Xantrex Technology SW Plus 4024 User Manual
Sine wave plus inverter/charger
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Table of contents
Document Outline
- Sine Wave Plus Inverter/Charger
- About This Manual
- Purpose
- Scope
- Audience
- Organization
- Conventions Used
- Related Information
- Important Safety Instructions
- 1. Before using the inverter, read all instructions and cautionary markings on the unit, the batt...
- 2. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a ...
- 3. The inverter is designed to be permanently connected to your AC and DC electrical systems. Xan...
- 4. To avoid a risk of fire and electric shock, make sure that existing wiring is in good conditio...
- 5. Do not operate the inverter if it has been damaged in any way. If the unit is damaged, see the...
- 6. This unit does not have any user-serviceable parts. Do not disassemble the inverter. See “How ...
- 7. To reduce the risk of electrical shock, disconnect both AC and DC power from the inverter befo...
- 8. The inverter must be provided with an equipment-grounding conductor connected to the AC input ...
- 9. Do not expose this unit to rain, snow, or liquids of any type. This product is designed for in...
- 10. To reduce the chance of short-circuits, always use insulated tools when installing or working...
- 11. Remove all jewelry while installing this system. This will greatly reduce the chance of accid...
- Explosive gas precautions
- FCC Information to the User
- Contents
- Figures
- Tables
- 1
- 2
- System Configuration
- Pre-Configuration Planning
- Importance
- Types of Applications
- System Considerations
- System Output Requirements
- System Input Requirements
- Location Considerations
- Grounding Considerations
- Battery Considerations
- CAUTION : Damage to Equipment
- Accessibility
- Vented enclosures
- Enclosure requirements
- More information
- Battery Bank Requirements
- Battery Cable Requirements
- Battery Requirements for Dual Inverter Systems
- Battery Temperature
- Wiring Considerations
- Generator Considerations
- Additional/Optional Equipment Considerations
- Important:
- AC Conduit Box (ACCB)
- DC Conduit Box (DCCB)
- DC Disconnect Boxes (DC175/DC250)
- Battery Status Meter (TM500A)
- Remote Monitors
- Generator Start Module (GSM)
- Auxiliary Load Module (ALM)
- 240 Vac Application Requirements
- Autotransformer for 240 VAC Applications (T240)
- Inverter Stacking Control – Series (ISC-S) Cable
- Renewable Energy DC Input Sources
- Off-Grid Applications
- Renewable Energy Systems with/without Generator Backup
- Single-Inverter Configurations (120 Vac)
- Single-Inverter Configurations (120/240 Vac)
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-17 Off-Grid Application – Renewable Energy System using a Single Inverter
- Dual-Inverter Configurations (240 Vac)
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-18 Off-Grid Application – Renewable Energy System using Dual Inverters
- Generator-Only Systems
- Single-Inverter Configurations
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-19 Off Grid Application - Generator-only System using a Single Inverter
- Dual-Inverter Configurations
- 240 Vac-only Input Source
- Important:
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-20 Off Grid Application – Generator-only System using Dual Inverters, Series-stacked
- Single-Inverter Configurations
- Renewable Energy Systems with/without Generator Backup
- On-Grid Applications
- Backup Systems
- Renewable Energy Backup (BX Mode)
- Utility Backup (SB Mode)
- Single-Inverter Configurations (120 Vac)
- Single-Inverter Configurations (240 Vac)
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-21 On-Grid Application – Backup System using a Single Inverter
- Dual-Inverter Configurations (240 Vac)
- 1. Always refer to your local electric codes for proper wiring instructions.
- 2. For purposes of this illustration, the ground for the AC generator is run through the inverter.
- 3. Separate grounding runs are shown in this illustration to demonstrate a single point ground.
- 4. If using a PC to monitor the system, the Xantrex ICA is required. If using a PC to monitor fro...
- 5. Ensure all the DC negatives in the system are bonded to earth ground in only one place (single...
- 6. If this is not a separately derived system (per the NEC), the AC neutrals should be bonded to ...
- Figure 2-22 On-Grid Application – Backup System using Dual Inverters, Series-stacked
- Energy Management
- Backup Systems
- 3
- Installation
- Pre-Installation
- Important:
- Important:
- Tools Required
- Hardware / Materials Required
- Optional System Accessories
- Battery Bank Preparation
- Important:
- Prepare the battery bank as follows:
- 1. Determine the type of batteries to be used.
- 2. Determine the appropriate battery bank size and battery configuration.
- 3. Determine the correct size of battery cables to use.
- 4. Determine the correct size of DC breaker/fuse to use.
- 5. Color code the cables with tape or heat shrink tubing. The standard colors for DC cables are r...
- Unpacking and Inspecting the Inverter
- Knockout Preparation
- Mounting
- Shelf-Mounting
- To mount the Sine Wave Plus on a shelf, follow the instructions below.
- 1. Ensure that the desired shelf location is strong enough to support the inverter weight and all...
- 2. Drill mounting holes in the shelf by one of the following methods. Be sure to use all of the i...
- 3. With assistance, lift the inverter into position and install it onto the shelf, using appropri...
- Figure 3-3 Dimensional Drawing
- To mount the Sine Wave Plus on a shelf, follow the instructions below.
- Wall-Mounting
- Wall Mounting using 2x4’s
- To mount the Sine Wave Plus on a wall, follow the instructions below.
- 1. Locate the studs and mark their location on the wall.
- 2. Measure the desired height from the floor for the inverter to be mounted. The height should pl...
- 3. Using a level, run a horizontal line. The length of the line must span at least 3 studs.
- 4. Place a pre-cut 2x4 on the marked location and drill pilot holes through the 2x4’s and studs.
- 5. Secure the 2x4 with #10 wood screws (length to penetrate 1º inches or more into the studs).
- 6. Repeat the procedure for the remaining 2x4 (paint the 2x4’s, if desired, to match the surr...
- 7. Drill mounting holes in the 2x4 mounting rails by one of the following methods. Be sure to u...
- 8. Ensure that the 2x4’s are securely fastened to the wall before mounting the inverter to them.
- 9. With assistance, lift the inverter into position and install it onto the 2x4’s using ¹ x 1º-...
- To mount the Sine Wave Plus on a wall, follow the instructions below.
- Figure 3-4 Wall-Mounting Method using 2x4’s
- Wall Mounting using Plywood
- Figure 3-5 Wall Mounting using Plywood
- Wall Mounting using 2x4’s
- Shelf-Mounting
- DC Wiring
- Preparing the Battery Bank
- Grounding the DC System
- Figure 3-6 Chassis Ground Lug Location on Inverter DC End
- Single Inverter
- To ground a single inverter:
- 1. Connect the ground bond in the DC disconnect to the primary grounding electrode, in accordance...
- 2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconn...
- 3. Connect an appropriately sized GROUND wire from the Chassis Bonding Lug on the inverter DC end...
- To ground a single inverter:
- Dual Inverters
- To ground a dual-inverter configuration:
- 1. Connect the ground bond in the DC disconnect between the inverters and the batteries to the pr...
- 2. Connect the NEGATIVE (–) terminal of the battery bank to the ground bond inside the DC disconn...
- 3. Connect an appropriately sized GROUND wire from the Chassis Bonding Lug on the L1 inverter DC ...
- 4. Connect a second appropriately sized GROUND wire from the Chassis Bonding Lug on the L2 invert...
- To ground a dual-inverter configuration:
- Connecting DC Input Sources – Renewable Energy Configurations
- Installing the Battery Temperature Sensor (BTS)
- Connecting the Batteries to the Inverter
- Figure 3-10 DC Terminal Connections on the Inverter
- Figure 3-11 Battery Cable Connection
- CAUTION : Damage to Equipment
- Procedure for Single Inverter Systems
- Use the following procedure to connect the battery (or battery bank) to the inverter.
- 1. Connect POSITIVE cables:
- 2. Connect a NEGATIVE cables:
- 3. Ensure the correct polarity of the cables with a DC voltmeter (DVM).
- 4. Use an insulated 1/2-inch wrench or socket to tighten the 5/16 SAE nuts to 10-15 foot/lb for e...
- 5. Apply antioxidant paste to the battery terminals, if desired.
- 6. Install the battery terminal covers (if used)—red for positive, black for negative—over the in...
- Figure 3-13 DC Connections to a Single Inverter
- Use the following procedure to connect the battery (or battery bank) to the inverter.
- Procedure for Dual-Inverter Systems
- Use the following procedure to connect the battery (or battery bank) to the inverters.
- 1. Connect POSITIVE cables:
- a) one cable from the battery POSITIVE terminal to a circuit breaker in the DC disconnect (torque...
- b) a second cable from the same battery POSITIVE terminal to another circuit breaker in the DC di...
- c) a third cable from the first circuit breaker in the DC disconnect to the L1inverter POSITIVE...
- d) a fourth cable from the second DC disconnect to the L2 inverter POSITIVE(+) terminal.
- 2. Connect NEGATIVE cables:
- a) one cable from the same battery NEGATIVE terminal (torque to manufacturer’s recommendations) t...
- b) a second cable from the same battery NEGATIVE terminal (torque to manufacturer’s recommendatio...
- c) a third one from the ground bond in the DC disconnect to the L1 inverter NEGATIVE(–) terminal.
- d) a fourth one from the ground bond in the DC disconnect to the L2inverter NEGATIVE(–) terminal.
- 3. Ensure the correct polarity of the cables with a DC voltmeter (DVM).
- 4. Use an insulated 1/2 inch wrench or socket to tighten the 5/16 SAE nuts to 10-15 foot/lb for e...
- 5. Apply antioxidant paste to the battery terminals, if desired.
- 6. Install the battery terminal covers (if used)—red for positive, black for negative—over the in...
- 1. Connect POSITIVE cables:
- Figure 3-14 DC Connections to Dual Inverters
- Use the following procedure to connect the battery (or battery bank) to the inverters.
- AC Wiring
- 1. An off-grid site with two generators, an auto-start generator connected to AC2 and spare manua...
- 2. An on-grid site with a generator wired into a main grid/generator transfer switch. The AC2 inp...
- CAUTION : Damage to the Inverter
- Accessing the AC Terminal Block and Ground Bar
- AC Wiring for Single Inverter Systems
- 1. “Install AC Output Wiring to the Inverter AC Distribution Panel” on page3–33.
- 2. “Install Generator Wiring to the Inverter” on page3–35.
- 3. “Install Utility Wiring to the Inverter Input (On-Grid Applications only)” on page3–38.
- Manual and Auto Start Generators
- Install AC Output Wiring to the Inverter AC Distribution Panel
- Install the inverter AC distribution panel and conduit as follows:
- 1. Determine the location for the inverter AC distribution panel and install it according to the ...
- 2. Install an AC conduit to the inverter panel and the inverter.
- 3. Determine which circuits the inverter will power and install the appropriate circuit breakers ...
- 4. For On-Grid systems:
- 5. Remove unused breakers from utility panel. It is now safe to re-energize the main utility panel.
- 6. Install a 60-amp maximum (disconnect) main circuit breaker in the inverter panel. This will la...
- CAUTION : Equipment Damage
- Make connections from the inverter to the inverter panel as follows:
- Install the inverter AC distribution panel and conduit as follows:
- Install Generator Wiring to the Inverter
- Generator Disconnect Switch (If used)
- With Step-down Autotransformer and using a 120/ 240Vac Generator
- To install the AC wiring from the generator to the inverter:
- 1. Connect GROUND (green or bare) wires:
- 2. Connect NEUTRAL (white) wires:
- 3. Connect HOT (black) wires:
- a) from the generator L1 HOT OUT to the Step-down autotransformer L1 HOT IN,
- b) and from the generator L2 HOT OUT to the Step-down autotransformer L2HOTIN,
- c) from the Step-down autotransformer HOT OUT to the generator disconnect switch HOT connector, and
- d) from the generator disconnect switch HOT connector to the inverter AC2 GEN terminal.
- 4. Torque all inverter terminal block connections to 25 inch-pounds.
- To install the AC wiring from the generator to the inverter:
- Without a Step-down Autotransformer Using a 120Vac-Only Generator
- Figure 3-20 Generator Input Wiring to a Single Inverter
- Install Utility Wiring to the Inverter Input (On-Grid Applications only)
- CAUTION : Damage to Equipment
- Install the wiring from the inverter to the utility panel as follows:
- Figure 3-21 Utility Wiring to the Inverter Input
- Optional Equipment
- 4
- Functional Test
- Basic Functional Test
- Confirm all Connections
- Applying Battery Power to the Inverter
- Turning ON the Inverter
- To turn on the inverter:
- AC Voltage Check
- To perform an AC voltage check:
- 1. With the inverter on (INVERT (yellow) LED on solid), verify with a handheld voltmeter the AC v...
- 2. Verify that neutral is bonded to ground in the system by measuring the hot and neutral voltage...
- 3. After confirming the correct AC voltage, turn on your AC output breaker and place a load on th...
- 4. Confirm that the AC load that was just applied works properly.
- To perform an AC voltage check:
- Confirming Battery Charger Operation
- Confirming Inverter Operation
- 5
- Navigation
- Navigating the Sine Wave Plus
- Inverter Control Module Features
- Menu Map
- Introduction
- The “User” Menu
- The “Basic Setup” Menu
- The “Advanced Setup” Menu
- User Menu (01-07)
- Figure 5-9 User Menu Map - Part 1
- Figure 5-10 User Menu Map - Part 2
- Figure 5-11 Basic Setup Menu Map Part 1
- Figure 5-12 Basic Setup Menu Map Part 2
- Figure 5-13 Advanced Setup Menu Map Part 1
- Figure 5-14 Advanced Setup Menu Map Part 2
- Figure 5-15 Complete User Menu Map
- Figure 5-16 Complete Basic Setup Menu Map
- Figure 5-17 Complete Advanced Setup Menu Map
- 6
- Basic Setup Programming
- Basic Setup Summary
- Before You Begin Programming
- DC Amps verses AC Amps
- Basic Setup Process
- 1. Setting the Time of Day – This sets the internal clock for all the features requiring time fun...
- 2. Selecting Inverter functions – This selects basic inverter operating functions.
- 3. Selecting Charger functions – This selects the basic charger functions.
- 4. Selecting Grid Usage functions – This selects basic Grid Usage functions.
- 5. Saving programmed parameters.
- Accessing the Basic Setup Menu
- To access the Basic Setup Menu:
- 1. If you have not already done so, turn on the inverter.
- 2. Press the button to move forward within the Menu Headings until the END USER MENU is displayed.
- 3. Press and hold down the green GEN button.
- 4. While holding the green GEN button down, press the red INV button to move into the Basic Setup...
- Figure 6-1 Accessing the Basic Setup Menu
- To access the Basic Setup Menu:
- Menu Item Descriptions
- 10 Time of Day Setup Menu
- 11 Inverter Setup Menu
- Battery Charger Functions
- 12 Battery Charging Menu
- Important:
- 12A Finish Stage
- 12B Bulk Volts DC
- 12C Float Volts DC
- 12D Equalize Volts DC
- 12E Max Charge Amps AC
- Calculating Maximum Charging Amps
- To calculate the 12E Max Charge Amps AC:
- Calculating Maximum Charging Amps
- 12F Bulk Done Amps AC
- To calculate the 12F Bulk Done Amps AC:
- 12G EQ VDC Done Timer
- 12H Max Bulk/EQ Timer h:m
- 12I Temp Comp
- 13 AC Inputs Menu
- 14 Save/Restore Settings Menu
- End Basic Setup Menu
- 7
- Advanced Setup
- Advanced Setup Summary
- Before You Begin Advanced Programming
- Accessing the Advanced Setup Menu
- Menu Item Descriptions
- 20 Silent Setup Menu
- When it works
- How it works
- External charging sources
- Advantages
- Disadvantage
- Summary
- 20A Refloat High Volts DC
- 20B Refloat Low Volts DC
- 20C Float Done Amps AC
- To calculate the 20C Float Done Amps AC:
- 1. Multiply the battery amp hours by 1%. This is the DC Max Charge Rate changed to float done amp...
- 2. Convert the DC Max Charge Rate to AC amps by dividing the DC Max Charge Rate by 4 for a 24-vol...
- 3. The result is the approximate amp setting that should be entered for the 20C Float Done Amps A...
- To calculate the 20C Float Done Amps AC:
- 20D Must Float Time Min
- 21 Grid (AC1) Usage Menu
- 22 Battery Xfer (BX) Menu
- 23 ALM Relays Menu
- Generator Starting Scenarios
- Important:
- Manual Generator Control
- Automatic Generator Control
- AC Current
- Battery Voltage
- Time of Day
- Exercise Period Days
- 1. The generator will be prevented from automatically starting when the inverter’s time of day is...
