Xantrex PH1800-GFP User manual

975-0289-01-01(PowerHub_1800_IG).book Page 2 Thursday, June 4, 2015 9:49 AM

PowerHub 1800
Installation Guide
975-0289-01-01(PowerHub_1800_IG).book Page i Thursday, June 4, 2015 9:49 AM

Copyright © 2006-2015 Schneider Electric. All Rights Reserved. All trademarks are owned by
Schneider Electric Industries SAS or its affiliated companies.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER
(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’S RISK; 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 CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS
POSTED AT WWW.XANTREX.COM.
Date and Revision
April 2015 Revision D
Part Number
975-0289-01-01
Product Number
PH1800-GFP
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 408 987 6030
Web: www.xantrex.com
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iii
About This Guide
Purpose
The purpose of this Installation 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 1800 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 features and functions of the PowerHub 1800.
Chapter 2 contains information on planning the installation of this
equipment.
Chapter 3 contains information on assembling and installing this
equipment.
Appendix A provides electrical and physical specifications for the
PowerHub 1800.
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About This Guide
iv 975-0289-01-01
Abbreviations and Acronyms
Related Information
You can find more information about this product by seeing the
PowerHub 1800 Operator’s Guide (part number 975-0288-01-01 Rev A).
You can find more information about Xantrex products and services at
www.xantrex.com.
A French version of the document (part number 975-0290-01-01) and a
Spanish version (part number 975-0288-03-01) are available at
www.xantrex.com.
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
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v
Important Safety Instructions
IMPORTANT: READ AND SAVE THIS INSTALLATION GUIDE FOR
FUTURE REFERENCE.
This guide contains important safety instructions for the PowerHub 1800
that must be followed during installation, operation, and troubleshooting.
Read these instructions carefully and look at the equipment to become
familiar with the device before trying to install, operate, service or
maintain it. The following special messages may appear throughout this
bulletin or on the equipment to warn of potential hazards or to call
attention to information that clarifies or simplifies a procedure.
The addition of either symbol to a “Danger” or “Warning” safety label indicates
that an electrical hazard exists which will result in personal injury if the
instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently hazardous situation, which, if not avoided,
will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation, which, if not avoided,
can result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, can
result in moderate or minor injury.
NOTICE
NOTICE indicates a potentially hazardous situation, which, if not avoided, can
result in equipment damage.
Important: These notes describe things which are important for you to know,
however, they are not as serious as a caution or warning.
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Safety
vi 975-0289-01-01
Safety Information
1. Before installing and using the PowerHub, 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 Warranty section.
7. Do not disassemble the PowerHub, except where noted to wire it for a
permanent installation. The PowerHub 1800 contains no user-
serviceable parts. See Warranty for instructions on obtaining service.
Attempting to service the 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 is not intended for use as an uninterruptible power
supply (UPS).
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Safety
975-0289-01-01 vii
WARNING
RISK OF CARBON MONOXIDE POISONING
Do not use generators indoors. When generators are used outdoors there must
be sufficient circulation to vent the carbon monoxide.
Failure to follow these instructions can result in death or serious injury.
WARNING
LIMITATION ON USE
The PowerHub 1800 is not intended for use in connection with life support
systems or other medical equipment or devices.
Failure to follow these instructions can result in death or serious injury.
Figure i
Basic Safety
No! No!
No! No!
Do not plug input cord into output
socket.
Do not pry.
Do not insert objects into the socket. See Limitation On Use.
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Safety
viii 975-0289-01-01
Precautions When Working With Batteries
NOTES:
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.
WARNING
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND
EXPLOSION FROM VENTED GASES HAZARDS
• Always wear proper, non-absorbent gloves, complete eye protection, and
clothing protection. Avoid touching your eyes and wiping your forehead
while working near batteries. See note #13.
• Remove all personal metal items, like rings, bracelets, and watches when
working with batteries. See notes #8 and #9 below.
• Never smoke or allow a spark or flame near the engine or batteries.
Failure to follow these instructions can result on death or serious injury.
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Safety
975-0289-01-01 ix
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.
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.
14. Use battery overcurrent protection such as a DC fuse or DC breaker.
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.
NOTICE
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.
Failure to follow these instructions can damage connected equipment.
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Safety
x 975-0289-01-01
FCC 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:
• 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.
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Safety
975-0289-01-01 xi
Power Down Procedure
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
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Safety
xii 975-0289-01-01
If hardwired...... To Power Down the PowerHub 1800:
WARNING
ELECTRIC SHOCK HAZARD
Physically disconnect DC input sources (solar or wind) to ensure that DC power is OFF.
Failure to follow these instructions can result in death or serious injury.
Figure iii
Power Down Procedure for Hardwired Installations
1
2
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 opening 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
opening the Inverter Output
Circuit Breaker.
Disconnect the
DC Input.(s)
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975-0289-01-01 xiii
Important Safety Instructions
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
Precautions for Using Rechargeable Appliances - - - - - - - - - - - - - - - - - - - - - - - - - - ix
FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -x
