Xantrex XPower Inverter 3000 User manual

This guide for use by qualified installers only.
TM
TM
XPower™Inverter 3000
Installation Guide

This guide for use by qualified installers only.
About Xantrex
Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in
the development, manufacturing and marketing of advanced power electronic products and systems for
the renewable and mobile power markets. The company's products convert and control raw electrical
power from any central, distributed, renewable, or backup power source into high-quality power
required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver,
Canada, with facilities in the United States, Germany, Spain, and a joint venture in China.
Trademarks
Xantrex, XPower, and Smart choice for power are trademarks of Schneider Electric International
Services sprl, registered in the U.S. 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
XPower Inverter 3000 Installation Guide © January 2010 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 Part Number Product Number
January 2010 Revision A 975-0556-01-01 813-3000-UL
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

iii
This guide for use by qualified installers only.
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for installing the XPower Inverter 3000.
Scope
The Guide provides safety guidelines and procedures for installing the
inverter. It does not provide details about particular brands of batteries.
You need to consult individual battery manufacturers for this information.
Refer to XPower Inverter 3000 Owner’s Guide (doc. part number: 975-
0555-01-01) for operational instructions.
Audience
The Guide is intended for qualified installers including licensed
technicians and electricians. It is intended for installers with 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.
Organization
This Guide is organized into two chapters.
Chapter 1 describes installation configurations, as well guidelines for
calculating battery requirements, choosing an effective charging system,
location and mounting orientations, cable sizes for your inverter and
selecting correct fuses or circuit breakers.
Chapter 2 describes installation procedures including planning, wiring,
and mounting the XPower Inverter 3000.

About This Guide
iv 975-0556-01-01
This guide for use by qualified installers only.
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 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,
however, they are not as serious as a caution or warning.

v
This guide for use by qualified installers only.
Important Safety Instructions
IMPORTANT: Read and save this Installation Guide
for future reference.
This chapter contains important safety instructions for the XPower
Inverter 3000.
1. Before installing and using the XPower Inverter 3000, read all
instructions and cautionary markings on or provided with the XPower
Inverter 3000, the batteries, and all appropriate sections of this guide.
2. Do not expose the XPower Inverter 3000 to rain, snow, spray, or bilge
water. This product is not intended for marine applications.
3. To reduce risk of fire hazard, do not cover or obstruct the ventilation
openings. Do not install the XPower Inverter 3000 in a zero-clearance
compartment. Overheating may result.
4. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition, adequately rated, and not undersized. Do
not operate the XPower Inverter 3000 with damaged or substandard
wiring.
5. Do not install or operate the XPower Inverter 3000 if it has received a
sharp blow, been dropped, or otherwise damaged in any way. If the
XPower Inverter 3000 is damaged, see the Warranty section.
6. Do not disassemble the XPower Inverter 3000. It contains no user-
serviceable parts. See Warranty for instructions on obtaining service.
Attempting to service the XPower Inverter 3000 yourself may result
in a risk of electrical shock or fire. Internal capacitors remain charged
after all power is disconnected.
WARNING: Shock, fire, and heat hazard. Risk of
injury to persons.

Safety
vi 975-0556-01-01
This guide for use by qualified installers only.
7. To reduce the risk of electrical shock, disconnect DC power from the
XPower Inverter 3000 before attempting any maintenance or cleaning
or working on any circuits connected to the XPower Inverter 3000.
Turning off controls will not reduce this risk.
8. The XPower Inverter 3000 must be provided with equipment-
grounding conductors connected to the vehicle chassis as described in
“Chassis Ground Wire Sizing” on page 1–10 and “Chassis Ground
Wire Sizing” on page 1–10.
Precautions When Working With Batteries
1. Follow all instructions published by the battery manufacturer and the
manufacturer of the equipment in which the battery is installed to
reduce the risk of battery explosion.
2. Working in the vicinity of lead-acid batteries is dangerous. Batteries
generate explosive gases during normal operation. Therefore, you
must read this guide and follow the instructions exactly before
installing or using your XPower Inverter 3000.
3. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower
Inverter 3000 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.
4. Make sure the area around the battery is well ventilated.
5. Never smoke or allow a spark or flame near the engine or batteries.
6. Use 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.
7. 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 a spark.
WARNING: Explosion or fire hazard

Safety
975-0556-01-01 vii
This guide for use by qualified installers only.
8. Remove all metal items, like rings, bracelets, and watches when
working with lead-acid batteries. Lead-acid batteries produce a short
circuit current high enough to weld metal to skin, causing a severe
burn.
9. Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
10. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
11. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
12. 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 XPower Inverter 3000. Do not use the following with the
XPower Inverter 3000:
• 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.
WARNING: Risk of personal injury due to burns or
battery acid
CAUTION: Risk of equipment damage
The output of the XPower Inverter 3000 is not sinusoidal and may not be
compatible with all loads. Follow the recommendations below.

viii

975-0556-01-01 ix
This guide for use by qualified installers only.
Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Choosing an Appropriate Location and Mounting Orientation - - - - - - - - - - - - - 1–5
Selecting Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Selecting a DC Input Fuse or Circuit Breaker - - - - - - - - - - - - - - - - - - - - - 1–9
Chassis Ground Wire Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10
Output Conductor Selection for Hardwire Installation - - - - - - - - - - - - - - 1–10
2Installing the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Installing the Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Connecting the AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Contents

x