Xantrex7 Ux - rev a User manual

Inverter/Charger

UX Series

Owner’s Manual

Smart choice for power

www.xantrex.com

P/N 975-0026-01-01 Rev A 06/2002

About Xantrex

Xantrex Technology Inc. develops, manufactures and markets leading advanced

power electronic and control products for the Distributed, Mobile, and

Programmable Power markets. The company’s enabling technology converts raw

electrical power from any central, distributed, or backup power source into high-

quality power required by electronic and electrical equipment.

Xantrex products are used for various applications: for renewable and distributed

power solutions such as solar, wind, microturbines and fuel cells; to supply

backup power for homes, small businesses and traffic lights during electric grid

disruptions; to provide auxiliary electricity in boats, recreational vehicles, cars

and heavy duty trucks; and to develop, test, and power precision equipment such

as semi-conductor manufacturing and medical equipment. The company sells its

products under the Xantrex, Trace, Heart and Statpower brands.

Trademarks

Xantrex is a registered trademark of Xantrex International.

Notice of Copyright

UX Series Inverter/Charger Owner’s Manual ©June 2002 Xantrex Technology Inc.

Disclaimer

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.

Please see Appendix C - Product Information and Warranty for specific

warranty coverage.

Date and Revision

June 2002, Revision A

Part Number

975-0026-01-01

Contact Information

Web: www.xantrex.com

Phone: 888.608.0721

Fax: 360.435.2229

P/N 975-0026-01-01 Rev A 06/2002 iii

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed

during the installation and maintenance of this product.

To reduce the risk of electrical shock, and to ensure the safe installation and

operation of this product, the safety symbols shown on this page have been

placed throughout this manual to indicate dangerous conditions and important

safety instructions.

• All electrical work must be done in accordance with local, national, and/or

international electrical codes.

• Before installing or using this device, read all instructions and cautionary

markings located in the manual, and in (or on) the inverter, the batteries, and

the PV array.

• Do not expose this unit to rain, snow, or liquids of any type. This product is

designed for indoor mounting only.

• To reduce the chance of short circuits, use insulated tools when installing or

working with the inverter, the batteries, or the PV array .

• Remove ALL jewelry while installing this system. This will greatly reduce the

chance of accidental exposure to live circuits.

• The inverter contains more than one live circuit (AC line, batteries and/or PV

array). Power may be present at more than one source.

• This product does not contain any user-serviceable parts. Do not attempt to

repair this unit. All repairs should be done by an Authorized Service Center.

• DO NOT install 120 volt AC stand-alone inverters onto 120/240 volt AC multi-

branch circuit wiring. This could pose a fire hazard due to an overloaded neutral

return wire in this configuration.

See Section 5.0, Troubleshooting, pages 59 - 63, for additional information on

multi-branch circuit wiring.

WARNING - A

DANGEROUS VOLTAGE OR

CONDITION EXISTS IN THIS

AREA. USE EXTREME

CAUTION WHEN

PERFORMING THESE

TASKS.

AVERTISSEMENT - UNE

TENSION OU CONDITION

DANGEREUSE EXISTE

DANS CETTE ZONE. FAIRE

PREUVE D’EXTRÊME

PRUDENCE LORS DE LA

RÉALISATION DE CES

TÂCHES.

NOTE: This statement is important.

Follow instructions closely.

NOTE: Cette déclaration est

importante. Suivre les

instructions de près.

CAUTION - This procedure is

critical to the safe installation

or operation of the unit.

Follow these instructions

closely.

ATTENTION - Cette procédure

est essentielle à l’installation

ou l’utilisation de l’unité en

toute sécurité. Suivre ces

instructions de près.

SAVE THESE INSTRUCTIONS

P/N 975-0026-01-01 Rev A 06/2002

BATTERY SAFETY INFORMATION

• Always wear eye protection, such as safety glasses, when working with batteries.

• Remove all jewelry before working with batteries.

• Never work alone. Have someone assist you with the installation or be close

enough to come to your aid when working with batteries.

• Always use proper lifting techniques when handling batteries.

• Always use identical types of batteries.

• Never install old or untested batteries. Check each battery’s date code or label

to ensure age and type.

• Batteries are temperature sensitive. For optimum performance, they should be

installed in a stable temperature environment.

• Batteries should be installed in a well-vented area to prevent the possible

buildup of explosive gasses. If the batteries are installed inside an enclosure,

vent its highest point to the outdoors.

• When installing batteries, allow at least 1 inch of air space between batteries to

promote cooling and ventilation.

• NEVER smoke in the vicinity of a battery or generator.