Power Down Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - xi
1 Introduction
Features and Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Softwired Generator Applications (Plug-and-go) - - - - - - - - - - - - - - - - - - - - - - 1–5
Hardwired Permanent Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Utility Backup Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Solar Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Wind Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Combination Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
2 Planning
Planning Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Tools Required- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Hardware / Materials Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Environmental Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Renewable Energy (RE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Solar Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Wind - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Solar and Wind Combination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
3 Installation
Installation Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1
Assembling the Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Preparing the Battery Bank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Connecting the Battery Bank to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Contents
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Contents
xiv 975-0289-01-01
Connecting Two Battery Boxes to the Inverter - - - - - - - - - - - - - - - - - - - - - - - 3–7
Replacing the Top to the Battery Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Plug-and-go (Softwiring) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Permanent Wiring (Hardwiring) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10
Terminal Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Removing the Factory-installed AC Cord and Knockouts - - - - - - - - - - - - 3–12
AC Input and Output Wiring from a Generator - - - - - - - - - - - - - - - - - - - 3–14
AC Input and Output Wiring from the Utility Grid - - - - - - - - - - - - - - - - 3–15
DC Wiring with Ground Fault Protection
(Renewable Energy Solar Panel; Maximum 400 W) - - - - - - - - - - - - - - - 3–16
DC Wiring with Ground Fault Protection
(Renewable Energy Solar Array; Maximum 1000 W) - - - - - - - - - - - - - - 3–17
DC Wiring (Renewable Energy Wind, Maximum 1000 W) - - - - - - - - - - - 3–18
Replacing the Top Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19
Double-check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–19
Power Up Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–20
Power Down Procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–22
Ground Fault Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–24
Replacing the Ground Fault Protection Fuse - - - - - - - - - - - - - - - - - - - - - - - - 3–24
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
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975-0289-01-01 xv
Figure i Basic Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
Figure ii Power Down Procedure for Softwired Installations- - - - - - - - - - - - - - - - - - xi
Figure iii Power Down Procedure for Hardwired Installations - - - - - - - - - - - - - - - - -xii
Figure 1-1 The PowerHub 1800 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Figure 1-2 PowerHub 1800 Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Figure 1-3 PowerHub 1800 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Figure 1-4 Softwired Utility or Generator Applications- - - - - - - - - - - - - - - - - - - - - 1–5
Figure 1-5 Hardwired Utility Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Figure 1-6 Hardwired Solar Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Figure 1-7 Hardwired Wind Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Figure 1-8 Hardwired Combination Applications- - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Figure 2-1 Dimensions (not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Figure 2-2 Battery Box and Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Figure 3-1 Preparing the Components for Assembly- - - - - - - - - - - - - - - - - - - - - - - 3–2
Figure 3-2 Connecting the Battery Box to the Inverter - - - - - - - - - - - - - - - - - - - - - 3–3
Figure 3-3 Preparing the Battery Bank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Figure 3-4 Battery Cabling for Two Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Figure 3-5 Connecting the Battery Bank to the Inverter - - - - - - - - - - - - - - - - - - - - 3–6
Figure 3-6 Connecting Two Battery Boxes to the Inverter - - - - - - - - - - - - - - - - - - - 3–7
Figure 3-7 Replacing the Top to the Battery Box - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Figure 3-8 Plug-n-Go Wiring (Softwired)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Figure 3-9 Terminal Access for Hardwiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Figure 3-10 Removing the AC Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Figure 3-11 Preparing the Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Figure 3-12 Connecting the AC Input and Output from a Generator - - - - - - - - - - - - - 3–14
Figure 3-13 Connecting the AC Input and Output from the Utility - - - - - - - - - - - - - - 3–15
Figure 3-14 Connecting the DC Input (Renewable Energy Solar Panel) - - - - - - - - - - 3–16
Figure 3-15 Connecting the DC Input (Renewable Energy Solar Array) - - - - - - - - - - 3–17
Figure 3-16 Connecting the DC Input (Renewable Energy Wind) - - - - - - - - - - - - - - 3–18
Figure 3-17 Replacing the Top Cover on the Inverter- - - - - - - - - - - - - - - - - - - - - - - 3–19
Figure 3-18 Power Up Procedure for Softwired Installations - - - - - - - - - - - - - - - - - - 3–20
Figure 3-19 Power Up Procedure for Hardwired Installations - - - - - - - - - - - - - - - - - 3–21
Figures
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Figures
xvi 975-0289-01-01
Figure 3-20 Power Down Procedure for Softwired Installations- - - - - - - - - - - - - - - - 3–22
Figure 3-21 Power Down Procedure for Hardwired Installations - - - - - - - - - - - - - - - 3–23
Figure 3-22 Replacing Ground Fault Protection Fuse- - - - - - - - - - - - - - - - - - - - - - - 3–25
Figure A-1 Three-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4
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975-0289-01-01 i
Table 2-1 Typical AC Appliances and Run Times - - - - - - - - - - - - - - - - - - - - - - - 2–7
Table 3-1 Recommended Wire Gauges for Input and Output Terminals - - - - - - - - - 3–11
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
Table A-6 10-amp Charging Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Tables
975-0289-01-01(PowerHub_1800_IG).book Page i Thursday, June 4, 2015 9:49 AM

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