- 2. If the generator is automatically stopped (except for Gen exercise), the stop command will be ...
- 3. Most generators will shut down immediately after receiving an automatic shutdown command. Some...
- 4. During Quiet Time, the auto-start generator is prevented from automatically starting unless th...
- 5. An auto-start generator will turn off if an AC source is connected to the AC1 terminal (unless...
- 6. If the inverter is OFF or in Bypass Mode (AC1 or AC2 selected) and RY7 Mode is not RN2, all ge...
- 7. The auto-start generator will stop immediately under any condition if OFF is selected under th...
- 8. No battery charging occurs if the auto-start generator is started based on exercise period.
- 9. The inverter will attempt up to six auto-generator starts if RY7 Mode = GS or RN1. The inverte...
- 10. The auto-start generator will always finish with cooldown unless turned off or exercise start...
- 11. The auto-start generator does not shut down, but begins the cooldown period when the 24C Quie...
- 24 Generator Timers Menu
- 25 Gen Starting Details Menu
- Generator Start Module (GSM)
- 25A RY7 Mode
- 25B Gen Warm-up Seconds/minutes
- 25C Pre Crank Seconds
- 25D Max Cranking Seconds
- 25E Post Crank Seconds
- 26 Gen Auto Run Setup Menu
- 27 Save/Restore Settings Menu
- End Advanced Setup Menu
- 20 Silent Setup Menu
- 8
- Operation
- Operating the Sine Wave Plus
- Operational Status Indicators
- The User Menu Summary
- Accessing the User Menu
- User Menu Description
- 9
- A
- Inverter Specifications
- Electrical Specifications
- Mechanical Specifications
- Theory of Operation
- Power Versus Efficiency
- Figure A-3 Power Versus Efficiency Curves for All Models
- Figure A-4 Sine Wave Plus Efficiency Curve for the SW Plus 2524
- Figure A-5 Sine Wave Plus Efficiency Curve for the SW Plus 2548
- Figure A-6 Sine Wave Plus Efficiency Curve for the SW Plus 4024
- Figure A-7 Sine Wave Plus Efficiency Curve for the SW Plus 4048
- Figure A-8 Sine Wave Plus Efficiency Curve for the SW Plus 5548
- Inverter Capacity versus Temperature
- Time versus Current
- B
- C
- Battery Information
- Introduction
- Battery Types
- Understanding Battery Capacity Ratings
- Battery Bank Sizing
- Running time and size
- Depth of discharge
- Days of autonomy
- Understanding Amp-hour Requirements
- Calculating Amp Hours
- Calculations
- Amps to watts
- Considerations
- Amp Hour Example Worksheet
- To calculate amp-hour requirements:
- 1. Determine the loads the inverter will power and enter their wattage in the watts column.
- 2. Determine the number of hours (or decimal portion of hours) the appliance is used each day. En...
- 3. Determine the number of days the appliance will be used during the week. Enter this figure in ...
- 4. Multiply Hours x Days for each load identified to determine the watt/ hours per week.
- 5. Add the total watt/hours per week for all loads then divide by 7 to obtain the average total w...
- 6. Divide the total average per day by the DC nominal voltage.
- Table C-1 Determining Average Daily Load in Amp-hours
- To calculate amp-hour requirements:
- Battery bank size worksheet
- Battery Configurations
- Battery Maintenance
- D
- E
- F
- G
- Emergency Power Off Switches
- The Purpose of an EPO switch
- Glossary of Terms
- Abbreviations and Acronyms
- Warranty
- What does this warranty cover?
- What will Xantrex do?
- How do you get service?
- What does this warranty not cover?
- a) the product if it has been misused, neglected, improperly installed, physically damaged or alt...
- b) the product if it has been subjected to fire, water, generalized corrosion, biological infest...
- c) the product if repairs have been done to it other than by Xantrex or its authorized service ce...
- d) the product if it is used as a component part of a product expressly warranted by another manu...
- e) the product if its original identification (trade-mark, serial number) markings have been defa...
- Disclaimer
- Return Material Authorization Policy
- Return Procedure
- Out of Warranty Service
- Information About Your System
- Xantrex Technology Inc.