Xantrex PowerHub PH1800 Manual

PowerHub 1800
Operator’s Guide
PH1800

PowerHub 1800
Operator’s Guide

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls
with products from 50 watt mobile units to 2.5 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
PowerHub 1800 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
PowerHub 1800 Operator’s Guide © June 2006 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
June 2006 Revision A
Part Number
975-0288-01-01 Rev B
Product Number
PH1800
Contact Information
Telephone: [phone] (toll free North America)
1 360 925 5097 (direct)
Fax: [phone] (toll free North America)
1 360 925 5143 (direct)
Email: [email protected]
Web: www.xantrex.com

iii
About This Guide
Purpose
The purpose of this Operator’s Guide is to provide procedures for
installing the PowerHub 1800.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, and procedures for installing the inverter. It does not provide
operational or troubleshooting information. It does not provide details
about particular brands of batteries. Consult individual battery
manufacturers for this information.
Audience
The PowerHub is an entry-level inverter system. This Guide is intended
for anyone who needs to plan for and install the PowerHub 1800.
Permanent installations should be done by certified technicians or
electricians. Installers should have adequate knowledge of national and
local electric code to ensure code-compliance by inspection from the local
electric authority.
Organization
This Guide is organized into three chapters and one appendix.
Chapter 1 describes the operational features and functions of the
PowerHub 1800. This section details how the unit functions as an
inverter, provides information on the control panel, and describes
operating limits for inverter operation.
Chapter 2 contains information on operating the PowerHub 1800.
Chapter 3 explains how to troubleshoot the PowerHub 1800 and describes
the error codes that may be displayed on the LCD.
Appendix A provides electrical and physical specifications for the
PowerHub 1800.

About This Guide
iv 975-0288-01-01 Rev B
Conventions Used
The following conventions are used in this guide.
Abbreviations and Acronyms
Related Information
You can find more information about this product by seeing the
PowerHub 1800 Installation Guide (part number 975-0289-01-01). You
can find more information about Xantrex Technology Inc. as well as its
products and services at www.xantrex.com.
A French version of this document is available 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.
Abbreviation or Acronym Definition
AAmps
AC Alternating Current
DC Direct Current
ft-lbs Foot-pounds (a measure of torque)
kW Kilowatts (1000 watts)
LED Light Emitting Diode
Nm Newton-meters (a measurement of torque)
PV Photovoltaic
RE Renewable Energy
Vac Volts AC
Vdc Volts DC
WWatts

v
Important Safety Instructions
1. Before installing and using the PowerHub 1800, read all
instructions and cautionary markings on the PowerHub, the
batteries, and in both this Installation Guide and the Operator’s
Guide.
2. The PowerHub is intended for indoor use only. Do not expose the
PowerHub to rain, snow, or spray. To reduce risk of fire hazard, do
not cover or obstruct the ventilation openings. Do not install the
PowerHub in a zero-clearance compartment. Overheating may result.
3. The PowerHub may connect to as many as three sources of DC Power
and one source of AC Power. To reduce the risk of electrical shock,
disconnect all sources of AC and DC power from the PowerHub
before attempting any maintenance or cleaning or working on any
circuits connected to the PowerHub. Turning off controls will not
eliminate this risk.
4. Use only attachments that are intended for use with this product.
Doing otherwise may result in a risk of fire, electric shock, or injury
to persons.
5. To avoid a risk of fire and electric shock, make sure that all of the
installation wiring is in good condition and that wire is not
undersized. Do not operate the PowerHub with damaged or
substandard wiring.
6. Do not operate the PowerHub if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the PowerHub is
damaged, see the “Return Procedure” on page WA–3.
7. Do not disassemble the PowerHub, except where noted to wire it for a
permanent installation or to install batteries. The PowerHub 1800
contains no user-serviceable parts. See “Warranty” on page WA–1 for
instructions on obtaining service. Attempting to service the
WARNING
This chapter contains important safety and operating instructions. Read and keep
this Operator’s Guide for future reference.
WARNING: Limitations on use
The PowerHub 1800 is not intended for use in connection with life support
systems or other medical equipment or devices.

