Xantrex Sw Plus 2524 Users Manual 976 0043 01 02 Rev B Sine Wave

SW Plus 2548 to the manual 4e44c489-8c27-4781-8699-ae9d53864577

2015-02-03

: Xantrex Xantrex-Sw-Plus-2524-Users-Manual-473755 xantrex-sw-plus-2524-users-manual-473755 xantrex pdf

Open the PDF directly: View PDF PDF.
Page Count: 344 [warning: Documents this large are best viewed by clicking the View PDF Link!]

Sine Wave Plus
Inverter/Charger
Owner’s Manual
SW Plus 2524
SW Plus 2548
SW Plus 4024
SW Plus 4048
SW Plus 5548
Sine Wave Plus Inverter/Charger
Owner’s Manual
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, micro turbines, 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.
Sine Wave Plus Inverter/Charger is a trademark of Xantrex International. Xantrex is a registered trademark of
Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used
herein for identification purposes only.
Sine Wave Plus Inverter/Charger Owner’s Manual © September 2003 Xantrex International. All rights reserved.
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER 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.
Due to continuous quality improvement and product updates, the photographs shown in this manual may not exactly
match the unit purchased.
September 2003, Revision B
976-0043-01-02 Rev B3
Telephone: 1-800-670-0707 (toll free in North America)
Telephone: 1-360-925-5097 (direct)
Fax: 1-800-994-7828 (toll free in North America)
Fax: 1-360-925-5143 (direct)
Email: customerservice@xantrex.com
Web: www.xantrex.com
976-0043-01-02 iii
About This Manual
Purpose
The purpose of this Owner’s Manual is to provide explanations and
procedures for installing, operating, maintaining, and troubleshooting the
Sine Wave Plus Inverter/Charger.
Scope
The Manual provides safety guidelines, detailed planning and setup
information, procedures for installing the inverter, as well as information
about operating and troubleshooting the unit. It does not provide details
about particular brands of batteries. You need to consult individual battery
manufacturers for this information.
Audience
The Manual is intended for anyone who needs to install and operate the
Sine Wave Plus Inverter/Charger. Installers should be certified
technicians or electricians.
About this Guide
976-0043-01-02 iv
Organization
This guide is organized into nine chapters and nine appendices.
Chapter 1, “Introduction” lists and describes the basic features and parts
of the Sine Wave Plus Inverter/Charger.
Chapter 2, “System Configuration” contains information to help you plan
for a Sine Wave Plus installation in an off-grid, on-grid, or backup power
application.
Chapter 3, “Installation” describes how to mount and install the Sine
Wave Plus Inverter/Charger and perform wiring and cabling procedures
for various configurations.
Chapter 4, “Functional Test” explains how to conduct a functional test of
the inverter.
Chapter 5, “Navigation” explains how to navigate through the Sine Wave
Plus Inverter/Charger menus using the Control Module and the menu
maps.
Chapter 6, “Basic Setup Programming” explains how to program the Sine
Wave Plus Inverter/Charger to operate under basic conditions.
Chapter 7, “Advanced Setup” explains how to program the Sine Wave
Plus Inverter/Charger to operate under special, advanced conditions, such
as automatic generator starting, energy management and auxiliary load
applications.
Chapter 8, “Operation” explains how to operate the Sine Wave Plus
Inverter/Charger. It also explains how to read the LED indicators and
User Menus to determine system status.
Chapter 9, “Troubleshooting” contains information and procedures for
solving possible problems with the Sine Wave Plus.
Appendix A, “Inverter Specifications” provides the electrical and
environmental specifications of this inverter. This section also provides
information about how an inverter works, as well as efficiency statistics.
Appendix B, “Configuration Settings” provides worksheets for
programming your inverter/charger for user-specific parameters. Use this
chapter to record the settings specific to your installation. This will make
programming or reprogramming easier.
Appendix C, “Battery Information” supplies general information about
batteries such as battery types, battery bank sizing, battery configurations,
and battery care. For detailed information, see your battery manufacturer
or your system designer. Reading this chapter will help you determine the
battery bank specifications required by your specific system (e.g., types
of batteries, size of battery bank, configuration of the battery bank etc.).
Appendix D, “Generators” supplies information about generator starting.
Reading this chapter will help you determine what kind of generator to
use, if any.
About this Guide
v976-0043-01-02
Appendix E, “Over-Charge Protection” supplies information about
options for over-charge protection.
Appendix F, “Multi-wire Branch Circuit Wiring” supplies information
about Multi-wire Branch Circuit Wiring Precautions when using stand-
alone 120 Vac inverters or generators. Reading this chapter will provide
information regarding identifying and correcting the potential fire hazard
that exists when using inverters in this situation.
Appendix G, “Emergency Power Off Switches” supplies information
about the requirements for installing an Emergency Power Off Switch.
“Glossary” contains a glossary of technical terms used in this manual.
The glossary also defines some common electrical terms. It also provides
a list of acronyms used in this manual.
“Warranty and Product Information” Reading this chapter will provide
clarification of the Limited Warranty and instructions for obtaining a
Return Material Authorization, if the product needs to be returned to
Xantrex or one of its authorized service centers.
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 Sine Wave Plus Inverter/Charger or other equipment.
About this Guide
976-0043-01-02 vi
Related Information
You can find more information about Xantrex Technology, Inc. as well as
its products and services at www.xantrex.com
You may also need to reference the following installation guides to assist
with this installation. These guides (with the exception of the NEC/CEC
Reference Guides) are all provided with the specific components when
purchased.
• Generator Start Module (GSM) Installation Guide
• Auxiliary Load Module (ALM) Installation Guide
• Inverter Stacking Control – Series (ISC-S) Cable Owner’s Guide
• Inverter Communications Adapter (ICA) Owner’s Guide
• Inverter Control Module (ICM) Installation Guide
• AC Conduit Box (ACCB) Owner’s Guide
• DC Conduit Box (DCCB) Installation Guide
• AC and/or DC Conduit Installation Instructions
• T240 Autotransformer Installation Guide
• Manufacturer’s instructions for Electrical Panels (Main, Sub, and
generator disconnect panels)
• Manufacturer’s instructions for battery installation and use
• Manufacturer’s instructions for generator installation and use
• NEC Guide for related electrical, grounding, and bonding
information.
• CEC Guide for related electrical, grounding, and bonding
information.
976-0043-01-02 vii
Important Safety Instructions
1. Before using the inverter, read all instructions and cautionary
markings on the unit, the batteries, and all appropriate sections of this
manual.
2. Use only attachments recommended or sold by the manufacturer.
Doing otherwise may result in a risk of fire, electric shock, or injury
to persons.
3. The inverter is designed to be permanently connected to your AC and
DC electrical systems. Xantrex recommends that all wiring be done
by a certified technician or electrician to ensure adherence to the local
and national electrical codes applicable in your jurisdiction.
4. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition and that wire is not undersized. Do not
operate the inverter with damaged or substandard wiring. See
Appendix, F “Multi-wire Branch Circuit Wiring” for information
about multi-wire branch circuits.
5. Do not operate the inverter if it has been damaged in any way. If the
unit is damaged, see the Warranty and Product Information section at
the end of this manual.
6. This unit does not have any user-serviceable parts. Do not
disassemble the inverter. See “How do you get service?” on page I–1
for instructions on obtaining service. Attempting to service the unit
yourself may result in a risk of electrical shock or fire. Internal
capacitors remain charged after all power is disconnected.
7. To reduce the risk of electrical shock, disconnect both AC and DC
power from the inverter before attempting any maintenance or
cleaning or working on any components connected to the inverter.
Turning off controls will not reduce this risk.
8. The inverter must be provided with an equipment-grounding
conductor connected to the AC input ground.
WARNING
This chapter contains important safety and operating instructions as
prescribed by UL and CSA standards for inverters used in residential
applications. Read and keep this Installation Guide for future reference.
Important Safety Instructions
viii 976-0043-01-02
9. Do not expose this unit to rain, snow, or liquids of any type. This
product is designed for indoor use only. Damp environments will
significantly shorten the life of this product and corrosion caused by
dampness will not be covered by the product warranty.
10. To reduce the chance of short-circuits, always use insulated tools
when installing or working with the inverter, the batteries, or the PV
arrays.
11. Remove all jewelry while installing this system. This will greatly
reduce the chance of accidental exposure to live circuits.
Explosive gas precautions
1. Working in the vicinity of lead acid batteries is dangerous. Batteries
generate explosive gases during normal operation. Therefore, you
must read this guide and follow the instructions exactly before
installing or using your inverter/charger.
2. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer and the manufacturer of
the equipment in which the battery is installed.
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 ratio/TV technician for help.
976-0043-01-02 ix
Important Safety Instructions
Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
1
Introduction
Basic Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2
Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
AC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4
Emergency Power Off (EPO) Option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
DC Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6
Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7
Top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–8
2
System Configuration
Pre-Configuration Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2
Types of Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2
System Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2
System Output Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4
System Input Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4
Location Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5
Mounting Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6
Ventilation Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6
Grounding Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7
DC System Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7
Inverter Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–8
Equipment or Chassis Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9
Grounding Electrodes/Ground Rods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9
Bonding the Grounding System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10
Battery Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–11
Battery Bank Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–12
Battery Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–12
Battery Requirements for Dual Inverter Systems - - - - - - - - - - - - - - - - - - - - - -2–15
Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17
Wiring Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18
Generator Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–19
Types of Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–20
Contents
Contents
x976-0043-01-02
Generator start types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20
Additional/Optional Equipment Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22
AC Conduit Box (ACCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22
DC Conduit Box (DCCB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Fuse Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
DC Disconnect Boxes (DC175/DC250) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
Battery Status Meter (TM500A) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Remote Monitors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Inverter Control Module (ICM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27
Inverter Communications Adapter (ICA) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27
Generator Start Module (GSM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
Auxiliary Load Module (ALM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
240 Vac Application Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–29
Autotransformer for 240 VAC Applications (T240) - - - - - - - - - - - - - - - - - - - - - - 2–29
Inverter Stacking Control – Series (ISC-S) Cable - - - - - - - - - - - - - - - - - - - - - - - - 2–29
Renewable Energy DC Input Sources - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–30
Off-Grid Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–32
Renewable Energy Systems with/without Generator Backup - - - - - - - - - - - - - - - - 2–32
Single-Inverter Configurations (120 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–32
Single-Inverter Configurations (120/240 Vac) - - - - - - - - - - - - - - - - - - - - - - - 2–32
Dual-Inverter Configurations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–34
Generator-Only Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–36
Single-Inverter Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–36
Dual-Inverter Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–38
240 Vac-only Input Source - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–38
On-Grid Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40
Backup Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40
Single-Inverter Configurations (120 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40
Single-Inverter Configurations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–40
Dual-Inverter Configurations (240 Vac) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–42
Energy Management - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44
RE Backup with Utility (SB Mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44
Peak Load Management - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44
Time-of-Use (TOU) Metering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–45
AC Load Support - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–46
Renewable Energy with Grid Backup (BX Mode) - - - - - - - - - - - - - - - - - - - - 2–47
3
Installation
Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Contents
976-0043-01-02 xi
Hardware / Materials Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3
Optional System Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3
Battery Bank Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–4
Unpacking and Inspecting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–5
Knockout Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–7
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8
Shelf-Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8
Wall-Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10
DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Preparing the Battery Bank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Grounding the DC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
Connecting DC Input Sources – Renewable Energy Configurations - - - - - - - - - - - - 3–18
Installing the Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - 3–18
Connecting the Batteries to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–20
Procedure for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–22
Procedure for Dual-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–24
AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–26
Accessing the AC Terminal Block and Ground Bar - - - - - - - - - - - - - - - - - - - - - - 3–28
AC Wiring for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–30
Manual and Auto Start Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–30
Install AC Output Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - 3–33
Install Generator Wiring to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–35
Install Utility Wiring to the Inverter Input (On-Grid Applications only) - - - - - - 3–38
Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–39
Stacking Dual Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–39
Installing the ISC-S Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–40
Remote Monitoring Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–41
Auxiliary Load Module (ALM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–42
Emergency Power Off (EPO) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43
EPO Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43
4
Functional Test
Basic Functional Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2
Confirm all Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2
Applying Battery Power to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2
Turning ON the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3
AC Voltage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–4
Confirming Battery Charger Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–4
Confirming Inverter Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–5
Contents
xii 976-0043-01-02
5
Navigation
Navigating the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
The Inverter Control Module (ICM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Inverter Control Module Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
The display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
The cursor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Display contrast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4
Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4
ON/OFF Menu Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4
Menu Heading Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Menu Item Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Set Point Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6
Reset Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6
Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7
6
Basic Setup Programming
Basic Setup Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–2
Before You Begin Programming - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–8
DC Amps verses AC Amps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–8
Basic Setup Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–9
Accessing the Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10
Menu Item Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11
10 Time of Day Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11
10A Set Hour - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11
10B Set Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–11
10C Set Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12
11 Inverter Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12
11A High Battery Cut Out VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12
11B Low Battery Cut In VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–12
11C Low Battery Cut Out VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–13
11D LBCO Delay Minutes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–13
11E Search Watts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–14
Battery Charger Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–15
Multi-Stage Charging Process - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–16
Equalize Charging the Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–18
12 Battery Charging Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–19
12A Finish Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–19
12B Bulk Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20
12C Float Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20
12D Equalize Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–20
Contents
976-0043-01-02 xiii
12E Max Charge Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–22
12F Bulk Done Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–23
12G EQ VDC Done Timer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–24
12H Max Bulk/EQ Timer h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–25
12I Temp Comp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–25
13 AC Inputs Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–26
13A Grid (AC1) Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–27
13B Gen (AC2) Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–27
13C Input Upper Limit VAC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–28
13D Input Lower Limit VAC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–28
14 Save/Restore Settings Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–29
14A Push INV now to Save Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–29
14B Push GEN to Restore Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–29
14C Push GEN for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–30
End Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–30
7
Advanced Setup
Advanced Setup Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–2
Before You Begin Advanced Programming - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–10
Accessing the Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–11
Menu Item Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–13
20 Silent Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–13
20A Refloat High Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–15
20B Refloat Low Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–15
20C Float Done Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–15
20D Must Float Time Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16
21 Grid (AC1) Usage Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–16
21A Grid Usage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–17
21B Grid Usage Begin h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–17
21C Grid Usage End H:M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–18
22 Battery Xfer (BX) Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–18
22A High Xfer (HBX) VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–19
22B Low Xfer (LBX) VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–19
23 ALM Relays Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–19
23A RY9 VDC Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20
23B RY9 VDC DeEnergized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20
23C RY9 Delay At DeEngz. Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20
23D RY10 VDC Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–20
23E RY10 Vdc DeEnergized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7–21
23F RY10 Delay at Engz. Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–21
Contents
xiv 976-0043-01-02
23G RY11 Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–21
Generator Starting Scenarios - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–23
Manual Generator Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–23
Automatic Generator Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–24
24 Generator Timers Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–26
24A Gen Run Time Start h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27
24B Gen Run Time Stop H:M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27
24C Quiet Time Begin h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–27
24D Quiet Time End h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28
24E Gen Exercise Period Days - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28
24F Gen Exercise Timer Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28
24G Gen Cooldown Timer Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–28
24H RN2/Max Gen Run h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29
25 Gen Starting Details Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29
Generator Start Module (GSM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–29
25A RY7 Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–30
25B Gen Warm-up Seconds/minutes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37
25C Pre Crank Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37
25D Max Cranking Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37
25E Post Crank Seconds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–37
26 Gen Auto Run Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26A Load Start Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26B Load Start Delay Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26C Load Stop Delay Min - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26D 24 Hr Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26E 2 Hr Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–38
26F 15 Min Start Volts DC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39
26G Read LBCO 30 Sec Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39
27 Save/Restore Settings Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39
27A Push INV now to Save Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–39
27B Push GEN to Restore Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40
27C Push GEN for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40
End Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–40
8
Operation
Operating the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2
Operational Status Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3
LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3
Inverter Operation Status (Yellow) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–4
AC Input Status (Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–5
Contents
976-0043-01-02 xv
Charge Status (Yellow and Green) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6
Operational Status Indication (Red and Yellow) - - - - - - - - - - - - - - - - - - - - - - -8–7
Error LED Reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–8
LED Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–9
The User Menu Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–11
Accessing the User Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–14
User Menu Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–15
01 Inverter ON/OFF Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–15
01A Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–15
01B EQ Charge OFF ON - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–16
01C Search Watts (SRCH) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–16
01D Bypass Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–17
02 Generator ON/OFF Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–17
02A Generator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–18
02B Gen Start Load Amps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19
02C Gen Start Volts/Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19
02D Gen Start Exercise Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19
02E Gen Start Run Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19
02F Days Left To Gen Exercise - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19
03 Time Of Day Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
03A SW Plus Software Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
03B System Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
03C Company Name and Address - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
03D City, State, and Zip Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
03E Xantrex Phone Numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20
Press Reset for Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–21
04 Meters Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–22
04A Battery Actual Vdc - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–22
04B Battery Comp Vdc - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23
04C Inverter/Charger Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23
04D Input Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23
04E Load Amps AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23
04F Inverter Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23
04G Grid (AC1) Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
04H Gen (AC2) Volts AC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
04I Frequency Hertz - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
04J Max Bulk/EQ Time h:m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
04K Battery Temp Degrees C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
04L Fan Speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24
05 Error Causes Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25
05A Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25
Contents
xvi 976-0043-01-02
05B Transformer Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25
05C Heatsink Overtemp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26
05D Low Battery Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26
05E High Battery Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27
05F External Err (Stacked) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27
05G Input Relay Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27
05H Gen Failed to Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28
05I Gen Stopped Due to V/F - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28
06 Status Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28
06A Bypass Mode Selected - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29
06B Chr Selected (No Backup) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29
06C Gen Signaled to Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29
06D Gen In Cooldown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–29
06E EQ Charge Selected - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
6F Battery VDC < LBCO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
6G Battery VDC > HBCO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
06H EPO Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
07 GSM/ALM Options Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
07A RY7 (GSM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30
07B RY8 (GSM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
07C RY9 (ALM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
07D RY9 DeEngz. Time Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
07E RY10 (ALM) Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
07F RY10 Engz. Time Minute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
07G RY11 Energized - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31
9
Troubleshooting
Inverter Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–2
Battery Charger Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–4
Error Causes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–7
A.
Inverter Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
Power Versus Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–8
Inverter Capacity versus Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–12
Time versus Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–13
Contents
976-0043-01-02 xvii
B
Configuration Settings
User Menu Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5
Advanced Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–10
C
Battery Information
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2
Deep-cycle Flooded Lead Acid (FLA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2
Sealed Batteries (Gel and AGM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3
NiCad and NiFe Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3
Understanding Battery Capacity Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4
Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4
Understanding Amp-hour Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5
Calculating Amp Hours - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–6
Amp Hour Example Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–7
Battery bank size worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8
Battery Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–9
Wiring Batteries in Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–9
Wiring Batteries in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–10
Wiring Batteries in Series-Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–11
Battery Connections for Stacked Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–12
Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–13
Battery charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–13
Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–15
General Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–16
D
Generators
Two-Wire Start Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2
Three-Wire Start Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2
Honda™ 3-Wire Type Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2
Onan™ 3-Wire Type Generators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–3
3-2 Wire Converters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–3
E
Over-Charge Protection
Overvoltage Protection using a Charge Controller- - - - - - - - - - - - - - - - - - - - - - - - - - - E–2
Diversion Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E–3
Contents
xviii 976-0043-01-02
F
Multi-wire Branch Circuit Wiring
Multi-wire Branch Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–2
Identifying Multi-wire Branch Circuits- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–4
Correcting Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–5
G
Emergency Power Off Switches
The Purpose of an EPO switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -G–2
How to use the EPO Port for an EPO Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - -G–4
Warranty and Product Information
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–1
Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–3
Out of Warranty Service- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–4
Information About Your System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I–5
976-0043-01-02 xix
Figure 1-1 The Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
Figure 1-2 The Front Side of the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
Figure 1-3 The AC side of the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4
Figure 1-4 Certification Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
Figure 1-5 The DC side of the Sine Wave Plus - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6
Figure 1-6 Battery Temperature Sensor (BTS) - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7
Figure 1-7 External Output Circuit Breaker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–8
Figure 2-1 AWG Wire Size Reference Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–13
Figure 2-2 Sample Warning Sticker for Backfeed Conditions - - - - - - - - - - - - - - - - -2–17
Figure 2-3 AC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22
Figure 2-4 DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–23
Figure 2-5 Sine Wave Plus with AC and DC Conduit Boxes Installed - - - - - - - - - - -2–23
Figure 2-6 Fuse Blocks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–24
Figure 2-7 DC250 Disconnect Box and TM500A Battery Status Meter - - - - - - - - - -2–25
Figure 2-8 Accessories for Remote Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - -2–26
Figure 2-9 Inverter Control Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–27
Figure 2-10 Inverter Communications Adapter - - - - - - - - - - - - - - - - - - - - - - - - - - -2–27
Figure 2-11 Generator Start Module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–28
Figure 2-12 Auxiliary Load Module- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–28
Figure 2-13 T240 Autotransformer- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29
Figure 2-14 ISC-S Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29
Figure 2-15 Xantrex C-Series Charge Controllers- - - - - - - - - - - - - - - - - - - - - - - - - -2–31
Figure 2-16 PV Ground Fault Protection (PVGFP) - - - - - - - - - - - - - - - - - - - - - - - - -2–31
Figure 2-17 Off-Grid Application – Renewable Energy System using a Single Inverter 2–33
Figure 2-18 Off-Grid Application – Renewable Energy System using Dual Inverters - -2–35
Figure 2-19 Off Grid Application - Generator-only System using a Single Inverter - - -2–37
Figure 2-20 Off Grid Application – Generator-only System using Dual Inverters,
Series-stacked - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–39
Figure 2-21 On-Grid Application – Backup System using a Single Inverter - - - - - - - -2–41
Figure 2-22 On-Grid Application – Backup System using Dual Inverters,
Series-stacked - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–43
Figure 2-23 Time-of-Use Metering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–45
Figure 2-24 AC Support Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–47
Figure 3-1 Certification Label Location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–6
Figure 3-2 Serial Number Sticker and Knockout Locations and Sizes- - - - - - - - - - - - -3–7
Figures
Figures
xx 976-0043-01-02
Figure 3-3 Dimensional Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Figure 3-4 Wall-Mounting Method using 2 x 4’s - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Figure 3-5 Wall Mounting using Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Figure 3-6 Chassis Ground Lug Location on Inverter DC End - - - - - - - - - - - - - - - - 3–15
Figure 3-7 DC Grounding of a Single Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - 3–16
Figure 3-8 DC Grounding of Dual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17
Figure 3-9 BTS (RJ11) Port Location and Installation- - - - - - - - - - - - - - - - - - - - - - 3–19
Figure 3-10 DC Terminal Connections on the Inverter - - - - - - - - - - - - - - - - - - - - - - 3–20
Figure 3-11 Battery Cable Connection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–21
Figure 3-12 Battery Terminal Covers and Associated Hardware - - - - - - - - - - - - - - - 3–21
Figure 3-13 DC Connections to a Single Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - 3–23
Figure 3-14 DC Connections to Dual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25
Figure 3-15 AC Wiring Access Cover Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–28
Figure 3-16 AC Input/Output Wiring Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - 3–29
Figure 3-17 Connecting the GSM Communications Cable to the Sine Wave Plus - - - - 3–31
Figure 3-18 AC Input and Output Wiring to a Single Inverter
with an Auto-Start AC Generator- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–32
Figure 3-19 AC Output Wiring to the Inverter AC Panel - - - - - - - - - - - - - - - - - - - - 3–34
Figure 3-20 Generator Input Wiring to a Single Inverter - - - - - - - - - - - - - - - - - - - - - 3–37
Figure 3-21 Utility Wiring to the Inverter Input- - - - - - - - - - - - - - - - - - - - - - - - - - - 3–39
Figure 3-22 Series-stacked Inverters with ISC-S Cable- - - - - - - - - - - - - - - - - - - - - - 3–40
Figure 3-23 Remote Monitor Port Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–41
Figure 3-24 Connecting the ALM Communications Cable to the Sine Wave Plus- - - - 3–42
Figure 3-25 Connecting the EPO - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–43
Figure 4-1 Power Up Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Figure 5-1 ICM Display Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Figure 5-2 ICM Display and Contrast Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 5–4
Figure 5-3 ICM ON/OFF Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4
Figure 5-4 ICM Menu Heading Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Figure 5-5 ICM Menu Item Push-uttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Figure 5-6 ICM Set Point Push-buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6
Figure 5-7 ICM Reset Defaults button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6
Figure 5-8 Menu Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7
Figure 5-9 User Menu Map - Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8
Figure 5-10 User Menu Map - Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9
Figure 5-11 Basic Setup Menu Map Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10
Figure 5-12 Basic Setup Menu Map Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11
Figures
976-0043-01-02 xxi
Figure 5-13 Advanced Setup Menu Map Part 1 - - - - - - - - - - - - - - - - - - - - - - - - - - -5–12
Figure 5-14 Advanced Setup Menu Map Part 2 - - - - - - - - - - - - - - - - - - - - - - - - - - -5–13
Figure 5-15 Complete User Menu Map- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14
Figure 5-16 Complete Basic Setup Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–15
Figure 5-17 Complete Advanced Setup Menu Map- - - - - - - - - - - - - - - - - - - - - - - - - 5–16
Figure 6-1 Accessing the Basic Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–10
Figure 6-2 Multi-Stage Battery Charging Process - - - - - - - - - - - - - - - - - - - - - - - - -6–16
Figure 7-1 Accessing the Advanced Setup Menu - Method 1 - - - - - - - - - - - - - - - - -7–11
Figure 7-2 Accessing the Advanced Setup Menu - Method 2 - - - - - - - - - - - - - - - - -7–12
Figure 7-3 Relay 11 Wiring Example to Dual Inverters with Cooldown selected - - - - 7–22
Figure 7-4 Generator Control Mode (GS and RN1)- - - - - - - - - - - - - - - - - - - - - - - - 7–29
Figure 7-5 Generator Control Mode (RN2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–30
Figure 7-6 RY7’s COM and N.O. Contacts Close (energize) to Run Generator - - - - - 7–31
Figure 7-7 Wiring examples of Honda™ and Onan™ Generators - - - - - - - - - - - - - -7–33
Figure 7-8 RY7 and RY8 Timing Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–34
Figure 7-9 RY7/RY8 Sequence of Events for RN1 or RN2 Selection- - - - - - - - - - - - 7–35
Figure 7-10 RY7/RY8 Sequence of Events for GS Selection - - - - - - - - - - - - - - - - - - 7–36
Figure 8-1 LED Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–3
Figure 8-2 Inverter Operation Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–4
Figure 8-3 AC Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–5
Figure 8-4 Charge Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–6
Figure 8-5 Error and Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–7
Figure 8-6 Inverter ON/OFF Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–14
Figure 8-7 Generator ON/OFF Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–14
Figure 8-8 Resetting Factory Default Settings - - - - - - - - - - - - - - - - - - - - - - - - - - -8–21
Figure A-1 Sine Wave Plus Simple Block Diagram - - - - - - - - - - - - - - - - - - - - - - - - A–6
Figure A-2 Sine Wave Plus Inverter Output Waveform - - - - - - - - - - - - - - - - - - - - - A–7
Figure A-3 Power Versus Efficiency Curves for All Models - - - - - - - - - - - - - - - - - - A–9
Figure A-4 Sine Wave Plus Efficiency Curve for the SW Plus 2524- - - - - - - - - - - - - A–9
Figure A-5 Sine Wave Plus Efficiency Curve for the SW Plus 2548 - - - - - - - - - - - - A–10
Figure A-6 Sine Wave Plus Efficiency Curve for the SW Plus 4024 - - - - - - - - - - - - A–10
Figure A-7 Sine Wave Plus Efficiency Curve for the SW Plus 4048 - - - - - - - - - - - - A–11
Figure A-8 Sine Wave Plus Efficiency Curve for the SW Plus 5548 - - - - - - - - - - - - A–11
Figure A-9 Time versus Current for the Sine Wave Plus 2524 - - - - - - - - - - - - - - - - A–13
Figure A-10 Time versus Current for the Sine Wave Plus 2548- - - - - - - - - - - - - - - - A–14
Figure A-11 Time versus Current for the Sine Wave Plus 4024- - - - - - - - - - - - - - - - A–14
Figures
xxii 976-0043-01-02
Figure A-12 Time versus Current for the Sine Wave Plus 4048 - - - - - - - - - - - - - - - - A–15
Figure A-13 Time versus Current for the Sine Wave Plus 5548 - - - - - - - - - - - - - - - - A–15
Figure C-1 6-volt Battery Wiring - “Series” Configuration - - - - - - - - - - - - - - - - - - - C–9
Figure C-2 12-volt Battery Wiring - “Series” Configuration- - - - - - - - - - - - - - - - - - C–10
Figure C-3 Battery Wiring in Parallel (Example Only) - - - - - - - - - - - - - - - - - - - - - C–10
Figure C-4 Step 1 - Wiring Batteries in “Series” - - - - - - - - - - - - - - - - - - - - - - - - - C–11
Figure C-5 Step 2 - Two series strings wiring in “Parallel” - - - - - - - - - - - - - - - - - - C–11
Figure C-6 “Series-Parallel” Configuration Wired to the Inverter - - - - - - - - - - - - - - C–12
Figure C-7 Example of Battery Connections for Stacked Inverters (24 Vdc shown) - - C–12
Figure E-1 Overvoltage using a C-Series Charge Controller- - - - - - - - - - - - - - - - - - - E–2
Figure E-2 Diversion Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E–3
Figure F-1 Conventional Home-type Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–2
Figure F-2 Multi-wire Branch Circuit Wiring and Current Flow - - - - - - - - - - - - - - - - F–3
Figure F-3 120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit - - - - - - F–3
Figure F-4 Multi-wire Branch Circuit Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - F–4
Figure F-5 Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring - F–6
Figure G-1 Emergency Power OFF Disconnect Switch - - - - - - - - - - - - - - - - - - - - - -G–2
Figure G-2 Modifying a 6-conductor Cable to connect to the EPO Port - - - - - - - - - - -G–4
976-0043-01-02 xxiii
Table 2-1 Recommended Minimum Safety Ground Wire and DC Disconnect
Sizes per NEC 2–8
Table 2-2 Recommendced Battery Cable Size Versus Length - - - - - - - - - - - - - - - 2–14
Table 2-3 Battery Cable to Maximum Breaker/Fuse Size - - - - - - - - - - - - - - - - - - 2–15
Table 3-1 AC Disconnect and Wire Sizing- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–27
Table 6-1 Basic Setup Menu Default Settings for the Sine Wave Plus
2524 and 2548 Models 6–2
Table 6-2 Basic Setup Menu Default Settings for the Sine Wave Plus
4024 and 4048 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6–4
Table 6-3 Basic Setup Menu Default Settings for the Sine Wave Plus
5548 Model 6–6
Table 6-4 Battery Voltages For Setting Charging Parameters- - - - - - - - - - - - - - - - 6–21
Table 6-5 Battery Charging Current and Timer Default Settings - - - - - - - - - - - - - 6–21
Table 6-6 Calculating the Maximum Charge Amps for a 24-volt,
700 amp-hour Battery 6–22
Table 6-7 Calculating the Maximum Charge Amps for a 48-volt,
350 amp-hour Battery 6–23
Table 6-8 Calculating the Bulk Done Amps for a 24-volt, 700 amp-hour Battery - - 6–24
Table 6-9 Calculating the Bulk Done Amps for a 48-volt, 350 amp-hour Battery - - 6–24
Table 6-10 Inverter Temperature Compensation Calculation using the BTS- - - - - - - 6–26
Table 7-1 Advanced Setup Default Settings for the Sine Wave Plus
2524 and 2548 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2
Table 7-2 Advanced Setup Default Settings for the Sine Wave Plus
4024 and 4048 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–5
Table 7-3 Advanced Setup Default Settings for the Sine Wave Plus Plus 5548 Models 7–7
Table 7-4 Calculating the Float Done Amps for a 24-volt, 700 amp-hour Battery - - 7–16
Table 7-5 Calculating the Float Done Amps for a 48-volt, 350 amp-hour Battery - - 7–16
Table 8-1 LED Summary Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–9
Table 8-2 User Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–11
Table A-1 Derating from continuous power (VA) at elevated ambient temperatures- A–12
Table B-1 User Menu Default and User Settings - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Table B-2 Basic Setup Default and User Settings for the Sine Wave Plus
2524 and 2548 Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5
Tables
Tables
xxiv 976-0043-01-02
Table B-3 Basic Setup Default and User Settings for the Sine Wave Plus
4024 and 4048 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6
Table B-4 Basic Setup Default and User Settings for the Sine Wave Plus
5548 Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8
Table B-5 Advanced Setup Default and User Settings for the Sine Wave Plus
2524 and 2548 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–10
Table B-6 Advanced Setup Default and User Settings for the Sine Wave Plus
4024 and 4048 Models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12
Table B-7 Advanced Setup Default and User Settings for the Sine Wave Plus
5548 Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–14
Table C-1 Determining Average Daily Load in Amp-hours - - - - - - - - - - - - - - - - - C–7
Table C-2 Determining Battery Bank Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8
Table C-3 Typical Appliance Wattage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–8
Table C-4 Variances in Charging Voltage based on Battery Temperature - - - - - - - C–14
Table C-5 Temperature Compensation Calculation - - - - - - - - - - - - - - - - - - - - - - C–14
Table C-6 Battery State-of-Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–17
1Introduction
Chapter 1, “Introduction” lists and describes the basic features
and parts of the Sine Wave Plus Inverter/Charger.
Introduction
1–2 976-0043-01-02
Basic Features
Congratulations on your purchase of a Sine Wave Plus Inverter/Charger
from Xantrex Technology, Inc. The Sine Wave Plus is one of the finest
inverter/chargers on the market today, incorporating state-of-the-art
technology, high reliability, and convenient control features.
Specific features include:
• FCC Part B compliant
• 2.5 kW, 4.0 kW, or 5.5 kW continuous output of sine wave power for
120 Vac/60 Hz applications (depending on model)
• expandable up to 11 kW for 120/240 Vac/60 Hz applications by
combining dual inverters using the Inverter Stacking Control – Series
(ISC-S) cable
• 24-volt or 48-volt models
• multi-stage battery charging
• battery temperature sensor which provides automatic temperature
compensation for battery charging
• push-button control module with a liquid crystal display (LCD) for
easy programming and troubleshooting
• light emitting diode (LED) display of system operational status
• automatic on/off control of electric-start generators
(requires additional equipment)
• remote monitoring (requires additional equipment)
• auxiliary load control (requires additional equipment)
• high surge/current capacity (depending on the unit, it will surge up to
5.9 times the continuous current rating for a minimum of 2 seconds).
See Appendix A, “Electrical Specifications”.
• energy management features control utility and/or generator usage
• energy efficient to 95% peak and less than 20 watts of idle current;
less than 2 watts in Search Mode
The default settings of the Sine Wave Plus Inverter/Charger allow the
system to perform in many installations without the need for additional
setup. However, if additional setup parameters are required, the push-
button features on the Inverter Control Module (ICM) display on the front
panel of the unit enables the system to be easily reprogrammed to meet
specific customer configurations.
Basic Features
976-0043-01-02 1–3
Front Panel
The front of the Sine Wave Plus has the following features:
• the Inverter Control Module (ICM) Display
• the AC Access Cover
Figure 1-1
The Sine Wave Plus
Figure 1-2
The Front Side of the Sine Wave Plus
AC Access Cover
Inverter Control Module Display
Introduction
1–4 976-0043-01-02
AC Side
The AC side of the Sine Wave Plus has the following features:
• The Remote Monitor Port for connecting a remote Inverter Control
Module (ICM) or the Inverter Communications Adapter (ICA)
• The Stacking Port for connecting two Sine Wave Plus inverters
• The AUX Port for connecting the Auxiliary Load Module (ALM)
• The GEN Port for connecting the Generator Start Module (GSM)
• The EPO Port for connecting an Emergency Power Off (EPO) switch
• Certification Label
• The Grid Tie Interface Port. The Grid Tie feature is currently not
available with the Sine Wave Plus models. However, the port has
been included in the event that the feature can be enabled with an
upgrade at a future date. Continue to check our website
www.xantrex.com for more information and future enhancements on
the Sine Wave Plus Inverter/Charger.
• The Serial Number Sticker is on the rail as shows in Figure 1-3.
Figure 1-3
The AC side of the Sine Wave Plus
Certification Label
Grid Tie
Interface
Port
(not used)
Remote Monitor Port Stacking Port
Serial
Number
Sticker
AUX Port GEN Port EPO Port
Basic Features
976-0043-01-02 1–5
Emergency Power Off (EPO) Option
The Sine Wave Plus offers an Emergency Power Off (EPO) option
through the use of the EPO Port. The EPO feature is designed to shut
down the inverter from a remote location (or switch).
Since the type of the switch will be dependent on the installation, EPO
switches are not provided with the Sine Wave Plus. However, many
commonly available emergency shut off switches will work with the Sine
Wave Plus EPO. Consult your local system designer or qualified
technician for assistance.
The EPO is connected to the Sine Wave Plus with a telephone cord
(RJ11type connector) to the dedicated EPO port on the AC (left) side of
the inverter.
See Appendix G, “Emergency Power Off Switches” for additional
information about this feature and how to prepare a cable for it.
Certification Label
The Sine Wave Plus has been tested to nationally recognized safety
standards and has been found to be free from reasonably foreseeable risk
of fire, electric shock, and related hazards when installed and operated in
accordance with all the instructions provided in this manual and in
accordance with all applicable local and national codes.
Please refer to the Certification Label affixed to the AC side of the
inverter for specific agency information.
See Figure 1-3, “The AC side of the Sine Wave Plus” on page 1–4 for the
location of this information.
Figure 1-4
Certification Label
Model Number
Date of
Manufacture
Certification
Statement
Introduction
1–6 976-0043-01-02
DC Side
The DC side of the Sine Wave Plus has the following features:
• the positive (+) battery terminal
• the negative (–) battery terminal
• the battery temperature sensor port
• the chassis ground lug
Figure 1-5
The DC side of the Sine Wave Plus
Positive (+)
Battery Terminal
Negative (–)
Battery Terminal
Chassis
Ground
Lug
Battery
Temperature
Sensor
Basic Features
976-0043-01-02 1–7
Battery Temperature Sensor (BTS)
A BTS is provided with each Sine Wave Plus Inverter/Charger. This
sensor can easily be installed in the system to ensure proper charging of
the batteries based on temperature. Installing a BTS extends battery life
by preventing overcharging in warm temperatures and undercharging in
cold temperatures.
If more than one BTS is being used, install them adjacent to each other so
that they all detect a common temperature.
See Table C-4, “Variances in Charging Voltage based on Battery
Temperature” on page C–14 and Table C-5, “Temperature Compensation
Calculation” on page C–14 for additional information.
Figure 1-6
Battery Temperature Sensor (BTS)
Introduction
1–8 976-0043-01-02
Top
The top of the unit has the following features:
• Circuit Breaker - This circuit breaker protects the unit’s internal
wiring while the unit is inverter or charging. It is not used for the
pass-through current. This is not a branch-circuit rated breaker.
Separate output breakers are still required. If the button is protruding
from the chassis as shown in Figure 1-7, it means the circuit breaker
has tripped open. Press the breaker back in to reset it.
• Warnings Label
• Ratings Label
Figure 1-7
External Output Circuit Breaker
Top View of Sine Wave Plus Inverter/charger
Ratings Label
Circuit Breaker
AC End DC End
Warnings Label
Circuit Breaker Open Circuit Breaker Reset
2System Configuration
Chapter 2, “System Configuration” contains information to
help you plan for a Sine Wave Plus installation in an off-grid,
on-grid, or backup power application.
System Configuration
2–2 976-0043-01-02
Pre-Configuration Planning
Importance Pre-configuration planning is essential to ensure optimal performance for
your system. This section outlines the components of a system and how
you can plan for them.
Types of Applications
The Sine Wave Plus Inverter/Charger can be configured for the following
applications:
• OFF-GRID (stand-alone) applications where no utility power is
available.
See Figure 2-17 through Figure 2-20 for illustrations of off-grid
applications.
• ON-GRID applications where it can operate the AC loads when the
Utility System (grid) fails, keep the batteries charged, and/or function
as an energy management controller.
