
Trace and Xantrex are registered trademarks of Xantrex International.
Notice of Copyrig t
Auxiliary Load Module (ALM) Owner’s Manual © September 2001 Xantrex
Technology Inc. All rights reserved.
Disclaimer
While every precaution has been taken to ensure the accuracy of the contents
of this guide Xantrex International assumes no responsibility for errors or
omissions. Note as well that specifications and product functionality may change
without notice.
Since the use of this manual and the conditions or methods of installation
operation use and maintenance of the unit are beyond the control of Xantrex
Technology Inc. the company does not assume responsibility and expressly
disclaims liability for loss damage or expense arising out of or any way connected
with such installation operation use or maintenance.
Due to continual improvement through product updates photographs and/or
illustrations used in this manual may not exactly match your unit. Xantrex
Technology Inc. reserves the right to update this product without notice or releasing
an updated manual when fit form or function are not affected.
Date and Revision
September 2001 Revision A
Part Number
975-0027-01-01
Contact Information
Web: www.xantrex.com
Email: [email protected]
Phone: [phone]
Fax: [phone]

©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
TT
TT
Table of Cable of C
able of Cable of C
able of Contentsontents
ontentsontents
ontents
1.0 INTRODUCTION1.0 INTRODUCTION
1.0 INTRODUCTION1.0 INTRODUCTION
1.0 INTRODUCTION ..............................................................................................................................................
..............................................................................................................................................
.......................................................................11
11
1
Unpacking and Inspection ...................................................................................1
Controls and Indicators ........................................................................................2
Indicator LEDs .................................................................................................. 2
AUX RELAY 9 LED ........................................................................................ 2
AUX RELAY 10 LED ...................................................................................... 2
INVERTER OPERATIONAL LED..................................................................2
Switches ............................................................................................................3
AUX RELAY Switch ....................................................................................... 3
INVERTER ERROR Switch ...........................................................................3
Internal Components ............................................................................................4
Relays ....................................................................................................................4
Relay Connections.................................................................................................4
Relay Terminal Block ....................................................................................4
Ground Stud.................................................................................................5
Fuses ..................................................................................................................... 5
2.0 INST2.0 INST
2.0 INST2.0 INST
2.0 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION ....................................................................................................................................................
....................................................................................................................................................
..........................................................................77
77
7
Tools Required ......................................................................................................7
Pre-Installation ......................................................................................................7
Mounting ............................................................................................................... 8
Wiring ..................................................................................................................10
Terminal Block Wiring ....................................................................................10
RY 11 Error Indicator Wiring ..............................................................................11
Communication Cable ........................................................................................ 12
Internal Sticker ....................................................................................................13
3.0 OPERA3.0 OPERA
3.0 OPERA3.0 OPERA
3.0 OPERATIONTION
TIONTION
TION ........................................................................................................................................................
........................................................................................................................................................
............................................................................ 1515
1515
15
Test Procedures ...................................................................................................15
Operation ............................................................................................................16
Active-High Type Relay ................................................................................... 16
Active-Low Type Relay ....................................................................................16
ALM Applications ...............................................................................................16
Active-High Configurations ................................................................................17
High-Voltage Alarm ........................................................................................17
Battery Exhaust Fan Controller ......................................................................17
Exhaust Fan Electrical Wiring .........................................................................18
Simple Charge Controllers .............................................................................18
Photovoltaic Charge Controller .................................................................18
Over-Voltage Protection Using a Grid-Tie Inverter ...................................19
Active-Low Configurations..................................................................................20
DC Load Controller .........................................................................................20
Load Diversion Controller .............................................................................. 20
Low-Voltage Alarm ......................................................................................... 21
i

©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
TT
TT
Table of Cable of C
able of Cable of C
able of Contentsontents
ontentsontents
ontents
(continued)(continued)
(continued)(continued)
(continued)
4.0 TROUBLESHOOTING4.0 TROUBLESHOOTING
4.0 TROUBLESHOOTING4.0 TROUBLESHOOTING
4.0 TROUBLESHOOTING ........................................................................................................................
........................................................................................................................
............................................................ 2323
2323
23
5.0 SERVICE INFORMA5.0 SERVICE INFORMA
5.0 SERVICE INFORMA5.0 SERVICE INFORMA
5.0 SERVICE INFORMATIONTION
TIONTION
TION ............................................................................................................
............................................................................................................
...................................................... 2525
2525
25
6.0 WARRANTY6.0 WARRANTY
6.0 WARRANTY6.0 WARRANTY
6.0 WARRANTY............................................................................................................................................................
............................................................................................................................................................
.............................................................................. 2727
2727
27
7.0 SPECIFICA7.0 SPECIFICA
7.0 SPECIFICA7.0 SPECIFICA
7.0 SPECIFICATIONSTIONS
TIONSTIONS
TIONS ........................................................................................................................................
........................................................................................................................................
.................................................................... 2929
2929
29
Electrical ..............................................................................................................29
Mechanical ..........................................................................................................29
ii

1
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
The Auxiliary Load Module (ALM) is an accessory for selected Trace™/Xantrex
inverter/charger models allowing battery voltage related tasks such as controlling
charging sources loads etc. and inverter error indication. The unit contains three
relays providing normally open (N.O.) normally closed (N.C.) and common (COM)
contacts. Relays RY9 and RY10 are independently adjustable DC auxiliary signal
relays. Relay RY11 is used to indicate an error condition (via an external indicator)
whenever the inverter’s output is shutdown. This could be a bell buzzer light etc.
The unit interfaces with the inverter through a phone-type cable. Commands
from the inverter control the relays when defined parameters (programmed via the
inverter’s control device e.g. display panel or remote control) are met. Refer to the
inverter operator’s manual for setting the various parameters for operation.
Front panel LEDs provide a visual display of relay activity whenever a relay
contact receives an engage command from the inverter. A highly visible blue LED
indicates the connected inverter is operational.
Unpacking and Inspection
Carefully inspect the contents of the shipping carton for damages. Report any
damages to the carrier immediately.
The following items are packed with the ALM:
• Auxiliary Load Module unit (ALM)
• 25-foot cable
• Operator’s manual
• Warranty Card
Report any missing items to your dealer immediately.
Figure 1-1
Auxiliary Load Module (ALM)
1.0 INTRODUCTION

1.0 INTRODUCTION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
2
Controls and Indicators
Indicator LEDs
Three LEDs located on the front panel of the ALM indicate the relay control
signal status from the inverter.
NOTE: The LEDs are unaffected by the ALM’s switch
positions or fuse condition.
AUX RELAY 9 LED
The yellow LED indicates whether relay RY9 has engaged or not. If this LED is
illuminated the N.O. to COM contacts are connected. If this LED is not illuminated
the N.C. to COM contacts are connected.
AUX RELAY 10 LED
The green LED indicates whether relay RY10 has engaged or not. If this LED is
illuminated the N.O. to COM contacts are connected. If this LED is not illuminated
the N.C. to COM contacts are connected.
INVERTER OPERATIONAL LED
The blue LED indicates the inverter’s operational status. If the inverter is
powered and ready for operation the blue SYSTEM OPERATIONAL LED turns ON as
soon as the phone-type cable is plugged into the inverter. If the blue LED does not
turn ON the inverter is either not powered is set to the CHG-only mode without any
utility pass-through or has no AC output which may be caused by an error
condition.
Figure 1-2
Indicator LEDs
Yellow LED
AUX RELAY 9
Green LED
AUX RELAY 10
Blue LED
INVERTER OPERATIONAL
OFF = INVERTER ERROR

1.0 INTRODUCTION
3
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
Controls and Indicators (continued)
Switc es
Two switches are provided on the right side of the ALM to effectively
disconnect the relay coils from the inverter’s supply voltage (11 VDC) thus
preventing the relays from engaging if a control signal is sent out from the inverter.
This safety feature allows you to work with the auxiliary relays without having to
power-down the connected inverter.
AUX RELAY Switc
The AUX RELAY switch enables the relays by providing the operating voltage to
the relay coils RY9 and RY10. When the relays are enabled they will respond to the
control signals provided by the inverter. When the switch is in the RELAYS
DISABLED position the inverter control signals have no effect on relay operation
(i.e. the COM and N.C. contacts engage). This switch does not affect the operation
of the LEDs which continue to light whenever the inverter sends a CLOSE CONTACT
command to the relays.
INVERTER ERROR Switc
The INVERTER ERROR switch provides a simple way to test an externally
connected alarm. Once the alarm is tested this switch should be set to the RELAY
READY position.
Figure 1-3
Switc es
AUX RELAY Switch
(RY9 and RY10)
INVERTER ERROR
Switch (RY 11)

1.0 INTRODUCTION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
4
Internal Components
The Auxiliary Load Module (ALM) is designed for multiple applications and
allows for simple installation. Components provided are listed below.
Relays
There are three single-pole double-throw relays rated at 10 amps/250 VAC
(8 amps/30 VDC–for resistive loads) with gold contacts providing “dry contact”
closures to increase the low-end signal range.
• Relay RY9 and RY10 are used for battery voltage related functions.
• Relay RY11 can be connected to an external indicator device to display or
sound an alarm whenever the inverter AC output is lost.
• The common normally open and normally closed contacts are available on
each relay.
Relay Connections
• Common (COM) - The COM contact switches between the N.C. and N.O.
terminals depending on whether the relay is energized or not (de-energized).
• Normally Closed (N.C.) - The N.C. contact is connected to the COM terminal
of the relay when the relay is de-energized.
• Normally Open (N.O.) - The N.O. contact is connected to the COM terminal
of the relay when the relay is energized.
CAUTION: These relays are not intended to directly
control a load or charging source. Rather they are used
to send a signal or operate the coil of another, higher
amperage device hich does the actual s itching of
po er. A 6.3-amp fuse is included to help protect each
of the relays. Connection to a high amperage device
ill open the fuse in the common line and possibly
damage the relay. Damage to these relays from
overloading is not covered by arranty and requires the
ALM to be returned to a repair center.
Relay Terminal Block
Connections to the ALM are accomplished by the nine position spring-clamp
terminal block with quick connect levers. All relay contacts (N.O. COM and N.C.)
are available at this connector which accepts wire sizes from #28 AWG to #14 AWG.
No tools are required to secure the wires as the spring clamp holds the wires
securely in place.

1.0 INTRODUCTION
5
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
Internal Components (continued)
Ground Stud
A ground screw is provided in the ALM to provide a safety ground path when
hazardous voltages are connected to the relays. Connect this screw to a grounded
conductor whenever high voltages (i.e. above 60 volts) are connected to the relays.
NOTE: No hazardous vo tages are supp ied from the
inverter to power or contro the re ays; however, 120 VAC
cou d be used to power an externa error indicator.
Fuses
Each relay’s common (COM) contact is protected with a 6.3 amp
(5 mm x 20 mm) 250 VAC fuse which will open if excess current is drawn
through the relay contacts. Always replace this fuse with the same type and
rating. Type GDC (Bussman) or 218 (Littlefuse) is recommended.
NOTE: These fuses can be rep aced with ower ower
ower ower
ower amperage
fuses to a so protect the connected circuitry, if desired. In
no no
no no
no case, shou d this fuse be rep aced with one of a higherhigher
higherhigher
higher
amperage.
Figure 1-4
Internal Components
F1 protects
RY 9
F2 protects
RY 10
F3 protects
RY 11
GROUNDING screw Terminal Block
Communication jack
J1

1.0 INTRODUCTION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
6
Notes:

7
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
6-9/64
4-27/32
19/32
3-11/16
4-7/8
19/32
J1
SW1
SW2
1-13/64
Figure 2-1
Dimensional Drawing (Not to Scale)
The ALM is required to be installed in a clean dry protected environment and
should be mounted close to the load in a location where it is easily accessible. Dual
knockouts in the sizes of ½ ¾ and 1 inch are provided for cable routing and
conduit connections. Mount the ALM to a flat vertical surface such as a wall.
Tools Required
screwdrivers (Phillips and flat blade) wood screws (#10)
drill and assorted bits anchors (if required)
wire strippers
WARNING: BEFORE MAKING ANY CONNECTIONS
TO THE LOAD OR INVERTER, ENSURE THAT ALL AC
AND DC POWER IS DISCONNECTED FROM THE
INVERTER AND THE ALM.
Pre-Installation
Before installing the ALM read all instructions and cautionary markings
located in this manual.
Determine the wire route (or conduit runs) to the ALM and loads.
NOTE: Check for existing e ectrica , p umbing, or other
potentia areas of accidenta damage prior to making cuts
in structura surfaces.
2.0 INSTALLATION

