Xantrex FREEDOM HF 1000 User manual

Freedom HF
Inverter/Charger
Installation Guide
Freedom HF 1000
Freedom HF 1800
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This guide for use by qualified installers only
Freedom HF
Inverter/Charger
Installation Guide
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This guide for use by qualified installers only
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products ranging from small mobile units to 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
Freedom HF Inverter/Charger is a trademark of Xantrex International. Xantrex is a registered trademark
of Xantrex International.
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
Xantrex Freedom HF Inverter/Charger Installation Guide © December 2007 Xantrex International. All
rights reserved.
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
December 2007 Rev A
Part Number
975-0395-01-01
Product Numbers
806-1020 (Freedom HF 1000)
806-1840 (Freedom HF 1800)
Contact Information
Telephone: [phone] (toll free North America)
1 408 987 6030 (direct)
Fax: [phone] (toll free North America)
Email: [email protected]
Web: www.xantrex.com
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About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for setting up and installing a Freedom HF Installation*.
For complete information on how to operate, maintain, and troubleshoot
the Freedom HF unit, see the Freedom HF Inverter/Charger Owner’s
Guide (Doc. Part Number: 975-0390-01-01)
* Recreational, Fleet Vehicle, or Marine installation.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, as well as procedures for installing the inverter/charger unit.
It does not provide details about particular brands of batteries. You need
to consult individual battery manufacturers for this information.
Audience
The Guide is intended for anyone who needs to install a Freedom HF
Inverter/Charger installation. Installers should be technicians or
electricians who are certified for the type of specific installation.
Organization
This Guide is organized into two chapters and two appendixes.
Chapter 1 provides information to help in installing a Freedom HF
Inverter/Charger Installation.
Chapter 2 explains how to configure the Freedom HF to best meet your
electrical system requirements.
Appendix A contains electrical performance information and product
specifications.
Appendix B illustrates a typical marine installation for the Freedom HF.
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Conventions Used
The following conventions are used in this guide.
Related Information
You can find more information about Xantrex Technology Inc. as well as
its products and services at www.xantrex.com
WARNING
Warnings identify conditions or practices that could result in personal injury or
loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or
other equipment.
Important: These notes describe things which are important for you to know,
but not as serious as a caution or warning.
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Important Safety Instructions
IMPORTANT: Read and save this Installation Guide
for future reference.
This chapter contains important safety and installation instructions
for the Freedom HF Inverter/Charger units–Freedom HF 1000 and
Freedom HF 1800.
1. BEFORE INSTALLING AND USING THE FREEDOM HF, READ ALL
INSTRUCTIONS AND CAUTIONARY MARKINGS ON THE FREEDOM HF,
THE BATTERIES, AND ALL APPROPRIATE SECTIONS OF THIS GUIDE.
2. Do not expose the Freedom HF to rain, snow, spray, or bilge water.
To reduce risk of fire hazard, do not cover or obstruct the ventilation
openings. Do not install the Freedom HF in a zero-clearance
compartment. Overheating may result.
3. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition and that wire is not undersized. Do not
operate the Freedom HF with damaged or substandard wiring.
4. The use of any attachments not recommended or sold by Xantrex,
may result in risk of fire, electric shock, or injury to persons.
5. Do not operate the Freedom HF if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the Freedom HF is
damaged, see the Warranty section.
WARNING: Limitations on use
The Freedom HF is not intended for use in connection with life support systems
or other medical equipment or devices.
CAUTION: Risk of injury
To reduce the risk of injury, charge only 12 Vdc lead-acid (GEL, AGM, and
Flooded) rechargeable batteries. Other battery types may burst, causing personal
injury and damage.
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6. Do not disassemble the Freedom HF. It contains no user-serviceable
parts. See Warranty for instructions on obtaining service. Attempting
to service the Freedom HF yourself may result in a risk of electrical
shock or fire and will void your warranty. Internal capacitors remain
charged after all power is disconnected.
7. To reduce the risk of electrical shock, disconnect both AC and DC
power from the Freedom HF before attempting any maintenance or
cleaning or working on any circuits connected to the Freedom HF.
Turning off controls will not reduce this risk.
8. The Freedom HF must be provided with an equipment-grounding
conductor connected to the AC input ground.
1. WORKING IN THE VICINITY OF BATTERIES IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION.
THEREFORE, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE
SERVICING THE UNIT IN THE VICINITY OF THE BATTERY, THAT YOU
READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
2. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the Freedom HF in
compartments containing batteries or flammable materials, or in
locations that require ignition-protected equipment. This includes any
space containing gasoline-powered machinery, fuel tanks, as well as
joints, fittings, or other connections between components of the fuel
system.
3. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer and the manufacturer of
any unit you intend to use in the vicinity of the battery.
WARNING: Explosion hazard
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Personal Precautions When Working With Batteries
1. Study and follow all of the battery manufacturer's specific
precautions, such as removing or not removing cell caps while
charging, and recommended rates of charge.
2. 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 cell caps,
carefully follow manufacturer's recharging instructions.
3. Make sure the area around the battery is well ventilated.
4. Never smoke or allow a spark or flame near the engine or batteries.
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. Remove all metal items, like rings, bracelets, and watches when
working with batteries. Batteries can produce a short circuit current
high enough to weld metal to skin, causing a severe burn.
7. Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
8. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
9. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
10. 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.
11. If you need to remove a battery, always remove the ground terminal
from the battery first. Make sure all accessories are off so you don’t
cause an arc.