• Always connect the batteries first, then connect the cables to the inverter. This

will greatly reduce the chance of spark in the vicinity of the batteries.

• Use insulated tools when working with batteries.

• When connecting batteries, always verify proper voltage and polarity.

• Do not short-circuit battery cables. Fire or explosion can occur.

• In the event of exposure to battery electrolyte, wash the affected area with soap

and water. If acid enters the eyes, flood them with running cold water for at

least 15 minutes and get immediate medical attention.

• Always recycle old batteries. Contact your local recycling center for proper

disposal information.

SAVE THESE INSTRUCTIONS

P/N 975-0026-01-01 Rev A 06/2002 v

Table of Cable of C

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1.0 Introduction ...............................................................................................................................................................................1

Features and Options .........................................................................................................................................................2

Standard Features ...................................................................................................................................................... 2

Options ......................................................................................................................................................................2

Unpacking and Inspection .................................................................................................................................................3

Model Identification and Numbering Conventions ............................................................................................................ 3

2.0 System Configuration ................................................................................................................................................................ 5

Types of Applications .........................................................................................................................................................5

Types of Configurations .....................................................................................................................................................5

120 Vac/60 Hz Models ...............................................................................................................................................5

230 Vac/50 Hz Models ...............................................................................................................................................5

Battery-Bank Requirements ...............................................................................................................................................5

Pre-Configuration Planning ............................................................................................................................................... 5

Off-Grid Applications ......................................................................................................................................................... 6

Renewable Energy Systems ........................................................................................................................................6

Renewable Energy Systems with Optional Generator Backup.................................................................................... 8

Generator-Only Systems .............................................................................................................................................10

120 Vac Generators using the SB Option on the Inverter .................................................................................... 10

120 Vac Generators using a Stand-alone Battery Charger .................................................................................. 12

240 Vac/60 Hz Generators ..........................................................................................................................................14

On-Grid Applications .........................................................................................................................................................16

Utility Backup with a Generator ................................................................................................................................. 16

Adding Accessories to the Inverter ....................................................................................................................................18

Remote Monitoring .................................................................................................................................................... 18

Battery Temperature Sensor ....................................................................................................................................... 19

Generators......................................................................................................................................................................... 20

Generator Requirements ............................................................................................................................................20

3.0 Installation ................................................................................................................................................................................21

Pre-Installation ..................................................................................................................................................................21

Tools Required ............................................................................................................................................................ 21

Hardware/Materials Required ....................................................................................................................................21

Pre-Installation Planning ...................................................................................................................................................21

Location Considerations ............................................................................................................................................. 22

Mounting Considerations ...........................................................................................................................................22

Ventilation Requirements ...........................................................................................................................................22

Wiring Considerations ................................................................................................................................................ 22

AC Connections ..................................................................................................................................................23

DC Connections .................................................................................................................................................. 23

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Grounding Considerations ......................................................................................................................................... 23

AC Grounding .....................................................................................................................................................23

DC Grounding ..................................................................................................................................................... 23

System Grounding ...................................................................................................................................................... 24

Equipment or Chassis Grounding .......................................................................................................................24

Grounding Electrodes/Ground Rods.................................................................................................................... 25

Bonding the Grounding System ..........................................................................................................................25

Battery Considerations ......................................................................................................................................................26

Battery Voltage ..........................................................................................................................................................26

Battery Location .........................................................................................................................................................26

Battery Temperature ...................................................................................................................................................26

Battery Pre-Installation .......................................................................................................................................27

Removing the Top Cover of the Inverter ............................................................................................................................ 28

Configuring the Inverter’s Optional Battery Charger ......................................................................................................... 29

Jumper Settings for the Optional Battery Charger......................................................................................................30

Wiring Pre-Installation .......................................................................................................................................................31

Main Service Panel .....................................................................................................................................................31

Sub-Panel ................................................................................................................................................................... 31

AC Circuit Breakers ....................................................................................................................................................31

DC Disconnect ............................................................................................................................................................31

Wire Routing .............................................................................................................................................................. 31

Inverter Mounting .............................................................................................................................................................32

Wall-Mounting Procedure .......................................................................................................................................... 33

DC Wiring ..........................................................................................................................................................................34

Battery Cables ............................................................................................................................................................34

DC Disconnect and Over-current Protection ...............................................................................................................35

DC Grounding ............................................................................................................................................................36

Battery Installation.....................................................................................................................................................37

Installing the Battery Temperature Sensor (BTS) ........................................................................................................ 38

AC Wiring ..........................................................................................................................................................................39

Sub-panel Mounting ..................................................................................................................................................39

Access to the Inverter’s AC Terminal Block ................................................................................................................. 39

AC Input Wiring to Inverter (only for inverters with the SB Option installed) ............................................................. 42

AC Output Wiring to the Sub-panel .................................................................................................................... 43

AC Input Wiring to the Main Utility Breaker Box ................................................................................................ 44

3.0 Installation (continued)

P/N 975-0026-01-01 Rev A 06/2002 vii

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Generators......................................................................................................................................................................... 45

Basic 120 Vac Generator Hookup (Off-Grid applications only) ...................................................................................45

Basic 120 Vac Utility/Generator Hookup .................................................................................................................... 46

Generator Connections (to AC transfer switch) .................................................................................................. 46

Utility Connections (to AC transfer switch) ......................................................................................................... 46

Inverter Connections (to AC transfer switch) ......................................................................................................46

Sub-panel Connections ..............................................................................................................................................46

Remote Monitoring .................................................................................................................................................... 48

4.0 Operation ..................................................................................................................................................................................49

Control Panel ..................................................................................................................................................................... 49

Power ON/OFF Button ................................................................................................................................................ 50

Green Status LED ....................................................................................................................................................... 50

Yellow Charger Status LED ......................................................................................................................................... 50

Search Sense Mode ........................................................................................................................................................... 50

Search Sense Operation ............................................................................................................................................. 50

Benefits of Using Search Sense .................................................................................................................................. 51

Setting Up Search Mode ............................................................................................................................................51

Standby (SB) Option ..........................................................................................................................................................52

SB Option Operation .................................................................................................................................................. 52

Transfer Switching Speed ...........................................................................................................................................52

Battery Charger LED Indicator.................................................................................................................................... 53

5.0 Troubleshooting .........................................................................................................................................................................55

Potential Problem Loads for the Inverter ...........................................................................................................................56

Ceiling Fans ................................................................................................................................................................ 56

Cell Phones ................................................................................................................................................................ 56

Computers and Sensitive Electronics ..........................................................................................................................56

Consumer Electronics ................................................................................................................................................. 56

Clocks ........................................................................................................................................................................ 56

Decreasing Loads ....................................................................................................................................................... 56

Dimmer Switches .......................................................................................................................................................57

Fluorescent Lights ...................................................................................................................................................... 57

Heavy Loads ...............................................................................................................................................................57

Microwave Ovens.......................................................................................................................................................57

Printers....................................................................................................................................................................... 57

Rechargeable Devices ................................................................................................................................................57

Undersized Loads ....................................................................................................................................................... 57

3.0 Installation (continued)

P/N 975-0026-01-01 Rev A 06/2002

viii

Potential Problem Loads related to Search Sense Mode ....................................................................................................58

Confirming Search Mode Operation ........................................................................................................................... 58

Incandescent Lights ............................................................................................................................................58

Fluorescent Bulbs ............................................................................................................................................... 58

Other loads .........................................................................................................................................................58

Multiwire Branch Circuits .................................................................................................................................................. 59

Identifying Multiwire Branch Circuits .........................................................................................................................62

Correcting Multiwire Branch Circuit Wiring ................................................................................................................ 63

Appendix A - Specifications ..............................................................................................................................................................A-1

Appendix B - Batteries ......................................................................................................................................................................B-1

Selection of a Battery Type ................................................................................................................................................B-1

Flooded Lead Acid (FLA) ............................................................................................................................................. B-1

RV and Marine ....................................................................................................................................................B-1

Golf Cart .............................................................................................................................................................B-1

Industrial (electric forklift) ..................................................................................................................................B-1

Sealed Batteries (GEL and AGM) ................................................................................................................................B-2

Gel Cell ...............................................................................................................................................................B-2

Absorbed Glass Mat ...........................................................................................................................................B-2

NiCad and NiFe Batteries ...........................................................................................................................................B-2

Battery-Bank Sizing ...........................................................................................................................................................B-3

Estimating Battery Requirements ............................................................................................................................... B-3

Typical Appliance Wattages ........................................................................................................................................B-7

Battery Cable Sizing ..........................................................................................................................................................B-8

Battery Configurations ......................................................................................................................................................B-9

Series .........................................................................................................................................................................B-9

Parallel ....................................................................................................................................................................... B-9

Series-Parallel ............................................................................................................................................................. B-9

Wiring Batteries in Series.................................................................................................................................... B-10

Wiring Batteries in Parallel ................................................................................................................................. B-12

Wiring Batteries in Series-Parallel ....................................................................................................................... B-13

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5.0 Troubleshooting (continued)

P/N 975-0026-01-01 Rev A 06/2002 ix

Battery Care and Maintenance ..........................................................................................................................................B-16

Charge Rate ............................................................................................................................................................... B-16

Bulk Voltage ...............................................................................................................................................................B-16

Float Voltage .............................................................................................................................................................. B-16

Temperature Compensation .......................................................................................................................................B-16

Equalization Charging ................................................................................................................................................B-16

Replenish Water Levels...............................................................................................................................................B-17

Clean Battery Cables and Posts ..................................................................................................................................B-17

Torque Battery Connections .......................................................................................................................................B-17

Check Battery’s State-of-Charge ................................................................................................................................B-18

Appendix C - Product Information and Warranty ..............................................................................................................................C-1

Limited Warranty ............................................................................................................................................................... C-1

What does this warranty cover and how long does it last?........................................................................................C-1

What will Xantrex do? ...............................................................................................................................................C-1

How do you get service? ............................................................................................................................................C-2

What does this warranty not cover? ..........................................................................................................................C-2

DISCLAIMER ......................................................................................................................................................................C-3

Product ......................................................................................................................................................................C-3

Exclusions ..................................................................................................................................................................C-3

Information ................................................................................................................................................................C-3

WARNING: LIMITATIONS ON USE ..............................................................................................................................C-4

Return Material Authorization Policy .................................................................................................................................C-5

Shipping Instructions.................................................................................................................................................. C-5

If you are returning a product from outside of the USA or Canada ............................................................................C-5

If you are returning a product to a Xantrex Authorized Service Center (ASC) ............................................................C-5

Service Information............................................................................................................................................................C-6

Appendix D - Index ...........................................................................................................................................................................D-1

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Appendix B - Batteries (continued)

P/N 975-0026-01-01 Rev A 06/2002

List of FiguresList of Figures

List of Figures

Figure 1-1 - UX Series Inverter/Charger ............................................................................................................................. 1

Figure 1-2 - Inverter/Charger Model Identification ............................................................................................................4

Figure 2-1 - Off-Grid Application, Renewable Energy System (with SB Option on the UX Inverter) ...................................7

Figure 2-2 - Off-Grid Application, Renewable Energy System (without SB Option on the UX Inverter) .............................. 9

Figure 2-3 - Off-Grid Application, 120 Vac Generator-only System (with SB Option on the UX Inverter) ...........................11

Figure 2-4 - Off-Grid Application, 120 Vac Generator-only System (without SB Option on the UX Inverter) ......................13

Figure 2-5 - Off-Grid Application, 240 Vac Generator-only System .................................................................................... 15

Figure 2-6 - On-Grid Application, Utility Backup with a Generator (with SB Option on the UX Inverter) ...........................17

Figure 2-7 - RC8 Remote Control .......................................................................................................................................18

Figure 2-8 - Battery Temperature Sensor ........................................................................................................................... 19

Figure 3-1 - Removing the Cover from the Inverter ........................................................................................................... 28

Figure 3-2 - Location of the Optional Battery Charger Configuration Jumpers .................................................................. 29

Figure 3-2a - Jumper Enlargement .....................................................................................................................................29

Figure 3-2b - Jumper Placement ........................................................................................................................................29

Figure 3-3 - Battery Charger Jumper Settings ....................................................................................................................30

Figure 3-4 - Wall-Mounting Method ..................................................................................................................................32

Figure 3-5 - Dimensional Drawing for Screw Hole Placement ............................................................................................33

Figure 3-6 - DC Grounding .................................................................................................................................................35

Figure 3-7 - Battery Cable Connections ............................................................................................................................. 34

Figure 3-8 - BTS (RJ11) Port Location .................................................................................................................................36

Figure 3-9 - BTS Installed on Battery .................................................................................................................................36

Figure 3-10 - AC Access Covers and Hardware .................................................................................................................. 37

Figure 3-11 - AC Input Wiring (only for inverters with the SB Option installed) .................................................................40

Figure 3-12 - AC Output Wiring .........................................................................................................................................41

Figure 3-13 - Utility Breaker Box Wiring Diagram ..............................................................................................................42

Figure 3-14 - Basic 120 Vac Generator Block Diagram (for Off-Grid applications) .............................................................43

Figure 3-15 - Basic 120 Vac Utility/Generator Block Diagram ............................................................................................ 45

Figure 3-16 - Remote Monitor Port Location .....................................................................................................................46

Figure 4-1 - Control Panel .................................................................................................................................................. 47

Figure 4-2 - Battery Charger Status LED ............................................................................................................................51