Safety
vi 975-0288-01-01 Rev B
PowerHub 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.
8. The PowerHub must be provided with an equipment-grounding
conductor. Grounding and all other wiring must comply with national
and local codes and regulations.
9. The PowerHub 1800 is not intended for use as an uninterruptible
power supply (UPS).
Figure i Basic Safety
No! No!
No! No!

Safety
975-0288-01-01 Rev B vii
Precautions When Working With Batteries
1. Use only SEALED batteries with the PowerHub 1800.
2. Follow all instructions published by the battery manufacturer.
3. Working in the vicinity of batteries may be dangerous. Unsealed
batteries can generate explosive gases during normal operation.
Therefore, you must read this guide and follow the instructions
exactly before installing or using the PowerHub.
4. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the PowerHub 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.
5. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer.
6. Make sure that nothing is blocking the air vents on the back of the
enclosure.
7. Never smoke or allow a spark or flame near the batteries.
8. Use caution to reduce the risk of dropping a metal tool on the
batteries. It could spark or short circuit the battery or other electrical
parts and could cause an explosion.
9. Remove all personal metal items, like rings, bracelets, and watches
when working with batteries. Batteries can produce a short circuit
current high enough to weld metal, causing a severe burn.
10. Have someone within range of your voice or close enough to come to
your aid when you work near a battery.
11. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
12. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
WARNING: Fire or Explosion Hazard

Safety
viii 975-0288-01-01 Rev B
13. 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.
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 PowerHub. Do not use the following with the PowerHub:
• 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.
FCC/ICES 003 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:
CAUTION: Equipment Damage
This equipment produces a modified sine wave output. Equipment damage may
occur if the rechargeable appliance is not designed to use modified sine wave
output. If you are unsure about using your rechargeable appliance with the
modified sine wave, contact the equipment manufacturer.

Safety
975-0288-01-01 Rev B ix
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment 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.
Power Down Procedure
The power down procedure will be depend on how the unit has been
installed. If using the AC cord to plug the PowerHub directly into a
generator, this is referred to as “softwiring” or “plug-and-go”. If installing
in a permanent location, that is referred to as “hardwiring”.
If softwired...... To Power Down the PowerHub 1800:
Figure ii Power Down Procedure for Softwired Installations
Disconnect Loads
Press ON/OFF Switch to turn
OFF Inverter/Charger
Disconnect the PowerHub
from the generator and
turn the generator OFF.
Disconnect the Battery Box(es)
from the Inverter
1
2
3
4
OFF

Safety
x 975-0288-01-01 Rev B
If hardwired...... To Power Down the PowerHub 1800:
WARNING: Shock Hazard
If no DC Disconnect is used, then the DC input generators (solar or wind) will
have to be physically disconnected to ensure power is OFF.
Figure iii Power Down Procedure for Hardwired Installations
12
3
6
4
5
Disconnect any loads directly
connected to the front panel of
the PowerHub
Press ON/OFF
Switch to turn OFF
Inverter/Charger
Disconnect the Utility
power by closing the AC
input circuit breaker in the
main panel.
Disconnect the Battery Box(es)
from the Inverter
Disconnect Loads connected to
the PowerHub through AC
Distribution Panel (Sub-panel)
by closing the Inverter Output
Circuit Breaker.
Disconnect the
DC Input.(s)

975-0288-01-01 Rev B xi
Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
Precautions for Using Rechargeable Appliances - - - - - - - - - - - - - - - - - - - - - - - - - viii
FCC/ICES 003 Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
Shutdown Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ix
1 Introduction
Introduction- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Principles of Inverter Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Basic Functions of the PowerHub 1800 - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Inverter Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Battery Charger Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
2 Operation
Inverter Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
User Controls and Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Operating Mode LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Input LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Output LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Selecting Charger Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Basic Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Power On and Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Changing the Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Changing Charging Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Connecting AC Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Typical Loads that might be used with the PowerHub 1800 - - - - - - - - - - - - - 2–12
Loads That Might Not Work Well With the PowerHub 1800 - - - - - - - - - - - - - 2–12
Loads that should NOT be used with the PowerHub 1800 - - - - - - - - - - - - - - - 2–12
Contents