WARNING: B ATTERIES PRESENT R ISK OF E LECTRICAL S HOCK ,
B
URN FROM H IGH S HORT -C IRCUIT C URRENT , F IRE OR
E
XPLOSION FROM V ENTED G ASES . O BSERVE P ROPER
P
RECAUTIONS .
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12. Never charge a frozen battery.
13. Clean battery terminals. Be careful to keep corrosion from coming
into contact with your eyes.
MARINE UNIT LOCATION
14. Locate the Freedom HF unit away from batteries in a separate, well
ventilated compartment.
15. Never place the Freedom HF unit directly above batteries; gases from
a battery will corrode and damage the unit
16. Never allow battery acid to drip on the unit when reading gravity, or
filling battery.
17. Do not operate the unit in a closed in area, or restrict the ventilation in
any way.
DC CONNECTION PRECAUTION
18. Connect and disconnect DC output connections only after setting any
marine unit switches to off position and opening AC disconnect
19. FOR MARINE INSTALLATIONS, EXTERNAL CONNECTIONS
TO THE UNIT SHALL COMPLY WITH THE UNITED STATES
COAST GUARD ELECTRICAL REGULATIONS(33CFR183, SUB
PART I)
20. PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO
YOUR LOCAL CODES FOR DISPOSAL REQUIREMENTS.
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Precautions for Using 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. Do not use 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.
CAUTION: Equipment damage
Important: 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 modified sine wave input voltage. See the detailed
description of the Freedom HF waveform in Appendix A, “Specifications” under
“Electrical Specifications: Inverter Mode” on page A–2.
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Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1 Installation
Materials List- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
High Level Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Basic Installation Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Step 1: Designing the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Step 2: Choosing a Location for the Freedom HF - - - - - - - - - - - - - - - - - - - - 1–12
Step 3: Mounting the Freedom HF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
Connecting the Equipment Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
Grounding Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
Step 4: Connecting the AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–15
General AC Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–15
AC Input Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–16
Step 5: Connecting AC Output to an Existing AC Circuit - - - - - - - - - - - - - - - 1–19
Step 6: Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–24
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–27
Step 7: Mounting the Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–28
Step 8: Testing Your Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–29
Testing in Invert Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–29
Testing in Shore Power Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–30
Drip Shield Installation (For Marine Installations) - - - - - - - - - - - - - - - - - - - - - - - 1–31
2. Configuration
Setting Battery Types on the Main Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Adjusting Display, Alarm, and Charging Current Settings- - - - - - - - - - - - - - - - - - - 2–3
Contents
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A Specifications
Electrical Specifications: Inverter Mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Electrical Specifications: Charge Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Inverter Overload Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Invert Power Derating vs. Ambient Temperature- - - - - - - - - - - - - - - - - - - - - - - - -A–6
Charger Output Current vs. AC Input Voltage- - - - - - - - - - - - - - - - - - - - - - - - - - -A–7
B Marine Installation Diagram
Marine Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
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Figure 1-1 What’s In The Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Figure 1-2 Typical Recreational Vehicle and Fleet Vehicle Installation- - - - - - - - - - 1–6
Figure 1-3 Approved Mounting Orientations- - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
Figure 1-4 DC Panel Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
Figure 1-5 Freedom HF AC Wiring Compartment - - - - - - - - - - - - - - - - - - - - - - - - 1–17
Figure 1-6 AC Wiring Diagram with an Inverter Subpanel - - - - - - - - - - - - - - - - - - 1–22
Figure 1-7 AC Wiring Diagram without an Inverter Subpanel - - - - - - - - - - - - - - - - 1–23
Figure 1-8 DC End - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–24
Figure 1-9 DC Cable Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–27
Figure 1-10 Drip Shields - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–31
Figure 1-11 Typical Drip Shield Placement on a Freedom HF 1800 - - - - - - - - - - - - - 1–32
Figure 2-1 Dip Switches (Default Settings Shown) - - - - - - - - - - - - - - - - - - - - - - - 2–2
Figure 2-2 Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Figure B-1 Typical Marine Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–3
Figures
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Table 1-1 Required AC Wire Size vs Breaker Rating - - - - - - - - - - - - - - - - - - - - - 1–9
Table 1-2 Recommended Cable Sizes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10
Table 1-3 Recommended Equipment Ground Cable size - - - - - - - - - - - - - - - - - - - 1–14
Table 1-4 Required AC wire size vs. required breaker rating - - - - - - - - - - - - - - - - 1–16
Table 1-5 Color codes for typical AC wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–16
Table 2-1 Charging Current Guidelines- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Table A-1 Charging Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7
Tables
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1Installation
Chapter 1 provides information to help in installing a
Freedom HF Inverter/Charger Installation.
It covers the following:
• Materials list.
• Safety instructions and various installation codes
that may be applicable to your installation.
• Sample installation tools and materials.
• High level overview of installation steps.
• Installation procedures starting on page 1–5
including mounting and connecting the equipment
ground, AC cabling, DC cabling, and grounding
steps.
• Drip shields installation (For Marine Installations).
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Materials List
Your Freedom HF Inverter/Charger package includes the items listed
below.
•1Freedom HF Inverter/Charger unit
• 1 Display panel with 7-inch (0.17 m) cable
• 1 Communications cable (25 feet) (7.5 m)
• 2 DC terminal covers
• 2 Strain-relief clamps (for AC input and output wiring)
• 1 Blanking plate
• 2 Reference materials–an Owner’s Guide and an Installation Guide
• 1 Set of mounting templates
• 1 Set of lock washers and nuts (not shown)
Figure 1-1 What’s In The Box
Owner’s Guide
Display panel is
attached to the unit.
mountingtemplate
Freedom HF unit
communications cable
DC terminal covers
InstallationGuide
blanking plate strain-relief clamps
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