2.0 INSTALLATION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
8
Mounting
• Remove the two Phillips screws from the unit’s front panel and remove the
cover. Figure 2-2.
• Open the inverter’s access panel and locate the AUX connector if necessary.
Refer to the inverter operator’s manual for the location of the connector.
• Hold the ALM against the surface to be mounted and use the unit as a
template to mark the four hole locations. See Figure 2-3.
NOTE: Six ho es are provided in the back pane of the
ALM. Use the two top and two bottom screw ho es. Do
not use the midd e two ho es.
• Drill holes for mounting and insert appropriate anchors if necessary.
• Use four #10 wood screws to mount the unit to the wall or other vertical
surface.
• Install conduit runs or strain reliefs for the RY9 and RY10 control wires error
indicator (if used) and communication cable (between the inverter and ALM).
Figure 2-2
Removing t e Front Cover
Remove the 2
Phillips screws

2.0 INSTALLATION
9
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
Mounting (continued)
Figure 2-3
Mounting Holes
Mounting
Hole
Do NOT use
this hole
for mounting.
Mounting
Hole
Do NOT use
this hole
for mounting.
Mounting
Hole
3/4" - 1" Dual
Knockouts
3/4" - 1"
Dual
Knockouts
3/4" - 1"
Dual
Knockouts
1/2" - 3/4"
Dual
Knockouts
1/2" - 3/4"
Dual
Knockouts
Figure 2-3a
Dual Knockout Locations

2.0 INSTALLATION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
10
Figure 2-4
Terminal Block Connections
RELAY 9
Connections
RELAY 10
Connections
RELAY 11
Connections
Wiring
NOTE: A wiring described in this manua must be
performed by a qua ified, icensed e ectrician and meet
oca and nationa codes, such as NEC.
Terminal Block Wiring
• Lift the appropriate lever for the relay contact.
• Insert the wire (stripped back 1/4 inch) into the terminal block.
• Snap the lever down to secure the wire.
Please refer to the auxiliary relay section of the inverter’s operation manual for
additional information.
NOTE: Due to the various ways the ALM can be wired,
detai ed wiring instructions can not be given in this
manua . P ease refer to the operation section of this
manua for wiring suggestions.
CAUTION: Do not ire the relays directly to a high-
amperage device. Connection to a high-current device
ill open the fuse in the common line and possibly
damage the relay.

2.0 INSTALLATION
11
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
RY 11 Error Indicator Wiring
If an error indicator is used (light buzzer bell etc.) connect the wires to the
RY11 relay contacts. Depending on the error indicator used either the N.O. or N.C.
contacts can be used. Typically the N.C. and COM contacts are used to complete a
circuit turning on a light buzzer etc. The N.C. contacts are held “open” until an
error condition is detected (or the AC output is OFF); at which time the N.C. contact
will “close” completing the circuit and activating the external device.
Figure 2-5
External Error Indicator Connections
N.O.
N.C.
COM
External Error
Indicator
External Alarm
OFF Switch
EXTERNAL
INDICATOR
POWER SOURCE
ALM
NO SIGNAL FROM
INVERTER
(relay disengaged)
For convenience add an external OFF switch in line with the alarm device. This
allows turning off the alarm until the inverter’s output is restored.
NOTE: The diagrams shown here are intended as an
examp e of how the re ays operate an externa a arm
device. Actua a arm types may operate different y from
these diagrams. Refer to the externa indicator’s owner’s
manua for specific a arm wiring. Do not exceed the
vo tage or amperage ratings of the re ay and fuse.
Figure 2-6
External Alarm OFF Switc
N.O.
N.C.
COM
EXTERNAL
INDICATOR
POWER SOURCE
NO SIGNAL FROM
INVERTER
(relay disengaged)
External Error
Indicator
External Alarm
OFF Switch
CONTROL SIGNAL
FROM INVERTER
(relay engaged)
N.O.
N.C.
COM
External Error
Indicator
External Alarm
OFF Switch
EXTERNAL
INDICATOR
POWER SOURCE
ALM ALM