Contents
xii 975-0288-01-01 Rev B
3 Troubleshooting
How to Troubleshoot the PowerHub 1800 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Error Codes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
If Utility Power is NOT Available- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
If Utility Power is Available- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Possible Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Ceiling Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Cell Phones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Clocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Dimmer Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Heavy Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Microwave Ovens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Printers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Rechargeable Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Battery Charger Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Charging Profiles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
40-amp Charging Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
10-amp Charging Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
0-amp Charging Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6

975-0288-01-01 Rev B xiii
Figure i Basic Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–vi
Figure ii Shutdown Procedure for Softwired Installations- - - - - - - - - - - - - - - - - - 1–ix
Figure iii Shutdown Procedure for Hardwired Installations - - - - - - - - - - - - - - - - - 1–x
Figure 1-1 Principals of Inverter Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Figure 1-2 PowerHub 1800 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Figure 1-3 Three-Stage Charging Process- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Figure 2-1 The PowerHub 1800 Inverter Control Panel - - - - - - - - - - - - - - - - - - - - 2–2
Figure 2-2 Basic Startup Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Figure 2-3 Input Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Figure 2-4 Output Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Figure 2-5 Input Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Figure 2-6 Connecting AC Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Figure 2-7 Loads That Should Never Be Used With the PowerHub 1800- - - - - - - - - 2–12
Figure A-1 Three-Stage Charging Process- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4
Figures

xiv

975-0288-01-01 Rev B i
Table 3-1 Error Codes for Troubleshooting the PowerHub 1800 - - - - - - - - - - - - - - 3–2
Table 3-2 Possible Problems if Utility Power is Not Available - - - - - - - - - - - - - - - 3–4
Table 3-3 Possible Problems if Utility Power is Available - - - - - - - - - - - - - - - - - - 3–6
Table A-1 Electrical Specifications for the Inverter - - - - - - - - - - - - - - - - - - - - - - - A–2
Table A-2 Electrical Specifications for the Battery Box - - - - - - - - - - - - - - - - - - - - A–2
Table A-3 Physical Specifications of the Inverter - - - - - - - - - - - - - - - - - - - - - - - - A–3
Table A-4 Physical Specifications of the Battery Box - - - - - - - - - - - - - - - - - - - - - A–3
Table A-5 40-amp Charging Profile (Default)- - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
Table A-6 10-amp Charging Profile (Default)- - - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Tables

ii

1Introduction
Chapter 1 describes the operational features and functions of the
PowerHub 1800. This section details how the unit functions as an
inverter, provides information on the control panel, and describes
operating limits for inverter operation.
For this topic... See...
“Principles of Inverter Operation” page 1–2
“Basic Functions of the PowerHub 1800” page 1–3
“Inverter Features” page 1–3
“Battery Charger Features” page 1–5

Introduction
1–2 975-0288-01-01 Rev B
Introduction
Thank you for your purchase of this Xantrex Home Power System. The
modified sine wave AC output from the inverter ensures AC loads
operating from the unit perform efficiently and correctly.
To get the most out of your PowerHub 1800, carefully read and follow the
instructions in this guide. Pay special attention to the Important Safety
Instructions and to the CAUTION and WARNING statements found
throughout this manual and on the product. Please retain all packaging.
Should you have any questions before, during, or after the installation,
please contact Xantrex Customer Support. Please see “How do you get
service?” on page WA–1 in this Guide for contact information.
Principles of Inverter Operation
The PowerHub 1800 converts power from the batteries in two stages. The
first stage is a DC-to-DC converter, used to raise the low voltage DC
input to high voltage DC. The second stage is the actual inverter stage,
taking the high voltage DC and converting it to a modified sine wave AC
output.
The DC-to-DC converter stage uses modern high frequency power
conversion technology that eliminates the bulky, low frequency
(50/60 Hz) based transformers found in inverters using older technology.
The inverter stage uses advanced power semiconductors that provide
excellent overload capabilities.
Output
Waveform The AC output waveform of the PowerHub 1800 is a “modified sine wave” .
Figure 1-1 Principles of Inverter Operation
High Voltage
DC
+
–
+
–
L
↓
N
DC to AC
Converter
DC to DC
Converter Transfer Relay
Modified
Sine Wave
AC
H
G
N
N
G
H
N
↓
L
AC
INPUT
AC
OUTPUT