See Figure 2-21 and Figure 2-22 for illustrations of on-grid
applications.
System Considerations
You need to consider the following issues as you design your system.
System output How much power will be required and how it will be produced:
❐Single or dual inverters (based on output voltage and output
watts required)
❐Output watts required (i.e., continuous capacity and surge capacity)
❐Output voltage (120 Vac or 240 Vac)
See “System Output Requirements” on page 2–4 for more information.
System input What are the sources of power for your system:
❐Utility power
❐AC generator (See “Generator Considerations” on page 2–19)
Important: Be sure to consult with your local utility company and/or permit
office to ensure that the desired configuration will be code-compliant. Be sure to
obtain the proper licenses and permits as required by law.
Important: Installations of this equipment should only be performed by skilled
personnel such as qualified electricians and Certified Renewable Energy (RE)
System Installers. For a list of Xantrex Certified RE dealers, please visit our
website at www.XantrexREdealers.com.
Pre-Configuration Planning
976-0043-01-02 2–3
❐Renewable energy systems (e.g., PV arrays, wind turbines etc.)
See “System Input Requirements” on page 2–4 for more information.
Location What are the safe, physical environmental requirements for your
installation:
❐Mounting location for optimal performance and easy access of all
components
❐Ventilation and clearance requirements for all components
❐Mounting method (wall or shelf)
❐Additional items/materials required for mounting
❐RFI or EMI considerations
See “Location Considerations” on page 2–5 for additional information.
Grounding What methods of protection and grounding are required:
❐Grounding type (i.e., ground bar, ground bus, or ground rod)
❐Neutral-to-ground bonding requirements
❐Lightning and surge protection
See “Grounding Considerations” on page 2–7 for additional information.
Battery What kind of DC storage will be used:
❐Battery type and size
❐Battery cables and sizes
❐Size of the battery bank and it’s configuration
❐Location of battery bank to rest of system
See “Battery Considerations” on page 2–11 for additional information.
Wiring What is needed/required for the AC and DC wiring for this installation:
❐Types and sizes of wires needed
❐Types and sizes of conduits needed
❐Types and sizes of fuses, disconnects and/or circuit breakers
❐Additional equipment for code compliance (e.g., service panels,
conduit boxes, emergency shutoff switches etc.)
❐Wire routing
See “Wiring Considerations” on page 2–18 for additional information.
System Configuration
2–4 976-0043-01-02
Generator Will a generator be used:
❐Voltage Output Requirements
(120 Vac only, 120/240 Vac, or 240 Vac only)
❐Auto-Start or Manual-Start
See “Generator Considerations” on page 2–19 for additional information.
Additional
equipment What additional equipment is needed:
❐Remote monitors, interface cables, stacking cables, DC charge
controllers, auxiliary load controllers, T240 autotransformers etc.
See “Additional/Optional Equipment Considerations” on page 2–22 for
additional information.
System Output Requirements
Determination Determine the inverter output size requirements by calculating the
maximum, continuous capacity and surge (inrush current) capacity the
system will demand.
• Add all potential loads which would be on at once to determine
continuous power requirements.
• Add the surge current of all loads which might start at once to
determine surge requirements (e.g., washer spinner, waterpump and
refrigerator compressor could all start at once).
More information See Appendix C, “Understanding Amp-hour Requirements” for
assistance in determining the System Output Requirements.
System Input Requirements
Determination Determine the input requirements based on the output requirements. In
other words, is grid power available or will renewable energy equipment
be used? Will a generator be used to supplement or backup the other input
sources?
More information See “Generator Considerations” on page 2–19 and Appendix D,
“Generators” for additional information regarding using generators for
system input.
Important: Auto-start generators require the addition of the GSM to enable
the inverter to control the operation of the generator.
Pre-Configuration Planning
976-0043-01-02 2–5
Location Considerations
Dry Inverters contain sophisticated electronic components and should be
located in a well-protected, dry environment away from sources of
fluctuating or extreme temperatures and moisture.
The better the environment, the longer the inverter will last. Consider
installing your inverter in the same type of location in which you would
store high quality electronic equipment of equal value.
Avoid saltwater Exposure to saltwater is particularly destructive and potentially
hazardous. Internal corrosion caused by improper installation may cause
the inverter to prematurely fail and additionally will void the warranty.
Close to battery
bank Locate the inverter as close to the batteries as possible in order to keep the
battery cable length short. However, note the following warnings and
important notes about inverter location.
RFI Interference Inverters can generate radio frequency interference (RFI). Locate any
sensitive electronic equipment susceptible to RFI as far away from the
inverter as possible. This includes radios and televisions.
Electromagnetic
Interference Inverters can emit strong electromagnetic fields. This should be
considered when choosing an installation location.
See “FCC Information to the User” on page viii for additional
information regarding RFI requirements.
WARNING: Explosion and Corrosion Hazard
Do not locate the inverter directly above the batteries or in the same compartment
as vented batteries.
Vented batteries generate hydrogen and oxygen, which if accumulated, can be
ignited by an arc caused by connecting the battery cables or switching a relay.
Vented batteries also generate hydrogen-sulfide gas, which is corrosive to
electronic equipment.
Batteries can sometimes release explosive gas, please see the battery
manufacturer’s recommendations for ventilation requirements.
CAUTION: Damage to Inverter
Do not mount the inverter in the same space as the generator. The heat and dust
from the generator can damage the inverter.
System Configuration
2–6 976-0043-01-02
Fire Safety All Sine Wave Plus inverter/chargers meet UL fire safety standards as
outlined in UL 1741. As such, in the event of a failure, the Sine Wave Plus
is designed to fail safe. Be sure the specific mounting and ventilation
requirements outlined in this Owner’s Manual are followed carefully.
Do not locate the inverter near readily flammable materials such as cloth,
paper, straw, plastic etc. Flammable materials should be kept a minimum
distance of 24 inches (60 cm.) from the top surface (when wall mounted)
and 12 inches (27 cm.) from either side surface and the front of the Sine
Wave Plus. Readily flammable materials refers to instantly combustible
substances such as cloth, paper, straw, and plastic sheeting.
Mounting Considerations
Method The inverter can be mounted on a vertical surface (or wall) or on a shelf.
The advantage of the wall mounting is to provide easier access to the
controls and displays.
Securing The mounting surface (wall or shelf) must be capable of supporting twice
the weight of the inverter. The keyhole slots should not be used as the
only method of securing the unit to the mounting surface. Use all ten
mounting holes and all four keyhole slots for securing the unit and use
0.25-inch diameter bolts for mounting.
Ventilation Requirements
Location Install the inverter in a well-ventilated area/enclosure for proper
operation. The inverter’s thermal shutdown point will be reached sooner
than normal in a poorly ventilated environment resulting in reduced peak-
power output and surge capability as well as shorter inverter life.
Requirements Provide a minimum clearance of 6 inches (12 inches is preferred) around
the top and 6 inches at the AC- and DC-side of the inverter for ventilation.
A fan-forced, fresh-air vent (on the inverter’s AC side) allows cool air to
enter the unit and exit from the DC-end of the inverter. Ensure that this
vent is not obstructed with foreign objects, such as dirt and dust and that
the minimum clearances are met.
Airflow clearance All air ventilation openings should have 6 inches of clearance and there
should be no nearby cover over the top of the unit. This is to prevent
warm, exhausted air from the unit from being drawn back into it. The
warm air could cause premature shutdown due to overheating.
Screening The unit is equipped with screening to prevent insects and rodents from
entering. This screening needs to be checked and cleaned regularly from
the outside to prevent dust buildup.
Pre-Configuration Planning
976-0043-01-02 2–7
Grounding Considerations
Types Whether you are installing a new system or integrating new parts into an
existing system, the four types of grounding to consider are:
• DC system grounding
• Inverter grounding
• Chassis grounding
• Bonding the grounding system
DC System Grounding
Systems The Sine Wave Plus can be used in either a positive or negative grounded
system. However, unless you are installing the inverter into an existing
positive grounded system (i.e., a telecommunications system), it is highly
recommended to use negative grounding.
Positive ground In a positive ground, the positive conductor from the
battery bank is bonded to earth ground. This arrangement is most often
used in telecommunications systems where an isolated ground is a
requirement.
Negative ground In a negative ground, the negative conductor from the
battery bank is bonded to earth ground. This is the most common form of
grounding methods used for residential and commercial applications. The
Sine Wave Plus meets FCC part 15 Class B regulations in a negative
grounded system. See “FCC Information to the User” on page viii for
additional information.
Convention The remainder of this guide will assume the negative ground convention.
Important:
The grounding requirements vary by country and by application.
All installations must comply with national and local codes and ordinances.
Consult local and/or national codes and the NEC/CEC for specific grounding and
bonding requirements for the desired installation.
Important:
The bonding of the DC negative (or positive in positive ground
applications) to ground can only be in one location in the DC system. This DC
ground bond must be made in a non-serviceable item in the DC system. The
Xantrex DC175 and DC250 can have the optional DC Bonding Block (DCBB)
installed to provide the DC system bond. Additionally, the Xantrex PVGFP can
also provide this bond and comply with NEC/CEC requirements for roof
mounted PV arrays installed on dwelling units (homes).
System Configuration
2–8 976-0043-01-02
Inverter Grounding
Requirement The inverter/charger should be connected to a grounded, permanent
wiring system with the AC and DC grounds commonly bonded to each
other and should be bonded to the grounding system at only one point in
the system. See “Bonding the Grounding System” on page 2–10 for
additional information.
Conductor size The size for the grounding conductor is usually based on the size of the
circuit breaker in the DC system. Table 2-1 provides battery DC
disconnect sizes and minimum wire sizes of copper ground wires for
grounding systems.
It is recommended that the size and gauge of grounding wire should be
more than the NEC/CEC minimum requirements when installing power
sources such as inverter/chargers or generators.
WARNING: Shock Hazard
Attach the ground lead BEFORE attaching any AC or DC power connections.
Table 2-1
Recommended Minimum Safety Ground Wire and
DC Disconnect Sizes per NEC
Battery DC
Disconnect Size
Minimum Size of Copper
Ground Wire
30 amp or 60 amp #10 AWG
100 amp #8 AWG
200 amp #6 AWG
300+ amp #2 AWG or greater
Note: Field experience has demonstrated that long distances or high
impedance grounds can cause equipment malfunction or damage.
WARNING: Explosion Hazard
Never use a gas pipe or gas line for grounding purposes. The inverter is a power
source and it is intended to be grounded at the service/main ground rod.
Pre-Configuration Planning
976-0043-01-02 2–9
Equipment or Chassis Grounding
Equipment or chassis grounding connects the metallic chassis of the
various enclosures together to have them at the same voltage potential,
thus reducing the possibility for electric shock. It also provides a path for
fault currents to flow through to blow fuses or trip circuit breakers. The
size of the connecting conductors should be coordinated with the size of
the over-current devices involved. Under some circumstances, the conduit
and enclosures themselves will provide the current paths.
Grounding Electrodes/Ground Rods
Purpose The purpose of the grounding electrode (often called a ground rod) is to
maintain the potential of equipment tie to it at “ground” potential to avoid
a shock hazard. It also shunts to ground fault currents and currents due to
ground tied filtering.
Size The size for the conductor to the grounding electrode or grounding system
is usually based on the size of the largest conductor in the system. Most
systems use a copper-plated rod as the grounding electrode. The rod
should be 5/8 inch (16 mm) round by 8 feet (2 meters) long and driven
into the earth. It is also common to use copper wire placed in the concrete
foundation of the building as a grounding system. Either method may be
acceptable, but the local code will prevail. Connection to the ground
electrode should be done with special clamps located above ground where
they can be periodically inspected.
Number of rods Many large systems use multiple ground rods. The most common
example is providing a direct path from the solar array to earth near the
location of the solar array. Most electrical codes expect multiple ground
rods to be connected by a separate wire with its own set of clamps. If this
connection is done, it is a good idea to make the connection with a bare
wire located outside of the conduit (if used) in a trench. The run of buried
WARNING: Shock Hazard
Attach the ground lead BEFORE attaching AC or DC power connections.
Note:
This inverter, along with all other power electronic devices in your
system, are subject to severe damage from the effects of lightning. Lightning
damage is not covered by your warranty. If your installation is in an area of
high probability for lightning, you should consult with a local lightning expert
or your authorized Xantrex installer to determine what extra precautions should
be taken to protect your equipment.
System Configuration
2–10 976-0043-01-02
wire may be a better grounding electrode than the ground rods. Well
casings and water pipes can also be used as grounding electrodes. Under
no circumstance should a gas pipe or line be used.
Bonding the Grounding System
Definition Bonding means connecting one of the current-carrying conductors
(usually the AC neutral and DC negative) to the grounding system. When
the other ungrounded conductor (the hot or positive) touches the
grounding system, current will flow through it to the point of connection
to the grounded conductor and back to the source. This will cause the
over-current protection to stop the flow of current, protecting the system.
This point of connection between the grounding system (ground rod), the
current carrying grounded conductor (AC neutral and DC negative), and
the equipment grounding conductor (green ground wire, equipment
ground) is called a “bond”.
Bonding locations Bonding is usually located in the over-current protection device
enclosures (both AC and DC).
Residential systems In residential systems bonding is located at the
utility panel, after the power has gone through the kilowatt-hour meter of
the utility (if present).
Renewable energy systems Renewable energy systems, with no grid
connection, can be grounded at the main AC distribution panel.
Renewable energy systems should be grounded to the same grounding
electrode as the AC distribution panel.
Bonding should not be done at the inverter. Codes do not generally allow
it because the inverter is considered a “serviceable” item that may be
removed from the sytem, in which case, the bonding would be broken.
Bonding at one
point
Bonding must be done at only one point in an electrical system.
Inherently, Xantrex systems have two separate electric systems; a DC
system and an AC system. This means that two bonding points will occur
in all inverter applications. The bonding point will also be connected to
the equipment (chassis) grounding conductors. It is common to have two
separate conductors connect the ground electrode and the two bonding
points. Each conductor should use a separate clamp.
Guidelines The ground and neutral must be bonded at one place, and only one
place, in the system. Use the following guidelines for ground and neutral
bonding:
Important:
Consult local codes and the NEC/CEC for more information.
Pre-Configuration Planning
976-0043-01-02 2–11
Generator If the generator is the main source of power, (that is, no
utility grid power) then the neutral and ground connections are bonded at
the main AC distribution panel.
Utility grid If the utility grid is the main source of power, then the bond
should be at the utility AC distribution panel.
No utility or generator If there is no utility or generator in the system,
then the ground/neutral bond should be in the inverter AC distribution
panel.
Battery Considerations
Accessibility Locate the batteries in an accessible location if maintenance is required.
Two feet clearance above the batteries is recommended for access to the
battery caps. They should be located as close to the inverter as possible
without limiting access to the inverter’s disconnects. Install the batteries
to the right of a wall-mounted inverter for easy access to the DC side of
the inverter and shorter cable runs. The battery bank may also be placed
on the opposite side of the wall on which the inverter is mounted.
Vented enclosures For safety and to limit access to the batteries, the batteries should be
housed in an enclosure or dedicated room that can be locked or screened,
and ventilated. It should be vented to the outside by a 1-inch minimum
vent pipe located at the top of the enclosure. An intake vent should be
installed at the bottom of the enclosure to promote air circulation.
Enclosure
requirements
The enclosure should be made of an acid resistant material or have a
finish that resists acid to prevent corrosion and must be capable of
containing the electrolyte from at least one battery should a leak occur.
Enclosures located outside must be rainproof and screened to prevent
access by rodents or insects and insulated from extreme temperatures.
Batteries will give their best performance and service life when operating
in a 20 to 25 °C (68 to 77° F) environment.
CAUTION: Damage to Equipment
The Sine Wave Plus is intended to operate with batteries as its source of DC
power. Do not connect DC charging sources, such as PV arrays, wind turbines, or
micro-hydro turbines, directly to the Sine Wave Plus. If DC charging sources are
connected directly to the inverter, the DC rating of the inverter can be exceeded
and the inverter can be damaged.
Important: These vents exhaust corrosive and explosive hydrogen sulfide
gases and must not be overlooked when designing an enclosure.
System Configuration
2–12 976-0043-01-02
More information Consult your battery vendor for additional information on battery
enclosure requirements.
Battery Bank Requirements
Determining
requirements To determine your battery requirements you need to know what type of
batteries to use, the number of batteries for the battery bank, and how to
configure the bank to optimize voltage output according to system
requirements.
See Appendix C, “Battery Information” for additional information on
determining battery bank type and configuration.
The DC voltage of your inverter must match the DC voltage of your
system and all of its accessories. If you have a 24-volt inverter, then the
battery bank and all other DC devices in the system must be configured
for 24 volts.
Battery Cable Requirements
Size and length Battery cables must be the correct size and length to optimize
performance and ensure the safety of the system. Larger diameter cables
(smaller AWG number) have less voltage drop and are, therefore, more
efficient when transferring power to and from the batteries. The use of
oversized cables (e.g., 4/0 cables) will allow you to take advantage of the
improved surge performance of the Sine Wave Plus inverters.
Note:
Based on the peak current of the inverter, the minimum allowed
battery bank is 100 Ah. The recommended battery bank size is determined by
the battery bank worksheet in Appendix C (Table C-1, “Determining Average
Daily Load in Amp-hours” on page C–7). The inverter is designed to operate
with batteries and should not be operated without them.
WARNING: Fire Hazard
Undersized cables can overheat and melt, creating a fire hazard when subjected
to heavy (peak) loads. Always use a cable of proper size and length, rated for the
amperage of the inverter and batteries.
Important:
Use only fine, stranded copper cables for battery and inverter DC
connections. Do not use coarse, stranded wire, as the lack of flexibility may
damage battery and inverter terminals.
Pre-Configuration Planning
976-0043-01-02 2–13
Important
recommendation Follow the battery cable recommendations listed in this guide. It is
absolutely imperative that you adhere to the battery cable size (wire
gauge) and length recommendations provided in this section. If cables are
used that are too long or of insufficient gauge (i.e., the diameter is too
small), then inverter performance will be adversely affected.
In addition to poor inverter performance, undersized cables can result in
fire caused by overheating wires. Any damage to the inverter caused by
overheating from undersized wire is not covered by the Xantrex warranty.
Battery cable length Cable length is another important factor. Runs should be kept as short as
practical. Longer cable runs increase resistance, thus lowering the overall
efficiency of the system. This is especially true in lower voltage systems
where, depending upon the length of the cable run, it may be necessary to
oversize the diameter of the wire, or parallel (double) the cables. Table 2-
2 provides recommended minimum cable sizes for various cable lengths
Important:
Figure 2-1 is for reference only. Sizes shown are for the
conductor. Do not include any insulation, or sheathing, when determining your
wire size. Due to printing anomalies, these dimensions may not be to scale.
Figure 2-1
AWG Wire Size Reference Chart
12
.072 10
.115 8
.146 6
.184 4
.235
14
.073
Size
iameter 3
.281 2
.295
3/0
.475 4/0
.530
2/0
.420
1
.335 1/0
.380
Size
Diameter
250 MCM
.580 300 MCM
.635 350 MCM
.690 400 MCM
.730 500 MCM
.820
Size
Diameter
System Configuration
2–14 976-0043-01-02
and inverter amperage per NEC/CEC guidelines. It is recommended that
the cable has battery acid resistant insulation and is rated for 90 °C
(32 °F) or better.
Be sure to check with any local regulatory agencies for additional
requirements.
Battery cable lugs Battery cables must have crimped copper compression lugs or crimped
and soldered copper compression lugs. Soldered connections alone are
not acceptable.
High quality battery cables are available from Xantrex in an assortment of
lengths from 1½ to 10 feet in #2/0 AWG and from 1½ to 15 feet in
#4/0 AWG sizes. These cables are color-coded with pressure crimped,
sealed ring terminals.
Overcurrent
protection For safety and compliance with regulations, battery overcurrent
protection is required. Fuses and disconnects must be sized to protect the
wiring in the system and are required to open before the wire reaches its
maximum current carrying capability.
Xantrex DC175 and
DC250
The NEC/CEC requires both overcurrent protection and a disconnect
switch for residential and commercial electrical systems. These items are
not supplied as part of the inverter. However, Xantrex offers a DC circuit
breaker disconnect module specifically designed for use with Xantrex
Table 2-2
Recommendced Battery Cable Size Versus Length
Inverter
Model
Maximum
Continuous
DC ampsa
a. “Maximum Continuous DC amps”, as shown in this table, is based on low
battery voltage with an efficiency of 85%.
NEC
ampsb
b. “NEC amps”, as shown in this table, is based on low battery voltage, and
efficiency of 85%, and a 125% NEC derating.
Up to 5 Feet
One-way
Up to 10 Feet
One-way
Up to 15 Feet
One-way
2524 134 167 #2/0 AWG
(67.4 mm2)
#4/0 AWG
(107 mm2)
Not
Recommended
2548 67 84 #2/0 AWG
(67.4 mm2)
#4/0 AWG
(107 mm2)
#4/0 AWG x 2
(107 mm2 x 2)
4024 214 267 #4/0 AWG
(107 mm2)
#4/0 AWG x 2
(107 mm2 x 2)
Not
Recommended
4048 107 134 #2/0 AWG
(67.4 mm2)
#4/0 AWG
(107 mm2)
Not
Recommended
5548 147 184 #4/0 AWG
(107 mm2)
#4/0 AWG x 2
(107 mm2 x 2)
Not
Recommended
Pre-Configuration Planning
976-0043-01-02 2–15
inverters to meet NEC/CEC compliance. Two amperage ratings are
available: a DC250 (250 amps) and a DC175 (175 amps) in either single-
or double-pole configurations for single or dual inverter installations.
See “DC Disconnect Boxes (DC175/DC250)” on page 2–24 for
additional information on the Xantrex DC175 and DC250.
After selecting battery cables based on the distance from the battery bank
to the inverter, add battery overcurrent protection in the battery cable line,
based on Table 2-3. This table will help you to determine your maximum
breaker/fuse size based on the cable size you selected previously.
Fuse Block (TFB) Some installations may not require conduit(s) or a disconnect device,
however, overcurrent protection is still required. Xantrex offers a fuse
block (TFBxxx) providing the code-required inverter overcurrent
protection for these applications. These fuses are available in 110, 200,
300 and 400 amp sizes.
Battery Requirements for Dual Inverter Systems
The success of “stacked” or “dual” inverter systems is dependent on the
quality and maintenance of the DC connections. Stacked inverter sets are
far less forgiving to long, undersized, uneven, and/or poor connections
than are single inverters.
Dual inverters
(not stacked) Dual inverter configurations can be used without using the stacking
interface cable. In this configuration, two inverters separately run isolated
loads from the same battery bank or individual battery banks.
Table 2-3
Battery Cable to Maximum Breaker/Fuse Size
Cable Size Required
Rating in
Conduit
Maximum
Breaker/Fuse
Size
Rating in
“Free Air”a
a. The term “free air” is defined by the NEC/CEC as cabling that is not
enclosed in a conduit or a raceway. Cables enclosed in conduit or
raceways have substantially lower continuous current carrying ability due
to heating factors.
Maximum
Breaker/Fuse
Size
#2/0 (00) AWG 175 Amps 175 Amps 265 Amps 300 Ampsb
b. The NEC/CEC allows rounding to the next highest standard fuse size
from the cable rating (i.e., 150 amp cable size rounds up to a standard
175 amp size).
#4/0 (0000) AWG 250 Amps 250 Amps 360 Amps 400 Ampsb
Important: From this point on in this guide, any reference made to a “DC
disconnect” means either a DC breaker or a fuse with a disconnect switch, which
will depend on your specific type of installation.
System Configuration
2–16 976-0043-01-02
Series stacked When inverters are “stacked” they must operate from a common battery
bank. In other words, the DC negative of one inverter must be common
with the second inverter and likewise for the DC positive.
For example:
If you have eight 6-volt batteries in a 24-volt configuration, they
would be arranged in two rows of four batteries (see Appendix C for
diagrams of various arrangements).
The negative ends of the two “strings” of batteries must be jumpered
together to become common with each other.
Likewise, the positive ends of the two “strings” must also be
jumpered together so that they are also common with each other.
Shunts near the
inverter Losses from the cables will cause each inverter to measure slight
differences in actual voltages, in spite of having the battery bank common
to both inverters. It is easy to have the DC negatives common closer to the
inverters if an in-line metering shunt is installed near the inverters before
the negative cables attach to the negative battery terminal.
Jumpers The use of optional bonding jumpers can improve how each inverter
measures the DC voltage. These measurements are used to determine
when charging amperages should be reduced as the batteries become
charged. The bonding jumpers allow the inverters to agree better on what
the voltage actually is. The longer the DC cables are, the more likely you
will need bonding jumpers.
Shunts near the
batteries
If a shunt is installed closer to the battery bank than the inverters, a
bonding jumper should be installed from one inverter’s negative terminal
to the other inverter’s negative terminal. By using a negative bonding
jumper and/or a metering shunt near the inverters, the inverters will have
a better zero volt (DC negative) reference to measure the DC voltage.
DC disconnects The DC positive is more difficult due to the need to have DC disconnects
in each cable for the inverters. The primary reason for the DC disconnects
is for overcurrent protection for the cable it is installed in. By using a
positive bonding jumper the inverters will have a more accurate DC
positive reference to measure the DC voltage.
Bonding Jumpers A bonding jumper may be installed from one inverter’s positive terminal
to the other inverter’s positive if a warning is placed near the DC
disconnects. This means that either DC disconnect can energize both
inverters while the other DC disconnect is not yet turned on. This is called
“backfeeding” a disconnect or circuit breaker. The 2002 NEC,
Section 404.6, C, Exception, allows switches to be backfed if a warning
such as the following is permanently marked on or adjacent to the
Pre-Configuration Planning
976-0043-01-02 2–17
disconnect switches. A sample of this warning label is provided in Figure
2-2. These labels are not available or provided by Xantrex, but may be
available from your local electrical warehouse.
DC disconnects and
overcurrent devices The size of the bonding jumper must be the same gauge as that of the
primary battery cable in which the overcurrent device (DC disconnect) is
installed, and as always, the overcurrent device must be sized
appropriately for all cables attached to it. If one overcurrent device trips
then there will be only half the amount of current available for both
inverters to run from. If you want to run only one inverter while the other
is shut down (for example, for maintenance procedures), the positive
bonding jumper must be removed or there must be an appropriately sized
switch installed in the bonding jumper.
Battery Temperature
Cold temperatures Cold temperatures drastically reduce battery capacity and performance.
Therefore, the battery enclosure should provide a fairly stable temperature
for the batteries. If batteries are installed in a cold environment, insulation
should be installed to protect the batteries from the cold. The insulation
will act as a barrier to the cold and also keeps the heat generated by the
batteries inside the enclosure providing a more stable temperature and
better system performance.
Hot temperatures High battery temperatures shorten the life of the batteries. The battery
enclosure should not be installed in direct sunlight where the sun can
overheat the batteries. Locate the enclosure where it will be protected
from the sun and provide vents in the top and bottom of the enclosure to
provide air flow throughout the enclosure.
For best performance, locate the batteries where they are in a room
temperature of 20 to 25 °C (68 to 77 °F)
Battery temperature
sensor A Battery Temperature Sensor (BTS) is provided with each Sine Wave
Plus. This sensor can easily be installed in the system to ensure proper
charging of the batteries based on temperature. Installing a sensor extends
battery life by preventing overcharging in warm temperatures and
undercharging in cold temperatures.
Figure 2-2
Sample Warning Sticker for Backfeed Conditions
WARNING: Shock Hazard
Load side terminals may
be energized by
backfeed.
Not provided by Xantrex.
May be available at your local
electrical warehouse.
System Configuration
2–18 976-0043-01-02
See “Installing the Battery Temperature Sensor (BTS)” on page 3–18 for
instructions on installing the Battery Temperature Sensor.
Wiring Considerations
Conduit boxes For maximum safety and, in some cases, for code-compliance, run the AC
and DC cables in conduit(s). Pre-plan the wire and conduit runs carefully
before installing any components.
Main AC
distribution panel
(utility fed)
The AC1 input to the inverter requires a 60-amp breaker maximum be
installed into the main AC distribution panel (double-poled if stacked) to
protect the wiring in accordance with NEC. This breaker supplies utility
grid power to the inverter. AC1 is not used in off-grid applications.
Generator
disconnect switch Installing a disconnect switch with an appropriately sized circuit breaker
(60 amp maximum) between the generator and inverter provides over-
current protection for the wiring between the generator and the inverter’s
AC2 terminal. This is also a good safety practice as it also provides a
means to prevent the inverter wiring from becoming energized in the
event that an electric-start generator starts unexpectedly while the inverter
is being serviced.
Subpanel/Inverter
Panel In on-grid applications, loads backed up by the inverter will need to be
rerouted from the main AC distribution panel to a subpanel. In off-grid
application, the inverter panel functions as the main electrical panel.
Always use properly rated circuit breakers.
Fuses and/or DC
disconnects
Install a DC disconnect breaker or fuse in the positive, ungrounded,
battery line. This breaker protects the DC wiring in the event of an
accidental short. Size the breaker in accordance with the battery cables.
Switch this breaker OFF (or remove the fuse) whenever servicing the
batteries or inverter(s).
Important:
Be sure to consult the local and national electrical codes to confirm
grounding and bonding requirements specific to the intended system. All wiring
and installation methods should conform to applicable electrical codes and
building codes.
WARNING: Fire Hazard
Check existing structure wiring for “multi-branch wiring”. For new construction,
do not use “multi-branch wiring”.
For both cases refer to Appendix F, “Multi-wire Branch Circuit Wiring” for
additional information.
Pre-Configuration Planning
976-0043-01-02 2–19
Wire size for AC
connections A minimum of #6 AWG THHN wire is recommended for all AC wiring
(input and output).
Wiring scenarios Determine all wire routes both to and from the inverter and which
knockouts are best suited for connecting the AC conduits. Possible
routing scenarios include the following.
• AC and DC grounds to an external ground rod
• AC input wiring from the main service panel to the inverter/charger
(on-grid applications only)
• AC input wiring from the generator to the inverter/charger (if used)
• AC output wiring from the inverter/charger to the subpanel
• DC input wiring from the PV array to the controller/batteries
• DC input wiring from the batteries to the inverter/charger
• BTS cable from the batteries to the inverter/charger (keep separate
from battery cables)
• Remote ICM cable to the inverter/charger (if used)
• Load circuit wiring rerouted from the main service panel to the
subpanel (on-grid applications only)
Generator Considerations
Purpose An engine generator can be used as follows:
• as an input power source instead of (or in conjunction with) the utility
power
• as a backup power source (connected with additional hardware) to
automatically power the loads when utility is not present (utility
outage)
• as a means to charge the batteries.
Note: A fuse without a switchable disconnect alone does not meet
NEC/CEC code.
Important:
Check for existing electrical wiring or plumbing prior to making
cuts in the walls. Cut holes in the walls at appropriate locations for routing
wiring/cables.
Important: The information contained in this guide is basic wiring
information which can aid the generator manufacturer or electrician in assisting
with your installation. Xantrex is not responsible for providing detailed technical
support or wiring instructions for generator operation.
System Configuration
2–20 976-0043-01-02
Stable Voltage The generator should provide a stable voltage and frequency output for
the inverter to synchronize with.
AC wind turbines and small scale AC water turbines are not
recommended for use as AC power sources as they may not be able to
provide a stable voltage and frequency as loads and charger requirements
change. The only way to practically use sources such as these is to take
the AC power and rectify it into DC. Be sure to include a diversion type
controller (e.g., Xantrex C-Series) to protect the batteries from
overcharging.
Types of Generators
There are AC generators and DC generators.
AC Generators AC generators can power AC loads and charge batteries. An AC
generator is better suited for residential applications, since the majority of
loads require AC power.
DC Generators DC generators can power DC loads and charge batteries. In a residential
application, DC generators are primarily used to charge the batteries.
Output
Requirements An AC generator can output 120 Vac only, 120 Vac and 240 Vac together,
or 240 Vac only depending on the overall needs of the system. The
generator must be large enough to provide adequate power to charge the
batteries and support a certain amount of AC loads. If the generator is not
large enough, the amount of time it takes the inverter to charge the
batteries will increase.
A DC generator is used primarily to charge the batteries. AC loads are
only powered by the energy stored in the batteries. The generator must be
large enough to provide adequate power to charge the batteries.
Generator start types
Starting types Generators can either be manually started, or when properly equipped,
automatically started. The Sine Wave Plus can operate well with either
kind of generator. It is recommended, however, to consult the desired
generator’s manufacturer to ensure the generator of choice is best suited
for the desired application.
Manual-start and
electric-start
generators
When using a manual-start or electric-start generator, the generator is
connected to the inverter AC2 input but is not controlled by the inverter.
The starting and stopping of the generator occurs at the generator.
Manual-start generators are started with a recoil-start pull cord. Electric-
start generators are started by turning an ignition/starter key, switch, or
similar means.
Pre-Configuration Planning
976-0043-01-02 2–21
Manual-start and electric-start generators typically do not have self-
protection features to shut down the generator in the event of low oil
pressure, over-heating, overcranking, etc., and, therefore, are not designed
for unattended starting and operation.
If using a manual-start or electric start generator, be sure that the
generator is located where it can be easily accessed to be started.
Auto-start
generators When using an auto-start generator, the generator is connected to the
inverter AC2 input. The inverter controls the operation of the generator
with the assistance of the optional GSM. Auto-start generators are
equipped with terminals for signal wires to be routed and connected to a
remote switch/relay (a "dry contact") to signal the generator to run and/or
stop.
Auto-start generators are equipped with self-protection features to disable
starting and/or to shut down a generator in the event of low oil pressure,
over-heating, overcranking, etc. When generators are equipped with these
protection features, they are designed for unattended starting and
operation and may be compatible with the Sine Wave Plus with the
optional GSM.
Be sure to locate an auto-start generator in a place protected from
extremes of temperature so it can successfully start and operate without
assistance.
Starting
requirements The generator can be set to start based on four different, user-specified,
scenarios with different requirements for each:
• battery voltage
• inverter load current
• time of day
• exercise time
If used with an application that includes utility power, the generator will
be started only if utility power is not available, as it is not possible to use
both generator and utility power at the same time (except for the
scheduled exercise time).
It is safe for both the utility and generator inputs to be energized at the
same time, although the inverter can only take power from one source at
any given time.
Important:
The automatic generator start feature of the Sine Wave Plus can
only function on generators equipped with two- or three-wire auto-start operation.
Most auto-start generators have this feature. Check with your generator supplier
and make sure this feature is available. Additional hardware may be required.
System Configuration
2–22 976-0043-01-02
See “Generator Starting Scenarios” on page 7–23 of this guide for
specific instructions on setting the generator-start/stop conditions.
Additional/Optional Equipment Considerations
The following components are available for use with the Sine Wave Plus.
Some of these items may be required depending upon the intended use of
the inverter to make the installation code-compliant. These components
are not provided with the inverter and must be purchased separately.
AC Conduit Box (ACCB)
The AC Conduit Box (ACCB) connects to the AC side of the inverter and
accepts AC conduit runs. The AC conduit box includes bypass/disconnect
breakers.
Important: Be sure to consult with your local inspector and/or utility
company to ensure complete compliance with local regulations.
Figure 2-3
AC Conduit Box
Additional/Optional Equipment Considerations
976-0043-01-02 2–23
DC Conduit Box (DCCB)
The DC Conduit Box (DCCB) connects to the DC side of the inverter and
accepts DC conduit runs.
Figure 2-4
DC Conduit Box
Figure 2-5
Sine Wave Plus with AC and DC Conduit Boxes Installed
System Configuration
2–24 976-0043-01-02
Fuse Block
The Xantrex fuse block (TFBxxx) protects the power system’s DC wiring
should an overcurrent condition occur. The fuse block is placed between
the battery’s ungrounded conductor (usually the positive cable) and the
DC input terminal of the inverter.
The fuse block includes a fast acting, current limiting class-T fuse
providing extremely fast protection when a short circuit occurs. When the
fuse is properly matched to the system current, its time delay allows the
inverter to surge to full power without blowing the fuse. A plastic cover
prevents accidental short circuits to the fuse terminals. Fuse sizes include
110, 200, 300, and 400 amps.
There are two types of fuse blocks available. The TFBxxxC fuse block
has “set” screw lugs for cables with no terminal connector’s on the ends
(known as C-type or stripped-end battery cables). The TFBxxx fuse block
has stainless steel bolt connections for cables with ring terminals (known
as ring-lugged battery cables). Both fuse blocks include a black poly
carbonate, fiberglass reinforced base and a clear poly carbonate snap-on
cover.
DC Disconnect Boxes (DC175/DC250)
Xantrex provides two options for disconnect boxes. The DC175 and
DC250 protects your batteries, inverter, and DC cables from damage
caused by short circuits and overloads through use of a UL listed, high
interruption capacity circuit breaker. This breaker is designed to interrupt
the tremendous amount of power a battery can deliver when short
circuited. It is also designed to have a long enough time delay to allow the
inverter to surge to full power without nuisance tripping of the breaker. If
the breaker does trip, it’s easily reset.
Figure 2-6
Fuse Blocks
Fuse Block for C-type
(stripped end) Battery Cables
(TFBxxxC)
Fuse Block for Ring-lugged
Battery Cables (TFBxxx)
Additional/Optional Equipment Considerations
976-0043-01-02 2–25
Battery Status Meter (TM500A)
The TM500A features six data monitoring functions and three indicators
including:
• State-of-charge/amp-hour content (full or percent of capacity)
• State-of-charge/voltage (real-time voltage level, historical high and
low system voltage)
• Amps (real-time amps, total charging amps, total load amps)
• Amp hours removed
• Days since fully charged
• Cumulative amp hours
• Recharge indicator
• Low-voltage indicator
• Full-charge indicator
The unit is configurable for specific system or application functions such
as setting the CHARGED indication parameters, battery capacity,
charging efficiency, low-battery warning conditions and a recharge
reminder. The TM500A can monitor any battery supply from
approximately 8 to 65 volts, track energy consumption, and estimate
remaining battery life.
The TM500A operates on 12-, 24-, or 48-volt battery systems (48-volt
systems require an optional shunt board).
Figure 2-7
DC250 Disconnect Box and TM500A Battery Status Meter
DC250
TM500A
System Configuration
2–26 976-0043-01-02
Remote Monitors
Three options are available for remote control and monitoring.
• Use a remote ICM, which is identical to the inverter control module
display on the inverter, for distances of 25 or 50 feet (7.5 or
15 meters).
• Use a personal computer to monitor system status using an optional
ICA (for distances up to 50 feet/15 meters). The ICA can be used
with cables up to 500 feet (152.4 meters). These longer cables,
however, are not provided by Xantrex.
• Use a personal computer off-site to monitor the system using an
external modem at the inverter site and the ICA.
Note: The ICM and the ICA use the same input port on the inverter. Both of
these options cannot be used at the same time.
Figure 2-8
Accessories for Remote Monitoring
CAUTION: Damage to Equipment
Never connect a grounded PC to the Remote Port if the inverter is configured in a
positive ground arrangement. Connecting a grounded PC to this port (in this
configuration) will damage both the PC and the inverter. Xantrex will not cover
damages to the PC or honor warranty claims on the inverter under these
circumstances.
Inverter Control Module (ICM)
(for distances of 25 or 50 feet)
Inverter Communications Adapter (ICA)
(for use with a personal computer
at distances up to 50 feet)
Note: For distances greater than
500 feet, a modem is required on site
.
Additional/Optional Equipment Considerations
976-0043-01-02 2–27
Inverter Control Module (ICM)
The remote ICM allows control, monitoring, and adjustment of all
inverter settings from a location other than the ICM display on the front of
the inverter. The remote ICM comes with cables in lengths of 25 feet (7.5
meters) or 50 feet (15 meters). The remote ICM duplicates all the
functions and controls of the ICM display on the front panel of the unit.
For distances greater than 50 feet (15 meters), see the Inverter
Communications Adapter (ICA).
Inverter Communications Adapter (ICA)
The ICA allows the inverter to be connected directly to a PC for
monitoring and adjustment. The ICA comes with a 50-foot cable. The
ICA can also be used up to 500 feet away, but additional cabling will be
needed and Xantrex does not provide longer cables at this time. It may
also be operated remotely with the addition of a modem at the inverter
site.
Figure 2-9
Inverter Control Module
Figure 2-10
Inverter Communications Adapter
CAUTION: Damage to PC
Do not connect a PC to the inverter when it is configured in a positive ground
system. Damage to the PC and the inverter may occur which is not covered under
warranty.
System Configuration
2–28 976-0043-01-02
Generator Start Module (GSM)
The GSM is an accessory that enables the inverter to start and stop
generators equipped with auto-start features.
See “Generator Considerations” on page 2–19, for information on using
generators and Appendix D, “Generators” for additional information
regarding generator types.
Auxiliary Load Module (ALM)
The ALM is an accessory that enables the inverter to start and stop
auxiliary loads such as alarms, water pumps, or ventilation fans.
See “Auxiliary Load Module (ALM)” on page 3–42 for additional
information regarding connecting the Auxiliary Load Module to the
inverter.
Figure 2-11
Generator Start Module
Figure 2-12
Auxiliary Load Module
Additional/Optional Equipment Considerations
976-0043-01-02 2–29
240 Vac Application Requirements
There are two options available for creating 240 Vac output using a
120 Vac inverter:
• using an autotransformer to step-up or step-down the voltage, or
• stacking two identical inverters.
Autotransformer for 240 VAC Applications (T240)
The T240 allows a single inverter to increase it’s output voltage from
120 volts to 240 volts or it will take 240 Vac from a generator and “step-
down” the voltage to 120 Vac for the single inverter. For step-up and step-
down functions, two T240s will be required.
A T240 Autotransformer can optimize the generator output of smaller
generators (< 3.9 kW) and improves charging time.
Inverter Stacking Control – Series (ISC-S) Cable
The ISC-S cable is a special communications cable that allows two Sine
Wave Plus inverters to be connected together in “series” to provide power
to both 120 Vac loads and 240 Vac loads.
See the ISC-S Owner’s Guide for more information on stacked inverter
applications.
Figure 2-13
T240 Autotransformer
Figure 2-14
ISC-S Cable
System Configuration
2–30 976-0043-01-02
Renewable Energy DC Input Sources
Renewable energy (RE) sources (for example, photovoltaic (PV) arrays,
wind turbines, DC micro-hydro generators) can be used with the inverter
to provide power for all applications—off grid and on grid. However, in
addition to the actual RE equipment being used, other items may be
needed to ensure safety in the overall system, such as charge controllers,
diversion load controllers, and/or PV ground fault protection.
Charge controller A charge controller must be used to regulate the charge supplied to the
batteries and prevents over-charging (or high battery conditions). A
charge controller prevents the batteries from exceeding a user-specified
voltage level. This preserves and extends the life of the battery by
preventing the damage caused by over-charging. The charge controller
can also take over the functions of bulk and equalize charging.
Diversion load
control Wind turbines and hydro-electric generators may be damaged if the DC
loads are suddenly removed from them. This can happen if the DC
disconnect should open (trip) or the batteries are fully charged and no
other DC loads are connected in the system. A diversion load controller
prevents damage to the generator system by diverting the power from the
generator to a diversion load device. This keeps a load on the generator
and controls over-spin if the batteries should be disconnected. Refer to
the controller manual for proper types of diversion load devices.
Important: Be sure to consult your authorized dealer and all local/national
electric codes to determine what additional equipment may be required for your
installation.
Important: Installations of this equipment should only be performed by
skilled personnel such as qualified electricians and Certified Renewable Energy
(RE) System Installers. For a list of Xantrex Certified RE dealers, please visit our
website at www.XantrexREdealers.com.
Note:
The “charger” built into the Sine Wave Plus is only for AC power
connected to either of the AC inputs on the inverter/charger. The Sine Wave
Plus cannot control or regulate DC voltages from DC sources. DC charge
controllers must be used for all DC sources such as PV arrays, wind turbines,
and water turbines.
Additional/Optional Equipment Considerations
976-0043-01-02 2–31
PVGFP The PV Ground Fault Protection (PVGFP) is designed to minimize the
possibility of a fire resulting from ground faults in a PV array (in
accordance with NEC/CEC for rooftop-mounted PV systems on
dwellings). It is not designed or intended to prevent electrical shock or to
be used for PV DC overcurrent.
Figure 2-15
Xantrex C-Series Charge Controllers
Figure 2-16
PV Ground Fault Protection (PVGFP)
System Configuration
2–32 976-0043-01-02
Off-Grid Applications
The Sine Wave Plus can be used as a primary source of AC power to
support off-grid, stand-alone systems where no utility power is available.
Sine Wave Plus applications in an off-grid situation include:
• renewable energy systems (with or without generator backup), and
• generator-only systems
• inverter only systems (charger in the inverter/charger is not used, but
batteries are maintained by an external DC charger).
Renewable Energy Systems with/without Generator Backup
In this configuration, the main power is generated by renewable energy
sources, such as solar, wind, micro-hydro or some other form of a
regulated DC charging source, and is stored in a battery bank. The Sine
Wave Plus will operate all AC loads from the power stored in this battery
bank.
In the event that renewable energy sources are insufficient to power the
required loads or keep the batteries charged, a generator can be used to
supplement the system.
Single-Inverter Configurations (120 Vac)
If only 120 Vac output is required from the system, a single inverter is
adequate to provide the required power, depending on the wattage
(output) requirements of the total system.
Single-Inverter Configurations (120/240 Vac)
If 240 Vac output is required from the system and the total of the loads
does not exceed the wattage output of the inverter, a step-up
autotransformer can be added to the output of the system to increase the
voltage output.
See Appendix F, “Multi-wire Branch Circuit Wiring”, for more
information on using single inverters with multi-wire branch circuits.
See Figure 2-17 for an example of both configurations (120 Vac and
240 Vac output) with all optional equipment. Disregard any part of this
illustration that does not apply to the components being installed. For
purposes of this publication, the main breaker (utility) panel is referred to
as the “inverter AC distribution panel” or simply “inverter panel”.
Off-Grid Applications
976-0043-01-02 2–33
Figure 2-17
Off-Grid Application – Renewable Energy System using a Single Inverter
NOTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–34 976-0043-01-02
Dual-Inverter Configurations (240 Vac)
If 240 Vac power is required and the wattage required exceeds the wattage
output of a single inverter, it may be necessary to add a second inverter.
Two inverters can be “series” stacked to provide both 120 Vac and 240
Vac, 60 Hz, power to the AC loads.
Series stacking is an excellent choice for providing power to multi-wire
branch circuits where single (120 Vac) inverters may require extensive
rewiring within the building.
See Figure 2-18 for an example of this configuration with all options
shown. Disregard any part of this illustration that does not apply to the
system configuration being installed.
Note:
Series-stacking inverters require the use of the ISC-S cable.
This interface cable is connected to the series stacking port of the
inverters (see “Inverter Stacking Control – Series (ISC-S) Cable” on
page 2–29).
Off-Grid Applications
976-0043-01-02 2–35
Figure 2-18
Off-Grid Application – Renewable Energy System using Dual Inverters
N
OTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–36 976-0043-01-02
Generator-Only Systems
In these applications, an AC generator serves as the main AC source
when batteries are insufficient to power the loads. Both an AC and a DC
generator can provide a power source for the battery charger. With the aid
of the Xantrex Generator Start Module (GSM), the Sine Wave Plus can
turn on automatically most remote-starting generators, on demand.
See “Generator Considerations” on page 2–19 and Appendix D,
“Generators” for additional information regarding using generators for
system input.
Single-Inverter Configurations
A single-inverter system is usually adequate to power most 120 Vac
loads. If 240 Vac is required from the system and doesn’t exceed the
wattage output of a single inverter, a step-up autotransformer can be
added to the output of the system to increase the voltage output.
See Figure 2-19 for an illustration of a 120 Vac generator-only system
using a single inverter. Disregard any part of this illustration that does not
apply to the system configuration being installed.
Off-Grid Applications
976-0043-01-02 2–37
Figure 2-19
Off Grid Application - Generator-only System using a Single Inverter
NOTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–38 976-0043-01-02
Dual-Inverter Configurations
If 240 Vac power is required and the wattage required exceeds the wattage
output of a single inverter, it may be necessary to add a second inverter.
Two inverters can be “series” stacked to provide both 120 Vac and 240
Vac, 60 Hz, power to the AC loads.
Series stacking is an excellent choice for providing power to multi-wire
branch circuits where single (120 Vac) inverters may require extensive
rewiring within the building.
See Appendix F, “Multi-wire Branch Circuit Wiring” for information on
identifying and correcting multi-wire branch circuit wiring.
See Figure 2-20 for an illustration of a 240 Vac Generator-Only System
using dual inverters
240 Vac-only Input Source
Note:
Series-stacking inverters require the use of the ISC-S cable. This
interface cable is connected to the series stacking port of the inverters (see
“Inverter Stacking Control – Series (ISC-S) Cable” on page 2–29).
Important:
When using a 240 Vac-only input source (with a L1 and L2
connection but no neutral) with a dual-inverter configuration, a neutral
connection needs to be provided from the 240 Vac source to the inverter’s
common neutral.
Off-Grid Applications
976-0043-01-02 2–39
Figure 2-20
Off Grid Application – Generator-only System using Dual Inverters, Series-stacked
NOTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–40 976-0043-01-02
On-Grid Applications
The Sine Wave Plus can be combined with utility power to provide
backup power in the event of a primary power source failure. It can use
utility power to backup renewable energy systems. It can use renewable
energy and/or a generator to backup utility grid power. It can be used as
an energy management tool to optimize energy consumption.
Backup Systems
Renewable Energy
Backup (BX Mode) This configuration uses renewable energy sources as the primary source
of power to operate the AC loads and grid power as an automatic backup
source.
Utility Backup
(SB Mode) In this configuration, the utility grid is the main source of power. The
energy stored in the batteries only provide backup power in the event of a
grid failure. Batteries can be charged by the utility grid when available,
RE sources, or with a backup generator.
Single-Inverter Configurations (120 Vac)
If only 120 Vac output is required from the system, a single inverter is
adequate to provide the required power, depending on the wattage
requirements of the total system.
See Appendix F, “Multi-wire Branch Circuit Wiring”, for information on
multi-wire branch circuits.
Single-Inverter Configurations (240 Vac)
If 240 Vac output is required from the system and the total of the loads
does not exceed the wattage output of the inverter, a step-up
autotransformer can be added to the output of the system to increase the
voltage output.
See Figure 2-21 for an example of a single inverter configuration for
either 120 Vac or 120/240 Vac output. Disregard any part of this
illustration that does not apply to the system configuration being installed.
On-Grid Applications
976-0043-01-02 2–41
Figure 2-21
On-Grid Application – Backup System using a Single Inverter
NOTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–42 976-0043-01-02
Dual-Inverter Configurations (240 Vac)
If 240 Vac power is required and the wattage required exceeds the wattage
output of a single inverter, it may be necessary to add a second inverter.
Two inverters can be “series” stacked to provide both 120 Vac and
240 Vac, 60 Hz, power to the AC loads.
Series stacking is an excellent choice for providing power to multi-wire
branch circuits where stand-alone (120 Vac) inverters may require
extensive rewiring within the building.
See Appendix F, “Multi-wire Branch Circuit Wiring” regarding multi-
wire branch circuits.
See Figure 2-22 for an example of this configuration showing all the
optional equipment. Disregard any part of this illustration that does not
apply to the system configuration being installed.
Note:
Series-stacking inverters require the use of the ISC-S cable. This
interface cable is connected to the series stacking port of the inverters (see
“Inverter Stacking Control – Series (ISC-S) Cable” on page 2–29).
On-Grid Applications
976-0043-01-02 2–43
Figure 2-22
On-Grid Application – Backup System using Dual Inverters, Series-stacked
NOTES:
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 from off-
site, an external modem is required at the inverter
site.
5. Ensure all the DC negatives in the system are
bonded to earth ground in only one place (single
point bond). If you are using a PVGFP, allow this
single “DC Negative to earth ground bond” to be
provided through the PVGVP.
6. If this is not a separately derived system (per the
NEC), the AC neutrals should be bonded to earth
ground in only one place.
System Configuration
2–44 976-0043-01-02
Energy Management
The Sine Wave Plus can be programmed to control how and when to use
utility power. Advanced features allow for peak load management and
time-of-use billing. Utility management features also allow the Sine Wave
Plus to use renewable energy sources on a first priority basis and only use
utility power if renewable energy is insufficient or unavailable to power
the loads.
See “21 Grid (AC1) Usage Menu” on page 7–16 for more information
about programming these applications.
RE Backup with Utility (SB Mode)
In Standby (SB) Mode, the Sine Wave Plus will automatically use power
from the DC source, generated by the RE source, over grid power even
when the inverter shows it is “charging” from the grid. When there is
excess DC power from the RE source, the inverter will automatically
reduce the current draw from the grid and power the loads from RE
generated power. During a time when loads exceed what the RE can
provide, the inverter will automatically bring in enough AC power from
the grid to power the loads.
See “SB (Standby) - Utility Backup” on page 7–17 for instructions for
setting these parameters.
Peak Load Management
Many utilities impose a surcharge on their customers based on the peak
load used by a facility. To reduce utility peak demand charges, the inverter
can be configured to limit the maximum draw the AC loads place on the
utility. The inverter can be programmed to provide power above a
specified level, eliminating the surcharge. When the utility current draw
reaches the maximum level, the inverter assists by providing battery
powered AC to the loads.
See “13A Grid (AC1) Amps AC” on page 6–27 for instructions for
setting these parameters.
For Peak Load Shaving to be effective, all loads must be connected to the
inverter. For large loads, multiple (or stacked) inverters may be required.
To further ensure the batteries are able to supplement the power
requirements of the connected load, an additional source of power (solar,
wind or hydroelectric) is recommended.
Peak Load Shaving can also be used in addition to the Time-of-Use
(TOU) metering.
On-Grid Applications
976-0043-01-02 2–45
Time-of-Use (TOU) Metering
Utilities use TOU metering to determine utility charges during peak usage
hours and to impose a surcharge. The inverter can be configured to
overcome these peak charges by using a battery (or battery bank) to store
energy during the inexpensive energy hours and consumes the battery
energy during expensive energy hours.
When in this mode, the inverter is programmed to only use utility power
during user-specified times during the day. This helps the consumer take
advantage of lower utility rates by using power from the battery bank
during times that utility power is most expensive.
See “21 Grid (AC1) Usage Menu” on page 7–16 for instructions for
setting these parameters.
Energy management determines when utility power is used. Start and
Stop times are programmed into Menu Items 21B and 21C depending on
when you want the inverter to use utility power.
In the example below, Figure 2-23 shows the inverter disconnects from
the utility grid at 6:00 PM and supports the connected load from batteries.
It continues to run until 9:00 PM. It then reconnects to the utility grid,
passing AC through to the connected load, and begins maintaining the
batteries based on the battery charger settings in the Basic Setup Menu
(Float or Silent).
Figure 2-23
Time-of-Use Metering
00
6
1
2
3
4
5
7
8
9
10
11
12
23
22
17
16
15
14
13
GRID USAGE END
TIME 18:00 (6 PM)
OPERATING FROM
UTILITY GRID AND
BATTERY CHARGING
OPERATING
FROM INVERTER
DURING PEAK
UTILITY PERIOD
18
21
20
19
GRID USAGE BEGIN
TIME 21:00 (9 PM)
System Configuration
2–46 976-0043-01-02
When using the system for TOU metering, the system should be designed
with a battery capacity large enough to support the load during the entire
peak rate period without reaching the 11C Low Battery Cut Out VDC
voltage.
To further ensure the batteries are able to support the load, an additional
source of power (solar, wind or hydroelectric) is recommended.
Depending upon the capacity of the system, certain heavy loads should
only be run during non-peak periods.
AC Load Support
This feature allows power to be automatically drawn from the batteries to
assist either the utility grid or an AC generator support heavy loads
(i.e., loads that exceed the available current from either the generator or
the utility grid). When the grid or generator requires additional AC
current to support the loads, current is drawn from the batteries.
Generators have a limited output current and it is possible to reach this
limit when operating heavy loads. The Sine Wave Plus is designed to
assist the generator when heavy current demands load down the generator
by supplying additional power from the batteries. In this way, the
generator can operate loads heavier than it would otherwise be capable of
running. When the inverter is in this mode, the batteries are not charging
even though the LED indicators on the inverter may indicate the charge
mode is on.
In addition, the battery charger can back off its charging current to the
batteries so the combined load of the charger and load support does not
load down the generator or trip its output breakers or fuses.
AC support parameters are controlled by the 13A Grid (AC1) Amps AC
and or 13B Gen (AC2) Amps AC depending on the application.
Note: In the event the batteries reach their 11C Low Battery Cut Out VDC
voltage, the inverter will automatically reconnect to the utility grid to maintain
the connected load.
Note: TOU Mode is usually used in conjunction with a renewable energy
system. Often these systems will provide their peak output at the high billing
times. Battery power used to supplement the renewable energy used during
peak times is replenished during non-peak times.
On-Grid Applications
976-0043-01-02 2–47
See “21 Grid (AC1) Usage Menu” on page 7–16 for instructions on
setting these parameters.
Renewable Energy with Grid Backup (BX Mode)
To have the inverter operate independently of the grid but use the grid in
times of low battery voltage, the inverter can be set up in the "BX" Mode.
In this mode, the inverter powers the AC loads using the RE sources and
only uses AC power from the grid to run the loads when the battery
voltage drops below user-specified levels.
When the batteries have recharged to a specified voltage by the renewable
energy sources, the inverter transfers from the utility grid to inverter
supplied AC power.
See “22 Battery Xfer (BX) Menu” on page 7–18 for instructions for
setting these parameters.
Figure 2-24
AC Support Mode
Note: Running and Start-up (Peak) currents are limited to the maximum
current limits of the inverter.
Note: In the AC support ModeMode, the BULK or FLOAT charge indicator
LEDs may be ON even though the batteries are draining. Use the 04 Meters
Menu heading and 04C INV/CHR Amps AC menu item to view the actual
amperage. A negative reading indicates the inverter is supporting the generator
from the batteries.
Utility Grid or
AC Generator
BATTERY
HEAVY
AC LOAD
INVERTER/CHARGER
AC
DC
UTILITY or GENERATOR + INVERTER
SUPPORT VOLTAGE (from battery)
AC
2–48
3Installation
Chapter 3, “Installation” describes how to mount and install
the Sine Wave Plus Inverter/Charger and perform wiring and
cabling procedures for various configurations.
Installation
3–2 976-0043-01-02
Pre-Installation
Before installing the Sine Wave Plus, read all instructions and cautionary
markings located in this manual.
Although the DC electrical system may be “low voltage”, significant
hazards may still be present, particularly from short-circuits of the battery
system. Inverter systems, by their nature, involve power from multiple
sources (inverter, generator, utility, batteries, solar arrays, etc.) that add
hazards and complexity that can be very challenging.
Tools Required
The following tools may be required for installing this equipment:
❐Assorted Phillips screw drivers
❐Level, pencil, and utility knife
❐Slotted screw driver
❐Wire strippers
❐Assorted open-end wrenches
❐Torque wrench
❐Socket wrench and sockets
❐Electrical tape
❐Multi-meter (AC/DC volts)
Important:
Be sure to obtain the appropriate permits, if necessary, prior to
starting this installation.
Important:
Installations should meet all local codes and standards.
Installations of this equipment should only be performed by skilled personnel
such as qualified electricians and Certified Renewable Energy (RE) System
Installers. For a list of Xantrex Certified RE dealers, please visit our website at
www.XantrexREdealers.com.
WARNING: Personal Injury
The Sine Wave Plus is can weight up to 145 lbs. Always use proper lifting
techniques and have someone available to assist with lifting it during installation
to prevent personal injury.
Pre-Installation
976-0043-01-02 3–3
Hardware / Materials Required
The following materials may be required for completing this installation.
❐4' x 8' sheet of ¾" plywood for mounting
❐2 x 4 boards for mounting
❐#10 and/or #12 wood screws (or ½" x 1¼" lag bolts)
❐Conduits and appropriate fittings for wire runs (e.g., wire nuts)
❐Electrical wire of appropriate size and length
❐Battery cable lugs (depending on types of battery cables used)
❐Breaker panels
❐Ground busses, bars, bonding blocks, and/or rods
Optional System Accessories
The following optional system accessories can be used in the installation
of the Sine Wave Plus. These accessories are available from any
authorized Xantrex dealer. Consult with your local system designer to
determine what optional equipment will be needed for your specific
installation.
Conduit boxes:
❐ACCB with input/output/bypass breakers
❐DCCB
Battery cables:
❐BC1.5 (Single) Battery Interconnects
❐BC2/0 AWG (Pair), available in 5 and 10 foot lengths
❐BC4/0 AWG (Pair), available in 5, 10, and 15 foot lengths
DC disconnects and fuses:
❐DC175 (175 Amp DC Disconnect with Bonding Bar)
❐DC250 (250 Amp DC Disconnect with Bonding Bar)
❐TFB 200 (200 Amp Class-T Fuse)
❐TFB 300 (300 Amp Class-T Fuse)
❐TFB 400 (400 Amp Class-T Fuse)
❐PV Ground Fault Projection (PVGFP1, PVGFP2, PVGFP3,
PVGFP4)
Installation
3–4 976-0043-01-02
Remote monitors:
❐ICM/25 (Inverter Control Module with 25 foot cable connection)
❐ICM/50 (Inverter Control Module with 50 foot cable connection)
❐ICA (Inverter Communications Adapter with 50 foot cable), for use
with your computer. (Can be used with a modem on site. A modem is
required for distances greater than 50 feet.)
Other accessories which might be required:
❐Generator Start Module (GSM)
❐Auxiliary Load Module (ALM)
❐C-Series Charge Controllers (C35, C40, C60)
❐TM500A Battery Status Meter
❐ISC-S Cable
Battery Bank Preparation
Be sure to have read the section titled “Battery Considerations” on
page 2–11 in the previous chapter before starting this procedure. For more
information, see Appendix C, “Battery Information”.
Prepare the battery bank as follows:
1. Determine the type of batteries to be used.
See “Battery Types” on page C–2 in Appendix C for information on
types of batteries and their applications.
2. Determine the appropriate battery bank size and battery
configuration.
See “Battery Requirements for Dual Inverter Systems” on page 2–15
for information on stacked (dual) inverter systems.
See “Battery Bank Sizing” on page C–4 for additional information on
calculating battery bank size and “Battery Configurations” on
page C–9 for information about how to wire the selected battery
configuration.
Important:
The inverter is not reverse polarity protected. Reversing the battery
polarity on the DC input connections will cause permanent damage to the inverter
which is not covered under warranty. Always check polarity BEFORE making
connections to the inverter
Pre-Installation
976-0043-01-02 3–5
3. Determine the correct size of battery cables to use.
See Table 2-2, “Recommendced Battery Cable Size Versus Length”
on page 2–14 for additional information and recommended battery
cable sizing.
4. Determine the correct size of DC breaker/fuse to use.
See Table 2-3, “Battery Cable to Maximum Breaker/Fuse Size” on
page 2–15 for additional information and recommended DC breaker/
fuse sizing.
5. Color code the cables with tape or heat shrink tubing. The standard
colors for DC cables are red for positive (+) and black for
negative (–).
Unpacking and Inspecting the Inverter
Before installing your Sine Wave Plus Inverter/Charger, perform the
following.
❐Carefully unpack the Sine Wave Plus from its shipping carton.
❐Inspect for shipping damage and contact the shipping company if
there is damage.
❐Verify that all of the following items are present. Please call your
authorized Xantrex dealer if any items are missing.
•The Sine Wave Plus Inverter/Charger
•The Sine Wave Plus Inverter/Charger Owner’s Guide
• The Battery Temperature Sensor
• Battery Terminal Covers (with associated hardware)
❐Save your proof-of-purchase. This is required if the unit should need
warranty service.
Important:
The battery voltage MUST match the voltage requirements of the
inverter. To determine the correct voltage for the system, check the last two digits
on the inverter’s model number. For example, the Sine Wave Plus 2524 is a
24-volt inverter and requires a 24 Vdc battery system.
WARNING: Personal Injury
Do not attempt to mount this unit on the wall by yourself as the unit is too heavy
for one person. Have additional help available to assist in lifting the unit during
installation.
Installation
3–6 976-0043-01-02
❐Save the original shipping carton and packing materials. If the
inverter ever needs to be returned for service, it should be shipped in
the original carton. This is also a good way to protect the inverter if it
ever needs to be moved.
❐Record the unit’s model number, serial number, and date-of-purchase
in the appropriate locations provided on page I–5 in the Warranty and
Product Information section at the back of this manual.
• Model Number information can be found on the Certification
Label located on the AC end of the unit. See Figure 3-1 for the
location of the this label.
• Serial Number information can be found on the Serial Number
Sticker located on the inverter rail adjacent to the AC side dual
knockouts and terminal access cover. See Figure 3-2, “Serial
Number Sticker and Knockout Locations and Sizes” on page 3–7
for the location of this sticker.
Figure 3-1
Certification Label Location
Serial
Number
(on rail)
AC End of the Inverter
Pre-Installation
976-0043-01-02 3–7
Figure 3-2
Serial Number Sticker and Knockout Locations and Sizes
Knockout Preparation
Remove your choice of knockouts from the chassis to facilitate conduit
installation for wire runs. This is much easier to do prior to mounting the
inverter. Figure 3-2 shows the locations and sizes of chassis knockouts.
Important: The exclamation symbol below the CSA logo on the certification
label indicates the need to add overcurrent protection. It shall be installed at the
battery as part of the installation in accordance with your local electrical code.
Table 2-3, “Battery Cable to Maximum Breaker/Fuse Size” on page 2–15
specifies the type and rating of the overcurrent protection needed.
3/4 and 1”
Dual-knockouts
Serial
Number
Sticker
3/4 and 1”
Dual-knockouts
Important:
Ensure there are no metal shavings left in the inverter after
removing the knockouts. Be sure to install bushings or conduits in the
knockout holes to protect the wires from damage.
Installation
3–8 976-0043-01-02
Mounting
The Sine Wave Plus can be either shelf-mounted or wall-mounted. Be
sure to use appropriate lifting techniques and have extra people available
to assist in lifting the inverter into position while it is being secured. Also
make sure the supporting surface is strong enough to support the weight
of the inverter.
Refer to “Location Considerations” on page 2–5 for information on
proper location of the Sine Wave Plus.
Be sure to use all ten mounting holes in addition to the four keyhole slots
provided for mounting. Just using the keyhole slots will not be sufficient
to safely mount the inverter.
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 allows adequate clearance for ventilation and
access to the indicators and controls.
2. Drill mounting holes in the shelf by one of the following methods. Be
sure to use all of the inverter mounting holes and keyhole slots for
mounting.
a) Using the measurements from Figure 3-3 drill out the mounting
hole locations for the inverter.
b) Create a cardboard template by tracing around the inverter and
marking the mounting holes and keyhole slots on the cardboard.
Use the cardboard template to locate and drill the mounting holes.
3. With assistance, lift the inverter into position and install it onto the
shelf, using appropriately sized lag bolts and washers.
WARNING: Personal Injury Hazard
Do not attempt to mount this unit on the wall by yourself. Have additional help
available to assist in lifting the unit during installation.
Pre-Installation
976-0043-01-02 3–9
Figure 3-3
Dimensional Drawing
1"
½"
1½"
1½"
1"
Keyhole slots
Keyhole slots
21" (533 cm)
16" (406 cm)
6½" (165 cm)
1½"
1" 1½"
14 "
8
3
15 "
18
4 (102 cm)
10½" (267 cm)
2½"
17" (432 cm)
8
3"
18 (467 cm)8
3"
20" (508 cm)
Mounting Holes*
***NOT TO SCALE***
6½" (165 cm)
(10 cm) (25 cm) (38 cm)
(38 cm) (38 cm)
(38 cm) (25 cm) (13 cm)
(365 cm)
*Size = 3/8" (10 cm) Diameter
(384 cm)
(25 cm)
(64 cm)
Mounting Holes*
Installation
3–10 976-0043-01-02
Wall-Mounting
Wallboard is not strong enough to support the weight of the inverter, so
additional support must be added. This can be in the form of reinforcing
2 x 4’s or a half sheet (4 ft x 4 ft) of ¾-inch plywood.
Wall Mounting
using 2 x 4’s The easiest method for securing the inverter to an existing wall is to place
two 2 x 4’s horizontally on the wall (spanning at least three studs) and
securing the inverter to the 2 x 4’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 place the inverter’s control module at the
operator’s eye level for easy viewing and setting.
3. Using a level, run a horizontal line. The length of the line must span
at least 3 studs.
4. Place a pre-cut 2 x 4 on the marked location and drill pilot holes
through the 2 x 4’s and studs.
5. Secure the 2 x 4 with #10 wood screws (length to penetrate 1½ inches
or more into the studs).
6. Repeat the procedure for the remaining 2 x 4 (paint the 2 x 4’s, if
desired, to match the surrounding wall).
7. Drill mounting holes in the 2 x 4 mounting rails by one of the
following methods. Be sure to use all of the inverter mounting holes
and keyhole slots for mounting.
a) Using the measurements from Figure 3-3 drill out the mounting
hole locations for the inverter.
b) Create a cardboard template by tracing around the inverter and
marking the mounting holes and keyhole slots on the cardboard.
Use the cardboard template to locate and drill the mounting holes.
8. Ensure that the 2 x 4’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
2 x 4’s using ¼ x 1½-inch lag bolts and washers.
Pre-Installation
976-0043-01-02 3–11
Figure 3-4
Wall-Mounting Method using 2 x 4’s
Wall studs 16 inches
on center
Wallboard
Floor
Ceiling
14–3/8"
c-c
Set Inv erter
OFF SRCH ON CHG
Sine Wave Plus
Inverter/Charger
Approx.
4–5 ft
2 x 4
mounting
supports
Mounting
Holes (10)
Keyhole Slots
(4)
Installation
3–12 976-0043-01-02
Wall Mounting
using Plywood Alternatively, a half sheet (4 ft x 4 ft) of ¾-inch plywood can also be
used as a backing, with the inverter mounted directly to the plywood
using ¼-inch diameter lag bolts and washers. The plywood must span
three studs for adequate support.
1. Drill the mounting holes in the plywood sheet by one of the following
methods. Be sure to use all the mounting holes and keyhole slots for
mounting.
a) Using the measurements from Figure 3-3 drill out the mounting
hole locations for the inverter.
b) Create a cardboard template by tracing around the inverter and
marking the mounting holes and keyhole slots on the cardboard.
Use the cardboard template to locate and drill the mounting holes.
2. Ensure the plywood is securely fastened to the wall before mounting
the inverter on it.
3. With assistance, lift the inverter into position and install it onto the
plywood using ¼ x ¼-inch lag bolts and washers.
Pre-Installation
976-0043-01-02 3–13
Figure 3-5
Wall Mounting using Plywood
Wall studs 16 inches
on center
Wallboard
Floor
Ceiling
Plywood
Set In ve r te r
OFF SRCH ON CH G
Sine Wave Plus
Inverter/Charger
Mounting
Holes (10) Keyhole
Slots (4)
Installation
3–14 976-0043-01-02
DC Wiring
DC wiring includes the following (described in the following locations).
❐Preparing the Battery bank - See “Preparing the Battery Bank” on
page 3–14.
❐Preparing Grounding - See “Grounding the DC System” on page 3–
15.
❐Connecting DC Input Sources - See “Connecting DC Input Sources –
Renewable Energy Configurations” on page 3–18.
❐Providing over-charge protection. See “Overvoltage Protection using
a Charge Controller” on page E-2.
❐Providing diversion loads if necessary. See “Diversion Load Control”
on page E-3.
❐Connecting the Battery Temperature Sensor - See “Installing the
Battery Temperature Sensor (BTS)” on page 3–18.
❐Connecting “Connecting the Batteries to the Inverter” on page 3–20.
Preparing the Battery Bank
Prepare the battery bank according to type of battery selected and
configure the battery bank to optimize voltage output according to system
requirements. See your battery manufacturer’s installation guide for
recommendations.
See Appendix C, “Battery Information” for additional information on
determining battery bank type and configuration.
Run the positive and negative battery cables as close to each other as
possible by taping them together after all the connections are made. This
reduces the effects of inductance, improves surge capacity, and reduces
RFI and EMI emissions.
Install a DC disconnect between the battery bank and the inverter.
Following the manufacturer’s installation instructions.
WARNING: Shock Hazard
Ensure that all AC and DC breakers are switched OFF before connecting or
disconnecting the battery cables and that all sources of power (both AC and DC)
are disconnected from the inverter’s inputs.
DC Wiring
976-0043-01-02 3–15
Grounding the DC System
The inverter’s chassis ground lug (see Figure 3-6) is used to connect the
chassis of the inverter to the DC grounding system. The terminal accepts
wires from #14 AWG to #2 AWG.
The Xantrex DC175 and DC250 have optional grounding blocks to
simplify grounding procedures and can be used as the DC disconnect as
shown in Figure 3-7 on page 3–16.
WARNING: Fire Hazard
Undersized cables can overheat and melt creating a fire hazard when subjected to
heavy (peak) loads. Always use a properly sized cable and length rated for the
amperage of the inverter and batteries.
WARNING: Shock Hazard
Always attach ground leads before attaching AC or DC power connections.
Figure 3-6
Chassis Ground Lug Location on Inverter DC End
Chassis
Ground Lug
DC End of Inverter
Installation
3–16 976-0043-01-02
Single Inverter To ground a single inverter:
1. Connect the ground bond in the DC disconnect to the primary
grounding electrode, in accordance with local and national electrical
codes.
2. Connect the NEGATIVE (–) terminal of the battery bank to the
ground bond inside the DC disconnect.
3. Connect an appropriately sized GROUND wire from the Chassis
Bonding Lug on the inverter DC end to the ground bond inside the
DC disconnect.
Figure 3-7
DC Grounding of a Single Inverter
DC Wiring
976-0043-01-02 3–17
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 primary grounding electrode, in accordance
with local and national electrical codes.
2. Connect the NEGATIVE (–) terminal of the battery bank to the
ground bond inside the DC disconnect.
3. Connect an appropriately sized GROUND wire from the Chassis
Bonding Lug on the L1 inverter DC end to the ground bond inside the
DC disconnect.
4. Connect a second appropriately sized GROUND wire from the
Chassis Bonding Lug on the L2 inverter DC end to a different
terminal in the ground bond inside the DC disconnect.
Figure 3-8
DC Grounding of Dual Inverters
Installation
3–18 976-0043-01-02
Connecting DC Input Sources – Renewable Energy Configurations
Renewable energy sources (e.g., PV arrays, wind turbines etc.) may
require additional equipment such as charge controllers, diversion load
controllers, PV Ground Fault Protection, and additional fuses and/or
disconnects. Since every configuration is unique, specific installation
instructions cannot be provided. Follow your manufacturer’s instructions
for installation of these components.
Be sure to consult your local authority to ensure code compliance for your
configuration.
Installing the Battery Temperature Sensor (BTS)
Install the sensor on the side of the battery below the electrolyte level so
as to measure the average battery temperature. If using multiple charging
devices (inverters and charge controllers), install all sensors together with
each other so they all measure the same temperature. It is best to mount
the sensor(s) between the batteries in an insulated box to reduce the
influence of the ambient temperature outside the battery enclosure.
Ventilate the battery box at the highest point to prevent hydrogen
accumulation.
To install the BTS, follow the steps below.
1. Run the BTS wire in the DC conduit (if used) and route the RJ11
connector end (via one of the knockouts) to the BTS port located on
the DC end of the inverter.
2. Secure the sensor to one of the batteries located in the center of the
battery pack.
3. If other devices are using battery temperature sensors, place all of
them on the same battery so that they all measure the same
temperature.
DC Wiring
976-0043-01-02 3–19
Figure 3-9
BTS (RJ11) Port Location and Installation
BTS (RJ11)
Port
DC End of the Inverter
Installation
3–20 976-0043-01-02
Connecting the Batteries to the Inverter
DC terminal connections are located on the DC end of the inverter.
Figure 3-10 shows the locations of the DC connectors.
WARNING: Shock Hazard
Before making any connections, verify that the DC disconnect device is
switched OFF.
Figure 3-10
DC Terminal Connections on the Inverter
DC End of the Inverter
Positive (+) Red
DC Terminal
Negative (–) Black
DC Terminal
DC Wiring
976-0043-01-02 3–21
Figure 3-11 shows the proper method to attach the cables to the inverter.
Figure 3-12 shows the battery terminal covers and associated hardware.
Figure 3-11
Battery Cable Connection
CAUTION: Damage to Equipment
Do not put anything between the battery cable lug and the terminal surface.
Overheating of the terminal may occur. Do not apply any type of antioxidant
paste until after the battery cable wiring is tightened. The same applies for all DC
connections.
Copper
Compressio
n
Lug
Battery
C
able Lug Terminal
Surface
Star
Washer
Figure 3-12
Battery Terminal Covers and Associated Hardware
Installation
3–22 976-0043-01-02
Procedure for Single Inverter Systems
Before starting this procedure, please review Figure 3-10, “DC Terminal
Connections on the Inverter” on page 3–20 and Figure 3-11, “Battery
Cable Connection” on page 3–21 for the locations of the terminals and
details on attaching positive (+) and negative (–) cables to terminals on
the inverter DC end. Ensure the unit is properly grounded before
proceeding.
While performing the following procedure, please refer to Figure 3-13,
“DC Connections to a Single Inverter” on page 3–23.
Use the following procedure to connect the battery (or battery bank)
to the inverter.
1. Connect POSITIVE cables:
a) Connect one cable from the battery POSITIVE terminal to a
circuit breaker in the DC disconnect (torque to manufacturer’s
recommendations). The DC disconnect should be located as close
to the batteries as possible.
b) Connect another cable from the other side of the same circuit
breaker to the inverter’s POSITIVE (+) terminal.
2. Connect a NEGATIVE cables:
a) Connect one cable from the battery NEGATIVE terminal (torque
to manufacturer’s recommendations) to the ground bond in the
DC disconnect.
b) Connect another cable from the ground bond to the inverter’s
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 each inverter input terminal.
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 inverter DC terminals and secure with the
screws and washers provided.
DC Wiring
976-0043-01-02 3–23
Figure 3-13
DC Connections to a Single Inverter
Installation
3–24 976-0043-01-02
Procedure for Dual-Inverter Systems
Before starting this procedure, please review Figure 3-10, “DC Terminal
Connections on the Inverter” on page 3–20 and Figure 3-11, “Battery
Cable Connection” on page 3–21 for the locations of the terminals and
details on attaching positive (+) and negative (–) cables to terminals on
the inverter DC end. Ensure the unit is properly grounded before
proceeding.
While performing the following procedure, please refer to Figure 3-14.
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 to manufacturer’s recom-
mendations). The DC disconnect should be located as close to the
batteries as possible.
b) a second cable from the same battery POSITIVE terminal to
another circuit breaker in the DC disconnect.
c) a third cable from the first circuit breaker in the DC disconnect to
the L1 inverter POSITIVE (+) terminal.
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) to the ground bond in the DC
disconnect.
b) a second cable from the same battery NEGATIVE terminal
(torque to manufacturer’s recommendations) to the ground bond
in the DC disconnect.
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
L2 inverter 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 each inverter input terminal.
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 inverter DC terminals and secure with the
screws and washers provided.
DC Wiring
976-0043-01-02 3–25
Figure 3-14
DC Connections to Dual Inverters
Installation
3–26 976-0043-01-02
AC Wiring
This section describes:
•“Accessing the AC Terminal Block and Ground Bar” on page 3–28,
and
•“AC Wiring for Single Inverter Systems” on page 3–30.
Disregard installation sections and illustrations that do not apply to your
configuration (for example, installing utility panels in Off-Grid
applications or wiring for generators when no generator is used, etc.)
Before wiring the input of the inverter, refer to Table 3-1 below for
Maximum AC wire sizes and disconnects devices. Determine the correct
AC wire size and disconnect size to use for installation.
The Sine Wave Plus inverter has two AC inputs, AC1 GRID and
AC2 GEN. The AC1 GRID input is intended to be used with grid power
and the inverter can do “grid features” (BX Mode, time-of-day usage)
with this input. The AC2 GEN input is intended to be used with AC
generators and the inverter can do “generator features” (auto-start) with
this input.
The inverter will accept and use AC power on either of these inputs. Be
aware that the inverter menu structure is organized and the features are
optimized around AC1 receiving grid power and AC2 receiving generator
power. If you install grid power on the AC2 GEN input or generator
power on the AC1 grid input the results may be different that expected or
noted in your users manual.
Examples of using an input source other than its factory designation.
1. An off-grid site with two generators, an auto-start generator
connected to AC2 and spare manual-start generator connected to
AC1.
2. An on-grid site with a generator wired into a main grid/generator
transfer switch. The AC2 input would need to be used to utilize the
auto start feature of the inverter. Note: the inverter's “grid features”
would not be available in this wiring configuration.”
AC Wiring
976-0043-01-02 3–27
Table 3-1
AC Disconnect and Wire Sizing
Full
Pass-Through
Capability
Maximum
Fuse/Breaker
Required
Cable Size
Required in
Conduit
60 Amps 60 Amps #6 AWG (THHN)
WARNING: Fire Hazard
There is risk of fire if 120 Vac only sources (such as inverters and generators) are
wired incorrectly into 120/240 Vac distribution panels containing multi-wire
branch circuits.
See Appendix F, “Multi-wire Branch Circuit Wiring”, which describes how to
check for multi-wire branch circuits in the load center and offers some possible
solutions/alternatives to this wiring method.
WARNING: Shock Hazard
Be sure to connect the ground wires first when connecting AC wiring to prevent
a potential shock hazard.
CAUTION: Damage to the Inverter
The inverter’s AC output must never be wired to the utility or generator output.
This will cause severe damage to the inverter which is not covered under
warranty.
Installation
3–28 976-0043-01-02
Accessing the AC Terminal Block and Ground Bar
All AC wiring connects to the AC terminal block located on the left-hand
side of the inverter beneath the AC access cover.
To remove the AC access cover:
1. Remove the Phillips screw from above the access cover. Place the
loose screw somewhere safe where it will not be lost.
2. Slide the access cover off of the front panel.
To replace the AC access cover:
1. Slide the access cover back into place.
2. Replace the Phillips screw that was removed and tighten into place.
Be sure not to over-tighten this screw.
The following photograph show the AC terminal block and AC ground
bar located beneath the AC access cover.
Figure 3-15
AC Wiring Access Cover Plate
AC Access Cover
Remove this screw to remove
the AC Access cover.
AC Ground Bar
AC Terminal Block
AC Wiring
976-0043-01-02 3–29
Figure 3-16
AC Input/Output Wiring Terminals
AC Terminal Block
AC Terminal Block Enlargement
Installation
3–30 976-0043-01-02
AC Wiring for Single Inverter Systems
There are three major steps in the procedure for AC wiring of
single-inverter systems. They are described in detail on the
following pages:
1. “Install AC Output Wiring to the Inverter AC Distribution Panel” on
page 3–33.
2. “Install Generator Wiring to the Inverter” on page 3–35.
3. “Install Utility Wiring to the Inverter Input (On-Grid Applications
only)” on page 3–38.
The completed wiring is shown in Figure 3-18, “AC Input and Output
Wiring to a Single Inverter with an Auto-Start AC Generator” on page 3–
32. This illustration shows an auto-start generator; a manual-start
generator would be wired in the same way except that there would be no
GSM. The T240 Autotransformer and generator disconnect switch are
optional, but the generator disconnect switch is strongly recommended.
Manual and Auto Start Generators
Some generators must be started manually at the generator. These kinds
of generators do not require the use of the Generator Start Module (GSM).
Some generators allow automatic starting. In this case, the addition of the
GSM is required for the inverter to start/stop the generator and to transfer
the AC input voltage to the inverter.
Exact wiring instructions cannot be given for auto-start generators as the
wiring configuration may vary depending on the type of auto-start circuit
used.
See “Generator Starting Scenarios” on page 7–23 and the GSM
Installation Guide for specific installation instructions for connecting a
generator to the GSM.
Important:
Wiring to the utility panel is performed after all other connections
have been made in the inverter. Be sure to make all the other connections to the
inverter first (steps 1 and 2 above).
AC Wiring
976-0043-01-02 3–31
WARNING: Shock Hazard
Auto-start generators can start automatically at any time.
Affix the warning label (supplied with the GSM) regarding auto-start generators
on or near the main AC distribution panel and near the generator. This will
remind the operator that AC power may still be supplied from the generator and
additional steps may be required to make the panel and the generator safe.
Figure 3-17
Connecting the GSM Communications Cable to the Sine
Wave Plus
Generator Start Module
The RJ11 Communications Cable
provided with the GSM connects to
the GEN Port on the inverter
See the GSM Installation Guide
for wiring instructions
AC end of the Inverter
Installation
3–32 976-0043-01-02
Figure 3-18
AC Input and Output Wiring to a Single Inverter with an Auto-Start AC Generator
AC Wiring
976-0043-01-02 3–33
Install AC Output Wiring to the Inverter AC Distribution Panel
An inverter AC distribution panel (referred to here as the inverter panel)
and AC conduit must be installed before AC output wiring is connected to
the inverter. The inverter panel is a subpanel.
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 manufacturer’s directions.
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 into the inverter panel.
4. For On-Grid systems:
a) Disconnect all power to the main utility panel.
b) Determine which circuits will be backed by the inverter(s) and
remove their wires from the main panel.
c) Reroute these wires to the new inverter subpanel.
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 later be wired to the inverter’s output.
CAUTION: Equipment Damage
Verify that only one neutral/ground bond exists in the system. Having more than
one neutral to ground bond in a system may create a shock hazard and cause
some sensitive equipment to malfunction.
On-Grid systems always have a ground-to-neutral bond provided by the utility
meter or service entrance, therefore, you do not need a ground to neutral bond
made in the inverter panel.
See “Bonding the Grounding System” on page 2–10 for details.
Important:
Under no circumstances should utility power or generator power
energize the inverter panel directly while the inverter also energizes the inverter
panel.
Installation
3–34 976-0043-01-02
Make connections from the inverter to the inverter panel as follows:
1. Connect the GROUND (green or bare) wire:
a) from the inverter AC GROUND bar
b) to the inverter panel GROUND bar
2. Connect the NEUTRAL (white) wire:
a) from the inverter NEUTRAL OUT terminal
b) to the inverter panel NEUTRAL bus
3. Connect the HOT (black) wire:
a) from the inverter AC OUT terminal
b) to the inverter panel main input circuit breaker
4. Torque all inverter terminal block connections to 25 inch-pounds.
Figure 3-19
AC Output Wiring to the Inverter AC Panel
AC Wiring
976-0043-01-02 3–35
Install Generator Wiring to the Inverter
Generator
Disconnect Switch
(If used)
Having a generator disconnect switch between the inverter and the
generator is strongly recommended. This will provide overcurrent
protection for the wiring between the inverter and the generator. It also
prevents the generator wiring inside the inverter from becoming
energized while the inverter is being serviced.
To install a generator disconnect switch:
◆Determine a location for the generator disconnect switch and install it
according to the manufacturer’s directions.
A conventional load center (breaker box) can be used to distribute the
power from the generator to the inverter input and to loads that cannot
be powered by the inverter. Loads such as air conditioners, large well
pumps, and arc welders are typically better suited to run directly from
the generator than to be “passed through” the inverter transfer relay. If
the load is too big for the inverter to operate from battery power, do
not install the load in the inverter powered electrical panel.
A good location for a generator disconnect switch is adjacent to the
inverter.
WARNING: Shock Hazard
Before connecting any AC wiring, ensure that there is no DC energy accessible
by the inverter by opening the DC disconnect switch.
Important: Be sure that the circuit breaker(s) within the switch are
appropriately sized to protect the wires between the inverter and the generator.
This is based on the generator’s output capacity.
Installation
3–36 976-0043-01-02
With Step-down
Autotransformer
and using a 120/
240 Vac Generator
The following instructions are illustrated in Figure 3-20, “Generator Input
Wiring to a Single Inverter” on page 3–37.
To install the AC wiring from the generator to the inverter:
1. Connect GROUND (green or bare) wires:
a) from the generator GROUND connector to the Step-down
autotransformer GROUND connector,
b) from the Step-down autotransformer GROUND connector to the
generator disconnect switch GROUND connector, and
c) from the generator disconnect switch GROUND connector to the
inverter AC GROUND bar.
2. Connect NEUTRAL (white) wires:
a) from the generator NEUTRAL connector to the Step-down
autotransformer NEUTRAL connector,
b) from the Step-down autotransformer NEUTRAL connector to the
generator disconnect switch Neutral connector, and
c) from the generator disconnect switch NEUTRAL connector to
the inverter NEUTRAL 2 terminal.
3. Connect HOT (black) wires:
a) from the generator L1 HOT OUT to the Step-down autotrans-
former L1 HOT IN,
b) and from the generator L2 HOT OUT to the Step-down autotrans-
former L2 HOT IN,
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.
Without a
Step-down
Autotransformer
Using a
120 Vac-Only
Generator
If not using a Step-down Autotransformer, install the AC wiring from
the generator to the inverter through the generator disconnect as
follows:
1. Connect GROUND (green or bare) wires:
a) from the generator GROUND connector to the ground in the
generator disconnect, and
b) from the ground in the generator disconnect to the ground bar in
the inverter.
2. Connect NEUTRAL (white) wires
a) from the generator NEUTRAL connector to the neutral in the
generator disconnect, and
AC Wiring
976-0043-01-02 3–37
b) from the neutral in the generator disconnect to the inverter
NEUTRAL 2 terminal.
3. Connect HOT (black) wires:
a) from the generator GEN HOT OUT terminal to the circuit
breaker in the generator disconnect, and
b) from the circuit breaker in the generator disconnect to the inverter
AC2 GEN terminal.
4. Torque all inverter terminal block connections to 25 inch-pounds.
Figure 3-20
Generator Input Wiring to a Single Inverter
AC
G
ROUND
BAR
(INSIDE)
Sine Wave Plus
Inverter/Charger
Generator
Disconnect Switch
(Optional)
GN
GROUND NEUTRAL
GEN HOT OUT
120/240 Vac
GENERATOR
L1 L2
GHOT OUT N
HOT IN
1a 2a
3a
Step-down
Autotransformer
(Optional)
2b
3b
3c
AC
GROUND
BAR
(INSIDE)
Sine Wave Plus
Inverter/Charger
AC TERMINAL
BLOCK
INV OUT
NEUTRAL OUT
NEUTRAL 2
NEUTRAL 1
AC1 GRID
AC2 GEN
AC TERMINAL
BLOCK
INV OUT
NEUTRAL OUT
NEUTRAL 2
NEUTRAL 1
AC1 GRID
AC2 GEN
1c
3d 2c
GROUND NEUTRAL
GEN HOT OUT
120 Vac ONLY
GENERATOR
GN
3b 2c
1b
1c
3a
Generator
Disconnect Switc
h
(Optional)
Generator connections using a
T240, a generator disconnect and
a 120/240 Vac Generator
Generator connections using a
generator disconnect and a
120 Vac Generator
Installation
3–38 976-0043-01-02
Install Utility Wiring to the Inverter Input (On-Grid Applications only)
The following instructions are illustrated in Figure 3-21, “Utility Wiring
to the Inverter Input” on page 3–39.
Install the wiring from the inverter to the utility panel as follows:
1. Feed the HOT, NEUTRAL, and GROUND input wires (via conduit)
from the inverter to the utility panel. Leave three to six inches of extra
wire at each end.
2. Connect a GROUND (green or bare) wire:
a) from the inverter AC GROUND bar, and
b) to the utility panel GROUND bar.
3. Connect a NEUTRAL (white) wire:
a) from the inverter NEUTRAL 1 terminal, and
b) to the utility panel NEUTRAL bus.
4. Connect a HOT (black) wire:
a) from the inverter AC1 GRID terminal, and
b) to the appropriate utility panel circuit breaker.
5. Torque all inverter terminal block connections to 25 inch-pounds.
CAUTION: Damage to Equipment
The inverter’s AC output must never be wired to any AC source voltage such as a
generator output or utility panel. This will cause severe damage to the inverter
which is not covered under warranty.
Important:
Make the connections to the inverter first. Wiring to the inverter’s
main breaker in the utility panel is performed after all connections have been
made in the inverter.
Optional Equipment
976-0043-01-02 3–39
Figure 3-21
Utility Wiring to the Inverter Input
Optional Equipment
Stacking Dual Inverter Systems
To power 120/240 Vac loads you can link or stack two identical inverters
together in series by using the ISC-S cable. The ISC-S cable connects to
the stacking ports on the AC end of the Sine Wave Plus.
This cable is not provided with the inverter and must be purchased
separately. Install this cable prior to making the AC wiring connections.
For complete installation and wiring instructions for using the ISC-S
cable, please see the ISC-S Cable Owner’s Guide.
The ISC-S cable does not allow programming or access to the display
from one inverter to the other. If there are changes to the default setting
necessary, each inverter must be programmed separately.
Installation
3–40 976-0043-01-02
Installing the ISC-S Cable
To install the ISC-S cable on the inverters:
1. Connect one end of the ISC-S cable to the Stacking Port on one
inverter.
2. Connect the other end of the ISC-S cable to the Stacking Port on the
other inverter.
The following diagram is for connecting the cable to the inverters only.
For information on wiring dual, stacked inverter systems please refer to
the ISC-S Cable Owner’s Guide.
CAUTION:
Equipment Damage
Damage can occur if the ISC-S cable is not properly installed. Do NOT use a
standard computer cable in place of the ISC-S cable.
Figure 3-22
Series-stacked Inverters with ISC-S Cable
AC End of Inverter L1 AC End of Inverter L2
ISC-S Cable
Stacking
Port Stacking
Port
Optional Equipment
976-0043-01-02 3–41
Remote Monitoring Options
The Sine Wave Plus can be controlled remotely by connecting an
additional ICM or by using an ICA connected to a personal computer. The
ICM operates identically to the ICM display on the front of the Sine Wave
Plus.
See the ICM Installation Guide for specific installation instructions for
installing the remote ICM.
See the ICA Owner’s Guide for specific installation instructions for
installing the ICA.
To install the remote monitor’s cable:
◆Connect the appropriate end of the cable from the remote monitor of
choice to the “REMOTE” port on the AC end of the inverter.
Figure 3-23
Remote Monitor Port Locations
Inverter Control Module (ICM)
(for distances of 25 or 50 feet)
Inverter Communications Adapter
(ICA) (for distances up to 50 feet)
For distances greater than 50
feet, a modem must be used.
The ICM and the ICA use the
same communications port to
connect to the inverter. You
cannot use both methods at the
same time for monitoring the
system.
AC End of Inverter
Installation
3–42 976-0043-01-02
Auxiliary Load Module (ALM)
The ALM can be used to signal loads to turn on and off based on battery
voltage. The ALM has a DC voltage controlled relay (switch) that require
the Sine Wave Plus in order to operate.
The DC voltage set points for energizing and de-energizing the relays are
adjustable as are the time delays.
To connect the ALM to the Sine Wave Plus:
◆Connect the ALM communications cable from the ALM to the AUX
port on the AC end of the inverter.
See “23 ALM Relays Menu” on page 7–19 for instructions on
programming the parameters required to use this feature.
Figure 3-24
Connecting the ALM Communications Cable to the Sine
Wave Plus
Auxiliary Load Module
AC End of Inverter
Optional Equipment
976-0043-01-02 3–43
Emergency Power Off (EPO)
The Sine Wave Plus has an EPO communications port that is designed to
allow a disconnect switch, using an RJ11-type jack, to function as an
emergency shutoff switch. Many different switches are available for this
purpose. Consult your local system designer or qualified technician for
specific installation instructions.
See Appendix G, “Emergency Power Off Switches” for additional
information about this feature and how to prepare a cable for it.
EPO Port
The EPO switch is connected to the Sine Wave Plus with a telephone cord
(RJ11 type connector) to the dedicated EPO port on the AC (left) side of
the inverter.
Important: The purpose of an EPO is to provide fire fighters and other
emergency personnel a means to turn off all sources of power to a building prior to
entering. For this reason, it is imperative to locate the remote EPO switch close to
other sources of power which may enter your building. For example, if your
building is serviced by utility and inverter, then the EPO should be located next to
the utility meter.
Figure 3-25
Connecting the EPO
AC End of Inverter
Emergency Power
Shut Off Switch
EPO Port
3–44
4Functional Test
Chapter 4, “Functional Test” explains how to conduct a
functional test of the inverter.
Functional Test
4–2 976-0043-01-02
Basic Functional Test
The following steps will complete a basic functional test of the Sine Wave
Plus. If any test fails, please refer to Chapter 9, “Troubleshooting” for
assistance.
Confirm all Connections
Once the AC and DC wiring have been installed and connected, take a
moment to go back over all connections and make sure they are secure
and have been installed properly.
Applying Battery Power to the Inverter
To apply battery power to the inverter:
1. Before applying DC power to the inverter, measure the voltage and
polarity of the cables (measure at the battery side of the disconnect or
breaker).
2. Apply battery (DC) power to the inverter by turning on the battery
bank DC disconnect.
The inverter will power up, the LCD display will illuminate, but the
inverter will remain in the OFF Mode (as shown in Figure 4-1).
Important:
The inverter is NOT reverse polarity protected. Reversing the
battery polarity on the DC input connections will cause permanent damage to the
inverter which is not covered under warranty. Always check polarity BEFORE
making connections to the inverter.
Basic Functional Test
976-0043-01-02 4–3
Turning ON the Inverter
To turn on the inverter:
1. Ensure that the LCD display is as shown in Figure 4-1.
2. Press the red inverter ON/OFF MENU switch twice (SRCH, then
ON) to turn on the inverter.
3. Monitor the INVERT (yellow) LED to confirm which mode the
inverter is in:
• Off – The inverter/charger is off. This is the default position of
the inverter upon power-up. No inverter or pass-through power
will be applied to the AC loads.
• One blink/sec – The inverter/charger is in the Search Mode and is
looking for an AC load greater than the Search Watts setting
(default = 8 watts).
• On – The inverter/charger is on. The inverter will produce a low
audible “buzz” and is able to provide power to the AC loads.
If the inverter does not produce an low audible “buzz” or illuminates the
INVERT LED, check all connections. Check the inverter’s DC voltage on
the positive (+) and negative (–) terminals. If the DC voltage is low, the
battery bank needs to be charged externally. Charge the battery bank and
restart the functional test.
WARNING
Prior to turning on the inverter, ensure that all AC loads are disconnected from
the output of the inverter.
Figure 4-1
Power Up Display
Functional Test
4–4 976-0043-01-02
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 voltage from INV HOT to NEU OUT
terminals of the inverter and ensure you get the correct AC voltage
for your particular unit.
2. Verify that neutral is bonded to ground in the system by measuring
the hot and neutral voltages relative to ground (See “Bonding the
Grounding System” on page 2–10). Neutral to ground should equal
zero (0) volts.
3. After confirming the correct AC voltage, turn on your AC output
breaker and place a load on the inverter (plug in a light or other load
to an outlet the inverter is powering).
4. Confirm that the AC load that was just applied works properly.
Confirming Battery Charger Operation
To confirm that battery charging is operating correctly:
◆Depending on your configuration, provide AC power to the AC1
GRID and AC1 NEU or AC2 GEN and AC2 NEU.
• The AC1 or AC2 (green) LED will initially blink until AC power
has synchronized and then turn solid to indicate the AC power is
getting to the inverter.
• After a 20-second to 2-minute delay depending on which AC
terminals were wired, the Battery BULK (yellow) LED or
FLOAT (green) LED should illuminate. This indicates the
charger is working properly.
• The control module lights should indicate which charge stage
(bulk or float) the inverter is currently in.
• Any AC loads powered by the inverter should also work at this
point since a portion of the AC input power (Utility or Generator)
is passed through the inverter to power the loads.
Important:
Unless the inverter/charger settings have been changed, the
inverter will charge as if it has a large (> 700 Ah) liquid battery bank. Note that
ALL systems will need to have the battery charging set points “fine tuned” to
validate your battery warranty with your battery supplier.
Basic Functional Test
976-0043-01-02 4–5
Confirming Inverter Operation
To confirm that the inverter is operating correctly:
◆Disconnect the AC input power by turning the input AC power
breaker off or unplugging the AC power cord.
• The inverter should transfer to inverter mode immediately. This
will be indicated by the INVERT (yellow) LED illuminating.
• The inverter will begin to produce an low audible “buzz” as it
takes power from the batteries and uses it to power the loads.
• The loads should continue to operate uninterrupted.
This completes the functional test. If all tests pass, the inverter is ready for
use. If any of the inverter’s internal set points are to be adjusted, consult
the programming chapters of this manual.
4–6
5Navigation
Chapter 5, “Navigation” explains how to navigate through the
Sine Wave Plus Inverter/Charger menus using the Control
Module and the menu maps.
Navigation
5–2 976-0043-01-02
Navigating the Sine Wave Plus
The Sine Wave Plus is programmed using the inverter control module
(ICM) to access “User” and “Setup” menus. Navigating through the
menus requires an understanding of the ICM and its features, what menus
are required to do specific functions, and to set or change parameters.
Check defaults The factory default settings may be adequate for most installations.
Check the factory default settings shown on the following model-specific
tables to see if your installation will require changes to these settings:
•Table 6-1, “Basic Setup Menu Default Settings for the Sine Wave
Plus 2524 and 2548 Models” on page 6–2
•Table 6-2, “Basic Setup Menu Default Settings for the Sine Wave
Plus 4024 and 4048 Models” on page 6–4
•Table 6-3, “Basic Setup Menu Default Settings for the Sine Wave
Plus 5548 Model” on page 6–6
•Table 7-1, “Advanced Setup Default Settings for the Sine Wave Plus
2524 and 2548 Models” on page 7–2
•Table 7-2, “Advanced Setup Default Settings for the Sine Wave Plus
4024 and 4048 Models” on page 7–5
•Table 7-3, “Advanced Setup Default Settings for the Sine Wave Plus
Plus 5548 Models” on page 7–7
Record changes If your installation will require that the settings be altered, changes can be
made using the features of the inverter control module. Record these
changes on the model-specific tables provided in Appendix B,
“Configuration Settings”. This provides a written record of the necessary
changes in the event that the inverter needs to be reprogrammed.
•Table B-2, “Basic Setup Default and User Settings for the Sine Wave
Plus 2524 and 2548 Models” on page B–5
•Table B-3, “Basic Setup Default and User Settings for the Sine Wave
Plus 4024 and 4048 Models” on page B–6
•Table B-4, “Basic Setup Default and User Settings for the Sine Wave
Plus 5548 Model” on page B–8
•Table B-5, “Advanced Setup Default and User Settings for the Sine
Wave Plus 2524 and 2548 Models” on page B–10
•Table B-6, “Advanced Setup Default and User Settings for the Sine
Wave Plus 4024 and 4048 Models” on page B–12
•Table B-7, “Advanced Setup Default and User Settings for the Sine
Wave Plus 5548 Model” on page B–14
Most installations will require that the user perform the Basic Setup
routine.
Inverter Control Module Features
976-0043-01-02 5–3
The Inverter Control Module (ICM)
The ICM is located on the front panel of the Sine Wave Plus. It’s used to
display status information regarding the operation and performance of the
unit. It is also used to access the “Basic Setup”, “Advanced Setup”, and
“User Menus”. All settings (except for Time of Day) can be saved in non-
volatile memory so they are not lost when DC power is removed from the
inverter.
If a remote ICM is installed, you may do all the same programming from
the remote control module instead.
Inverter Control Module Features
There are nine push-buttons, eight Light Emitting Diodes (LEDs), one
contrast adjustment and one Liquid Crystal Display (LCD) on the front of
the ICM. The push-buttons are grouped into sets depending on their
function. The LEDs also are grouped by function.
The display
The system information, menu items, and set points are all displayed on a
Liquid Crystal Display (LCD). The contrast of the display can be adjusted
by the Contrast Adjustment screw at the bottom of the panel.
The cursor
When navigating through the menu system, the selected item is indicated
in the LCD by a shaded, flashing box over the first letter/number of the
set point. This special highlighting is called the "cursor". Pressing the
SET POINT buttons will move the cursor left (–) or right (+) within the
available options.
Figure 5-1
ICM Display Location
ICM Display
Navigation
5–4 976-0043-01-02
Display contrast
To change the display contrast, use a small, flat-blade screwdriver in the
slot provided to make the adjustment.
Push-buttons
Eight push-buttons enable access to internal software to program user-
specific parameters and to monitor the system. These push-buttons access
the User Menu, Basic Setup Menu, and the Advanced Setup Menu. One
push-button is available for resetting factory defaults.
ON/OFF Menu Buttons
These push-buttons directly access either the Inverter User Menu or the
Generator User Menu.
• INV ON/OFF (Red) Button - Pressing the red INV ON/OFF button
directly accesses the menu item 01A Inverter.
• GEN ON/OFF (Green) Button - Pressing the green GEN ON/OFF
button directly accesses menu item 02A Generator.
Figure 5-2
ICM Display and Contrast Adjustment
LCD Display
Cursor
Contrast
Adjustment
Figure 5-3
ICM ON/OFF Push-buttons
Inverter Control Module Features
976-0043-01-02 5–5
Menu Heading Buttons
The Menu Heading push-buttons are used to move either forward or
backward through the Menu Heading selections.
• Press the Menu Heading button to move forward.
• Press the Menu Heading button to move backward.
Menu Item Buttons
Below the Menu Headings are subdirectories called Menu Items. Menu
Items contain the selectable parameters or set points.
•Press the Menu Item button to move up.
•Press the Menu Item button to move down.
Figure 5-4
ICM Menu Heading Push-buttons
Figure 5-5
ICM Menu Item Push-uttons
Navigation
5–6 976-0043-01-02
Set Point Buttons
The SET POINT buttons change the value of a parameter or select a mode
from the displayed menu.
• Press the SET POINT button (+) to move the cursor to the right or
raise an adjustable value.
• Press the SET POINT button (–) to move the cursor left or lower an
adjustable value.
Reset Factory Defaults
The Reset Defaults push-button at the bottom of the ICM refreshes the
LCD display.
Pressing this button when the “Press Resets for Factory Default” menu is
displayed resets the unit to the factory defaults. See “Press Reset for
Factory Defaults” on page 8–21 for instructions on using this feature.
Figure 5-6
ICM Set Point Push-buttons
Figure 5-7
ICM Reset Defaults button
CAUTION: Equipment Damage
Ensure all devices connected to the ALM or GSM are disabled prior to pressing
the Reset Factory Defaults button.
Menu Map
976-0043-01-02 5–7
Menu Map
Introduction The menu system contains three main menu maps. Each Menu Map is
made up of:
• Menu Headings,
• Menu Items, and
• Set Points.
A set point is selected when the cursor highlights the first letter, or
number, of the selection.
Each of the Menu Headings will have “END Menu” menu items to
indicate the end of the Menu Heading category.
The “User” Menu • The User Menu contains the basic operational functions of the unit
and provides system status information. The User Menu uses Menu
Headings 1-7.
The “Basic Setup”
Menu • The Basic Setup Menu contains the basic setup information to run the
equipment in basic inverter/charger Mode. Basic programming
includes setting the time-of-day clock, configuring the inverter
functions, determining the battery charging parameters, and selecting
the AC input characteristics. The Basic Setup Menu uses Menu
Headings 10-14 with applicable menu items to support each function.
The “Advanced
Setup” Menu
• The Advanced Setup Menu contains the setup information for the
system to use to perform special (or advanced) features such as
automatic generator starting, auxiliary load control, remote
monitoring, and energy management features. The Advanced Setup
Menu uses Menu Headings 20-27.
Figure 5-8
Menu Structure
Navigation
5–8 976-0043-01-02
User Menu (01-07) The USER MENU allows access to the daily operational functioning of
the unit. These Menu Headings do not set configuration parameters, but
do provide system performance information.
See “The User Menu Summary” on page 8–11 for a summary of the
default settings and display descriptions.
See “Accessing the User Menu” on page 8–14 for instructions on
accessing the User Menu.
Figure 5-9
User Menu Map - Part 1
Menu Map
976-0043-01-02 5–9
Figure 5-10
User Menu Map - Part 2
Navigation
5–10 976-0043-01-02
Basic Setup Menu
(10-14)
The BASIC SETUP MENU follows the User Menu in the menu
architecture. This menu allows access to the settings required for system
configuration and modes of operation. Establishing these parameters upon
initial power-up will be required.
See “Basic Setup Process” on page 6–9 for overview instructions on
programming the Basic Setup.
See “Accessing the Basic Setup Menu” on page 6–10 for instructions on
accessing the Basic Setup Menu.
Figure 5-11
Basic Setup Menu Map Part 1
Menu Map
976-0043-01-02 5–11
Figure 5-12
Basic Setup Menu Map Part 2
Navigation
5–12 976-0043-01-02
Advanced Setup
Menu (20-27)
The ADVANCED SETUP MENU contains specialized configuration
settings such as automatic generator starting details, auxiliary load usage,
and energy management (grid usage) parameters.
See “Advanced Setup Summary” on page 7–2 for a listing of all the
default settings for this menu structure.
See “Accessing the Advanced Setup Menu” on page 7–11 for specific
instructions on accessing the Advanced Setup Menu.
Figure 5-13
Advanced Setup Menu Map Part 1
Menu Map
976-0043-01-02 5–13
Figure 5-14
Advanced Setup Menu Map Part 2
Navigation
5–14 976-0043-01-02
Figure 5-15
Complete User Menu Map
Menu Map
976-0043-01-02 5–15
Figure 5-16
Complete Basic Setup Menu Map
Navigation
5–16 976-0043-01-02
Figure 5-17
Complete Advanced Setup Menu Map
6Basic Setup
Programming
Chapter 6, “Basic Setup Programming” explains how to
program the Sine Wave Plus Inverter/Charger to operate under
basic conditions.
Basic Setup Programming
6–2 976-0043-01-02
Basic Setup Summary
Check Defaults The following tables provides the default settings for the Sine Wave Plus
Basic Setup Menu for each model and the cross-reference pages for
locating information on each menu item.
•Table 6-1, “Basic Setup Menu Default Settings for the Sine Wave
Plus 2524 and 2548 Models” on page 6–2
•Table 6-2, “Basic Setup Menu Default Settings for the Sine Wave
Plus 4024 and 4048 Models” on page 6–4
•Table 6-3, “Basic Setup Menu Default Settings for the Sine Wave
Plus 5548 Model” on page 6–6
Record Changes If your system requires changes to these default settings, record the
changes on the model-specific tables in Appendix B, “Configuration
Settings” before your start programming. These tables are found on the
following pages:
•Table B-2, “Basic Setup Default and User Settings for the Sine Wave
Plus 2524 and 2548 Models” on page B–5
•Table B-3, “Basic Setup Default and User Settings for the Sine Wave
Plus 4024 and 4048 Models” on page B–6
•Table B-4, “Basic Setup Default and User Settings for the Sine Wave
Plus 5548 Model” on page B–8
For directions on how to access the Basic Setup Menu, see “Accessing the
Basic Setup Menu” on page 6–10.
Table 6-1
Basic Setup Menu Default Settings for the Sine Wave Plus 2524 and 2548 Models
Basic Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See Page
Range/
Display Default
Range/
Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00 00:00:00 to
23:50:00
00:00:00 page 6–11
10B Set Minute 00:00:00 to
00:09:00
00:00:00 00:00:00 to
00:09:00
00:00:00 page 6–11
10C Set Second 00 to 59 00:00:00 00 to 59 00:00:00 page 6–12
End Menu 10
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 16.1 to 34.0 32.0 32.2 to 68.0 64.0 page 6–12
11B Low Battery Cut In Vdc 16.1 to 33.9 26.0 32.2 to 67.8 52.0 page 6–12
Basic Setup Summary
976-0043-01-02 6–3
11C Low Battery Cut Out Vdc 11.0 to 33.9 22.0 32.0 to 67.8 44.0 page 6–13
11D LBCO Delay Minutes 01 to 255 15 01 to 255 15 page 6–13
11E Search Watts (SRCH) 00 to 248 08 00 to 248 08 page 6–14
End Menu 11
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT
FLOAT
FLOAT SILENT
FLOAT
FLOAT page 6–19
12B Bulk Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6 page 6–20
12C Float Volts DC 20.0 to 32.0 26.8 40.0 to 64.0 53.6 page 6–20
12D Equalize Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6 page 6–20
12E Max Charge Amps AC 01 to 20 20 01 to 20 20 page 6–22
12F Bulk Done Amps AC 00 to 20 10 00 to 20 10 page 6–23
12G EQ Vdc Done Timer 00:00 to 23:50 02:00 00:00 to
23:50
02:00 page 6–24
12H Max Bulk/EQ Timer 00:00 to 23:50 05:00 00:00 to
23:50
05:00 page 6–25
12I Temp Comp LeadAcid
NiCad
LeadAcid LeadAcid
NiCad
LeadAcid page 6–25
End Menu 12
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60 00 to 60 60 page 6–27
13B Gen (AC2) Amps AC 00 to 60 30 00 to 60 30 page 6–27
13C Input Upper Limit Vac 125 to 150 130 125 to 150 130 page 6–28
13D Input Lower Limit Vac 80 to 115 110 80 to 115 110 page 6–28
End Menu 13
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
14A Push INV now to save
settings
Push INV now to save settings page 6–29
14B Push GEN to restore settings Push GEN to restore settings page 6–29
Table 6-1
Basic Setup Menu Default Settings for the Sine Wave Plus 2524 and 2548 Models
Basic Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See Page
Range/
Display Default
Range/
Display Default
Basic Setup Programming
6–4 976-0043-01-02
14C Push GEN for factory
defaults
Push GEN for factory defaults page 6–30
End Menu 14
END BASIC SETUP MENU
Table 6-2
Basic Setup Menu Default Settings for the Sine Wave Plus 4024 and 4048 Models
Basic Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
See Page
Range/
Display Default
Range/
Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00 00:00:00 to
23:50:00
00:00:00 page 6–11
10B Set Minute 00:00:00 to
00:09:00
00:00:00 00:00:00 to
00:09:00
00:00:00 page 6–11
10C Set Second 00 to 59 00:00:00 00 to 59 00:00:00 page 6–12
End Menu 10
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 16.1 to 34.0 32.0 32.2 to 68.0 64.0 page 6–12
11B Low Battery Cut In Vdc 16.1 to 33.9 26.0 32.2 to 67.8 52.0 page 6–12
11C Low Battery Cut Out Vdc 11.0 to 33.9 22.0 32.0 to 67.8 44.0 page 6–13
11D LBCO Delay Minutes 01 to 255 15 01 to 255 15 page 6–13
11E Search Watts (SRCH) 00 to 248 08 00 to 248 08 page 6–14
End Menu 11
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT
FLOAT
FLOAT SILENT
FLOAT
FLOAT page 6–19
12B Bulk Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6 page 6–20
12C Float Volts DC 20.0 to 32.0 26.8 40.0 to 64.0 53.6 page 6–20
12D Equalize Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6 page 6–20
Table 6-1
Basic Setup Menu Default Settings for the Sine Wave Plus 2524 and 2548 Models
Basic Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See Page
Range/
Display Default
Range/
Display Default
Basic Setup Summary
976-0043-01-02 6–5
12E Max Charge Amps AC 01 to 30 30 01 to 30 30 page 6–22
12F Bulk Done Amps AC 00 to 30 10 00 to 30 10 page 6–23
12G EQ Vdc Done Timer 00:00 to
23:50
02:00 00:00 to
23:50
02:00 page 6–24
12H Max Bulk/EQ Timer 00:00 to
23:50
05:00 00:00 to
23:50
05:00 page 6–25
12I Temp Comp LeadAcid
NiCad
LeadAcid LeadAcid
NiCad
LeadAcid page 6–25
End Menu 12
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60 00 to 60 60 page 6–27
13B Gen (AC2) Amps AC 00 to 60 30 00 to 60 30 page 6–27
13C Input Upper Limit Vac 125 to 150 130 125 to 150 130 page 6–28
13D Input Lower Limit Vac 80 to 115 110 80 to 115 110 page 6–28
End Menu 13
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
14A Push INV now to save
settings
Push INV now to save settings page 6–29
14B Push GEN to restore settings Push GEN to restore settings page 6–29
14C Push GEN for factory
defaults
Push GEN for factory defaults page 6–30
End Menu 14
END BASIC SETUP MENU
Table 6-2
Basic Setup Menu Default Settings for the Sine Wave Plus 4024 and 4048 Models
Basic Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
See Page
Range/
Display Default
Range/
Display Default
Basic Setup Programming
6–6 976-0043-01-02
Table 6-3
Basic Setup Menu Default Settings for the Sine Wave Plus 5548 Model
Basic Setup Menus
Sine Wave Plus 5548
See Page
Range/
Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00 page 6–11
10B Set Minute 00:00:00 to
00:09:00
00:00:00 page 6–11
10C Set Second 00 to 59 00:00:00 page 6–12
End Menu 10
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 32.2 to 68.0 64.0 page 6–12
11B Low Battery Cut In Vdc 32.2 to 67.8 52.0 page 6–12
11C Low Battery Cut Out Vdc 32.0 to 67.8 44.0 page 6–13
11D LBCO Delay Minutes 01 to 255 15 page 6–13
11E Search Watts (SRCH) 00 to 248 08 page 6–14
End Menu 11
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT
FLOAT
FLOAT page 6–19
12B Bulk Volts DC 40.0 to 64.0 57.6 page 6–20
12C Float Volts DC 40.0 to 64.0 53.6 page 6–20
12D Equalize Volts DC 40.0 to 64.0 57.6 page 6–20
12E Max Charge Amps AC 01 to 45 40 page 6–22
12F Bulk Done Amps AC 00 to 50 10 page 6–23
12G EQ Vdc Done Timer 00:00 to
23:50
02:00 page 6–24
12H Max Bulk/EQ Timer 00:00 to
23:50
05:00 page 6–25
12I Temp Comp LeadAcid
NiCad
LeadAcid page 6–25
End Menu 12
Basic Setup Summary
976-0043-01-02 6–7
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60 page 6–27
13B Gen (AC2) Amps AC 00 to 60 30 page 6–27
13C Input Upper Limit Vac 125 to 150 130 page 6–28
13D Input Lower Limit Vac 80 to 115 110 page 6–28
End Menu 13
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
14A Push INV now to save
settings
Push INV now to save
settings
page 6–29
14B Push GEN to restore settings Push GEN to restore
settings
page 6–29
14C Push GEN for factory
defaults
Push GEN for factory
defaults
page 6–30
End Menu 14
END BASIC SETUP MENU
Table 6-3
Basic Setup Menu Default Settings for the Sine Wave Plus 5548 Model
Basic Setup Menus
Sine Wave Plus 5548
See Page
Range/
Display Default
Basic Setup Programming
6–8 976-0043-01-02
Before You Begin Programming
Some items must be pre-determined or confirmed before you start
programming the inverter/charger for use. These items include the voltage
levels to operate the inverter, charging parameters for the battery charger,
and AC input amperage limits.
DC Amps verses AC Amps
Some of the settings in the Basic Setup Menu may require you to convert
DC amps to AC amps.
Inverters convert DC power into AC power. Since the DC voltage will be
lower than the AC voltage, the DC amps will be higher than the AC amps.
The formula or ratio of DC amps to AC amps is the actual AC voltage
divided by the actual DC voltage. This ratio is not exact as there will be
losses, although small, in the power conversion process.
Actual AC Voltage ÷ Actual DC Voltage ≈ Amp ratio
There are two “rules of thumb” using this inverter to estimate the
amperages.
• If you are running on battery power:
24 Vdc inverters have about a 5 to 1 ratio of DC amps to AC amps.
48 Vdc inverters have about a 2.5 to 1 ratio of DC amps to AC amps.
• If you charging battery from AC power:
24 Vdc inverters have about a 4 to 1 ratio of DC amps to AC amps.
48 Vdc inverters have about a 2 to 1 ratio of DC amps to AC amps.
For example:
• A 24 Vdc inverter operating from a battery at 25 Vdc and making
120 Vac will use approximately 4.8 amps DC for every 1 amp AC
consumed by the loads (120 Vac/25 Vdc = 4.8)
• A 48 Vdc inverter charging a battery at 60 Vdc from a generator
supplying the inverter with 120 Vac will make approximately
2 amps DC for every 1 amp AC (120 Vac/60 Vdc = 2)
Note: The AC ammeters have an approximate 1 amp tolerance.
Before You Begin Programming
976-0043-01-02 6–9
Basic Setup Process
The Basic Setup procedure is comprised of the following items:
1. Setting the Time of Day – This sets the internal clock for all the
features requiring time functions.
See “10 Time of Day Setup Menu” on page 6–11 for instructions on
setting the Time of Day.
2. Selecting Inverter functions – This selects basic inverter operating
functions.
See “11 Inverter Setup Menu” on page 6–12 for instructions on
setting the Inverter functions.
3. Selecting Charger functions – This selects the basic charger functions.
See “12 Battery Charging Menu” on page 6–19 for instructions on
setting the Charger functions.
4. Selecting Grid Usage functions – This selects basic Grid Usage
functions.
See “13 AC Inputs Menu” on page 6–26 for instructions on setting
the Grid Usage functions.
5. Saving programmed parameters.
See “14 Save/Restore Settings Menu” on page 6–29 for instructions
on saving programmed parameters.
Basic Setup Programming
6–10 976-0043-01-02
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 Menu.
Figure 6-1
Accessing the Basic Setup Menu
While holding the green GEN
button down, press the red INV
button to move into the Basic
Setup Menu.
Press the Menu Heading button
until the END USER MENU is
displayed.
Press and hold down the
green GEN button.
Power up Display
Menu Item Descriptions
976-0043-01-02 6–11
Menu Item Descriptions
10 Time of Day Setup Menu
This menu allows for setting the time of day in hours, minutes, and
seconds. The time is displayed in a 24-hour format (i.e., 00:00:00 to
23:59:59 hours).
To set the time of day:
◆When the BEGIN BASIC SETUP MENU is displayed, press the
button to move forward until 10 Time of Day Setup Menu is
displayed.
10A Set Hour
To set the hour display:
1. When the 10 Time of Day Setup Menu is displayed, press the
button to select 10A Set Hour.
2. When 10A Set Hour is displayed, press the SET POINT buttons (+)
or (–) to change the time displayed. The "minute" section of the
display will change in 10-minute increments.
3. Keep pressing the SET POINT buttons until the appropriate hour is
displayed.
10B Set Minute
To set the minute display:
1. Press the button to select 10B Set Minute.
2. When 10B Set Minute is displayed, press the SET POINT buttons
(+) or (–) to change the time displayed. The "minute" section of the
display will change in 1-minute increments.
3. Press the SET POINT buttons (+) or (–) until the proper minutes are
displayed.
Important: If the system is being setup for the first time or the DC batteries
were disconnected from the inverter, then the time must be reset. The
programmed time does not reset when the “Press for Factory Defaults” button is
pressed.
Basic Setup Programming
6–12 976-0043-01-02
10C Set Seconds
To set the second display:
1. Press the button to select 10C Set Second.
2. When 10C Set Second is displayed, press the SET POINT buttons
(+) or (–) to change the time displayed. The “seconds” section of the
display will change in 1-second increments.
3. Press the SET POINT buttons (+) or (–) until the proper seconds are
displayed. Seconds will stay fixed as set until you exit the display.
11 Inverter Setup Menu
The following inverter settings are intended to protect the batteries from
excessive discharging. These settings prevent the inverter from drawing
excessive DC voltage from the batteries. To do this, it is necessary to
determine the voltage levels where the inverter will start and stop drawing
power from the battery bank.
The factory default settings for inverter functions are set to protect most
types of batteries. It may not be necessary to alter these settings. Before
changing the default settings, check with your battery dealer/installer.
11A High Battery Cut Out VDC
This voltage level is the maximum voltage the batteries will be allowed to
reach. If the battery voltage exceeds this limit for more than 1 minute, the
inverter will shut down. The inverter will not support AC loads when in
this condition. The inverter automatically restarts when the voltage drops
to 3 Vdc (24-volt models) or 6 Vdc (48-volt models) below the HBCO
setting. This setting is not temperature compensated.
11B Low Battery Cut In VDC
This menu item sets the battery voltage level that turns the inverter back
on after being shut down by the LBCO setting. Set this voltage level
lower than the Bulk or Float volts DC setting.
Important:
Both 11A High Battery Cut Out (HBCO) and 11C Low Battery
Cut Out (LBCO) values lock the upper and lower limits of the inverter/charger
and will override and/or readjust other settings programmed.
Be sure to recheck and reset, if necessary, all settings affected by changes to
11B Low Battery Cut in VDC, 20A Refloat High Volts DC, 20B Refloat Low
Volts DC, 22A High Xfer (HBX) Vdc, 22B Low Xfer (LBX).
Menu Item Descriptions
976-0043-01-02 6–13
This voltage level is used to indicate that the batteries have a sufficient
level of charge for the inverter to start using power from the battery bank.
11C Low Battery Cut Out VDC
When the batteries discharge to the level set in 11C Low Battery Cut
Out VDC, and are held at or below this level for the 11D LBCO Delay
time, the inverter output shuts down and transfers any available AC
source (generator or grid) to the charger to bring the battery level back up
to the 11B Low Battery Cut In Vdc level. The inverter will not support
any AC loads when in this condition. AC loads will have to be powered
by either a generator or grid power. This is the lowest voltage level
acceptable for battery use by the inverter.
11D LBCO Delay Minutes
Menu item 11D LBCO Delay Minutes is used to set the length of time
(in minutes) that the inverter is allowed to continuously operate at or
below the LBCO level set in menu item 11C Low Battery Cut Out
before it shuts off.
Once the inverter has shut off, the battery voltage must rise above the
value (set in menu 11B Low Battery Cut In) for inverter operation to
resume.
Guidelines for setting this menu item:
• If using an automatic generator starting system, do not set this delay
period shorter than the amount of time it takes the generator to start
and connect. Otherwise, the power will go OFF and then back ON
when the generator auto-starts due to the LBCO condition.
Basic Setup Programming
6–14 976-0043-01-02
11E Search Watts
This menu item sets the inverter’s search sensitivity. Any load that is
below this setting does not cause the inverter to produce an AC output
voltage when running from batteries. The SRCH function must be
selected in 01A Inverter.
How does Search
Sense work While idling in the Search Sense Mode, the inverter sends out a pulse
about once per second. This electrical pulse travels through the AC wiring
“looking” for loads that are connected to the system.
When a load is detected, the inverter then has to make a decision as to
whether or not the load is large enough to provide power to. This decision
point is user adjustable using the Search Sensitivity control on the
inverter.
Why use search
sense Search sense allows you to selectively power only items that draw more
than a certain amount of power, but the bigger reason lies in power
savings.
For example:
Imagine an inverter that has a no-load idle power of 8 watts. This
means the inverter needs 8 watts to power itself even if no loads are
present.
If a water pump is driven by the inverter for only one hour total per
day then the other twenty-three hours out of the day the inverter is
using 8 watts per hour just to sit there and do nothing. That power
comes from the batteries.
If search sense is set so that the inverter sleeps until the pump wants
to run, the scenario described above greatly improves. Now instead of
the inverter idling at 8 watts, only ½ watt is drawn while in Search
Mode. This is a savings of 7½ watts per hour or 172.5 watt-hours.
This converts directly to 7 amp-hours for a 24 volt battery system.
In systems with small batteries or limited charging capability, this could
be a substantial savings.
How to set up the
Search Mode
feature on the
inverter
The Search Sense feature on the inverter is only valuable if the inverter
can spend a fair amount of time "sleeping" each day. Therefore, if Search
Sense is to be utilized it must be adjusted properly. The initial adjustment
should be made so that the inverter comes on only when needed.
Note: This item is duplicated for your convenience in menu item 01C and
11E. Changes to settings made at 01C will also change the setting in 11E.
Likewise, changes to 11E will also change the setting in 01C.
Menu Item Descriptions
976-0043-01-02 6–15
The sensitivity control should be adjusted so that the smallest load being
run can "wake" the inverter up and cause it to deliver power to the load.
If loads change significantly, then re-tuning of the search sensitivity will
be required. It may take several adjustments to tweak the sensitivity to
just the right point.
Certain types of loads can cause Search Mode to not work as expected.
These types of loads are described on page 9–3 of the Troubleshooting
Section. If these kinds of loads are in the system, follow the suggestions
given to eliminate the problem. Some televisions with instant on circuits
have a menu or control to disable it. If clocks are the problem load,
consider using battery powered units.
If the problem loads just can't be eliminated in one of the suggested
manners, there are two work-around solutions:
1. disable the search sense feature, causing the inverter to always remain
at full output voltage, or
2. use a “search-friendly companion load” whose only purpose is to be
switched on to “wake up” the inverter to power the load that is unable
to bring the inverter out of Search Mode.
Guidelines for setting this menu item:
• Setting this mode to 00 disables this function. Default is 08 watts.
• When the inverter is searching the output for loads, lights that have a
wattage lower than this setting, may flash momentarily.
Battery Charger Functions
When AC power is available, the inverter can operate as a battery charger.
Different batteries will require different charging voltage levels. Not
charging batteries at the required levels can shorten battery life or
possible damage them. It will be necessary to select the voltage levels
required and to set the voltage limits for the various stages of charging.
Battery charging parameters are set in 12 Battery Charging Menu.
Note: Search Mode, by function cannot work with timers or devices that need
power 24 hours a day.
Examples of devices with timers include coffee makers with brew timers,
refrigerators, and freezers with defrost timers.
Examples of devices that need power 24 hours a day include telephone
answering machines, alarm systems, motion detection lights, and some
thermostats.
Basic Setup Programming
6–16 976-0043-01-02
Multi-Stage Charging Process
The charging cycle uses a multi-stage charging process to maintain the
batteries. Whenever AC power that is within the range of the inverter’s
settings is present at the inverter’s input, it passes power through to the
connected load and begins charging the batteries, indicated by the Bulk or
Float charge indicator LED on the control module.
Figure 6-2
Multi-Stage Battery Charging Process
Bulk Stage Bulk charge is the first stage in the charging process and provides the
batteries with a controlled, constant current. Once the battery voltage rises
to the bulk voltage threshold, the charger switches to the Absorption
Stage.
Important: The default settings of the Sine Wave Plus may or may not work
for your specific installation. Take the time to review the default settings to make
sure they are appropriate for your installation. If not, you will need to adjust the
settings according to the battery manufacturer’s recommendations. The following
information is provided to help you make the necessary calculations.
Note: This information is provided for guidance only. Variations in battery
chemistry, as well as, site specific environmental considerations mean that you
should consult your system designer or battery manufacturer for specific
recommendations for appropriate battery voltage and current settings.
If a generator was automatically
started by the inverter to charge
the batteries, it will shut off
when the charger reaches the
FINISH stage after the bulk/
absorption period.
(GENERATOR must be in
AUTO MODE).
Bulk Stage Absorption Stage Finish Stage
DC
Voltage
AC
Current Constant
Current Reduced
Current
Reduced Current (Float)
Bulk Volts Setting Float Volts Setting
Time
Max Charge
Amps Setting
C
harging
Started
Increased
Voltage Constant
Voltage Reduced Voltage
Silent (battery voltage)
BULK DONE AMPS
or
MAX BULK/EQ TIME
No Current (Silent)
Absorption
Time
Menu Item Descriptions
976-0043-01-02 6–17
Absorption Stage Absorption charge is the second stage of battery charging and provides
the batteries a controlled, constant voltage for a set period of time. During
this stage, the current supplied to the batteries slowly decreases. When
this current decreases to or below the setting in menu item 12F Bulk
Done Amps AC, the charger switches to the Finish stage.
Finish Stage The Finish Stage contains two selections for the final stage of battery
charging: Silent or Float Modes as described below.
Float Mode Float charge maintains a trickle charge on the batteries
whenever AC is present on the inverter’s input. Float charging reduces
battery gassing, minimizes watering requirements (for flooded batteries),
and ensures the batteries are in a constant state of readiness. When this
mode is selected, the charger will automatically switch to the float stage
after the batteries have received a bulk and absorption charge. The
batteries will be maintained at the level set in menu item
12C Float Volts DC.
Silent Mode After a bulk and absorption charge cycle is complete, the
charger will shut down (go silent). AC voltage on the inverter’s input will
pass-through to the loads. The charger continues to monitor the battery
voltage in this mode and starts a float charge when certain conditions are
met:
• The batteries have discharged below the setting in menu item
20A Refloat Low Volts DC.
• The battery voltage has increased above the value set in menu
20B Refloat High Volts DC.
Note: If there are DC loads on the batteries, the charger’s current may never
decrease to a level to initiate the finish stage of charging. To ensure the charger
does not stay indefinitely in the bulk stage, set the adjustable timer menu item
12H Max Bulk/EQ Timer h:m to limit the time the batteries are bulk charged.
This timing circuit is activated at the start of the Absorption stage and
terminates bulk charging if the charge current does not decrease to the setting in
menu item 12F Bulk Done Amps AC before the 12H Max Bulk/EQ Timer
h:m setting is reached.
Note: The battery voltage can increase above the float voltage when using an
external charging device such as PV arrays, wind turbines, micro-hydro
generators, etc. Be sure to include appropriate charge management equipment
with all external DC sources.
Basic Setup Programming
6–18 976-0043-01-02
Equalize Charging the Batteries
Many battery manufacturers recommend periodic equalize charging to
level out the voltage between individual cells resulting in better battery
performance and life.
Over time, the battery’s electrolyte can become “stratified” causing
inactive areas in the plate material. If this condition is allowed to continue
for extended periods, the battery plates can “sulfate” and become
unusable. Equalizing the batteries is a controlled overcharging method
that mixes up the electrolyte and reactivates the unused areas of the plate
material, restoring batteries to a full state of charge.
Consult the battery manufacturer’s recommendation for equalize charging
settings.
Notes:
• When in Silent Mode after entering the Float Charge, the charger remains in
the Float Mode until the time set in 20F Must Float Time and the level set
in 20E Float Done Amps have been reached.
• In Silent Mode, the transfer time between utility power and the inverter is
slower than in Float Mode. If your application is dedicated to sensitive loads
(such as computers), we recommend Float Mode. Silent Mode is not
recommended for off-grid applications.
• If the AC input should fail or drops below the lower Vac limit (as set in
menu item 13D Input Lower Limit VAC), the complete multi-stage charge
cycle (Bulk, Absorption, Finish) will be re-initiated once the source AC
returns to an in-tolerance condition.
• Selecting Silent Mode for the Battery Charging Finish Stage is an Advanced
Setup Application and requires additional parameters be established in
Menu Heading 20 Silent Setup Menu.
WARNING: Explosion Hazard
Only flooded or vented batteries should be equalize-charged. Hydrogen and
oxygen gases are produced when batteries are equalize-charged. Provide
adequate ventilation and remove all sources of ignition to prevent explosion.
Menu Item Descriptions
976-0043-01-02 6–19
12 Battery Charging Menu
Battery Charging parameters are programmed in 12 Battery Charging
Menu using the following menu items. Some of the menu items will
require making calculations. Others just require making selections
between the set points.
The voltage level settings should be adjusted with the battery at a
reference temperature of 25 °C (77° F).
12A Finish Stage
This menu item determines the Charging Mode (Silent or Float) after the
bulk and absorption charge have finished. Select either mode depending
on your installation.
See “Finish Stage” on page 6-17 for additional information.
Additional programming will be required if Silent Mode is selected. See
“20 Silent Setup Menu” on page 7–13 for additional information on the
Silent Mode programming.
CAUTION: Damage to DC Loads and Batteries
DC loads should be disconnected from the batteries during equalization charging
to protect DC loads from high battery voltages.
Equalization was designed for use on standard, liquid electrolyte (lead acid)
batteries. Other battery types can be permanently damaged if equalized. If you
have sealed or gel cell batteries, do not use the equalization charging function
without first checking with the battery manufacturer.
Batteries will heat up when equalize charging. Always monitor the battery
temperature in 04K Battery Temp Degrees C and shut down the charger if the
temperature exceeds the manufacturer’s specifications. The BTS must be
installed for the inverter to monitor battery temperature.
Important: Please consult your system designer or battery manufacturer for
specific battery charging recommendations.
Basic Setup Programming
6–20 976-0043-01-02
12B Bulk Volts DC
This is the voltage level at which the charger switches to the absorption
stage. The charger will use up to the parameter set in 12E Max Charge
Amps AC until the parameter set in 12B Bulk Volts DC is reached. The
actual battery charging voltage will be adjusted from this value when the
BTS is used.
See Table 6-4, “Battery Voltages For Setting Charging Parameters” on
page 6–21 for recommended bulk voltages.
12C Float Volts DC
This is the voltage level at which the charger will maintain the batteries
after a bulk and absorption charge. The actual battery charging voltage
will be adjusted from this value when the BTS is used.
See Table 6-4, “Battery Voltages For Setting Charging Parameters” on
page 6–21 for recommended float voltages.
12D Equalize Volts DC
This the voltage level at which the charger performs an “equalize charge”
on the batteries. The factory default setting is the same as the
12B Bulk Volts DC settings. This is to prevent accidental damage to
batteries from an unintentional equalize charge. The actual battery
charging voltage will be adjusted from this value when the BTS is used.
Guidelines for setting this menu item:
• Be sure to adjust the equalize voltage level up or down depending
upon your battery chemistry and whether or not you desire an
equalize charge on the system.
• If this feature is not desired, set this parameter to be identical to the
12B Bulk Volts DC setting.
See Table 6-4, “Battery Voltages For Setting Charging Parameters” on
page 6–21 for recommended voltages for equalize charging.
Menu Item Descriptions
976-0043-01-02 6–21
The following settings (Table 6-5) are guidelines only. Refer to your
battery vendor for specific settings and battery maintenance guidelines.
Table 6-4
Battery Voltages For Setting Charging Parameters
Battery Type
BULK VOLTS FLOAT VOLTS
Equalization Charge
Process
Set
Temp
Comp
24-volt
models
48-volt
models
24-volt
models
48-volt
models
Sealed Gel
Lead Acid
28.2 Vdc 56.4 Vdc 27.2 Vdc 54.4 Vdc Not recommended -
consult manufacturer
LeadAcid
AGM
Lead Acid
28.8 Vdc 57.6 Vdc 26.8 Vdc 53.6 Vdc Charge to 31.0 Vdc
(24-volt models) or 62
Vdc (48-volt models) or
as per manufacturer
recommendations
LeadAcid
Maintenance-Free
RV/Marine
Lead Calcium
Battery
28.8 Vdc 57.6 Vdc 26.8 Vdc 53.6 Vdc Not recommended -
consult manufacturer
LeadAcid
Deep-cycle,
Liquid Electrolyte
Lead Antimony
Battery
29.2 Vdc 58.4 Vdc 26.8 Vdc 53.6 Vdc Charge to 31.0 Vdc
(24-volt models) or 62
Vdc (48-volt models) or
as per manufacturer
recommendations
LeadAcid
NiCad or NiFe
Alkaline Battery
(using 10 cells in
series)
32.0 Vdc 64.0 Vdc 29.0 Vdc 58.0 Vdc Consult Manufacturer NiCad
Table 6-5
Battery Charging Current and Timer Default Settings
Menu Item
SW Plus
2524
Default
Settings
SW Plus
2548
Default
Setting
SW Plus
4024
Default
Settings
SW Plus
4048
Default
Setting
SW Plus
5548
Default
Setting
12E Max Charge Amps 20 amps 20 amps 30 amps 30 amps 40 amps
12F Bulk Done Amps AC 10 amps 10 amps 10 amps 10 amps 10 amps
12G EQ Vdc Done Timer h:m 02:00 02:00 02:00 02:00 02:00
12H Max Bulk/EQ Timer h:m 05:00 05:00 05:00 05:00 05:00
12I Temp Comp LeadAcid LeadAcid LeadAcid LeadAcid LeadAcid
Basic Setup Programming
6–22 976-0043-01-02
12E Max Charge Amps AC
This is the maximum AC amperage the inverter will provide to the battery
charger to get the battery voltage up to the level set in one of the
following menu items depending on which mode the battery charger is in
as indicated by the LEDs on the inverter’s display:
•12B Bulk Volts DC,
•12C Float Volts DC, or
•12D Equalize Volts DC.
Use menu 12E Max Charge Amps AC to reduce the charging current to
10% (or less) of the battery capacity.
Guidelines for setting this menu item:
• Small battery banks may overheat if charged at too high of a current.
Setting this value higher than the default and continuously drawing
the maximum current may put the inverter in an Overtemp Error
condition.
The following settings are guidelines only. Refer to your battery vendor
for specific settings and battery maintenance guidelines.
Calculating
Maximum Charging
Amps
To calculate the 12E Max Charge Amps AC:
1. Multiply the battery amp hours by 10%. This is the DC Maximum
Charge Rate.
2. Convert the DC Maximum Charge Rate to AC amps by dividing the
DC Maximum Charge Rate by 3.5 for a 24-volt system or 1.75 for a
48-volt system.
3. The result is the approximate amp setting that should be entered for
the 12E Set Max Charge Amps AC menu item.
For stacked inverters, use half the battery amp hour rating in the
calculations.
Table 6-6
Calculating the Maximum Charge Amps for a 24-volt,
700 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp hours by
10%
700 x 10% = 70
(DC Max Charge Rate)
2 Divide the DC Max Charge Rate by 3.5 70 ÷ 3.5 = 20
3Set the 12E Max Charge Amps AC
parameter.
20
Menu Item Descriptions
976-0043-01-02 6–23
12F Bulk Done Amps AC
This is the AC current threshold where the battery charger will transfer
from Absorption Charging to Finish Charging. It is recommended to set
this value at 2 to 4% of the battery bank’s total amp-hour capacity.
Guidelines for setting this menu item:
• Setting the 12F Bulk Done Amps AC to 0 (zero) will keep the
charger in the Bulk Mode until the setting in 12G Max Bulk/EQ
Timer h:m is reached.
• If there are any DC loads connected to the batteries (and are actively
drawing current), this additional current must be added to the
12F Bulk Done Amps AC setting (after conversion from DC amps).
If this additional current is not accounted for, the charger will
continue to charge at the bulk voltage until the 12G Max Bulk/EQ
Timer h:m period is reached and switches the charger out of the bulk
stage.
To calculate the 12F Bulk Done Amps AC:
1. Multiply the battery amp hours by 2% to 4%. This is the AC Bulk
Done Charge Rate.
2. Convert the AC Bulk Done Charge Rate to AC amps by dividing the
AC Bulk Done Charge Rate by 4 for a 24-volt system or 2 for a
48-volt system.
3. The result is the approximate amp setting that should be entered for
the 12F Bulk Done Amps AC menu item.
For stacked inverters, use half the battery amp-hour rating in the
calculations.
Table 6-7
Calculating the Maximum Charge Amps for a 48-volt,
350 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp hours by
10%
350 x 10% = 35
(DC Max Charge Rate)
2 Divide the DC Max Charge Rate by
1.75
35 ÷ 1.75 = 20
3 Set the 12E Max Charge Amps AC
parameter.
20
Basic Setup Programming
6–24 976-0043-01-02
12G EQ VDC Done Timer
This is the maximum time the batteries will be allowed to charge at the
equalize voltage level set in 12D Equalize Volts DC. This setting is
limited by 12H Max Bulk/EQ Timer h:m, which sets the maximum
period for the EQ charge stage. This is a safety feature that ensures that
abnormal conditions will not cause the charger to hold the batteries at
high voltages for prolonged periods of time. This timer starts when the
EQ voltage is reached as set in menu item 12D Equalize Volts DC.
Table 6-8
Calculating the Bulk Done Amps for a 24-volt,
700 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp
hours by 2% (3%, 4%)
700 x 2% (3%, 4%) = 14 (21, 28)
(AC Bulk Done Charge Rate)
2 Divide the AC Bulk Done Charge
Rate by 4
14 ÷ 4 = 3.5 (for 2%)
21 ÷ 4 = 4 (for 3%)
28 ÷ 4 = 7 (for 4%)
3Set the 12F Bulk Done Amps
AC parameter.
3 to 7 amps AC
Table 6-9
Calculating the Bulk Done Amps for a 48-volt,
350 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp
hours by 2% (3%, 4%)
350 x 2% (3%, 4%) = 7 (10.5, 14)
(AC Bulk Done Charge Rate)
2 Divide the AC Bulk Done Charge
Rate by 2
7 ÷ 2 = 3.5 (for 2%)
10.5 ÷ 2 = 5.25 (for 3%)
14 ÷ 2 = 7 (for 4%)
3Set the 12F Bulk Done Amps
AC parameter.
3 to 7 amps AC
Menu Item Descriptions
976-0043-01-02 6–25
12H Max Bulk/EQ Timer h:m
This is the maximum time the charger is allowed to keep the batteries in
the Bulk or EQ Charge Stage. This timer starts when either the Equalize
Charge starts or when the Bulk Charge starts. Ensure this setting doesn't
interfere with the 12G EQ Vdc Done Timer h:m or the 12F Bulk Done
Amps AC settings.
Guidelines for setting this menu item:
• Check menu item 04J Max Bulk/EQ Time h:m (see page 8–24 for
information) for the amount of time the charger has been in the Bulk
or EQ charge stage.
• This is a safety feature ensuring that abnormal conditions (e.g., DC
loads connected to the batteries) will not cause the battery charger to
hold the batteries at high voltage levels for prolonged periods of time.
As a protection feature, this timer overrides settings programmed in
12F Bulk Done Amps AC and 12G EQ Vdc Done Timer menu
items.
12I Temp Comp
This menu item provides for the selection of the appropriate temperature
compensation for your particular battery type. Temperature compensation
reduces the battery charge voltage when the environmental temperature is
hot to prevent battery over-gassing or overcharging. In cold temperatures,
the voltage is increased to assure complete battery charging. Temperature
compensation only occurs if the BTS is installed.
The BTS automatically fine tunes the charging process of the SW Plus
inverter.
When the BTS is installed, the battery charging set points (12B Bulk
Volts DC, 12C Float Volts DC, and 12D Equalize Volts DC) are
automatically adjusted based on the temperature of the battery being
25 °C (77 °F). Actual charging voltage may vary above or below these
setting due to adjustments for battery temperature.
The Sine Wave Plus inverter adjusts the bulk, float, and equalizing set
point by 60 mV for 24 Vdc systems and 120 mV for 48 Vdc systems per
degree Celsius for the “LeadAcid” temperature compensation setting. For
the “NiCad” setting, the inverter adjusts the set points by 40 mV for
24 Vdc systems and 80 mV for 48 Vdc systems per degree Celsius.
If the wiring to the sensor is damaged and the wires are shorted or cut, the
inverter will charge at non-temperature compensated settings and the
inverter may not charge as expected.
Basic Setup Programming
6–26 976-0043-01-02
Temperature compensation calculations are derived from the following
table:
Temperature compensation is based on battery type: 5 mv/cell for Lead
Acid type batteries and 2 mv/cell for alkaline type batteries (NiCad or
NiFe).
The default for this menu item is LeadAcid. This setting only needs to be
changed if using NiCad or Alkaline type batteries. Before changing the
default settings, check with your battery manufacturer.
13 AC Inputs Menu
The AC input parameters establish the voltage settings and current limits
for AC power usage. AC input is the AC power that the inverter draws on
to either power the loads (pass through) or power the battery charger. AC
power can be provided by the utility grid or an AC generator. These
settings provide the limit at which the inverter will start drawing power
from the batteries in order to meet the demand of the AC loads.
Configuring the AC inputs includes determining the following parameter
values. These settings are programmed into 13 AC Inputs Menu under
the following menu items:
• 13A Grid (AC1) Amps
• 13B Gen (AC2) Amps
• 13C Input Upper Limit Vac
• 13D Input Lower Limit Vac
Table 6-10
Inverter Temperature Compensation Calculation
using the BTS
Battery Type 24-volt Systems 48-volt Systems
Lead Acid 0.060 volts (60 mV)
per degree Celsius
0.120 Volts (120 mV)
per degree Celsius
NiCad 0.040 volts (40 mV)
per degree Celsius
0.080 volts (80 mV)
per degree Celsius
Note: If the battery temperature is allowed to fall to extremely cold
temperatures, the inverter with a BTS may not be able to properly recharge cold
batteries due to maximum voltage limits of the inverter. Ensure the batteries are
protected from extreme temperatures.
Menu Item Descriptions
976-0043-01-02 6–27
13A Grid (AC1) Amps AC
This is the maximum amount of current that can be drawn from the grid
(AC1 input) by the loads and battery charger combined. This settings
determines the amperage level at which point the inverter starts drawing
power from the batteries to add to the utility power to meet the demand of
the loads. This is the AC load support feature.
If the loads exceed this setting, the inverter will draw from the batteries
and add it to the utility power to meet the demand of the loads.
Typically, this value is set to the size of the AC circuit breakers feeding
the inverter's AC input.
13B Gen (AC2) Amps AC
This is the maximum amount of current that can be drawn from the
generator (AC2 input) by the loads. This settings determines the
amperage level at which point the inverter starts drawing power from the
batteries to add to the generator power to meet the demand of the loads.
This is the AC load support feature.
If the loads exceed this setting, the inverter will draw from the batteries
and add it to the generator power to meet the demand of the loads.
Typically, this value is set to the size of the generator's AC circuit breaker
feeding the inverter's input or the maximum output amperage capacity of
the generator.
This setting is very dependent on the performance of the generator. Other
factors such as altitude, line losses between the generator and the inverter
will require lowering this setting to below what the generator is rated for.
For best results, begin with a setting half your expected generator current
capacity and gradually increase this setting while verifying the AC
voltage on the AC2 inverter terminals stays at lease several volts above
the 13D Input Lower Limit VAC setting.
Basic Setup Programming
6–28 976-0043-01-02
13C Input Upper Limit VAC
This menu item sets the highest voltage at which the inverter is allowed to
connect to either AC1 or AC2 inputs. When this voltage is reached the
inverter disconnects from the grid or generator and provides power to the
loads from the batteries as long as the inverter selection in menu
01A Inverter is ON or SRCH.
The inverter reconnects to the AC source when the voltage drops below
this setting.
Guidelines for setting this menu item:
• Ensure this value is within the upper limits of any AC operated
equipment connected to the inverter.
13D Input Lower Limit VAC
This menu item sets the lowest voltage at which the inverter is allowed to
connect to either AC1 or AC2 inputs.
This setting determines the voltage level at which point the inverter starts
drawing power from the batteries to aid to the grid power (AC1) or GEN
(AC2) power depending on which one is being used to meet the demands
of the loads.
When the AC voltage reaches this level, the inverter stops battery
charging and operates in parallel (in the inverter mode) with the AC
source, to aid the utility power to meet the demands of the load. This
reduces the loading effect on the AC source.
If the voltage drops below this level, the inverter disconnects the AC
source and powers the load directly from the batteries as long as the
inverter’s selection in 01A Inverter is ON or SRCH. This is part of the
AC support feature.
Guidelines for setting this menu item:
• Ensure this value is within the lower limits of any AC operated
equipment connected to the inverter.
CAUTION: Damage to Loads
Adjusting upper and lower AC voltage parameters allows the higher and lower
voltages than the inverter output to pass through to connected AC loads. Ensure
that all connected AC loads will not be damaged by the higher and lower settings.
Menu Item Descriptions
976-0043-01-02 6–29
14 Save/Restore Settings Menu
This menu provides the means to:
• save user programmed settings,
• restore previously saved programmed settings, or
• restore factory default settings.
If DC power is removed from the inverter, all user defined set points will
be intact if they were saved before the power was removed. If new
settings are not saved, the inverter will restart with the last saved set
points or with the factory defaults (if none were ever saved).
14A Push INV now to Save Settings
This menu item provides the means to save settings currently
programmed into the inverter.
To save settings:
1. Press the button until 14A Push Inv Now to Save Settings is
displayed.
2. Press the red INV button to save the settings.
14B Push GEN to Restore Settings
This menu item provides the means to restore settings previously set and
saved on the inverter.
To restore settings previously programmed into the inverter:
1. Press the button until 14B Push Gen to Restore Settings is
displayed.
2. Press the green GEN button to restore previously programmed
settings.
Note: The settings in this menu are identical to Menu 27. Saving or restoring
settings at either menu will apply to all menu settings (Basic and Advanced).
Basic Setup Programming
6–30 976-0043-01-02
14C Push GEN for Factory Defaults
This menu item provides the means to restore the factory default settings.
To restore the factory default settings:
1. Press the button until 14C Push Gen For Factory Defaults is
displayed.
2. Press the green GEN button to restore the factory default settings.
End Basic Setup Menu
You have reached the end of the Basic Setup Menu.
To exit the Basic Setup Menu and go on to the Advanced Setup
Menu:
1. Press the Menu Heading button until END BASIC SETUP
MENU is displayed.
2. Press the green GEN button and hold it down.
3. While holding down the green GEN button, press the red INV button.
This will move you forward to the ADVANCED USER SETUP
MENU.
7Advanced Setup
Chapter 7, “Advanced Setup” explains how to program the
Sine Wave Plus Inverter/Charger to operate under special,
advanced conditions, such as automatic generator starting,
energy management and auxiliary load applications.
Advanced Setup
7–2 976-0043-01-02
Advanced Setup Summary
Check Defaults The following model-specific tables provide the default settings for the
Sine Wave Plus Advanced Setup Menu and cross-reference pages for
locating information on each menu item.
•Table 7-1, “Advanced Setup Default Settings for the Sine Wave Plus
2524 and 2548 Models” on page 7–2
•Table 7-2, “Advanced Setup Default Settings for the Sine Wave Plus
4024 and 4048 Models” on page 7–5
•Table 7-3, “Advanced Setup Default Settings for the Sine Wave Plus
Plus 5548 Models” on page 7–7
Record Changes If your system requires changes to these default settings, record the
changes on the model-specific tables in Appendix B, “Configuration
Settings” before your start programming. These tables are found on the
following pages:
•Table B-5, “Advanced Setup Default and User Settings for the Sine
Wave Plus 2524 and 2548 Models” on page B–10
•Table B-6, “Advanced Setup Default and User Settings for the Sine
Wave Plus 4024 and 4048 Models” on page B–12
•Table B-7, “Advanced Setup Default and User Settings for the Sine
Wave Plus 5548 Model” on page B–14
For directions on how to get to the Advanced Setup Menu, see
“Accessing the Advanced Setup Menu” on page 7–11.
Table 7-1
Advanced Setup Default Settings for the Sine Wave Plus 2524 and 2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See PageRange/Display
Default
Settings Range/Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 16.1 to 33.9 28.4 32.2 to 67.8 56.8 page 7–15
20B Refloat Low Volts DC 16.1 to 33.8 25.0 32.2 to 67.8 50.0 page 7–15
20C Float Done Amps AC 00 to 40 10 00 to 40 10 page 7–15
20D Must Float Time Min 00 to 255 05 00 to 255 05 page 7–15
End Menu 20
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB SB BX SB page 7–17
21B Grid Usage Begin h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00 page 7–17
Advanced Setup Summary
976-0043-01-02 7–3
21C Grid Usage End h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00 page 7–18
End Menu 21
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 16.1 to 33.9 27.0 32.2 to 67.8 54.0 page 7–19
22B Low Xfer (LBX) Vdc 16.1 to 33.8 23.0 32.2 to 67.8 46.0 page 7–19
End Menu 22
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
23A RY9 VDC Energized 22.1 to 35.5 26.0 44.2 to 71.0 52.0 page 7–20
23B RY9 VDC DeEnergized 20.0 to 35.5 22.0 40.0 to 71.0 44.0 page 7–20
23C RY9 Delay at DeEngz.
Min
00 to 255 10 00 to 255 10 page 7–20
23D RY10 VDC Energized 10.0 to 32.0 28.8 20.0 to 64.0 57.6 Vdc page 7–20
23E RY10 VDC DeEnergized 10.0 to 32.0 26.8 20.0 to 64.0 53.6 Vdc page 7–21
23F RY10 Delay at DeEngz.
Min
00 to 255 10 00 to 255 10 page 7–21
23G RY11 Mode Cooldown Error Error Cooldown Error Error page 7–21
End Menu 23
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
24B Gen Run Time Stop h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
24C Quiet Time Begin h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
24D Quiet Time End h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–28
24E Gen Exercise Period Days 00 to 255 30 00 to 255 30 page 7–28
24F Gen Exercise Timer Min 00 to 255 15 00 to 255 15 page 7–28
24G Gen Cooldown Timer
Min
00 to 255 02 00 to 255 02 page 7–28
24H RN2/Max Gen Run h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–29
End Menu 24
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
Table 7-1
Advanced Setup Default Settings for the Sine Wave Plus 2524 and 2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See PageRange/Display
Default
Settings Range/Display
Default
Settings
Advanced Setup
7–4 976-0043-01-02
25A RY7 Mode GS RN1 RN2 GS GS RN1 RN2 GS page 7–30
25B Gen Warm-up
Second/Minute
0 to 127
/0 to 127
10
Seconds
0 to 127
/0 to 127
10
Seconds
page 7–37
25C Pre Crank Seconds 00 to 255 10 00 to 255 10 page 7–37
25D Max Cranking Seconds 01 to 15 10 01 to 15 10 page 7–37
25E Post Crank Seconds 00 to 255 30 00 to 255 30
End Menu 25
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
26A Load Start Amps AC 00 to 63 20 00 to 63 20 page 7–38
26B Load Start Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0 page 7–38
26C Load Stop Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0 page 7–38
26D 24 hr Start Volts DC 10.0 to 35.5 24.6 20.0 to 71.0 49.2 page 7–38
26E 2 hr Start Volts DC 10.0 to 35.5 23.6 20.0 to 71.0 47.2 page 7–38
26F 15 min Start Volts DC 10.0 to 35.5 22.6 20.0 to 71.0 45.2 page 7–39
26G Read LBCO 30 sec Start LBCO setting
(11C)
22.0
Read Only
LBCO setting
(11C)
44.0
Read Only
page 7–39
End Menu 26
27 Save/Restore Settings Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
27A Push INV now to save
Settings
Push INV now to Save Settings page 7–39
27B Push GEN to restore
settings
Push GEN to restore settings page 7–40
27C Push GEN for factory
defaults
Push GEN for factory defaults page 7–40
End Menu 27
END ADVANCED SETUP
MENU
Table 7-1
Advanced Setup Default Settings for the Sine Wave Plus 2524 and 2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
See PageRange/Display
Default
Settings Range/Display
Default
Settings
Advanced Setup Summary
976-0043-01-02 7–5
Table 7-2
Advanced Setup Default Settings for the Sine Wave Plus 4024 and 4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
See PageRange/Display
Default
Settings Range/Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 16.1 to 33.9 28.4 32.2 to 67.8 56.8 page 7–15
20B Refloat Low Volts DC 16.1 to 33.8 25.0 32.2 to 67.8 50.0 page 7–15
20C Float Done Amps AC 00 to 40 10 00 to 40 10 page 7–15
20D Must Float Time Min 00 to 255 05 00 to 255 05 page 7–15
End Menu 20
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB SB BX SB page 7–17
21B Grid Usage Begin h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00 page 7–17
21C Grid Usage End h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00 page 7–18
End Menu 21
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 16.1 to 33.9 27.0 32.2 to 67.8 54.0 page 7–19
22B Low Xfer (LBX) Vdc 16.1 to 33.8 23.0 32.2 to 67.8 46.0 page 7–19
End Menu 22
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
23A RY9 VDC Energized 22.1 to 35.5 26.0 44.2 to 71.0 52.0 page 7–20
23B RY9 VDC DeEnergized 20.0 to 35.5 22.0 40.0 to 71.0 44.0 page 7–20
23C RY9 Delay at DeEngz.
Min
00 to 255 10 00 to 255 10 page 7–20
23D RY10 VDC Energized 10.0 to 32.0 28.8 20.0 to 64.0 57.6 Vdc page 7–20
23E RY10 VDC DeEnergized 10.0 to 32.0 26.8 20.0 to 64.0 53.6 Vdc page 7–21
23F RY10 Delay at DeEngz.
Min
00 to 255 10 00 to 255 10 page 7–21
23G RY11 Mode Cooldown Error Error Cooldown Error Error page 7–21
End Menu 23
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
Advanced Setup
7–6 976-0043-01-02
24B Gen Run Time Stop h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
24C Quiet Time Begin h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–27
24D Quiet Time End h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–28
24E Gen Exercise Period
Days
00 to 255 30 00 to 255 30 page 7–28
24F Gen Exercise Timer Min 00 to 255 15 00 to 255 15 page 7–28
24G Gen Cooldown Timer
Min
00 to 255 02 00 to 255 02 page 7–28
24H RN2/Max Gen Run h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00 page 7–29
End Menu 24
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
25A RY7 Mode GS RN1 RN2 GS GS RN1 RN2 GS page 7–30
25B Gen Warm-up
Second/Minute
0 to 127
/0 to 127
10
Seconds
0 to 127
/0 to 127
10 Seconds page 7–37
25C Pre Crank Seconds 00 to 255 10 0 to 255 10 page 7–37
25D Max Cranking Seconds 01 to 15 10 01 to 15 10 page 7–37
25E Post Crank Seconds 00 to 255 30 00 to 255 30
End Menu 25
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
26A Load Start Amps AC 00 to 63 33 00 to 63 33 page 7–38
26B Load Start Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0 page 7–38
26C Load Stop Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0 page 7–38
26D 24 hr Start Volts DC 10.0 to 35.5 24.6 20.0 to 71.0 49.2 page 7–38
26E 2 hr Start Volts DC 10.0 to 35.5 23.6 20.0 to 71.0 47.2 page 7–38
26F 15 min Start Volts DC 10.0 to 35.5 22.6 20.0 to 71.0 45.2 page 7–39
26G Read LBCO 30 sec Start LBCO setting
(11C)
22.0
Read Only
LBCO setting
(11C)
44.0
Read Only
page 7–39
End Menu 26
27 Save/Restore Settings Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
Table 7-2
Advanced Setup Default Settings for the Sine Wave Plus 4024 and 4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
See PageRange/Display
Default
Settings Range/Display
Default
Settings
Advanced Setup Summary
976-0043-01-02 7–7
27A Push INV now to save
Settings
Push INV now to Save Settings page 7–39
27B Push GEN to restore
settings
Push GEN to restore settings page 7–40
27C Push GEN for factory
defaults
Push GEN for factory defaults page 7–40
End Menu 27
END ADVANCED SETUP
MENU
Table 7-3
Advanced Setup Default Settings for the Sine Wave Plus Plus 5548 Models
Advanced Setup Menus
Sine Wave Plus 5548
See PageRange/Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 32.2 to 67.8 56.8 page 7–15
20B Refloat Low Volts DC 32.2 to 67.8 50.0 page 7–15
20C Float Done Amps AC 00 to 40 10 page 7–15
20D Must Float Time Min 00 to 255 05 page 7–15
End Menu 20
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB page 7–17
21B Grid Usage Begin h:m 00:00 to 23:50 21:00 page 7–17
21C Grid Usage End h:m 00:00 to 23:50 21:00 page 7–18
End Menu 21
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 32.2 to 67.8 54.0 page 7–19
22B Low Xfer (LBX) Vdc 32.2 to 67.8 46.0 page 7–19
End Menu 22
Table 7-2
Advanced Setup Default Settings for the Sine Wave Plus 4024 and 4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
See PageRange/Display
Default
Settings Range/Display
Default
Settings
Advanced Setup
7–8 976-0043-01-02
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
23A RY9 VDC Energized 44.2 to 71.0 52.0 page 7–20
23B RY9 VDC DeEnergized 40.0 to 71.0 44.0 page 7–20
23C RY9 Delay at DeEngz. Min 00 to 255 10 page 7–20
23D RY10 VDC Energized 20.0 to 64.0 57.6 Vdc page 7–20
23E RY10 VDC DeEnergized 20.0 to 64.0 53.6 Vdc page 7–21
23F RY10 Delay at DeEngz. Min 00 to 255 10 page 7–21
23G RY11 Mode Cooldown Error Error page 7–21
End Menu 23
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to 23:50 08:00 page 7–27
24B Gen Run Time Stop h:m 00:00 to 23:50 08:00 page 7–27
24C Quiet Time Begin h:m 00:00 to 23:50 08:00 page 7–27
24D Quiet Time End h:m 00:00 to 23:50 08:00 page 7–28
24E Gen Exercise Period Days 00 to 255 30 page 7–28
24F Gen Exercise Timer Min 00 to 255 15 page 7–28
24G Gen Cooldown Timer Min 00 to 255 02 page 7–28
24H RN2/Max Gen Run h:m 00:00 to 23:50 08:00 page 7–29
End Menu 24
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
25A RY7 Mode GS RN1 RN2 GS page 7–30
25B Gen Warm-up
Second/Minute
0 to 127
/0 to 127
10
Seconds
page 7–37
25C Pre Crank Seconds 00 to 255 10 page 7–37
25D Max Cranking Seconds 01 to 15 10 page 7–37
25E Post Crank Seconds 00 to 255 30
End Menu 25
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
Table 7-3
Advanced Setup Default Settings for the Sine Wave Plus Plus 5548 Models
Advanced Setup Menus
Sine Wave Plus 5548
See PageRange/Display
Default
Settings
Advanced Setup Summary
976-0043-01-02 7–9
26A Load Start Amps AC 00 to 63 45 page 7–38
26B Load Start Delay Min 00.0 to 25.5 05.0 page 7–38
26C Load Stop Delay Min 00.0 to 25.5 05.0 page 7–38
26D 24 hr Start Volts DC 20.0 to 71.0 49.2 page 7–38
26E 2 hr Start Volts DC 20.0 to 71.0 47.2 page 7–38
26F 15 min Start Volts DC 20.0 to 71.0 45.2 page 7–39
26G Read LBCO 30 sec Start LBCO setting
(11C)
44.0
Read
Only
page 7–39
End Menu 26
27 Save/Restore Settings Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
27A Push INV now to save
Settings
Push INV now to Save
Settings
page 7–39
27B Push GEN to restore settings Push GEN to restore settings page 7–40
27C Push GEN for factory defaults Push GEN for factory
defaults
page 7–40
End Menu 27
END ADVANCED SETUP MENU
Table 7-3
Advanced Setup Default Settings for the Sine Wave Plus Plus 5548 Models
Advanced Setup Menus
Sine Wave Plus 5548
See PageRange/Display
Default
Settings
Advanced Setup
7–10 976-0043-01-02
Before You Begin Advanced Programming
The Sine Wave Plus is designed to provide advanced application
programming. Advanced applications include:
• SILENT SETUP - Sets the parameters for the Silent finish stage of
battery charging. This feature is programmed in Menu Heading 20.
See “20 Silent Setup Menu” on page 7–13 for information on
programming this feature.
• GRID USAGE - Sets parameters for when and how the utility grid is
used. It supports energy management applications such as
Time-of-Use Metering and Peak Load Shaving (SB Mode). It also
controls transfer of grid power to protect the batteries (BX Mode).
These features are programmed in Menu Heading 21 and 22.
See “21 Grid (AC1) Usage Menu” on page 7–16 and “22 Battery Xfer
(BX) Menu” on page 7–18 for information on programming this
features.
• AUXILIARY LOADS - Sets the parameters by which the relays in
the ALM are used. This feature is programmed in Menu Heading 23.
See “23 ALM Relays Menu” on page 7–19 for information on
programming these parameters.
• GENERATOR CONTROL AND SUPPORT - Sets the parameters for
starting a generator based on time, type of generator being used, and
the inverter’s voltage and current. This feature is programmed in
Menu Headings 24, 25 and 26.
See “24 Generator Timers Menu” on page 7–26 for information on
programming the generator to run based on “time” settings.
See “25 Gen Starting Details Menu” on page 7–29 for information on
programming the generator to run based on type of generator being
used.
See “26 Gen Auto Run Setup Menu” on page 7–38 for information on
programming the generator to run based on voltage or current
settings.
• SAVING/RESTORING SETTINGS - Saves or restores previously
programmed user settings. This feature can also restore factory
defaults.
Accessing the Advanced Setup Menu
976-0043-01-02 7–11
Accessing the Advanced Setup Menu
To access the Advanced Setup Menu from the User Menu:
1. Press the button to move forward within the Menu Headings until
the END USER MENU is displayed.
2. Press and hold down the green GEN button.
3. While holding the green GEN button down, press the red INV button
to move into the BEGIN BASIC SETUP MENU.
4. Release the GEN and INV buttons.
Figure 7-1
Accessing the Advanced Setup Menu - Method 1
While holding the green GEN
button down, press the red INV
button to move into the Basic
Setup Menu.
Press the Menu Heading button
until the END USER MENU is
displayed.
Press and hold down the
green GEN button.
Access the User Menu
Advanced Setup
7–12 976-0043-01-02
5. From here you can, either:
a) Press the button to move forward within the Menu Headings
until the END BASIC SETUP MENU is displayed.
b) Or proceed to Steps 6 and 7.
6. Press and hold down the green GEN button.
7. While holding the green GEN button down, press the red INV to
move into the ADVANCDED SETUP MENU.
Figure 7-2
Accessing the Advanced Setup Menu - Method 2
Press the green GEN button and
hold down.
While holding down the green
GEN button, push the red INV
button.
Press to scroll through the
Basic Setup Menu Headings.
Press the green GEN button
and hold down. While holding down the green GEN
button, push the red INV button.
OR
Menu Item Descriptions
976-0043-01-02 7–13
Menu Item Descriptions
20 Silent Setup Menu
This menu is used only when SILENT is selected in menu 12A Finish
Stage. When the Silent Modeis selected, the charger is turned OFF and
does not supply any charging current to the batteries until certain
conditions based on battery voltage are met.
Silent Modeis defined as no inverting or charging and the input AC (if
available) will pass-through to the output and is recommended for use
only if utility power is the AC source.
When it works This menu provides the settings which will maintain the float voltage on
the batteries by:
• Turning ON the charger when the batteries drain to the level set in
menu 20B Refloat Low VDC.
• Attempts to maintain the battery voltage at the float level by diverting
the excess power to the loads when the battery voltage increases to
the level set in menu 20A Refloat High VDC
The battery voltage can only go above the 20A Refloat High VDC limit
if an external source is used to provide power to the batteries such as a PV
array, wind generator, micro-hydro generator, etc. When this level is met
or exceeded, the unit turns on the charger and directs the excess DC
power to the AC loads and attempts to maintain the battery at the float
voltage level.
Whenever one of these conditions is met, the batteries will be maintained
at the float level for both:
• the period of time set in menu 20D Must Float Time, then
• the level set in menu 20C Float Done Amps AC.
How it works The Silent Mode does not maintain the battery at float voltage all the
time. The battery charger only operates if required and the AC power
from the utility grid is passed through the inverter to the loads 24 hours a
day. This option is recommended only if utility power is the only AC
source.
After the batteries are given a bulk and absorption charge cycle, the
inverter will then go totally silent and will wait for the DC voltage to fall
or until utility power fails. If the battery voltage falls, the inverter will
allow the AC source to recharge the battery. If there is a power outage, the
inverter will perform another bulk and absorption charge cycle and return
to the Silent Mode once the AC source has returned.
Advanced Setup
7–14 976-0043-01-02
Silent Mode will begin after the charge routine has finished the bulk/
absorption charge and if the Silent charge has been selected (from Menu
Item 12A Finish Stage). After entering the Silent mode, there will be a
minimum 60 second delay, then the inverter will monitor the battery
voltage to determine if the voltage is at or above the 20A Refloat High
Volts DC setting or if the voltage has fallen to or below the 20B Refloat
Low Volts DC setting.
If the battery voltage has reached one of these Refloat Vdc settings
(20A Refloat High Volts DC or 20B Refloat Low Volts DC) then the
inverter will come out of Silent Mode and begin to maintain the batteries
at the float voltage level.
If the battery voltage falls below the float level, the inverter will use
current from the utility grid connected to the AC1 input to continue to
maintain the float voltage level.
External charging
sources If some external current (renewable energy source) is used to increase the
battery voltage above the float voltage level, the inverter will use this
excess power above the float voltage requirements to power the inverter
output loads.
If the external current source provides more current that what is needed to
maintain the batteries at the float voltage and power the inverter loads, the
battery voltage will rise.
The inverter will continue to maintain the batteries at the float voltage
level until the 20D Must Float Time Min time has expired and the
current (as read on the 04C INV/CHR Amps AC meter display) has
fallen below the 20C Float Done Amps setting. At this time, the inverter
will return to the Silent mode.
If AC power is lost, after it has returned, the inverter will complete
another Bulk and Absorption charge to the battery and again return to the
silent stage.
Advantages The advantage of the Silent stage is slightly less power consumption
under most conditions and quieter operation since the battery charger is
off most of the time.
Disadvantage The disadvantages of Silent charge is the loss of the natural power
conditioning ability of the inverter, the ability to provide the AC load
support (except during the time that the inverter is charging) and a longer
transfer to inverter power from the loss of utility power. These
disadvantages are only present when the inverter is not charging batteries.
Summary Silent Mode engages on based on DC volts as programmed in
20A Refloat High Volts DC and 20B Refloat Low Volts DC (after 60
second delay)
Menu Item Descriptions
976-0043-01-02 7–15
Silent Mode terminates based on time 20D Must Float Time Min, then
amps 20C Float Done Amps.
20A Refloat High Volts DC
This menu item sets the upper battery voltage level that triggers the float
charge. When this level is met or exceeded, the unit turns on the charger
and directs the excess DC power to the AC loads and attempts to maintain
the battery at the float voltage level.
20B Refloat Low Volts DC
This menu item sets the lower battery voltage level to which the batteries
are allowed to discharge. When the batteries drop to or below this level
the charger will turn ON and provide a float charge to the batteries. It will
not initiate a bulk charge.
20C Float Done Amps AC
This menu item is used by the charger to determine the AC current level
(after the 20D Must Float Time Min period has been reached) when it
should change back to the Silent mode.
As the batteries charge, their current demands decrease. This setting
specifies at what point the current supplied to the batteries is allowed to
decrease to in order to trigger the Silent mode.
The 20C Float Done Amps AC setting is usually set to 1% of the total
battery bank capacity.
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 amps expressed in DC terms.
2. Convert the DC Max Charge Rate to AC amps by dividing the DC
Max Charge Rate by 4 for a 24-volt system or 2 for a 48-volt system.
3. The result is the approximate amp setting that should be entered for
the 20C Float Done Amps AC menu item.
For stacked inverters, use half the battery amp-hour rating in the
calculations.
Note: This information is provided for guidance only. Variations in battery
chemistry, as well as site specific environmental considerations, mean that you
should consult your system designer or battery manufacturer for specific
recommendations for appropriate battery voltage and current settings. An
amp-hour meter (e.g., Xantrex TM500A) would be useful to verify your
settings are correct to maintain a proper charge on the batteries.
Advanced Setup
7–16 976-0043-01-02
20D Must Float Time Min
This menu item sets the minimum amount of time after the 20A Refloat
High Volts DC and 20B Refloat Low Volts DC settings have been
reached that the inverter will maintain the float voltage level on the
batteries before it reaches the 20C Float Done Amps AC setting and
returns to the Silent mode.
21 Grid (AC1) Usage Menu
This menu sets the conditions that determine how and when the inverter’s
AC1 (grid) input will be used.
To program grid usage parameters, the Advanced Setup Menu Headings
21 Grid (AC1) Usage Menu and 22 Battery Xfer Menu are used.
Table 7-4
Calculating the Float Done Amps for a 24-volt,
700 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp
hours by 1%
700 x 1% = 7
(DC Max Charge Rate)
2 Divide the DC Max Charge Rate
by 4
7 ÷ 4 = 1
3Set the 20C Float Done Amps
AC parameter.
1 amps AC
Table 7-5
Calculating the Float Done Amps for a 48-volt,
350 amp-hour Battery
Step Instruction Equation
1 Multiply the total battery amp
hours by 1%
350 x 1% = 3.5
(DC Max Charge Rate)
2 Divide the DC Max Charge Rate
by 2
3.5 ÷ 2 = 1
3Set the 20C Float Done Amps
AC parameter.
1 amps AC
Menu Item Descriptions
976-0043-01-02 7–17
21A Grid Usage
This menu item allows you to select between the set points SB and BX as
described below.
SB (Standby) - Utility Backup This set point is the first set point
selection in the 21A Grid Usage menu. It sets the inverter to be used as a
backup power supply. When AC power is available at the inverter’s AC1
input, the batteries are maintained until the AC power is lost. At which
point, the inverter supplies AC power to the load from the batteries.
This is the default setting for grid usage. This mode also allows for energy
management features such as Time-of-Use Metering and Peak Load
Shaving which are programmed in menu items 21B Grid Usage Begin
h:m and 21C Grid Usage End h:m.
See “Energy Management” on page 2–44 for information regarding
Energy Management Features.
BX (Battery Transfer) - Renewable Energy Backup This set point is
the second selection in 21A Grid Usage and works in conjunction with
Menu Heading 22 Battery Xfer (BX). It allows the batteries to power the
AC loads until the batteries discharge to the settings in menu 22B Low
Xfer (LBX) VDC and then transfers to the utility.
Utility grid power is then used as a backup source to keep the loads
powered. When the batteries have recharged from an external DC source
to the setting in menu 22A High Xfer (HBX) VDC, the inverter transfers
from the utility grid back to inverter supplied AC power.
Guidelines for setting this menu item:
• In the BX Modethe batteries will only be charged from the DC
source, not by the Sine Wave Plus. The utility grid is only used to
pass-through the AC to the loads when the batteries are discharged to
a preset level.
• The BX Mode and Grid Usage Timer are not optimized to work
together. These two features can have different priorities and may
conflict with each other.
21B Grid Usage Begin h:m
This menu sets the daily begin time when the inverter is allowed to be
connected to the grid. This timer is only used when SB is selected in
21A Grid Usage. When the timer allows the inverter’s AC1 input to
connect to the grid, the inverter samples the utility grid power, and if
within acceptable tolerances, starts to charge the batteries at the bulk then
float voltage levels or goes Silent (based on the selection made in menu
item 12A Finish Stage.
Advanced Setup
7–18 976-0043-01-02
The clock is in a 24-hour format (00:00 to 23:59 hours).
Guidelines for setting this menu item:
• Ensure the current time is set correctly in menu 10 Time Of Day
Setup Menu.
• The timer function is deactivated if the 21C Grid Usage Begin h:m
is the same as the 21D Grid Usage End h:m time.
• This setting only operates with the AC1 input (Grid Input).
21C Grid Usage End H:M
This menu sets the time the inverter stops using the grid to charge the
batteries or power the loads. This timer is only used when SB is selected
in menu 21A Grid Usage.
Guidelines for setting this menu item:
• Ensure the current time is set correctly in menu 10 Time Of Day
Setup Menu.
• The timer function is deactivated if the 21C Grid Usage Begin h:m
is the same as the 21D Grid Usage End h:m time.
• This setting only operates with the AC1 input (grid input).
22 Battery Xfer (BX) Menu
This menu heading provides settings that determine the transfer levels
when the loads will be powered from the inverter or from the utility
power (pass-through only). These menu items are only used when BX is
selected in menu 21A Grid Usage.
Guidelines for setting this menu item:
• These settings only operate with the AC1 input (grid input).
• The upper and lower ranges of these settings are locked by the set
point levels in Menus 11A High Battery Cut Out VDC and
11C Low Battery Cut Out.
Note: The Grid Usage Timer feature is designed to work with the SB Mode,
selected under the 21A Grid Usage menu, and is enabled by setting the 21B
Grid Usage Begin h:m and 21C Grid Usage End h:m times differently. If BX
Mode is selected and the Grid Usage Timer is also enabled, the results cannot
be guaranteed as these two features can have conflicting priorities (i.e., to use or
not use grid power.)
Menu Item Descriptions
976-0043-01-02 7–19
22A High Xfer (HBX) VDC
This menu is used to set the voltage transfer point when the inverter turns
back on and resumes powering the AC loads from the batteries. When this
setting is reached, the inverter transfers from the AC1 input (grid) to the
batteries to power the loads.
An external DC charging source (wind, solar, etc.) must raise the battery
voltage above this setting before the system resumes inverter operation.
There is no delay in transferring from the grid to the inverter after the
battery voltage reaches this level. This setting is not temperature
compensated.
22B Low Xfer (LBX) VDC
This menu is used to set the voltage transfer point from the batteries to the
AC1 input (grid) due to a low battery condition. The transfer occurs only if
the battery voltage reaches or remains below this setting for 10 seconds.
The system returns to powering the AC loads from the battery once the
battery voltage increases to the level set in menu 22A High Xfer (HBX)
VDC above. This setting is not temperature compensated.
23 ALM Relays Menu
Auxiliary load functions are controlled by setting parameters in Menu
Heading 23 ALM Relays. Using this feature requires the additional
purchase of a Xantrex Auxiliary Load Module (ALM).
The ALM can be used to operate auxiliary loads such as water pumps or
alarms. The two auxiliary relays operate independently of the inverter/
charger status (inverter being ON or OFF). As long as the control circuit is
powered, as evident by the text on the ICM LCD screen being visible, the
AUX relays will operate.
Two voltage-controlled relays (RY9 and RY10) and an AC Output Fault
Relay (RY11) are provided on the optional ALM.
RY9 RY9 (load control relay) is dedicated for use as a load control relay
to prevent battery discharge and is not temperature compensated for the
battery. This relay operates in both the inverter and charger modes.
RY10 RY10 (charge control relay) is dedicated as a control relay for
regulating either a source of DC power or for controlling a load to utilize
excess power from DC sources. This relay is temperature compensated and
uses the 04B Battery Comp VDC display to determine its DC value. This
relay operates in both the inverter and charger modes.
Advanced Setup
7–20 976-0043-01-02
RY11 RY11, when ERROR is selected, is used as an inverter error
detection indicator device to display or sound an alarm when the inverter
AC output is lost. If COOLDOWN is selected, this will allow both
inverters to have a cooldown period when used in a series-stacked
configuration.
23A RY9 VDC Energized
This menu item sets the voltage trip point for relay RY9. When the battery
voltage reaches or exceeds this setting, the relay closes (energizes)
between the N.O. and COM terminals. There is a 2-second time delay on
the reaction of this setting, allowing fast response to rapid voltage
changes in the system. This setting is not temperature compensated when
a BTS is installed.
23B RY9 VDC DeEnergized
This menu item sets the voltage trip point for the auxiliary relay RY9.
When the battery voltage drops to or below this setting for the variable
time period set in menu 23C RY9 Delay At DeEngz. Min, the relay
de-energizes and closes the contacts between the N.C. and COM
terminals. This setting is not temperature compensated when a BTS is
installed.
23C RY9 Delay At DeEngz. Min
This menu item sets the delay time period in minutes at which the voltage
level must remain at or below before relay RY9 is deenergized. This is an
“active low” type of control. The relay closes between the N.C. and COM
terminals when the battery voltage falls to or below the level set in menu
23B RY9 VDC DeEnergized for the time period set here.
23D RY10 VDC Energized
This menu item sets the voltage trip point for the auxiliary relay RY10.
When the battery voltage, based on the 04B Battery Comp VDC display,
rises to or above this setting for the time period set in menu 23F RY10
Delay At Engz. Min, the relay energizes and closes the contacts between
the N.O. and COM terminals. This setting is temperature compensated
when the optional BTS is installed.
Menu Item Descriptions
976-0043-01-02 7–21
23E RY10 Vdc DeEnergized
This menu item sets the trip point where the relay de-energizes. When the
voltage, based on the 04B Battery Comp VDC display, drops to or below
this setting, the relay de-energizes and opens the contacts between the
N.O. and COM terminals immediately. There is no time delay on the
reaction of this setting, allowing fast response to rapid voltage changes in
the system. This setting is temperature compensated when a BTS is
installed and operates in both inverter and charger modes.
23F RY10 Delay at Engz. Min
This menu item sets the delay time period in minutes at which the voltage
level must remain at or below before relay RY10 is deenergized. This is
an “active low” type of control. The relay closes when the battery voltage
falls to or below the level set in menu 23E RY10 VDC DeEnergized for
the time period set here.
23G RY11 Mode
These two settings allow the RY11 relay in the ALM or GSM to function
differently based on your selection.
Cooldown In a multiple Sine Wave Plus inverter installation and using
the inverter’s automatic generator feature, you can use the cooldown
selection to enable an external contactor to allow both legs of a generator
to go through a cooldown period.
When using the generator “AUTO” selection and connecting two
inverters in a “series-stacked” installation (for 120/240Vac operation), the
inverter that controls the generator will disconnect from the generator to
allow a cooldown period prior to stopping the generator. The other
inverter not controlling the generator does not know the generator is about
ready to be stopped; so it cannot disconnect from the generator to allow
this leg a cooldown period. Selecting “cooldown” under RY11 mode and
using the RY11 relay to control an external contactor - that feeds both
inputs to the inverters - will allow both legs of the generator to be
disconnected and unloaded at the same time and go thru the cooldown
period prior to shutting down.
See Figure 7-3 on page 7–22 for the installation diagram using this
feature.
Error This selection allows the RY11 relay to function as an Error
Detection Relay. The blue LED (controlled by the RY11 relay) on the
GSM or ALM is on to indicate that the inverter is on (or in SCRCH
mode). If the blue LED does not turn on, the inverter is not powered (or
OFF), is in CHR mode or there is an error condition.
Advanced Setup
7–22 976-0043-01-02
Figure 7-3
Relay 11 Wiring Example to Dual Inverters with Cooldown selected
Menu Item Descriptions
976-0043-01-02 7–23
Generator Starting Scenarios
The Sine Wave Plus can be configured to start and stop a majority of
backup generators, either manually or automatically. Automatic operation
can be triggered based on time, AC current, battery voltage, or to
exercising the generator.
Using automatic generator control features will require the programming
of the following Advanced Menu Headings:
•24 Generator Timers Menu – This Menu sets parameters for
starting the generator based on time. In this menu, you can set the
generator to start and stop at a specified time. You can specify a quiet
time, an exercise time, and a cooldown period for the generator.
See “24 Generator Timers Menu” on page 7–26 for specific
instructions on programming these menu items.
•25 GEN Starting Details Menu – This Menu sets parameters for
starting the generator based on type of generator used.
See “25 Gen Starting Details Menu” on page 7–29 for specific
instructions on programming these menu items into the Sine Wave
Plus.
•26 GEN Auto Run Setup Menu – This Menu sets parameters for
starting the generator based on AC current and/or battery voltage.
See “26 Gen Auto Run Setup Menu” on page 7–38 for more
information on setting the parameters for starting generators based on
AC current and battery voltage.
Manual Generator Control
The generator equipped for remote starting capabilities can be remotely
started by selecting ON from 02A Generator. If the generator started in
this manner, the 02C GEN Start Volts/Manual menu item will display
YES.
Important: Automatic generator control features require the additional purchase of the
Xantrex GSM.
CAUTION: Damage to Generator
Generators used with this feature must have automatic-start capabilities and be
designed for stand-alone operation. Engine systems should self-protect against
any conditions that may cause the generator to malfunction or become damaged.
Advanced Setup
7–24 976-0043-01-02
The generator will continue to run unless one of the following procedures
is performed:
1. Manual Stop – Manually stop the generator by selecting OFF from
the 02A Generator menu item. The generator will receive the stop
command immediately if manually stopped.
2. Auto Stop – Select AUTO directly (without allowing the cursor to
pass through OFF) will allow the generator to automatically stop. It
will shut off once the bulk and absorption stages of the battery
charging have completed, thus fully recharging the batteries.
Automatic Generator Control
The generator can be programmed to start and stop automatically based
on the following scenarios:
• AC Current
• Battery Voltage
•Time of Day
• Required Exercise Period
AC Current
The generator starts whenever the current demand through the inverter to
the AC loads remains above the 26A Load Start Amps AC setting for the
selected 26B Load Start Delay Min period. The current can be
monitored by the 04E Load Amps AC menu item under the 04 Meters
Menu.
The generator will start, unless the timer is in the “quiet time” period, at
which time it will only start if the 26G Read LBCO 30 Sec Start Vdc
setting is reached.
Whenever the generator starts automatically, based on load amps, it will
shut off once the load current drops below the 26A Load Start Amps
value for the selected 26B Load Stop Delay Min period.
Battery Voltage
The generator starts whenever the battery voltage reaches one of the four
adjustable low-battery voltage levels for the selected delay periods
(24 hours, 2 hours, 15 minutes, or 30 seconds).
The low-battery voltage levels are set under the 26 Gen Auto Run Setup
Menu. Actual battery voltage can be monitored from the 04A Battery
Actual Volts DC menu item.
Menu Item Descriptions
976-0043-01-02 7–25
If set point RN1 is selected in 25A RY7 Mode, the generator will
automatically shut off once the BULK and ABSORPTION stages of the
battery charging have completed or if the 24H RN2/Max Gen Run h:m
has elapsed.
If RN2 is selected in menu item 25A RY7 Mode, the generator will
automatically shut off once the 24H RN2/Max Gen Run Time h:m
period has elapsed.
Time of Day
The generator is automatically started each day at a pre-selected time
determined by the 24A GEN Run Time Start h:m value. Whenever the
generator starts automatically, based on this time, it will shut off once the
Time of Day clock has reached the 24B Gen Run Time Stop h:m value.
Exercise Period Days
The generator is automatically started at a pre-selected time (based on the
24D Quiet Time End h:m) whenever it exceeds a set number of days
without running.
Once the start command is initiated, the generator starts and runs for the
time period set by the 24F Gen Exercise Timer Minute setting. This is to
ensure that it remains fully operational and that the generator’s starting
battery is maintained at an optimal state of charge.
If the 24D Quiet Time End h:m is set for 13:00 and 24E Gen Exercise
Period Days is set to 10, the generator will start at 1:00 p.m. every tenth
day of continuous non-operation. To disable this feature, set the value
24E Gen Exercise Period Days to zero.
If the generator starts for any reason and runs for at least 5 minutes, this
timer counter resets.
Advanced Setup
7–26 976-0043-01-02
24 Generator Timers Menu
This menu heading sets parameters for starting the generator based on
time. In this menu, you can set the generator to start and stop at a
specified time each day. You can specify a quiet time, an exercise time,
and a cooldown period for the generator.
Notes:
1. The generator will be prevented from automatically starting when the
inverter’s time of day is in the “quiet time” period–between 24C Quiet
Time Begin h:m and 24D Quiet Time End h:m. At which time, it will
only start if the 11C Set Low Battery Cut Out VDC or 26G Read LBCO
30 Sec Start setting for the LBCO delay period is reached.
2. If the generator is automatically stopped (except for Gen exercise), the stop
command will be provided after the adjustable cooldown period (24G Gen
Cooldown Timer Minutes) has finished.
3. Most generators will shut down immediately after receiving an automatic
shutdown command. Some generators may have an internal automatic
cooldown period and continue to run.
4. During Quiet Time, the auto-start generator is prevented from
automatically starting unless the battery voltage reaches the LBCO setting
for the LBCO delay period.
5. An auto-start generator will turn off if an AC source is connected to the
AC1 terminal (unless AUTO start was based on exercise start or RN 2
Mode was selected for the RY7 Mode.)
6. If the inverter is OFF or in Bypass Mode (AC1 or AC2 selected) and RY7
Mode is not RN2, all generator auto-start functions (except for exercise
start) are disabled.
7. The auto-start generator will stop immediately under any condition if OFF
is selected under the 02 Generator Menu Item.
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 inverter will attempt one auto-generator start if RY7 Mode =
RN2.
10. The auto-start generator will always finish with cooldown unless turned off
or exercise start/stop.
11. The auto-start generator does not shut down, but begins the cooldown
period when the 24C Quiet Time h:m is reached.
Menu Item Descriptions
976-0043-01-02 7–27
24A Gen Run Time Start h:m
This menu item sets the hour and minute for the generator to start. This
will occur each day at the same time. The set points for this menu item
change in 10-minute increments.
24B Gen Run Time Stop H:M
This menu item sets the hour and minute for the generator to stop. This
will occur each day at the same time. The set points for this menu item
change in 10-minute increments.
24C Quiet Time Begin h:m
This menu item specifies the start time (hour and minutes) when the
generator will not run or allowed to be started unless the actual battery
voltage reaches the level set in menu 11C Low Battery Cut Out VDC
(for a continuous period of 30 seconds). If you want to override this
generator start feature and not have the generator start, select OFF in the
02A Generator ON/OFF menu item.
During quiet time the automatic generator start system ignores the AC
load start and the 24 hr, 2 hr, and 15 min battery voltage start settings and
the Generator run time.
Guidelines for setting this menu item:
• Before setting this function, verify the internal clock has been
properly set to your current local time. The setting can quickly be
viewed under USER MENU heading 03 Time Of Day and changed,
if required, in 10 Time Of Day Setup Menu (24-hour clock).
Remember to reset the time-of-day setting if DC power is lost.
• The generator will stop at this time, even if it is started prior to the
24C Quiet Time Begin h:m.
• The set points for this menu item change in 10-minute increments.
Advanced Setup
7–28 976-0043-01-02
24D Quiet Time End h:m
This menu item ends the quiet time, after which the generator can be
started if required, if an auto-start condition exists.
To completely disable the quiet-time feature, set the start and stop times to
the same value.
The generator exercise timer uses this setting to determine when to start
the generator exercise. The generator will start and run for the time set in
menu 24F Gen Exercise Time Min at the end of the quiet time. If the
selection in menu 24E Gen Exercise Period Days has been set for 01
(every day), the generator will run every day at the end of the quiet time.
To disable the generator exercise system, set the number of days to zero.
The set points for this menu item change in 10-minute increments.
24E Gen Exercise Period Days
This menu item sets the maximum number of days between generator
operation. When the internal counter reaches the number of days set, the
generator starts (at the end of the quiet time setting). If the generator is
run for 5 minutes at any time during this period, this counter resets, and
the period starts again. If the menu item is set to 1, the generator runs
every day at this time.
Setting this value to 00 disables this function.
24F Gen Exercise Timer Min
This menu item sets the number of minutes the generator will perform an
exercise run after being started by the setting in menu item 24E Gen
Exercise Period Days.
The set points for this menu item change in 1-minute increments.
24G Gen Cooldown Timer Min
This menu item sets time the generator is allowed to run unloaded (the
inverter is now powering the loads). It is good practice to allow the
generator to run unloaded for a period of time, to properly cool off before
shutting it down. Refer to the manufacturer’s specifications on cooldown
time.
The set points for this menu item change in 1-minute increments.
Menu Item Descriptions
976-0043-01-02 7–29
24H RN2/Max Gen Run h:m
This menu item sets the limit on how long a generator can run when the
RY7 Relay is programmed for RN2 under menu item 25A RY7 Mode.
The set points for this menu item change in 10-minute increments.
25 Gen Starting Details Menu
Menu Heading 25 Gen Starting Details provides menu items for setting
the starting parameters for specific kinds of generators and the cranking
requirements for each.
Generator Start Module (GSM)
The GSM controls many types of auto-start generators. Two relays, RY7
and RY8, provide the control signals for the generator:
• RY7 provides either a STOP or a RUN signal. It can also provide a
GLOW signal for diesel generator engines. This mode is selected in
menu item 25A RY7 Mode.
• RY8 provides a crank signal to the generator’s starter (not used on
two-wire auto-cranking generators). These parameters are set in
Menu Items 25B Gen Warm-up second/minute, 25C Pre Crank
Seconds, 25D Max Cranking Seconds, and 25E Post Crank
Seconds.
To accommodate a wide variety of generators, three different start
configurations (GS, RN1, and RN2) are provided.
Figure 7-4
Generator Control Mode (GS and RN1)
AC
LOADS
INVERTER/
CHARGER
DC
AC
GEN START
MODULE
CONTROL
BATTERY
CONTROL
AC2
AC
GENERATOR
AC
Advanced Setup
7–30 976-0043-01-02
Guidelines for setting this menu item:
• When using a DC generator as a charging source, none of the
inverter's charge control features (bulk, absorption, float) will be
available. For battery protection, insure that external charge
management equipment is installed between the charger and the
batteries.
25A RY7 Mode
This menu item allows relay 7 (RY7) to provide three different relay
functions to accommodate either AC or DC generators.
The settings available for AC generators are GS and RN1. These
selections are monitored from the AC2 (generator) input, which tell the
inverter the generator is running.
The setting available for DC generators (or AC generators which do not
require monitoring) is RN2. Since there is no monitoring of the generator
by the inverter in this mode, only one attempt is made to start the
generator.
GS This selection (GlowStop) provides a momentary contact closure
between contacts N.O. (Normally Open) and COM.
When GS is selected as the function of the RY7 relay, the RY7 COM and
RY7 N.O. contacts remain open while the generator is running. The
contacts close when it is time for the generator to be stopped, then they
reopen. This is useful for generators that require a stop signal to shut
down the generator.
The glowstop setting can also be used for a diesel generator. This relay
can be used to provide both the glow and stop signals. RY7 is signaled to
close (between RY7’s COM and N.O. contacts) before cranking (Glow
Plug warming) and when stopping.
Figure 7-5
Generator Control Mode (RN2)
AC
LOADS
INVERTER/
CHARGER
DC
AC
GEN START
MODULE
CONTROL
BATTERY
CONTROL
DC
GENERATOR DC
Menu Item Descriptions
976-0043-01-02 7–31
RN1 This selection provides a run signal by holding the RY7 relay
closed between contacts N.O. and COM. and requires the AC generator
output to be monitored by the inverter’s AC2 input.
RN2 This selection provides a run signal by holding the RY7 relay
closed between contacts N.O. and COM. but does not require the
generator output to be monitored by the AC2 terminal. This selection can
allow the DC generator to be started/stopped by the inverter.
Guidelines for setting this menu item:
• Many diesel generators provide their own glow and stop signals as
well as powering the glow plugs during the cranking signal period.
Check with the generator’s manufacturer for specific details.
• The RN1 setting requires AC2 input to sense the generator output to
stop cranking.
• The RN2 setting does NOT require AC2 input to sense the generator
output to stop cranking.
• When either RN1 or RN2 is selected as the function of the RY7 relay,
the RY7 COM and RY7 N.O. contacts remain closed while the
generator is running. The RY7 N.C. (Normally Closed) contact is
open (not connected to the common terminal) while the generator is
running.
• When the generator is off, the RY7 N.C. terminal is connected to the
RY7 COM terminal. This configuration is useful for starting a two
wire (auto-crank) type generator.
Figure 7-6
RY7’s COM and N.O. Contacts Close (energize) to Run
Generator
GSM
COM N.O.
N.C.
RY7
REMOTE START/
STOP
TERMINALS
5 AMP
FUSE
2-WIRE START TYPE
GENERATOR
Advanced Setup
7–32 976-0043-01-02
RY8 Relay (GS and RN1 only)
The RY8 is energized (COM and N.O. contacts remain closed) only
during the 25D Max Cranking Seconds. This is usually wired to the
starter solenoid (relay) of the generator engine. The RY8 relay energizes
after an initial 25C Set Pre Crank Seconds delay period or de-energizes
once the inverter senses AC voltage above 80 Vac on its AC2 input
terminal.
If the generator does not start, RY8 will energize again after a 25E Post
Crank Seconds delay period. The inverter attempts to start the generator
up to six times.
Guidelines for setting this menu item:
• If the required voltage level is not reached, relay RY7 closes (in the
GS mode) to stop the generator before another attempt is started. This
reduces the chance the starter motor will engage on a spinning
generator engine. This protection is inherent in the RN1 mode.
RY8 Relay (RN2 only)
The RY8 relay remains energized (COM and N.O. contacts remain
closed) during the 25D Max Cranking Seconds. This is usually wired to
the starter solenoid (relay) of the generator engine. This relay energizes
after an initial 25C Set Pre Crank Seconds delay period. The inverter
attempts to energize RY8 (start the generator) only once.
Menu Item Descriptions
976-0043-01-02 7–33
Figure 7-7
Wiring examples of Honda™ and Onan™ Generators
GENERATOR START MODULE
RY7
STOP SWITCH
CONTACTS
ONAN TYPE GENERATOR
COM N.O.
N.C.
RY8
COM N.O.
N.C.
START
SWITCH
CONTACTS
5 AMP FUSE
5 AMP FUSE
RY7
RUN/STOP
SWITCH
CONTACTS
HONDA TYPE GENERATOR
COM N.O.
N.C.
RY8
COM N.O.
N.C.
START
SWITCH
CONTACTS
5 AMP FUSE
5 AMP FUSE
GENERATOR START MODULE
Advanced Setup
7–34 976-0043-01-02
Figure 7-8
RY7 and RY8 Timing Diagram
The generator auto-stop sequence is initiated if:
1) The time set in 24C QUIET TIME BEGIN has been reached or passed. This setting will disable 2, 3, and 4 start-scenarios below.
2) If the battery voltage has been held at the 12B BULK VOLTS DC setting for the time set in 12H MAX BULK/EQ TIMER H:M or if
the voltage has reached the 12F BULK DONE AMPS AC setting.
3) If the load amps remains below the 26A LOAD START AMPS AC setting and remains longer than the period set in 26C LOAD
STOP DELAY MINUTES.
4) If the time set for the generator to stop in 24B GEN RUN TIME STOP H:M is reached.
5) If the time set in 24H RN2/MAX GEN RUN H:M is reached and 25A RY7 MODE is set to RN2.
The generator manual-stop sequence is initiated if OFF is selected in 02A GENERATOR (OFF AUTO ON).
The next generator auto-start sequence is initiated.
(RN1 and GS modes will make six attempts to start the generator.
RN2 will only make one attempt to start the generator.)
The Generator auto-start sequence is initiated if:
1) The time set in 24D QUIET TIME END has been reached or passed.
2) If the battery voltage remains below the 11C LOW BATTERY CUT OUT VDC setting for the required period of time or if below the READ
LBCO 30 SEC START VDC setting for 30 seconds.
3) If the load amps reaches the 26A LOAD START AMPS AC setting and remains longer than the period set in 26B LOAD START DELAY
MINUTES.
4) If the time set for the generator to run in 24A GEN RUN TIME START H:M is reached.
The manual generator start sequence is initiated if generator is manually turned on via SET GENERATOR to ON.
The generator will stop immediately (no cooldown period) if an inverter fault is
detected or if OFF is selected in 02A GENERATOR (OFF AUTO ON).
Time (Sec)
RY8
Relays on GEN START MODULE (GSM)
OFF = relay contact closed from N.C. to COM (relay de-energized)
ON = relay contact closed from N.O. to COM (relay energized)
0 8 18 28 88 100 +100 +220 0818
OFF ON
ON
OFF OFF ON
ENERGIZED (COM to N.O. connected)
OFF OFF
ENERGIZED (COM to N.O. connected)
START
DELAY
PERIOD
8 seconds
FIXED
SET PRE
CRANK
SECONDS
10 seconds
default
SET MAX
CRANK
SECONDS
10
seconds
default
(RY8 goes
off with a
1 second
delay when
AC HOT IN
exceeds
80 Vac
Set Gen
WARM-UP SECONDS
60 seconds
default
(Starts once voltage
exceeds
80 Vac)
Lock on
Good
Delay
period
12
seconds
fixed
(Starts
when AC
is within
110 to 130
Vac
(default)
and
53 to 67
Hz)
GEN RUN PERIOD
(Determined by
generator auto-run
configuration settings
COOL
DOWN
PERIOD
2 minutes
default
(Only used
if AUTO is
selected in
02A
Generator
(OFF AUTO
ON)
Generator
is OFF
and
waiting for
next auto-
generator
start
sequence)
START
DELAY
PERIOD
8 seconds
fixed
SET PRE
CRANK
SECONDS
10 seconds
default
OFF (COM to N.C. connected)DE-ENERGIZED ON OFF ON
DE-ENERGIZED (COM to N.C. connected)
RY7
RN1
GS
RN2
Menu Item Descriptions
976-0043-01-02 7–35
Figure 7-9
RY7/RY8 Sequence of Events for RN1 or RN2 Selection
Advanced Setup
7–36 976-0043-01-02
Figure 7-10
RY7/RY8 Sequence of Events for GS Selection
Menu Item Descriptions
976-0043-01-02 7–37
25B Gen Warm-up Seconds/minutes
This menu item sets the number of seconds or minutes the generator is
allowed to warm up before the load is connected and the battery charger
started. If the generator is located in a cold location, a longer setting may
be required.
25C Pre Crank Seconds
This menu item sets the number of seconds the system delays engaging
RY8 (the crank signal relay) once relay RY7 is engaged. Also if GS is
selected from 25A RY7 Mode, this setting will allow selection of the
delay time between RY7 disengaging and RY8 engaging. If this number is
even, the delay is immediate. If the number is odd the delay is three
seconds.
Refer to “Automatic Generator Control” on page 7–24 for more
information. This period may also be the amount of time the glow plug is
ON if it is connected to the automatic-start system.
25D Max Cranking Seconds
This menu item sets the maximum number of seconds the starter is
cranked during the starting sequence by engaging relay RY8.
Guidelines for setting this menu item:
• If GS or RN1 (RY7 Mode) are selected, RY8 will disengage when the
generator AC output is sensed (> 80 Vac) on the inverters AC2 input.
• If RN2 (RY7 Mode) is selected, RY8 will stay engaged (crank) for the
entire time set in menu 25D Max Cranking Seconds.
25E Post Crank Seconds
This menu item sets the number of seconds after an unsuccessful crank
attempt, the system will delay before attempting another auto-start
sequence. If the generator has not started, this sequence is repeated up to
five times.
This period is provided to allow the starter motor to cooldown. It can also
allow generators with built-in warm-up delay contactors to provide AC
output before the inverter attempts a re-crank cycle.
Advanced Setup
7–38 976-0043-01-02
26 Gen Auto Run Setup Menu
Menu Heading 26 Gen Auto Run Setup Menu provides the menu items
for setting the parameters for starting the generator based on AC current
and/or battery voltage.
26A Load Start Amps AC
This menu items sets the AC load current that initiates automatic
generator start. When the current remains above this setting continuously
for time set in 26B Load Start Delay Min, the generator starts.
26B Load Start Delay Min
This menu items sets the time delay period that initiates automatic
generator starting. When the current remains above the 26A Load Start
Amps AC setting continuously for this period, the generator starts.
26C Load Stop Delay Min
This menu item sets the amount of time the generator continues to run
after the load current (determined by the 04E Load Amps AC meter)
decreases below the 26A Load Start Amps AC setting.
26D 24 Hr Start Volts DC
This menu item sets the battery’s DC voltage level which initiates
automatic generator starting whenever the voltage drops below this
setting continuously for 24 hours. This item is not temperature
compensated and is defeated during the quiet time period set in the
24 Generator Timers Menu.
26E 2 Hr Start Volts DC
This menu item sets the battery’s DC voltage level which initiates
automatic generator starting whenever the voltage drops below this
setting continuously for 2 hours. This item is not temperature
compensated and is defeated during the quiet time period set in the
24 Generator Timers Menu.
Menu Item Descriptions
976-0043-01-02 7–39
26F 15 Min Start Volts DC
This menu item sets the battery’s DC voltage level which initiates
automatic generator starting whenever the voltage drops below this
setting continuously for 15 minutes. This item is not temperature
compensated and is defeated during the quiet time period set in the
24 Generator Timers Menu.
26G Read LBCO 30 Sec Start
This menu item monitors the 11C Low Battery Cut Out VDC level and
initiates automatic generator starting whenever the voltage drops below
the LBCO setting continuously for 30 seconds. The LBCO setting is not
temperature compensated. This display is linked and adjusted in menu
11C Low Battery Cut Out VDC. The 30 second start attempts to
auto-start the generator even if the quiet time (as set in menu
24 Generator Timers Menu) is enabled. This is a read-only display.
27 Save/Restore Settings Menu
This menu provides the means to:
• save recently programmed settings,
• restore previously programmed settings, or
• to restore factory default settings.
27A Push INV now to Save Settings
This menu item provides the means to save settings currently
programmed into the inverter.
To save settings:
1. When 27 Save/Restore Settings Menu is displayed, press the
button to select 27A Push INV Now to Save Settings.
2. Press the red INV button to save the settings.
Note: The settings in this menu are identical to Menu 14. Saving or restoring
settings at either menu will apply to all menu settings (Basic and Advanced).
Advanced Setup
7–40 976-0043-01-02
27B Push GEN to Restore Settings
This menu item provides the means to restore settings previously set and
saved on the inverter.
To restore settings previously programmed into the inverter:
1. Press the button to select 27B Push Gen Now To Restore
Settings.
2. Press the green GEN button to save the settings.
27C Push GEN for Factory Defaults
This menu item provides the means to restore the factory default settings.
To restore the factory default settings:
1. Press the button to select 27C Push Gen For Factory Defaults.
2. Press the green GEN button to restore the factory default settings.
End Advanced Setup Menu
There are two ways to exit the Advanced Setup Menu:
Method 1:
◆Press the red INV button to go straight to the 01A Inverter Menu.
Method 2:
◆Press the green GEN button to go straight to the 02A Generator
Menu.
8Operation
Chapter 8, “Operation” explains how to operate the Sine Wave
Plus Inverter/Charger. It also explains how to read the LED
indicators and User Menus to determine system status.
Operation
8–2 976-0043-01-02
Operating the Sine Wave Plus
User Menu The Sine Wave Plus uses the User Menu architecture to navigate through
the operational functions of the inverter/charger. The User Menu contains
Operational Menus (01-02) and Operational Status Menus (03-07) to
assist the user to determine what the system is doing at any given time.
Startup checks When you first power up the system, perform the following system
checks. Use these same checks to monitor the system performance
throughout it’s operation.
❐Check the LED indicators for system status information.
See “LED Indicators” on page 8–3 for the description of their
meaning.
❐Check the 04 Meters Menu to confirm current, voltage, frequency,
battery temperature, and fan speed.
See “Accessing the User Menu” on page 8–14 for instructions on
accessing the User Menu system.
❐If the Status LED is illuminated, check the 06 Status Menu to ensure
the system is in the proper operational mode.
❐If using GSM and/or ALM accessories, check the 07 GSM/ALM
Options Menu to determine the status of the GSM and/or ALM.
❐If the Error Status LED is illuminated, check the 05 Error Causes
Menu. Correct any error conditions immediately.
Operational Status Indicators
976-0043-01-02 8–3
Operational Status Indicators
The Sine Wave Plus uses a combination of LED indicators and User
Menu Headings (2-7) to display system status. Use both of these features
to assess operational status.
LED Indicators
Eight, colored status LEDs indicate the various operating conditions of
the inverter. Unless otherwise indicated, the LEDs will be ON solid and
not flashing or blinking. The LEDs also are grouped by function.
LEDs provide system status indication for the following areas.
• Inverter Operation Status: INVERT or GRID TIE
(Grid Tie feature is not available at this time.)
• AC Input Status (AC1 or AC2)
• Charging Status (BULK or FLOAT)
• Operational Conditions (ERROR or STATUS)
Figure 8-1
LED Indicators
LEDs
Operation
8–4 976-0043-01-02
Inverter Operation Status (Yellow)
There are two yellow LEDs to indicate the following inverter operational
modes.
• GRID TIE LED - This feature is not available at this time.
• INVERT LED
GRID TIE LED The Grid Tie feature is not enabled on these models. Therefore, the GRID
TIE LED will not be illuminated during normal operation. It might,
however, flash during initial startup or during an LED test.
INVERT LED The INVERT LED indicates the inverter is operational and inverter power
to the AC output is available to power the load if needed. Therefore, this
LED will be illuminated during normal operation.
Search Mode Indication If the INVERT LED is blinking and no other
LEDs are illuminated, the inverter is in the energy saving SEARCH Mode
and monitoring the output for a load greater than the 01C and 11E Search
Watts setting.
Standby Mode Indication If the INVERT LED blinks and the AC1 or
AC2 LEDs are illuminated, the inverter is in Standby Mode and is ready
to engage and provide power if the AC source is lost.
Figure 8-2
Inverter Operation Status LEDs
Operational Status Indicators
976-0043-01-02 8–5
AC Input Status (Green)
Status LEDs There are two green LEDs to indicate AC status conditions.
• AC1 LED (grid)
• AC2 LED (generator)
AC1 (Grid)
LED The AC1 LED indicates power has been applied to the inverter’s AC1
(grid) input terminals. When AC is initially detected, the LED blinks
slowly (once per second). If the AC source is within the user’s input
settings, the inverter will connect to the source and the LED will be ON
solid. If the AC source falls out of tolerance, the LED will start to blink
and the AC input source will be disconnected. If using BX Modeor the
Grid Usage Timer, this LED will continue to blink even if the source is
within tolerance.
AC2 (Generator)
LED The AC2 LED indicates power has been applied to the inverter’s AC2
(generator) input terminals. When AC is initially detected, the LED blinks
slowly (once per second). If the AC source is within the user’s input
settings, the inverter will connect to the source and the LED will be ON
solid. If the AC source falls out of tolerance, the LED will start to blank
and the AC input source will be dropped.
Bypass Mode If the inverter is being used in Bypass Mode, the AC1 or AC2 LEDs,
along with the STATUS LED will illuminate solidly, depending on which
AC input source is selected. However, the inverter will not monitor the
AC inputs for power quality.
Figure 8-3
AC Status LEDs
Operation
8–6 976-0043-01-02
Charge Status (Yellow and Green)
Charging indicators There are two LEDs for battery charging indications.
• Bulk Charge LED (yellow)
• Float Charge LED (green)
Bulk Charge LED
(Yellow) The BULK charge LED indicates if the inverter is in the Bulk or
Absorption charge stage. The LED will illuminate solidly during the bulk
and absorption charging stages.
The BULK LED turns off when the battery voltage is held at the
12B Bulk Volts DC setting and the charge current equals or is below the
12F Bulk Done Amps AC setting or meets the 12H Max Bulk/EQ
Timer h:m value, which ever comes first. The inverter then switches over
to the FINISH stage of charging.
This LED is also used to indicate an equalization charge. When this LED
is blinking, it indicates the battery is being charged to the EQ volts DC
setting for the equalize period.
Float Charge LED
(Green) The FLOAT charge LED turns ON when the battery voltage reaches the
float stage of charging.
Float provides a maintenance charge to the batteries until another bulk
charge cycle is initiated or the AC source is disconnected.
The Float Mode of charging can be changed to Silent mode, where float
charging only occurs if certain conditions are met. When the LED is not
illuminated, the inverter is not actively float charging (Silent Mode only).
Figure 8-4
Charge Status LEDs
Operational Status Indicators
976-0043-01-02 8–7
Operational Status Indication (Red and Yellow)
There are two LEDs for Error and Status Indications:
• ERROR LED (red)
• STATUS LED (yellow)
ERROR LED (Red) The ERROR LED indicates an operating error occurred or an error
condition exists. Select Menu Heading 05 Error Causes to determine
which error condition has occurred.
Error conditions include:
• Over-current (menu item 05A)
• Transformer Over-temp (menu item 05B)
• Heatsink Over-temp (menu item 05C)
• Low Battery Voltage (menu item 05D)
• High Battery Voltage (menu item 05E)
• External Error (Stacked) (menu item 05F)
• Input Relay Failure (menu item 05G)
• Gen Failed to Start (menu item 05H)
• Gen Stopped due to Voltage or Frequency (menu item 05I)
For a complete description of the Error Menus, see “05 Error Causes
Menu” on page 8–25.
Figure 8-5
Error and Status LEDs
Operation
8–8 976-0043-01-02
Error LED Reset
Reset To reset the inverter after resolving an error condition, press the red INV
button (INVERTER ON/OFF Menu) and select OFF and then ON with
the SET POINT buttons.
STATUS LED
(Yellow) The STATUS LED illuminates to indicate various conditions of the
inverter/charger. This is not an error condition, but an indication that the
inverter/charger is in a special mode or condition (i.e., such as Bypass
Mode, Charger-only Mode, Generator Cooldown Period etc.)
Status conditions include:
• Bypass Mode was selected (06A)
• Charger only (CHR) was selected (06B)
• Generator was signaled to run (06C)
• Generator is in cooldown (06D)
• EQ charge is selected (06E)
• Battery Vdc is less than the LBCO (06F)
• Battery Vdc is greater than the HBCO (06G)
• EPO Shutdown command was received (06H)
For a complete description of the Status Menus, see “06 Status Menu” on
page 8–28.
Operational Status Indicators
976-0043-01-02 8–9
LED Summary
Table 8-1 summarizes the LED indicators.
Table 8-1
LED Summary Table
LED Name OFF ON FLASHING
GRID TIE
LED
(yellow)
Not available
INVERT
LED
(yellow)
Inverter is OFF. No
power is available
from the batteries in
case of a power
failure.
The inverter is on and is
currently providing power from
the batteries to the load(s).
SLOW FLASH (1 blink/4 sec):
Inverter is in Standby Mode and
is waiting to provide power to
the loads if the AC power is
lost.
FAST FLASH (1 blink/1 sec):
Inverter is on in Search Mode and
is waiting for a load to be turned
on that meets or exceeds the
Search Watts parameter set in
menu items 01C and 11E.
AC1 LED
(green)
There is no AC
power present
(less than 80 volts)
on the AC1 input
terminal.
AC power present on the AC1
terminal has been qualified
(i.e., is within voltage and
frequency limits) and is
providing pass-thru power to
the loads or AC1 is selected
under the 01D Bypass Mode
menu item.
AC power is present on the
AC1 input terminal. The AC
power may not be within
voltage or frequency limits or
may be waiting to be used
depending on the user settings
(e.g., BX mode, grid usage
timer).
AC2 LED
(green)
There is no AC
power present
(less than 80 volts)
on the AC2 input
terminal.
AC power present on the AC2
terminal has been qualified
(i.e., is within voltage and
frequency limits) and is
providing pass-through power
to the loads.
This is only possible if there is
no AC power present on the
AC1 terminal or AC2 is
selected under the 01D Bypass
Mode menu item.
AC power is present on the
AC1 input terminal. The AC
power may not be within
voltage or frequency limits or
voltage may be present on the
AC1 terminals (AC1 input has
priority).
BULK LED
(green)
Bulk or EQ charges
are not enabled
A Bulk Charge is being
performed.
An Equalize (EQ) charge is
being performed.
FLOAT LED
(green)
Float Charge is not
enabled.
Float charge is enabled.
Operation
8–10 976-0043-01-02
ERROR LED
(red)
No error has been
detected.
An Inverter error condition has
been detected.
Use 05 Error Causes Menu to
determine the cause of the error.
This error LED will be on if
either an inverter and/or a
generator error condition has
been detected.
A generator error has been
detected.
Use 05 Error Causes Menu to
determine the cause of the
Error.
If the Error LED flashes and no
Error cause is displayed in
05 Error Causes, then the AC
input frequency is in need of
adjustment.
STATUS
LED
(yellow)
No Status condition
has been detected.
A Status condition has been
detected as described in
“STATUS LED (Yellow)” on
page 8–8.
Use 06 Status Menu to
determine your particular status
condition.
A Status condition has been
detected and a pending error
condition may occur if this
status condition continues.
Use 06 Status Menu to
determine your particular status
condition.
Table 8-1
LED Summary Table
LED Name OFF ON FLASHING
The User Menu Summary
976-0043-01-02 8–11
The User Menu Summary
The User Menu provides all the controls and settings that may be required
on a daily basis such as turning ON the inverter and/or generator, reading
the AC and DC meters, checking the possible causes of an error, or
adjusting the inverter’s real-time clock.
Most menu headings in the User Menu do not set configuration
parameters (Read Only) but do provide system performance information.
Those menu items which are not specified as “Read Only” may be
configured through the user menu.
Table 8-2
User Menu
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548,4048, and 5548
See Page
Range/
Display
Default
Settings
Range/
Display
Default
Settings
01 Inverter ON/OFF Menu See “01 Inverter ON/OFF Menu” on page 8–15 for details.
01A Inverter OFF SRCH
ON CHR
OFF OFF SRCH
ON CHR
OFF page 8–15
01B EQ Charge OFF ON OFF OFF ON OFF page 8–16
01C Search Watts (SRCH) 00 to 248 08 00 to 248 08 page 8–16
01D Bypass Mode AC1 NORM
AC2
NORM AC1 NORM
AC2
NORM page 8–17
End Menu 01
02 Generator ON/OFF Menu See “02 Generator ON/OFF Menu” on page 8–17 for details.
02A Generator OFF AUTO
ON
OFF OFF AUTO
ON
OFF page 8–18
02B Gen Start Load Amps YES NO Read Only YES NO Read Only page 8–19
02C Gen Start Volts/Manual YES NO Read Only YES NO Read Only page 8–19
02D Gen Start Exercise Run YES NO Read Only YES NO Read Only page 8–19
02E Gen Start Run Time YES NO Read Only YES NO Read Only page 8–19
02F Days left to Gen Exercise 00 to 255 Read Only 00 to 255 Read Only page 8–19
End Menu 02
03 Time of Day (00:00:00) See “03 Time Of Day Menu” on page 8–20 for details.
SW Plus
Version 2.01 Info.
Displayed
Read Only Info.
Displayed
Read Only page 8–20
X.X KVA ** 120 Vac 60 Hz
(where X.X = 2.5, 4.0 or 5.5) **24 Vdc Read Only **48 Vdc Read Only page 8–20
Operation
8–12 976-0043-01-02
Xantrex Tech Inc
5916 195th St NE Info.
Displayed
Read Only Info.
Displayed
Read Only page 8–20
Arlington, WA
98223 USA Info.
Displayed
Read Only Info.
Displayed
Read Only page 8–20
Ph 1-800-446-6180
www.xantrex.com Info.
Displayed
Read Only Info.
Displayed
Read Only page 8–20
Press reset for factory defaults Press to refresh the LCD display. page 8–21
End Menu 03 Info.
Displayed
Read Only Info.
Displayed
Read Only
04 Meters Menu See “04 Meters Menu” on page 8–22 for details.
04A Battery Actual VDC 13.2 to 35.5 Read Only 20.0 to 71.0 Read Only page 8–22
04B Battery Comp VDC 13.2 to 35.5 Read Only 20.0 to 71.0 Read Only page 8–23
04C Inv/Chr Amps AC -63 to 63 Read Only -63 to 63 Read Only page 8–23
04D Input Amps AC 00 to 63 Read Only 00 to 63 Read Only page 8–23
04E Load Amps AC 00 to 63 Read Only 00 to 63 Read Only page 8–23
04F Inverter Volts AC 00 to 163 Read Only 00 to 163 Read Only page 8–23
04G Grid (AC1) Volts AC 00 to 163 Read Only 00 to163 Read Only page 8–24
04H Gen (AC2) Volts AC 00 to 163 Read Only 00 to 163 Read Only page 8–24
04I Frequency Hertz 52 to 68 Read Only 52 to 68 Read Only page 8–24
04J Max Bulk/EQ Time him 00:00 to
23:50
Read Only 00:00 to
23:50
Read Only page 8–24
04K Battery Temp Degrees C -28 to 60, OL Read Only -28 to 60, OL Read Only page 8–24
04L Fan Speed 00, 01, 02,
03, 04
Read Only 00, 01, 02,
03, 04
Read Only page 8–24
End Menu 04
05 Error Causes Menu See “05 Error Causes Menu” on page 8–25 for details.
05A Over Current NO YES Read Only NO YES Read Only page 8–25
05B Transformer overtemp NO YES Read Only NO YES Read Only page 8–25
05C Heatsink overtemp NO YES Read Only NO YES Read Only page 8–26
05D Low Battery Voltage NO YES Read Only NO YES Read Only page 8–26
05E High Battery Voltage NO YES Read Only NO YES Read Only page 8–27
Table 8-2
User Menu
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548,4048, and 5548
See Page
Range/
Display
Default
Settings
Range/
Display
Default
Settings
The User Menu Summary
976-0043-01-02 8–13
05F External err (stacked) NO YES Read Only NO YES Read Only page 8–27
05G Input Relay Failure NO YES Read Only NO YES Read Only page 8–27
05H Gen Failed to Start NO YES Read Only NO YES Read Only page 8–28
05I Gen Stopped due to V/F NO YES Read Only NO YES Read Only page 8–28
End Menu 05
06 Status Menu See “06 Status Menu” on page 8–28 for details.
06A Bypass Mode Selected NO YES Read Only NO YES Read Only page 8–29
06B CHR Selected (no backup) NO YES Read Only NO YES Read Only page 8–29
06C Gen Signalled to Run NO YES Read Only NO YES Read Only page 8–29
06D Gen in Cooldown NO YES Read Only NO YES Read Only page 8–29
06E EQ Charge Selected NO YES Read Only NO YES Read Only page 8–30
06F Battery Vdc < LBCO NO YES Read Only NO YES Read Only page 8–30
06G Battery Vdc > HBCO NO YES Read Only NO YES Read Only page 8–30
06H EPO shutdown NO YES Read Only NO YES Read Only page 8–30
End Menu 06
07 GSM/ALM Menu See “07 GSM/ALM Options Menu” on page 8–30 for details.
07A RY7 (GSM) Energized NO YES Read Only NO YES Read Only page 8–30
07B RY8 (GSM) Energized NO YES Read Only NO YES Read Only page 8–31
07C RY9 (ALM) Energized NO YES Read Only NO YES Read Only page 8–31
07D RY9 DeEngz. Time Minute 00 to 255 Read Only 00 to 255 Read Only page 8–31
07E RY10 (ALM) Energized NO YES Read Only NO YES Read Only page 8–31
07F RY10 Engz. Time Minute 00 to 255 Read Only 00 to 255 Read Only page 8–31
07G RY11 Energized NO YES Read Only NO YES Read Only page 8–31
End Menu 07
END USER MENU
Table 8-2
User Menu
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548,4048, and 5548
See Page
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Operation
8–14 976-0043-01-02
Accessing the User Menu
To directly access the 01A Inverter User Menu:
◆Press the red INV button to go directly to 01A Inverter.
To directly access the 02 Generator User Menu:
◆Press the green GEN button to go directly to 02A Generator.
Figure 8-6
Inverter ON/OFF Display
Figure 8-7
Generator ON/OFF Display
User Menu Description
976-0043-01-02 8–15
User Menu Description
01 Inverter ON/OFF Menu
The INVERTER ON/OFF Menu Heading accesses the startup and
shutdown function of the inverter.
01A Inverter
The 01A Inverter menu item has four set points to select from for
inverter operation: OFF, SRCH, ON, and CHR. This display will be the
initial power up display and is the first display to appear whenever the red
INV button is pushed.
OFF If in Bypass mode, this selection disables the inverter and charger,
but can provide pass through AC power on the inverter’s outputs. OFF is
the default when the inverter is first powered up. The batteries will not be
charging in this mode.
SRCH This is the automatic load search function of the inverter. When
AC power is not present on the inverter’s input, the inverter will not
provide an output voltage to the load until the load exceeds the value set
for the 01C Search Watts and 11E Search Watts setting. Use this
function to conserve battery power when AC power is not required.
ON This mode turns the inverter ON and supplies inverter output power
from the batteries plus allows an external AC source (i.e., utility or
generator power), connected to the inverter’s input, to begin charging the
batteries.
CHR This charger mode puts the unit into the Charger-only mode,
allowing the inverter to act as a stand-alone battery charger. In this mode,
the charger will maintain the batteries based on your charge configuration
(Silent or Float). The inverter will not function if there is a utility outage.
The Charge mode is intended to be used at times when no loads are
required to be operated if the utility fails.
Operation
8–16 976-0043-01-02
01B EQ Charge OFF ON
OFF When OFF is selected in the menu, the inverter is not set to
equalize the batteries.
ON This selection triggers the battery charger to initiate the
equalization process. If the AC source is present on the AC1 grid or AC2
GEN terminals, the equalization process will begin. The cursor
automatically returns to OFF after the EQ cycle is finished.
If the only AC source is connected to the AC2 GEN terminal (generator
input) but not present (that is, waiting for the generator to start), the
generator will start the equalization process the next time the generator is
started. After the EQ cycle has finished, the generator is stopped, after
cooldown if started automatically, and the cursor returns to OFF.
A BULK charge can be initiated by moving the cursor to ON, then OFF.
01C Search Watts (SRCH)
This menu item sets the inverter’s search sensitivity. Any load that is
below this setting does not cause the inverter to produce an AC output
voltage when running from batteries. The SRCH function must be
selected in 01A Inverter.
Setting this mode to 00 disables this function.
The default setting for this menu item is 8 watts.
See “11E Search Watts” on page 6–14 for additional information about
how this feature works and how to determine the value for this setting.
Note: This item is duplicated for your convenience in menu item 01C and
11E. Changes to settings made at 01C will also change the setting in 11E.
User Menu Description
976-0043-01-02 8–17
01D Bypass Mode
The Bypass Modecloses the internal bypass relays and allows the AC
connected to the selected input (AC1 or AC2) to pass directly through to
the loads without being monitored for AC voltage or frequency quality.
NORM When NORM is selected in the menu, the available inputs are
monitored for voltage and frequency.
AC1, AC2 If AC1 or AC2 is selected in this menu, the AC applied to
that input will not be monitored for voltage or frequency problems which
will pass directly through to the load, bypassing the inverter’s monitoring
circuits.
02 Generator ON/OFF Menu
The 02 Generator ON/OFF Menu is used for controlling a generator
equipped with remote start features and connected to the inverter by way
of the optional GSM. The generator can be manually switched ON or
OFF using the inverter control module or set to run automatically based
on programmed usage parameters. This menu heading also provides
generator status menus (02B through 02F) to help determine “why” a
generator started.
Important: All system functions are disabled in this mode and can only be
restored by selecting NORM. After returning to NORM, you must reselect your
user settings in the 01A Inverter menu item.
CAUTION: Damage to AC Loads
When Bypass Mode is selected, the Sine Wave Plus allows any AC power
supplied (utility or generator) to pass through the inverter to AC loads. If the
source of AC is not adequately regulated it can cause instability in voltage and
frequency which can damage connected AC loads. Xantrex does not recommend
use of Bypass Mode in areas of unstable AC power supply.
Note:
Auto-starting or controlling a generator with the inverter is only
possible with generators that have an electric starter and are compatible with
two- or three-wire external relay control. The optional GSM accessory is
required to perform automatic-generator starting operations.
Operation
8–18 976-0043-01-02
02A Generator
The 02A Generator menu item provides three set points to choose from
for generator control.
OFF This set point disables the auto-start system or immediately turns
OFF a generator (without cooldown) started by the inverter. It is also used
to reset the automatic generator start system after an ERROR condition
occurs.
AUTO This set point enables the auto-start system features and allows
the generator to be started automatically based on battery voltage, load
amps, exercise time, or a preset time. The generator may be started based
on battery voltage, load amps, or exercise time with the following
distinctions:
• If the generator is started automatically based on battery voltage, it
will shut off after the charger completes its Bulk and Absorption
battery charging stages or if the 24H RN2/Max Gen Run Timer is
met.
• If the generator started automatically based on load amps, it will turn
off when the current, as shown on the 04E Load Amps AC display,
decreases below the 26A Load Start Amps setting for the 26C Load
Stop Delay Min period.
• If the generator started automatically based on exercise time, it will
turn off after the setting in menus 24F Exercise Time Min and
24G Gen Cooldown Time Min periods has been reached.
ON This set point turns on the generator connected to the GSMs
generator control relays. When ON is selected, the generator must be
stopped by selecting the OFF setting.
Generator Status
Menu Items Menu Items 02B through 02F are generator status menus. They are Read-
Only displays for determining “why” the generator has started. They will
indicate either NO or YES depending on whether the generator has started
based on the parameters of time, voltage, or current.
Note: The “AUTO” generator start/stop function is disabled if the inverter is
OFF or Bypass Mode is selected.
Note:
By pausing the cursor at ON then selecting AUTO (Do not pass-
through OFF), the generator is manually turned ON and will be automatically
stopped after the Bulk/Absorption charge is finished.
User Menu Description
976-0043-01-02 8–19
Menu items 02B through 02F will indicate “NO” unless the generator-
start parameters are met as programmed in the Advanced Setup Menu
(Menu items 24, 25, and 26).
02B Gen Start Load Amps
A “YES” displayed in this menu item indicates the generator has or is
about to start and run as the current has maintained the 26A Load Amp
Start setting continuously for the time set in 26B Load Start Delay Min.
02C Gen Start Volts/Manual
A “YES” displayed in this menu item indicates the generator has or is
about to automatically start and run because the battery voltage reached
one of the “start volts” settings, selected in 26D through 26G, or has been
manually started by selecting ON from menu 02A Generator.
This automatic start setting is delayed by the time period set by the
26 Gen Auto Run Setup Menu settings (e.g., 24 hours (26D), 2 hours
(26E), 15 minutes (26F), 30 seconds (26G).
02D Gen Start Exercise Run
A “YES” displayed in this menu item indicates the generator has or is
about to start because the 24E Exercise Period Days setting in menu item
24E has been reached. The generator will continue to run for the time set
in menu item 24F Gen Exercise Time Min.
This automatic start setting is delayed by the time period set in menu
24E Exercise Period Days.
02E Gen Start Run Time
A “YES” displayed in this menu item indicates the generator is starting or
running because the setting in menu 24A Gen Run Time Start h:m has
been reached. The generator will stop when the time set in menu
24B Gen Run Time Stop h:m or 24C Quiet Time Begin h:m setting has
been reached.
02F Days Left To Gen Exercise
Displays the number of days left before the generator will be exercised
(run) again. This time is based on the last time it was exercised as set in
menu heading 24E Exercise Period Days. This setting will be reset if the
generator is turned on and sensed at the AC2 terminals.
Operation
8–20 976-0043-01-02
03 Time Of Day Menu
Menu Heading 03 Time Of Day displays information such as the current
time of day, software revision number, system information (e.g., model
type), Xantrex’s mailing address and phone/fax numbers.
Use the information contained in this menu when contacting Xantrex for
technical assistance or service request.
03A SW Plus Software Level
This menu item displays the software revision level. You will need to
know the software revision level if you have to contact Xantrex Customer
Service.
03B System Information
The System Information menu item displays system information such as
rated load output, DC system voltage, AC output voltage, and output
frequency. Depending on your model, either 2.5 KVA, 4.0 KVA or
5.5 KVA will be displayed in this menu item.
03C Company Name and Address
Menu item 03C displays the company name and street address where the
Sine Wave Plus Inverter/Charger was built.
03D City, State, and Zip Code
Menu item 03D displays the City, State and Postal Code where the Sine
Wave Plus Inverter/Charger was built.
03E Xantrex Phone Numbers
Menu item 03E displays the toll-free phone number for Xantrex Customer
Service. It also displays the name of the website for Xantrex Technology
Inc.
Important: Do not return units to the address displayed in menu item 03C and
03D for replacement or service. Contact the Xantrex Customer Service
Department for an RMA to obtain the appropriate mailing address.
User Menu Description
976-0043-01-02 8–21
Press Reset for Factory Defaults
In addition to providing information, this menu includes a reset function
that allows all system settings to be returned to their original default
values.
Pressing the RESET DEFAULTS button while this menu item is
displayed resets the inverter to the factory default settings. Only the
system clock will remain unchanged using the reset function.
It also runs an LED and relay test which allows users to check the LEDs
on the inverter display and the relays and LEDs on any ALM or GSM that
is connected.
WARNING: Personal Injury
Ensure all devices connected to the ALM or GSM are disabled prior to
pressing the Reset Factory Defaults button.
Figure 8-8
Resetting Factory Default Settings
When the PRESS
RESET FOR
FACTORY
DEFAULTS
menu item is
displayed, press
the RESET
DEFAULTS
button
Operation
8–22 976-0043-01-02
04 Meters Menu
The Meters Menu provides information about system performance. The
menus under this heading are read-only. This information includes the
following menu items to assist the user in monitoring system
performance:
• 04A Battery Actual Volts DC
• 04B Battery Compensated Volts DC
• 04C Inverter/Charger Amps AC
• 04D Input Amps AC
• 04E Load Amps AC
• 04F Inverter Volts AC
• 04G Grid (AC1) Volts AC
• 04H Generator (AC2) Volts AC
• 04I Frequency Hertz
• 04J Maximum Bulk/EQ Time
• 04K Battery Temp Degrees C
• 04L Fan Speed
04A Battery Actual Vdc
This menu item displays the actual DC battery voltage. This value is used
for setting the following menu items.
• 11C Low Battery Cut Out Vdc
• 11A High Battery Cut Out Vdc
• 22B Low Battery Xfer Vdc
• 11B Low Battery Cut In Vdc
• 22A High Battery Xfer Vdc
Note: The AC ammeters have an approximate 1-amp tolerance. Additionally,
the meters provided in menus 04C, 04D and 04E measure the real, in-phase AC
component of the current. This is the portion of the power that is actually drawn
from the batteries, allowing better estimation of the DC power consumed by the
load or the battery charger. Measurements taken with conventional AC DVMs
usually read apparent current and may differ from these readings.
User Menu Description
976-0043-01-02 8–23
04B Battery Comp Vdc
This menu item display shows the battery voltage after it has been
compensated based on the battery temperature and the input current.
These two compensation values are used by the battery charger for its
regulation settings and are only used when the inverter is charging.
The temperature compensation value will decrease from the actual battery
voltage if the battery is cold and will increase if the battery is hot. This
improves the performance of the battery in cold weather and reduces
gassing in hot weather.
The current compensation helps coordinate a large difference in current
requirements between two units on the same battery bank. The
compensation is usually not enabled unless one unit is using a large
amount of battery current to power its AC loads and the other unit is using
a large amount of current to keep the battery charged.
04C Inverter/Charger Amps AC
This menu item displays the AC amperage. A positive (+) amp reading
indicates the inverter/charger is charging the batteries. A negative (–)
reading indicates the inverter/charger is powering the AC loads and the
batteries are being discharged.
04D Input Amps AC
This menu item displays the total AC amperage supplied to the inverter/
charger from the AC HOT IN terminals. This meter indicates the inverter/
charger is drawing power from the AC source to charge the battery or
power the AC loads.
04E Load Amps AC
This menu item displays the AC amperage supplied to the AC loads.
04F Inverter Volts AC
This menu item displays the inverter’s AC output voltage. When
synchronized to the AC source, the inverter’s output voltage matches the
AC source.
Note:
The BTS must be installed for the battery voltage to be adjusted based
on temperature.
