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: