RS3000 Installation Guide RS3000 Sine Wave Inverter/Charger
RS3000 Sine Wave Inverter/Charger Installation 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 one 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.
About This Guide Purpose The RS3000 Sine Wave Inverter/Charger Installation Guide describes the procedure for installing the RS3000 Sine Wave Inverter/Charger (RS3000). Scope The Installation Guide provides safety guidelines, detailed planning and setup information, and procedures for installing the inverter/charger. It does not provide information on operation, configuration, troubleshooting, and warranty and product information. Refer to the RS3000 Sine Wave Inverter/Charger Operation Guide.
About This Guide Conventions Used The following conventions are used in this guide. 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: Important notes provide information that is important for you to know. They are not as critical as Cautions or Warnings.
About This Guide Related Information For related materials on this Xanbus-enabled product and its available accessories, see also: RS3000 Sine Wave Inverter/Charger Operation Guide (975-0170-01-01) Automatic Generator Start Owner’s Guide (975-0082-01-01) System Control Panel Owner’s Guide (975-0083-01-01) Xanbus System Installation Guide (975-0136-01-01) More information about Xantrex Technology Inc.
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Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS The RS3000 Sine Wave Inverter/Charger Installation Guide contains important safety instructions. Before you install and use your RS3000 Sine Wave Inverter/Charger, be sure to read, understand, and save these safety instructions and those in the other product guides. Read all cautionary markings on the inverter/charger, the batteries, and all appropriate sections of this guide.
Safety 6. Do not disassemble the inverter/charger; it does not contain user serviceable parts. Take it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. For instructions on obtaining service, see the section in the RS3000 Sine Wave Inverter/Charger Operation Guide. 7. Do not expose the inverter/charger to rain, snow, or water. 8.
Safety Explosive Gas Precautions WARNING: Risk of explosive gases Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation. For this reason, it is of utmost importance that each time before servicing equipment in the vicinity of the battery, you must read this guide and follow the instructions closely. 1.
Safety 7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 8. Never charge a frozen battery. 9. If it is necessary to remove a battery, always remove the grounded terminal from the battery first. Make sure all the accessories are off, so as not to cause an arc. 10.
Contents Important Safety Instructions Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii Personal Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - vii FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii Installation Installation Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 Be
Contents Step 2: Mounting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Step 3: Connecting the AC Input and AC Output Wires - - - - - - - - - - - - - - - - - - - - - 21 General AC Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21 Connecting AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 975-0171-01-01 Typical Xanbus System Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Typical Recreational Vehicle Electrical System - - - - - - - - - - - - - - - - - - - - - 7 RS3000 Hardware Materials as Shipped - - - - - - - - - - - - - - - - - - - - - - - - - 15 Mounting Orientations - - - - - - - - - -
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Installation The Installation Guide provides detailed information for installing the RS3000 Sine Wave Inverter/Charger and the battery temperature sensor, wiring the inverter/charger to the AC and DC circuits, and connecting the inverter/charger to the Xanbus® system. The RS3000 is a Xanbus-enabled device that typically powers the Xanbus system. For information on installing the Xanbus system, see the Xanbus System Installation Guide which is available for download at www.xantrex.
Installation Installation Information Before You Begin the Installation Before beginning your installation: • • • • • Read the entire Installation Guide so you can plan the installation from beginning to end. Read the Xanbus System Installation Guide to plan your network requirements. Assemble all the tools and materials you require for the installation. Review the Important Safety Instructions on page v. Be aware of all safety and electrical codes which must be met.
Installation About the Xanbus System The Xanbus system includes the RS3000 Sine Wave Inverter/Charger and other Xanbus-enabled devices, as shown in Figure 1, “Typical Xanbus System Diagram”. Each Xanbus-enabled device interacts and communicates with the other devices on the network, creating a power system that can be precisely configured to your needs. The RS3000 is the device that typically provides power in a Xanbus system.
Installation Xanbus Enabled The Xanbus-enabled designation means that this product will work on a Xanbus network. Xanbus-enabled products are: • • • • Easy to use. The Xanbus network simplifies operation and automates routine tasks. Reliable. Software control eliminates analog signalling errors. Accurate. Digital information is less susceptible to interference and line loss. Upgradeable. Firmware upgrades mean your purchase will remain up to date.
Installation Planning the Installation This section provides information to help you plan for a basic installation of the RS3000. As your system configuration is determined, record the details in Information About Your System on page WA-4 of the RS3000 Sine Wave Inverter/Charger Operation Guide. Two Key Performance Factors Two key factors in particular will have a major impact on system performance.
Installation Planning AC, DC, and Network Components For a successful installation, you need to plan for AC, DC, and network components of the power system. The AC and DC components are described in this section and illustrated in Figure 2 on page 7.
Installation Sine Wave Inverter/Charger Automatic Generator Start System Control Panel AC In AC Out DC + DC Fuse DC - House Battery AC Main Panel Battery Temperature Sensor Isolator Engine Battery RESET R ESET TEST T EST TEST MONTHLY Non-Inverter Loads Inverter AC Panel Transfer Switch Alternator Generator UtilityPower Xanbus-enabled Devices Sensing and control Figure 2 Typical Recreational Vehicle Electrical System Important: Figure 2 does not show all required grounding or overcurrent
Installation AC Components AC Input AC input to the RS3000 can be supplied from a split-phase or dual-input AC source such as the utility grid (power company), a generator, or the output of a transfer switch. The RS3000 can be operated from the following types of 120 volt 60 Hz AC sources: • • Split phase: This source type has two lines, one neutral, and one ground. The two 120 VAC lines are 180 degrees out of phase with each other, so that the two voltages total to 240 VAC.
Installation WARNING: Shock Hazard Do not connect 240 VAC loads to the RS3000 outputs. Doing so may result in 120 VAC on exposed parts of the appliance. AC Disconnect and Over-Current Protection Device To meet CSA, UL, and electrical code requirements, and to protect system wiring, the AC inputs and outputs of the inverter/charger must be provided with overcurrent protection on both the AC input and output.
Installation Tested GFCIs Compliance with UL standards requires that Xantrex test and recommend specific GFCIs for use on the output of the inverter. Table 1 lists models that have been tested and will function properly when connected to the AC output of the RS3000. Table 1 Tested GFCI Models Manufacturer Model Number Hubbell GFR5252WA Leviton 8599-GY Pass & Seymour 1594-W Disconnect Devices Each system requires a method of disconnecting the AC circuits.
Installation Size of Input Wiring Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved, in accordance with the electrical codes or regulations applicable to your installation. Therefore, the wiring used between the AC input circuit breaker and the inverter/ charger input must be sized to match the input breaker rating. Table 2 AC Wire Size In and Out of the Inverter/Charger Split phase Dual input Breaker Size Used 50 A 25 A Wire Size No. 8 AWG No.
Installation AC Output Neutral Bonding The AC source must have its neutral conductor bonded to ground. Bonding system The RS3000 provides a system that automatically connects the neutral conductor of the inverter’s AC output circuit to safety ground (“bonding” it) while the inverter/charger is inverting, and disconnects it (“unbonding” it) when the inverter/charger is connected to external AC power.
Installation DC Components Batteries The RS3000 system requires a 12 volt, lead-acid deep-cycle battery or group of batteries to provide the DC current that the inverter/charger converts to AC power. The battery may be a flooded, gel, or AGM type. See “Battery Information” on page 40 for information on: • • • Estimating the battery size that will meet your requirements. Designing battery banks. Restrictions on the size of appliances.
Installation DC Cabling Definition DC cabling includes all of the cables and connectors between the batteries, the DC disconnect and over-current protection device, and the inverter/charger. Type All installations require multi-strand insulated cables. The DC cables must be copper and must be rated 105 °C minimum. Size and Length See Table 3 for required DC cable length, cable size and required fuse size for the RS3000. Wire size is usually marked on the cables.
Installation Unpacking and Inspecting the Inverter/Charger WARNING: Heavy load The RS3000 Sine Wave Inverter/Charger is heavy (see “Inverter/Charger Physical Specifications” on page 38). The unit is too heavy for one person to safely lift and mount. Xantrex recommends that two people lift and mount the unit. Always use proper lifting techniques during installation to prevent personal injury.
Installation 3. Save your purchase receipt to use as proof-of-purchase. This is required if the inverter/charger should need warranty service. 4. Save the original shipping carton and packing materials. If the inverter/ charger needs to be returned for service, it should be shipped in the original carton. This is also a good way to protect the inverter/charger if it ever needs to be moved.
Installation Installing the Inverter/Charger Overview This section provides detailed information on installing the RS3000.
Installation Dry Do not allow water or other fluids to drip or splash on the inverter. Do not expose to rain, snow or water. Cool Normal air temperature should be between 32 °F and 122 °F (0 °C and 50 °C)—the cooler the better within this range. Clearance Allow as much space around the inverter/charger as possible. Xantrex recommends that other objects and surfaces be at least 3 inches (76 mm) away from the ventilation openings for best performance.
Installation Step 2: Mounting the Inverter/Charger Considerations Before mounting the RS3000, take the following two factors into account. 1. The weight of the inverter/charger requires two people to install it. 2. Mounting considerations are shown in Figure 4 on page 20. WARNING: Heavy load The RS3000 Sine Wave Inverter/Charger is heavy (see “Inverter/Charger Physical Specifications” on page 38). The unit is too heavy for one person to safely lift and mount.
Installation Figure 4 Mounting Orientations Orientation Desktop Mount Upside-down Mount Approved Mounting Orientation? Yes Maybe Comment Suitable only for applications with no risk of condensation or dripping water. Wall Mount DC on Left Yes Wall Mount DC on Right Maybe On a vertical surface with DC terminals facing down. This orientation is suitable only for applications with no risk of condensation or dripping water. Wall Mount DC Up Maybe On vertical surface with DC terminals facing up.
Installation Step 3: Connecting the AC Input and AC Output Wires WARNING: Fire, shock, and energy hazards Make sure wiring being connected to the inverter/charger is disconnected (physically or by opening the breaker) from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes. General AC Wiring Considerations AC and DC Wiring Separation Do not mix AC and DC wiring in the same conduit or panel.
Installation Connecting AC Input Wires Figure 5 shows the wiring compartment, which contains a grounding bus (used to wire the AC input and output gound wires) and a terminal block (used to wire the AC input and AC output connections). Grounding bus Terminal block Figure 5 AC Wiring Compartment CAUTION: Equipment damage The terminal block is split into INPUT and OUTPUT sections. Damage may occur if the unit is wired incorrectly. Do not remove or loosen factory installed wiring.
Installation 7. Using a 1/4" blade slot screwdriver, loosen the terminal screws on the terminals. Do not remove the screws. 8. Connect the line and neutral wires to the input terminals (labeled AC Input on the terminal block, Figure 5 on page 22). Connect Line 1 to L1, Neutral to N, Line 2 to L2. 9. Tighten the terminal screws. Leave some slack wire inside the wiring box. 10. Connect the ground wires to a free position on the ground bus, Figure 5 on page 22.
Installation Connecting the AC Output Wires CAUTION: Risk of equipment damage Do not connect the output of the inverter to any incoming AC source. To make the AC output wiring connections: 1. Remove one of the AC knockouts from the front or side of the unit. Do not leave the knockout inside the wiring compartment. Important: The applicable installation code may not allow you to run the AC input and AC output wiring through the same AC knockout. 2.
Installation Step 4: Connecting the DC Cables DC Connection Precautions WARNING: Energy hazard Connect and disconnect DC wiring only after opening the disconnect switches or breakers at all AC and DC sources. Recommended Cable Sizes and Lengths and Fuse Size For recommended DC cables and fuse size, see Table 3 on page 14. Preparing the Cables To prepare the DC cables: 1. Cut the negative and positive cables to the required length.
Installation Guidelines for Routing the DC Cables Follow these guidelines to ensure maximum performance. WARNING: Fire and shock hazard Route the cables away from sharp edges that might damage the insulation. Avoid sharp bends in the cable. • • • • 26 Do not attempt to use the chassis in place of the battery negative connection for grounding. The inverter requires a reliable return path directly to the battery.
Installation Connecting the DC Cables to the Inverter/Charger WARNING: Fire hazard Use only appropriately sized copper cable. Loose connections or improper connections will overheat. Make sure the bolts supplied by Xantrex on the inverter/charger are tightened to a torque of 15–16 ft-lbs (20.4–21.7 Nm). Torque all other connections to the manufacturer’s specifications. Make sure the DC cable, washers, and bolt are assembled in the order shown in Figure 6.
Installation Figure 6 DC Cable Connections 7. Before proceeding, check that the cable polarity is correct: POSITIVE (+) on the inverter/charger is connected to the POSITIVE (+) on the battery, and NEGATIVE (–) cable is connected to the NEGATIVE (–) terminal on the inverter/charger. Important: The next step is the last cable connection you need to make. A spark is normal when this connection is made. 8. Connect the other end of the cable to the NEGATIVE (–) terminal on the battery. 9.
Installation DC Grounding The Chassis Ground point on the inverter/charger is used to connect the chassis of the inverter/charger to your system’s DC grounding point, as required by regulations for some installations. Use copper wire that is either bare or provided with green insulation. The grounding guideline given below assumes you are using the code-compliant DC supply cable and fuse sizes indicated on page 14. If you are using different sizes, refer to the applicable code for DC grounding detail.
Installation Step 5: Connecting the Battery Temperature Sensor (BTS) Installing a battery temperature sensor (BTS) extends the life of a battery by preventing overcharging in warm temperatures and undercharging in cold temperatures. With a BTS monitoring the battery temperature, the voltage delivered to the battery is adjusted according to the battery’s actual temperature. The BTS has a self-adhesive backing and attaches to the side of the battery. A 25-foot (7.
Installation Mounting to the Negative Battery Terminal To mount the sensor on the negative battery terminal: See Figure 10. Figure 10 BTS Mounted on the Negative Battery Terminal 1. Select the battery to be monitored. The BTS should be connected to the battery bank that is directly connected to the inverter/charger. 2. Switch off all devices operating from the battery, or open the battery switch (if present) to disconnect the battery. 3. Wait 10 minutes for any explosive battery gases to dissipate. 4.
Installation Figure 11 Connecting the BTS Cable to Battery Temp.
Installation Mounting to the Side of the Battery Case To mount the sensor on the battery case: See Figure 12. Figure 12 BTS Mounted on the Battery Case 1. Select the battery to be monitored. The BTS should be connected to the battery bank that is directly connected to the inverter/charger. 2. Select a side suitable for attaching the sensor. The surface where the sensor is to be mounted must be flat and free from reinforcing ribs or other raised features.
Installation Step 6: Connecting to the Network For your reference, Figure 13 shows where the network connections are made on the RS3000. To connect the RS3000 to the Xanbus network: u Plug a network cable connected to the Xanbus network into either one of the two network jacks on the RS3000. CAUTION: Equipment damage Connect the RS3000 only to other Xanbus compatible devices.
Installation Step 7: Performing Checks Prior to Initial Start-Up Before testing your installation, ensure these conditions are met: p Chassis and AC grounds are properly installed. p AC input connections and AC output connections are wired correctly on the terminal block and not reversed. p Positive (+) battery cable is connected to the positive (+) battery terminal through the DC fuse and disconnect switch or DC circuit breaker.
Installation Step 8: Testing Your Installation WARNING: Shock hazard The Inverter Enable button on the RS3000 and the optional accessories do not disconnect DC or AC input power to the RS3000. There are several tests to be performed for testing your installation.
Installation 3. Press the Inverter Enable button. Verify that: • • The Inverter Enable button light illuminates The Invert On light illuminates 4. Connect the RS3000 to the test load by closing the AC breaker that controls the circuit that the test load is connected to. If the light bulb illuminates, the Invert mode is working. 5. Press the Inverter Enable button to disable the inverter. The Invert On light and Inverter Enable button light are off. Testing in Charge Mode and AC Bypass Mode 1.
Installation Inverter/Charger Physical Specifications For complete inverter/charger specifications, refer to the RS3000 Sine Wave Inverter/Charger Operation Guide. The physical specifications of the RS3000 are shown in Figure 15 on page 39 and described in Table 4. Table 4 RS3000 Physical Specifications 38 Length 16.19 inches (411 mm) Width 14.20 inches (361 mm) Height 8.
Installation 14.
Installation Battery Information Battery Bank Sizing Battery capacity Battery size or capacity is just as important as the battery type selected for use with the RS3000. The batteries are the most important part of your system, so Xantrex recommends that you purchase as much battery capacity as possible. A large battery will extend running time and ensure that your inverter/charger delivers full rated surge.
Installation 4. Enter this information on the blank calculation worksheet (page 42). Step 2: Calculate Battery Size 5. Complete the rest of the worksheet; see Table 1-1, “Battery Sizing Example” on page 41 for an example. Size the batteries at approximately twice the estimated total amp-hour usage. Doubling the expected amp-hour usage ensures that the batteries will not be overly discharged and extends battery life. Resist the temptation to skip this doubling step.
Installation Battery Banks As your power requirements increase, you may need to use more than one battery to obtain sufficient capacity. Batteries can be connected in parallel, in series, or in series-parallel to create higher capacity systems. See “Cabling and Hook-up Configurations” on page 44 for more information about battery inter-connection schemes. Mixing Batteries Batteries connected in parallel should be of the same type and amp-hour rating and from the same manufacturer.
Installation Table 1-2 Battery Sizing Worksheet (A) Power Consumption (Watts) Appliance (B) Operating Time per Day (Hours) Daily watt-hours needed for this appliance (= A × B) W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh Total daily watt-hours of AC load Wh × Number of days between charges = Total watt-hours of AC load between charges Wh Battery Ah used between charges (divide by 10 for 12 volt system; divide by 20 for 24 volt syst
Installation Cabling and Hook-up Configurations Several smaller batteries can be connected to create a battery bank of substantial size. You can connect batteries in three ways: in parallel, series, or series-parallel. To make a larger battery bank, connect individual batteries with heavy cables. The actual size of the cable depends on whether the batteries are connected in parallel or series.
Installation Series Connection When batteries are connected with the positive terminal of one battery to the negative terminal of the next battery, they are connected in series. In a series configuration, the battery bank has the same Ah rating of a single battery, but an overall voltage equal to the sum of the individual batteries. See Figure 17.
Installation Series-Parallel Connections As the name series-parallel implies, both the series and parallel configurations are used in combination. The result is an increase in both the voltage and the capacity of the total battery bank. This is common with all battery-inverter system voltages. The smaller, lower voltage batteries are first connected in series to obtain the necessary voltage, and then these “batteries connected in series” sets are connected in parallel to increase the battery bank capacity.
Index A G AC and DC wiring separation 21 AC input wiring connections 22 AC input, defined 8 AC knockout dimensions 21 AC output neutral bonding 12 AC output wiring connections 24 AC wiring defined 10 size 11 type 10 AC wiring compartment, illustrated 21 AC wiring considerations 21 AC wiring terminal, illustrated 21 gases, hydrogen 18 GFCI 9 GFCI models, tested 10 ground fault circuit interrupter. See GFCI.
Index T tools, installation 16 two key performance factors 5 V ventilation openings, recommended clearance 18 X Xanbus-enabled designation, meaning of 3 Xantrex, web site iii 48 975-0171-01-01
Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.