2.0 INSTALLATION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
12
Communication Cable
The ALM is supplied with a 25-foot telephone-type cable with RJ11 connectors
on each end.
NOTE: Longer cab e engths are avai ab e for purchase
from your Xantrex Dea er: part numbers TC/50 for 50 feet
(15.24 m) and TC/100 for 100 feet (30.48 m).
• Route the telephone-type cable through one of the knockouts fitted with a
strain relief (or conduit).
• Connect one end of the cable to the jack labeled J1 on the ALM circuit board.
• Connect the other end of the cable to the jack labeled AUX inside the inverter
(refer to the inverter’s operator’s manual for location).
• Reinstall the cover on the ALM using the two Phillips screws.
• Reinstall the inverter’s cover.
NOTE: Recheck a wiring before proceeding to the
Operation section of this manua .
Figure 2-7
J1 Control Signal Connection
J1 Connector
Communication
cable to inverter

2.0 INSTALLATION
13
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
Internal Sticker
Please refer to the component layout sticker located inside the front cover.
This label can be used as a quick reference for component location and fuse sizing
information.
91
TB1
LED1
LED2
J1
PN 110-0035 - -
LED3
F3F2
F1
R1R2R3
NC C C NO NO NO C NC NC
R4
D1
SW1
SW2
Terminal Block wire size: 14-28 AWG
Interconnect cable (J1):
WARNING:
DO NOT OPERATE WITH COVER REMOVED.
HAZARDOUS VOLTAGES MAY BE PRESENT.
Connect to Gen Port of
Trace Inverter
SUPPLIED FUSE RATING: 6.3 AMP 250VAC
FUSE TYPE: 5mm X 20mm
MAXIMUM RELAY CONTACT RATINGS: (RESISTIVE LOAD)
10 AMPS @ 250VAC
8 AMPS @ 30VDC
FUSE SHOULD BE SELECTED FOR PROPER
PROTECTION OF CONNECTED DEVICES.
ALM - AUXILIARY LOAD MODULE
Wire strip length: .25" (6mm)
(DO NOT EXCEED RELAY CONTACT RATING)
™
RY9
RELAY
SW1
RELAY
RY10
SW1
RELAY
RY11
SW2
Figure 2-8
Internal Component Identification Sticker

2.0 INSTALLATION
©2001 Xantrex Technology Inc.
P/N 975-0027-01-01 Rev A 09/01
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Notes:

15
©2001 Xantrex Technology Inc.
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Test Procedures
NOTE: Refer to the inverter’s operator’s manua for
setting the RY11 re ay for testing.
Immediately after installation the ALM should be tested for proper operation.
• Ensure the AUX RELAY switch on the ALM is in the ON (ENABLED) position
and the INVERTER ERROR relay is in the RELAY READY position.
• Reconnect all power to the inverter.
• Using the inverter’s control device (i.e. display SWRC remote) press the
INV MENU button to access the inverter menu. Select ON from the display.
The blue INVERTER OPERATIONAL LED should immediately turn ON.
NOTE: The LEDs wi turn ON different y, depending
upon the function se ected from your inverter.
• If an external alarm is connected to the ALM turn the INVERTER ERROR
switch to the RELAY TEST position. The external device should activate.
• Place the INVERTER ERROR switch in the RELAY READY position.
NOTE: If the tests did not pass, recheck the wiring and
the ALM for proper re ay contact se ection (N.O. or N.C.).
3.0 OPERATION

©2001 Xantrex Technology Inc.
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3.0 OPERATION
Operation
The inverter that is connected to the ALM monitors its battery voltage to
determine when to signal relays RY9 and RY10. These relays are individually
controlled and each responds to user-programmable voltage setpoints via the
inverter’s control panel. These two auxiliary relays operate independently of the
inverter’s status - whether the inverter is ON or OFF.
The software revision of your inverter determines whether RY9 and RY10
operate as active-high or active-low type relays. This depends on whether the
inverter has:
1) the programming to allow for a “user-defined delay” when the relay energizes
or de-energizes
2) a hysteresis voltage setting (the difference between the relay activation and
deactivation) or
3) a temperature compensation setting.
For specifics on the operation programming and adjustment values for the
ALM refer to your inverter’s manual (Auxiliary Relay section).
Active-Hig Type Relay
This relay type energizes when the voltage is above the high-voltage setpoint
and de-energizes when the voltage goes below the low-voltage setpoint.
Active-Low Type Relay
This relay type energizes when the voltage is below the low-voltage setpoint
and de-energizes when the voltage goes above the high-voltage setpoint.
ALM Applications
There are a number of applications for the ALM. These applications are based
on the configuration of the relays – whether configured active-high or active-low.