Operation
8–24 976-0043-01-02
04G Grid (AC1) Volts AC
This menu item displays the AC input voltage connected to the inverter's
AC1 terminals. This input voltage display may drift slightly before the
inverter has synchronized to the grid.
04H Gen (AC2) Volts AC
This menu item displays the AC input voltage connected to the inverter's
AC2 terminals. This input voltage display may drift slightly before the
inverter has synchronized to the generator.
04I Frequency Hertz
This menu item displays the frequency of the active AC source (inverter,
grid or generator). This value may drift slightly until the inverter fully
synchronizes to an external AC source. Once synchronized, the inverter
follows the frequency of the AC source.
04J Max Bulk/EQ Time h:m
This menu item display shows the time the system has been charging the
batteries in either bulk, absorption, or equalize mode.
04K Battery Temp Degrees C
This menu item display shows actual battery temperature as measured by
the BTS. Use this menu item to monitor or check the temperature of the
batteries.
If the BTS is not installed, this display will show “OL”.
04L Fan Speed
The inverter/charger contains two internal cooling fans. The speed of the
fans is determined by the internal temperature of the unit and is controlled
automatically.
This menu item displays the current fan speed by displaying the number
00, 01, 02, 03, or 04. The slowest speed is 1 and the fastest speed is 4.
“00” indicates the fan is off or not running.
User Menu Description
976-0043-01-02 8–25
05 Error Causes Menu
Detected inverter errors cause the red ERROR LED to illuminate. These
menu items help determine the cause of error conditions.
These menu items normally display “NO” for all menu items in which no
error is detected. The display changes to “YES” for menu items where
errors were detected.
05A Over Current
If “Yes” is displayed, the AC output wiring of the inverter is short-
circuited or has had an excessive load connected for too long.
To clear this fault, disconnect the loads and restart the inverter by pressing
the red INV ON/OFF MENU button to directly access the 01A Inverter
menu item and select OFF, then ON or SRCH. Reconnect the loads (one
at a time) to find the load, or combination of loads, causing the problem.
05B Transformer Overtemp
If “yes” is visible in this display, the transformers have exceeded their
designed operating temperature and the inverter will shut off.
If the unit is operating as a battery charger when this error condition
occurs, the inverter stops charging to prevent further overheating.
In the inverter mode, overheating can be caused by:
• powering an excessive load for too long,
• blocked air vents or a fan failure, and/or
• insufficient circulation that allows the exhaust from the unit to be
drawn back into the unit.
When the inverter has this error condition, AC current from the source
(utility grid or generator) is passed through the inverter to power the
loads. Power management features provided by the inverter are not
available with this error.
The inverter automatically resets when it has cooled.
Note:
All errors except “05A Overcurrent”, “05F External Err
(Stacked)”, and “05G Input Relay Failure” will allow the external AC
source (if within acceptable tolerances) to pass-through to the inverter’s
output.
Note:
An over-current condition will shut down the inverter.
Operation
8–26 976-0043-01-02
05C Heatsink Overtemp
If “yes” is visible in this display, the power transistors have exceeded their
designed operating temperature and the inverter is shut off.
When this error condition occurs, if the unit is operating as a battery
charger, the inverter stops charging to prevent further overheating.
In the inverter mode, overheating can be caused by:
• powering an excessive load for too long,
• blocked air vents or a fan failure, and/or
• insufficient circulation that allows the exhaust from the unit to be
drawn back into the unit.
When the inverter has this error, AC current from the source (utility grid
or generator) is passed through the inverter to power the loads. Power
management features provided by the inverter are not available with this
error.
The inverter automatically resets when it has cooled.
05D Low Battery Voltage
If “yes” is visible in this display, the battery voltage has dropped below
the 11C Low Battery Cutout VDC setting continuously for the
11D LBCO Delay Minutes period.
When a battery protection fault occurs (due to either a high or low battery
charge condition), the yellow STATUS LED will flash. If this condition
continues without being corrected, then the inverter will shut down and
the red ERROR LED will illuminate solidly.
After shutting down from a low battery protection condition, the inverter
will return to normal operation when:
• the AC source power is restored and the inverter operates as a battery
charger,
• the inverter is manually restarted by pushing the red INV button on
the control module to access the 01A Inverter menu item and
selecting OFF, then SRCH or ON from the display, or
• the battery voltage rises above the setting in menu setting
11B Low Battery Cut In VDC.
AC current is still passed-through to the load if an AC source within
acceptable tolerance is available.
User Menu Description
976-0043-01-02 8–27
05E High Battery Voltage
If “Yes” is displayed, the DC battery voltage has increased above the
value set in the 11A High Battery Cut Out VDC menu item.
This can be caused by a solar array or other charging source not being
regulated. Check the operational status of all the DC controllers in the
system.
If NiCad batteries are used, it might be necessary to increase the value in
the 11A High Battery Cut Out VDC menu item.
The inverter automatically resets once the battery voltage decreases to
3 volts for 24-volt models, or 6 volts 48-volt models, below the HBCO
setting.
AC current is still passed-through to the load if the AC source is within
acceptable tolerances.
05F External Err (Stacked)
If “Yes” is displayed, then the inverter showing the error (Inverter 1) has
received a shutdown command from the stacked inverter (Inverter 2).
Check the stacked inverter (Inverter 2) for error conditions and clear the
error condition.
After the error condition is resolved, on the primary inverter (Inverter 1),
go to 01A Inverter and turn the inverter OFF, then back ON to clear this
error message.
05G Input Relay Failure
If “Yes” is displayed, an internal AC transfer relay (AC1 or AC2) has
failed. This condition maybe caused by an AC backfeed (AC plugged into
the inverter’s output) or a welded relay condition.
Note:
The External Error condition will shut down both inverters.
Note:
This condition will shut down the inverter.
Operation
8–28 976-0043-01-02
05H Gen Failed to Start
If “Yes” is displayed, the automatic generator-start system did not
successfully start the generator.
The system completes six start cycles and requires the generator to
operate for a minimum of five minutes before the starting attempts
counter is cleared.
To manually clear this error, press the green GEN buttons to directly
access the menu item 02A Generator and select OFF.
05I Gen Stopped Due to V/F
If “Yes” is displayed, the automatic generator-start system did not
successfully connect to the generator after it was running. If the generator
runs for 20 minutes without meeting the AC voltage and frequency
tolerance window, the automatic start-system stops the generator (after
the cooldown period) and indicates the error.
Whenever this error occurs, the inverter is prevented from starting the
generator until this error is cleared.
To clear this error, select OFF from menu item 02A Generator.
Determine and correct the reason the generator was out-of-tolerance, then
select AUTO from menu item 02A Generator if you want the generator
start system to be enabled.
06 Status Menu
The 06 Status Menu displays various conditions or special operating
modes of the inverter/charger in one convenient location. The information
in these displays is read-only and cannot be altered. Refer to this menu
whenever the yellow STATUS LED is illuminated.
A “No” displayed in this series of menu items indicate that no status
condition has occurred and provides no additional information. If the
Status light is on, scroll through the Menu Items under this Menu Heading
to look for a “Yes” to determine what’s happening.
User Menu Description
976-0043-01-02 8–29
06A Bypass Mode Selected
If “Yes” is displayed, the Bypass Mode is selected for either the AC1 or
AC2 input.
When the inverter is setup to operate in the Bypass Mode it does not
check the AC inputs for quality and will allow any anomalies appearing
on the grid (AC1) or generator output (AC2) to pass through to the loads.
This is a special operating mode which bypasses the inverter’s internal
sensing circuits and disables the inverter/charger’s normal operation.
Backup power and charging functions are not available in this operating
mode.
06B Chr Selected (No Backup)
If “Yes” is displayed, the CHR (charger only) Mode is selected.
In this mode, the inverter will not supply AC power if the AC input
source fails. Whenever AC is present on the input (AC1 or AC2), it will
pass through to the loads and the charger will continue to charge the
batteries, providing a float charge if Float is selected or a silent charge (as
necessary) if Silent is selected.
06C Gen Signaled to Run
If “Yes” is displayed, the generator was issued a command to start. This
menu item only acknowledges that a generator run command was issued.
If you need to know why the generator has been signaled to run, check
menu items 02B Gen Start Load Amps, 02C Gen Start Volts/Manual
and 02D Gen Start Exercise Run for either a load amps start, voltage or
manual start, or an exercise start.
If the generator is not running, but has received a signal to start, check the
Menu Items 07 to determine which relay did, or did not, energize. Or
check the troubleshooting section of your generator’s owner’s manual.
06D Gen In Cooldown
If “Yes” is displayed, the generator’s AC output is no longer synchronized
to the inverter’s input and the generator is in its cooldown cycle (set in
menu 24G Gen Cooldown Period).
Once the cooldown time has elapsed, the generator is sent a command to
stop.
Operation
8–30 976-0043-01-02
06E EQ Charge Selected
If “Yes” is displayed, the charger is set to run in the Equalize Charge
Mode.
Be sure to monitor menu items 04I Battery Temp and 04K Read Bulk/
EQ Time when equalize charging the batteries.
6F Battery VDC < LBCO
If “Yes” is displayed, the battery voltage has dropped below the voltage
set in menu 11C Low Battery Cut Out VDC.
When the batteries have dropped below the setting for the time set in
menu 11D LBCO Delay Minutes, the inverter will shut off.
6G Battery VDC > HBCO
If “Yes” is displayed, the battery voltage has risen to or exceeded the
voltage set in menu 11A High Battery Cut Out VDC.
When the battery voltage has risen above the setting in menu 11A High
Battery Cut Out VDC and remains there for approximately one minute,
the inverter will shut off.
06H EPO Shutdown
If “Yes” is displayed, the inverter has received an Emergency Power OFF
Shutdown command from an externally located shut off switch to the
inverter’s EPO Port.
07 GSM/ALM Options Menu
The 07 GSM/ALM Options Menu displays the various conditions of the
relays on the GSM and ALM. The information provided here can assist in
finding the reason for an auto-generator start or to determine the GEN and
AUX relay state which can be used as a troubleshooting aid if necessary.
Using the GSM for auto-starting or controlling a generator is only
possible with generators that have an electric starter and are compatible
with two- or three-wire external relay control.
07A RY7 (GSM) Energized
If “Yes” is displayed, the inverter has sent out a command to energize the
relay (between the N.O. to COM connections) in the GSM.
This display can be used for troubleshooting purposes by helping to
isolate the cause of a generator problem.
User Menu Description
976-0043-01-02 8–31
07B RY8 (GSM) Energized
If “Yes” is displayed, the inverter has sent out a command to energize the
relay (between the N.O. to COM connections) in the GSM.
This display can be used for troubleshooting purposes by helping to
isolate the cause of a generator problem.
07C RY9 (ALM) Energized
If “Yes” is displayed, the inverter has sent out a command to energize the
RY9 relay (between the N.O. to COM connections) in the ALM.
This display can be used for troubleshooting purposes by helping to
isolate the cause of an ALM problem.
07D RY9 DeEngz. Time Minute
This menu item displays the delay time period in minutes at which the DC
voltage level has been displayed at or below the level set in menu item
23B RY9 DeEnergized.
07E RY10 (ALM) Energized
If “Yes” is displayed, the inverter has sent out a command to energize the
RY10 relay (between the N.O. to COM connections) in the ALM.
This display can be used for troubleshooting purposes.
07F RY10 Engz. Time Minute
This menu item displays the delay time period in minutes at which the DC
voltage level has been at or below the level set in menu 23E RY10 Vdc
DeEnergized.
07G RY11 Energized
If “Yes” is displayed, the inverter has sent out a command to energize the
RY11 relay (between the N.O. to COM connections) in the GSM or ALM.
This display can be used for troubleshooting purposes.
This display applies to both the GSM and ALM
8–32
9Troubleshooting
Chapter 9, “Troubleshooting” contains information and
procedures for solving possible problems with the Sine Wave
Plus.
Troubleshooting
9–2 976-0043-01-02
Inverter Troubleshooting
If the red ERROR LED illuminates on the control module, see “05 Error
Causes Menu” on page 8–25 to determine the cause of the error condition
then refer to the troubleshooting solutions below to resolve the situation.
Unit will not come on (no
LEDs are on) and the
ICM display is blank or
off.
DC voltage on the
inverter’s DC terminals is
incorrect.
Check the battery voltage, fuses or breakers and DC
cable connections to the inverter.
If the DC voltage on the inverter’s DC terminals is
correct, have unit serviced.
Unit comes on, but goes
off quickly (several
attempts made).
Excessive load on output,
unit is in over-
temperature protection
and needs to cooldown,
incorrect battery voltage.
Look under the 05 Error Causes Menu.
No AC power output.
INVERT LED is on, with
no ERROR LED.
Open AC output breakers
or fuses and bad output
wire connections.
Look at the ICM display under 04F Inverter Volts
AC and check AC voltage on the inverter AC
terminal block.
If there is correct AC voltage on the ICM display but
no AC voltage on the inverter AC terminal block,
check for open circuit breaker on the inverter. If the
circuit breaker is open, press it back in to reset it. If
circuit breaker on the inverter is not open, the
inverter may need to be serviced.
If there is correct AC voltage on the ICM display
and on the inverter AC terminal block, check for
open AC output breakers or fuses and bad output
wire connections.
If AC voltage on the ICM display or inverter AC
terminal block is incorrect, have unit serviced.
No AC power output.
INVERT LED is flashing.
AC load too small for
Search Mode circuit to
detect.
Reduce search watts setting, increase load above
search watts setting, or defeat Search Mode by
selecting ON.
If the AC1 LED is on, check inverter output
connections/voltage.
Inverter Troubleshooting
976-0043-01-02 9–3
Low AC power output or
Low surge power
INVERT LED is on.
AC inductive loads are
not running at full speed.
Insufficient DC current
being provided to the
inverter to operate the AC
loads.
Check the battery voltage, fuses or breakers and
cable connections.
Ensure the battery bank is sufficient (check for low
DC voltage while running the load).
Ensure the cable length and size is correct (see
owner’s manual for correct cable). Tie the battery
cables together to reduce inductance.
Inverter turns on and then
off or doesn’t turn on at
all.
Search Sense setting is
too low or high.
Potential problem loads
for Search Sense:
Incandescent Lights:
These have a higher
starting wattage when the
filament is cold than the
continuous rating of the
bulb.
Fluorescent Bulbs: These
work the opposite of
incandescent light bulbs.
If the inverter is set to
detect a 30 watt load and
a 40 watt fluorescent is
switched on, the inverter
will not detect it, This is
because the fluorescent
tube is less than 30 watts
until the gas in the tube
ionizes.
Other loads: There are
some appliances which
draw power even though
they are turned off. TV's
with instant on circuits,
microwaves with digital
clocks, VCR's, and
clocks.
If the search sensitivity is set higher than the
combined loads, then an auxiliary load must be used
to bring the inverter out of Search Mode before the
appliances can be turned on.
If the sensitivity is set lower than the combination of
the loads, the loads will remain on and excess battery
drain will occur since the inverter won't ever go to
sleep.
One solution is to turn the item off at the wall, use an
extension cord with a rocker switch, a switch at the
outlet, or an appropriate circuit breaker.
Troubleshooting
9–4 976-0043-01-02
Battery Charger Troubleshooting
If the red ERROR LED illuminates on the ICM display, see “05 Error
Causes Menu” on page 8–25 to determine the cause of the error condition.
Then use the solutions below to resolve the situation.
AC1 LED is flashing, but
will not start charging
(allow 40 seconds to
synchronize).
Battery voltage is below
the 22B Low Xfer (BX)
VDC setting.
You are outside of the
21 Grid Usage timer
period.
Check for the correct AC voltage or frequency at the
AC input terminal. If it is normal:
1) Check to see if the BX Mode is enabled. The AC
input is not allowed to synchronize and pass-through
unless the battery voltage reaches the 22B Low Xfer
(BX) VDC setting.
2) Check to see if the 21 Grid Usage timer (21B and
21C) is enabled and that you are outside of the
21 Grid Usage timer period. The AC is not allowed
to synchronize and charge unless you are within the
21 Grid Usage timer period.
AC1 or AC2 LED is
flashing, but will not start
charging
(allow 40 seconds to
synchronize).
AC frequency at the AC
input terminal may be
out-of-tolerance (too high
or low) or the AC voltage
may be outside the
13C Input Upper Limit
VAC or 13D Input
Lower Limit VAC
settings.
Check for the correct AC voltage or frequency at the
AC input terminal. If the AC source is a generator,
adjust the AC voltage or frequency accordingly.
AC1 or AC2 LED is
flashing and repeatedly
connects and disconnects
to the source.
AC frequency at the AC
input terminal may be
out-of-tolerance (too high
or low) or the AC voltage
may be outside the
13C Input Upper
Limit VAC or 13D Input
Lower Limit VAC
settings.
Or the inverter circuit
breaker has opened.
Check for the correct AC voltage or frequency at the
AC input terminal. If the AC source is a generator,
adjust the AC voltage or frequency accordingly.
If the circuit breaker is open, press it back in to reset
it.
If circuit breaker on the inverter is not open, the
inverter may need to be serviced.
Battery Charger Troubleshooting
976-0043-01-02 9–5
Charger drops off before
full charging has finished
(no ERROR comes on).
AC frequency at the AC
input terminal may be
out-of-tolerance (too high
or low) or the AC voltage
may be outside the 13C
Input Upper Limit VAC
or 13D Input Lower
Limit VAC settings.
Circuit breaker on
inverter is open.
Ambient temperature
may be high causing unit
to overheat and ramp
down the charging.
Check for the correct AC voltage or frequency using
the ICM Display.
If the AC source is a generator, adjust the AC
voltage/frequency accordingly.
Reduce your 13A Grid (AC1) Amps AC or
13B Gen (AC2) Amps AC setting (based on the
input you are using) to limit the pull on the AC
source.
Open the 13C Input Upper Limit VAC or
13D Input Lower Limit VAC settings “window” to
allow synchronization.
Engage circuit breaker on top of unit (press on
breaker button to ensure it is engaged).
Cool the unit down or check the inverter cooling fan,
or check for anything preventing air flow.
Charger drops off before
full charging (or
equalization) has
finished.
ERROR LED flashes and
AC output drops
momentarily.
Cold temperature around
batteries with BTS
installed may be causing
unit to reach 11A High
Battery Cut Out VDC
setting.
Disconnect BTS during charging or increase
11A High Battery Cut Out VDC setting.
Charger drops off before
full charging has finished.
ERROR comes on.
Check 05 Error Causes Menu in the ICM display to
determine where the failure occurred. Then see the
troubleshooting section on page 9–7 for a solution.
Charger output is low. Loose or corroded battery
connections.
Loose AC input
connections.
Worn out batteries.
Battery cables too small
or too long.
Check and clean all connections.
Check all AC wiring connections.
Replace batteries.
Refer to cable and battery recommendations in
owner’s manual.
Troubleshooting
9–6 976-0043-01-02
Batteries being charged
above the Bulk/Float
setting.
If BTS is installed, it may
be in a cold area or have
fallen off the batteries.
Another DC charging
source may be on the
batteries.
Monitor the 04B Battery Temp Comp VDC while
charging.
NOTE: To bring batteries that are cold to the correct
state of charge may require charging at a higher
voltage. Remove the BTS and determine if your
voltage returns to the bulk/float voltage.
The red Error LED and
the STATUS LED
illuminate at the same
time and the inverter
shuts down.
The inverter has detected
a low battery voltage
condition. In other words,
the voltage has dropped
below the 11C Low
Battery Cut Out VDC
setting for the amount of
time set in 11D LBCO
Delay Minutes.
Restore an AC source to allow the inverter to charge
the batteries back up to acceptable levels.
To manually restart the inverter, press the red INV
button to access the 01A Inverter menu. Then select
OFF, then SRCH or ON from the display.
Error Causes
976-0043-01-02 9–7
Error Causes
This table refers to 05 Error Causes Menu messages. Refer to these
messages when the ERROR LED is on or flashing.
05A Over Current Excessive load on the AC
output.
Reset the inverter by pressing the On/Off switch to
OFF, then to SRCH or ON. If unit comes on, then
check for a heavy load (above the inverter’s
capacity) on the inverter’s output. If the 05A Over
Current error happens again, disconnect all wires on
the AC input and output and reset the inverter again.
If the inverter comes on, then check your AC wire
system for shorts or miswired connections.
05B Transformer
Overtemp or
05C Heatsink
Overtemp
AC input voltage may be
too high while charging.
Operating too large of a
load for too long while
inverting.
Ambient temperature may
be high.
Inverter cooling fan may
have failed.
Inverter airflow intake
may be blocked.
Charging setting is too
high based on ambient
temperature around
inverter.
Check for high input AC voltage.
Remove excessive loads.
Let inverter cooldown and try restarting.
Hold a piece of paper to inverter vents to check the
fan (the fan is hard to hear). If the fan has failed, have
the inverter serviced.
Increase clearance around the inverter or unclog the
fan air intake.
Lower the 12E Max Charge Amps AC setting.
05D Low Battery
Voltage Battery voltage is below
the 11C Low Battery
Cut Out VDC settings.
Check for the correct battery voltage at the inverter’s
DC input terminals. Check for an external DC load
on the batteries. Check condition of batteries and
recharge if possible or adjust your
11C Low Battery Cut Out VDC to a lower setting.
05E High Battery
Voltage Battery voltage is above
the 11A High Battery
Cut Out VDC settings.
Check for the correct battery voltage at the inverter’s
DC input terminals. Ensure your DC source is
regulated below your high battery cut out or adjust
your 11A High Battery Cut Out VDC to a higher
setting.
Troubleshooting
9–8 976-0043-01-02
05G Input Relay
Failure The AC transfer relay is
bad or an AC source was
wired directly to the AC
output.
Disconnect the inverter’s output wiring. If error
continues, have unit serviced.
05H Gen Failed To
Start Indicates that six “auto
generator start attempts”
have occurred without
successfully starting the
generator.
Voltage has not reached
80 Vac during the
25D Max Cranking
Seconds period.
Voltage did not maintain
greater than 80 Vac for
the majority of time while
the inverter was charging.
Reset the auto-generator control system by selecting
OFF at the 02A Generator menu.
Verify that when the generator is running (manually
started) that there is voltage on the AC2 input
terminals inside the inverter’s AC access door.
If you do not have an automatic start generator that is
started by the inverter, leave it in the OFF selection.
If you do have an automatic start generator that is
started by the inverter, test by selecting ON.
Measure the AC voltage on the AC2 input terminals
while the generator is starting. Check the setting at
25D Max Cranking Seconds. Tune up generator if
necessary.
Measure AC voltage on the AC2 input terminals
while generator is running. Check for poor
connections or too small of wires between the
generator and inverter. Tune up generator if
necessary.
05I Gen Stopped Due
To V/F The generator was
running but was not
operating within the
voltage or frequency
tolerances and was not
able to connect.
Check the generator’s output voltage and frequency.
Ensure that 13C Input Upper Limit VAC and
13D Input Lower Limit VAC are set correctly.
Error LED is flashing and
there is no error under 05
Error Causes Menu.
AC source frequency is
just out of tolerance
(53 to 57 Hz or 63 to
67 Hz).
No problem with AC source or inverter. The error
LED is a visual indicator to fine tune your AC
frequency. This error does not affect operation.
A Inverter
Specifications
Appendix A, “Inverter Specifications” provides the electrical
and environmental specifications of this inverter.
Inverter Specifications
A–2 976-0043-01-02
Electrical Specifications
AC Input Voltage (nominal) 120 Vac 120 Vac
AC Input Voltage Range 80 to 150 Vac 80 to 150 Vac
AC Input Current 60 amps AC Pass-
through/ 20 amps
AC Charging
60 amps AC Pass-
through/ 20 amps
AC Charging
AC1 Input Frequency Range 55 to 65 Hz 55 to 65 Hz
AC2 Input Frequency Range 54 to 67 Hz 54 to 67 Hz
Continuous Power (@ 25°C) 2500 VA 2500 VA
Efficiency (Peak) in inverter mode 95% 95%
Inverter Voltage (RMS) 120 Vac 120 Vac
Inverter Voltage Regulation ± 3% ± 3%
Frequency (Nominal ±0.04% Crystal
Controlled - Invert Mode)
60 Hz 60 Hz
Continuous Output (@25° C) 21 amps rms 21 amps rms
Surge Capability (@25° C)
5 second rating (resistive) 80 amps RMS 80 amps RMS
Over current trip point 125 amps Peak 175 amps Peak
Inverter Voltage THD
(Total Harmonic Distortion)
(Resistive Load)
< 5% < 5%
Automatic Transfer Relay 60 amps rms 60 amps rms
DC Input Voltage (Nominal) 25.2 Vdc 50.4 Vdc
DC Input Voltage Range 22 to 32 Vdc 44 to 64 Vdc
DC Current at Rated Power (Invert
Mode, Internal temp. stabilized)
120 amps DC 60 amps DC
Idle Consumption (Invert Mode/No
Load)
< 16 watts < 20 watts
Search Mode Consumption
(Default setting)
< 2 watts < 2 watts
Continuous Charge Rate
(at 120 Vac input)
70 amps DC 40 amps DC
Electrical Specifications
976-0043-01-02 A–3
AC Input Voltage (nominal) 120 Vac 120 Vac 120 Vac
AC Input Voltage Range 80 to 150 Vac 80 to 150 Vac 80 to150 Vac
AC Input Current 60 amps AC Pass-
through/ 30 amps
AC Charging
60 amps AC Pass-
through/ 30 amps
AC Charging
60 amps AC Pass-
through/ 45 amps
AC Charging
AC1 Input Frequency Range 55 to 65 Hz 55 to 65 Hz 55 to 65 Hz
AC2 Input Frequency Range 54 to 67 Hz 54 to 67 Hz 54 to 67 Hz
Continuous Power (@ 25°C) 4000 VA 4000 VA 5500 VA
Efficiency (Peak) in inverter mode 94% 95% 95%
Inverter Voltage (RMS) 120 Vac 120 Vac 120 Vac
Inverter Voltage Regulation ± 3% ± 3% ± 3%
Frequency (Nominal ±0.04%
Crystal Controlled - Invert Mode)
60 Hz 60 Hz 60 Hz
Continuous Output (@25° C) 33 amps rms 33 amps rms 46 amps rms
Surge Capability (@25° C)
5 second rating (resistive) 85 amps rms 95 amps rms 105 amps rms
Over current trip point 125 amps Peak 175 amps Peak 175 amps Peak
Inverter Voltage THD
(Total Harmonic Distortion)
(Resistive Load)
< 5% < 5% < 5%
Automatic Transfer Relay 60 amps 60 amps 60 amps
DC Input Voltage (Nominal) 25.2 Vdc 50.4 Vdc 50.4 Vdc
DC Input Voltage Range 22 to 32 Vdc 44 to 64 Vdc 44 to 64 Vdc
DC Current at Rated Power (Invert
Mode, Internal temp. stabilized)
190 amps DC 95 amps DC 135 amps DC
Idle Consumption (Invert Mode/No
Load)
< 16 watts < 20 watts < 20 watts
Search Mode Consumption
(Default setting)
< 2 watts < 2 watts < 2 watts
Continuous Charge Rate
(at 120 Vac input)
110 amps DC 60 amps DC 75 amps DC
Inverter Specifications
A–4 976-0043-01-02
Mechanical Specifications
Operating Temperature
Range
SPECIFIED
(will meet specified
tolerances)
32 °F to 77 °F
(0 °C to 25 °C)
32 °F to 77 °F
(0 °C to 25 °C)
ALLOWED
(may not meet
specified tolerances)
-13 °F to 140 °F
(-25 °C to 60 °C)
-13 °F to 140 °F
(-25 °C to 60 °C)
NON-OPERATING
(storage)
-67 °F to 284 °F
(-55 °C to 140 °C)
-67 °F to 284 °F
(-55 °C to 140 °C)
Enclosure Type Indoor, ventilated,
Galvaneel steel chassis
with powder coat finish
Indoor, ventilated,
Galvaneel steel chassis
with powder coat finish
Unit Weight 105 lb (48 kg) 105 lb (48 kg)
Shipping Weight 114 lb (52 kg) 114 lb (52 kg)
Inverter Dimensions
(H x W x D)
15 1/8" x 21" x 8 7/8"
(38 cm x 53 cm x 22 cm)
15 1/8" x 21" x 8 7/8"
(38 cm x 53 cm x 22 cm)
Shipping Dimensions
(H x W x D)
20" x 27 7/8" x 14 1/4"
(51 cm x 71 cm x 36 cm)
20" x 27 7/8" x 14 1/4"
(51 cm x 71 cm x 36 cm)
Mounting Wall or Shelf Mount Wall or Shelf Mount
See Certification Label for specific regulatory agency approval information.
Mechanical Specifications
976-0043-01-02 A–5
Operating
Temperature Range
SPECIFIED
(will meet specified
tolerances)
32 °F to 77 °F
(0 °C to 25 °C)
32 °F to 77 °F
(0 °C to 25 °C)
32 °F to 77 °F
(0 °C to 25 °C)
ALLOWED
(may not meet
specified tolerances)
-13 °F to 140 °F
(-25 °C to 60 °C)
-13 °F to 140 °F
(-25 °C to 60 °C)
-13 °F to 140 °F
(-25 °C to 60 °C)
NON-OPERATING
(storage)
-67 °F to 284 °F
(-55 °C to 140 °C)
-67 °F to 284 °F
(-55 °C to 140 °C)
-67 °F to 284 °F
(-55 °C to 140 °C)
Enclosure Type Indoor, ventilated,
Galvaneel steel chassis
with powder coat finish
Indoor, ventilated,
Galvaneel steel chassis
with powder coat finish
Indoor, ventilated,
Galvaneel steel chassis
with powder coat finish
Unit Weight 117 lb (53 kg) 117 lb (53 kg) 136 lb (62 kg)
Shipping Weight 126 lb (57 kg) 126 lb (57 kg) 145 lb (66 kg)
Inverter Dimensions
(H x W x D)
15 1/8" x 21" x 8 7/8"
(38 cm x 53 cm x 22 cm)
15 1/8" x 21" x 8 7/8"
(38 cm x 53 cm x 22 cm)
15 1/8" x 21" x 8 7/8"
(38 cm x 53 cm x 22 cm)
Shipping Dimensions
(H x W x D)
20" x 27 7/8" x 14 1/4"
(51 cm x 71 cm x 36 cm)
20" x 27 7/8" x 14 1/4"
(51 cm x 71 cm x 36 cm)
20" x 27 7/8" x 14 1/4"
(51 cm x 71 cm x 36 cm)
Mounting Wall or Shelf Mount Wall or Shelf Mount Wall or Shelf Mount
See Certification Label for specific regulatory agency approval information.
Inverter Specifications
A–6 976-0043-01-02
Theory of Operation
The Sine Wave Plus employs a patented inverter design. This design uses
a combination of three transformers, each with its own low frequency
switches, coupled in series and driven by separate interconnected micro-
controllers. In essence, it is three inverters linked together by their
transformers.
Sine Wave Plus
Waveform By mixing the outputs from the different transformers, a sine wave is
produced. This waveform is shown in Figure A-2, “Sine Wave Plus
Inverter Output Waveform” on page A–7. Notice the “steps” form a
staircase that is shaped like a sine wave. The total harmonic distortion in
this sine wave approach is typically 3-5%. The multi-stepped output is
formed by modulation of the voltage through mixing of the transformers
in a specific order. Anywhere from 34-52 “steps” per AC cycle are
present in the waveform. The heavier the load or lower DC input voltage
the more steps there are in the waveform.
This type of inverter solves many of the problems associated with high
frequency or ferroresonant sine wave inverters. The low frequency
method described has excellent surge ability, high efficiency (typically 85
to 95%), good voltage and frequency regulation, and low total harmonic
distortion.
Figure A-1
Sine Wave Plus
Simple Block Diagram
Batteries
Low Frequency
H-Bridge
Low Frequency
H-Bridge
Low Frequency
H-Bridge
Transformer
Transformer
Transformer
AC Loads
Micro-controllers Bridges are “mixed” by
Micro-controllers
controlling the H-Bridges
Sine Wave Plus Inverter Charger
Theory of Operation
976-0043-01-02 A–7
The inverter runs in two basic formats: as a stand-alone inverter
(converting DC to AC), or as a parallel inverter (with its output
synchronized to another AC source). In inverter mode, only 60 Hz
waveforms are created. As the battery voltage rises, waveforms with
progressively fewer steps are generated. More steps are used when battery
voltage decreases. Since the battery voltage tends to drop with increased
load, the waveform has increased number of steps with heavier AC loads.
Synchronized with
other AC sources The inverter is able to synchronize with other AC sources before
connecting it to the AC load. The frequency of the AC source is tracked
and the inverter constantly adjusts its frequency to maintain a lock. A
normally open contactor is used to parallel the inverter’s output and the
AC source.
Bi-Directional
Topology The inverter’s power topology is bi-directional. If the waveform created
by the inverter has a higher voltage than the paralleled AC source, then
power flows from the batteries to the load. If the waveform generated has
a lower voltage than the AC source, power flows from the source to the
battery.
Waveform Size The various modes of operation use different algorithms for determining
the size of the waveform to be created by the inverter. In battery charger
mode, for example, waveforms smaller than the AC source are created to
cause current to flow into the batteries. This process is fully regulated to
provide a three-stage charge cycle. If the level of AC current exceeds the
user programmed generator or grid size, and then the inverter will switch
to a generator support mode and create waveforms that are larger than the
AC source. This causes power to flow from the batteries to the AC loads
to prevent overloading of the AC source.
Figure A-2
Sine Wave Plus
Inverter Output Waveform
Inverter Specifications
A–8 976-0043-01-02
Power Versus Efficiency
There are two primary losses that combine to create the efficiency curve
of the Sine Wave Plus. The first is the energy that is required to operate
the inverter at full output voltage while delivering no current. This is the
no load or idle power.
At low power levels, the idle power is the largest contributor to efficiency
losses. At high power, the largest source of loss is a result of the resistance
in the transformer and power transistors. The power lost here is
proportional to the square of the output power.
For example, losses at 2,000 watts will be four times higher than losses at
1,000 watts. This graph represents a typical inverter's efficiency while
operating resistive loads. Inductive loads, such as motors, are run less
efficiently due to the impact of power factor losses.
The Sine Wave Plus offers an extremely good efficiency curve. The
inverter reaches high efficiency at very low AC load levels, which is
important because the inverter often spends the majority of the time at the
lower power range. The high efficiency is maintained over a wide power
range. Only when operating at high power levels at or above the
continuous power levels does the efficiency begin to drop off. Since this
usually only occurs for short periods of time, the impact may be
negligible.
If your application involves the inverter powering heavy loads for
significant periods of time, selecting a model with a higher continuous
power rating and a higher DC input voltage would improve the operation
of the system. Since the low power efficiency of the Sine Wave Plus is
extremely good, oversizing the inverter does not reduce system
performance.
Power Versus Efficiency
976-0043-01-02 A–9
Figure A-4
Sine Wave Plus Efficiency Curve for the SW Plus 2524
Figure A-3
Power Versus Efficiency Curves for All Models
SW Plus Efficiency Curves
75%
80%
85%
90%
95%
100 %
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Output Power in Watts
Efficiency
Me asur ement s made usi ng r esist iv e load bank and Yokogawa WT2030 Digit al Power Met er or Yok ogawa PZ4000 P ower
Analyzer
SW Plus 2524
SW Plus 5548
SW Plus 2548
SW Plus 4024
SW Plus 4048
SW Plus 2524 Efficiency Curve
0%
10 %
20%
30%
40%
50%
60%
70%
80%
90%
10 0 %
0 500 1000 1500 2000 2500
Output Power in Watts
Efficiency
Measurements made using resistive load bank and Yokogawa WT 2030 Digital Power Meter
Inverter Specifications
A–10 976-0043-01-02
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
SW Plus 2548 Efficiency Curve
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 500 1000 1500 2000 2500
Output Power in Watts
Efficiency
Measurements made using resistive load bank and Yokogawa WT 2030 Digital Power Meter
SW Plus 4024 Efficiency Curve
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
10 0 %
0 500 1000 1500 2000 2500 3000 3500 4000
Output Power in Watts
Efficiency
M easurement s mad e using resist ive load b ank and Y o kogawa PZ4 0 00 Power A nalyzer
Power Versus Efficiency
976-0043-01-02 A–11
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
SW Plus 4048 Efficiency Curve
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
10 0 %
0 500 1000 1500 2000 2500 3000 3500 4000
Output Power in Watts
Efficiency
M easurement s made using resistive load bank and Yoko gawa PZ4000 Power Analyzer
SW Plus 5548 Efficiency Curve
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Output Power in Watts
Efficiency
Measurements made using resistive load bank and Yokogawa PZ4000 Power
Analyzer
Inverter Specifications
A–12 976-0043-01-02
Inverter Capacity versus Temperature
The output power of the inverter diminishes as ambient temperature rises.
However, as can be seen below, with the exception of the SWP5548, these
inverters are sized to be able to run a full rated output power up to 40C.
However, it should be noted that the overcurrent circuit on the unit is
temperature compensated to protect the unit and that the thermal circuit
breaker will trip at a lower current as the temperature rises. Therefore, the
surge ability of the unit decreases with increased temperature.
This table refers to output VA only. Testing was conducted in a thermal
chamber with the inverters as stand-alone units without accessories.
Table A-1
Derating from continuous power (VA) at elevated ambient
temperatures
SW Plus 2524 No Derating No Derating No Derating No Derating
SW Plus 2548 No Derating No Derating No Derating No Derating
SW Plus 4024 No Derating No Derating No Derating No Derating
SW Plus 4048 No Derating No Derating No Derating No Derating
SW Plus 5548 No Derating No Derating No Derating 5.3KVA
Time versus Current
976-0043-01-02 A–13
Time versus Current
Loads presented to the inverter are seldom constant. Typically, large loads
are operated for only short periods of time. In order to provide the
maximum utility, Xantrex inverters are allowed to operate at power levels
that exceed their continuous power ratings. This graph shows how loads
that are larger than the inverter can sustain continuously can be operated
for useful periods of time.
The length of time that the inverter can operate at high power is limited by
temperature. When large loads are run, the inverter’s temperature
increases. At the point where more heat is created in the inverter than can
be dissipated, its ability to operate becomes time limited.
Figure A-9
Time versus Current for the Sine Wave Plus 2524
Inverter Specifications
A–14 976-0043-01-02
Figure A-10
Time versus Current for the Sine Wave Plus 2548
Figure A-11
Time versus Current for the Sine Wave Plus 4024
Time versus Current
976-0043-01-02 A–15
Figure A-12
Time versus Current for the Sine Wave Plus 4048
Figure A-13
Time versus Current for the Sine Wave Plus 5548
A–16
B Configuration
Settings
Appendix B, “Configuration Settings” provides worksheets
for programming your inverter/charger for user-specific
parameters.
Configuration Settings
B–2 976-0043-01-02
User Menu Settings
Table B-1 provides a list of User Menu headings and menu items, with
available set points. This table also provides the default settings for each
menu item as programmed in the factory. The last column “User Settings”
is provided for you to write in the settings specific to your installation.
Table B-1
User Menu Default and User Settings
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548, 4048, and 5548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
01 Inverter ON/OFF Menu See “01 Inverter ON/OFF Menu” on page 8–15 for details.
01A Inverter OFF SRCH
ON CHR
OFF OFF SRCH
ON CHR
OFF
01B EQ Charge OFF ON OFF OFF ON OFF
01C Search Watts (SRCH) 00 to 248 08 00 to 248 08
01D Bypass Mode AC1 NORM
AC2
NORM AC1 NORM
AC2
NORM
02 Generator ON/OFF Menu See “02 Generator ON/OFF Menu” on page 8–17 for details.
02A Generator OFF AUTO
ON
OFF OFF AUTO
ON
OFF
02B Gen Start Load Amps YES NO Read Only YES NO Read Only
02C Gen Start Volts/Manual YES NO Read Only YES NO Read Only
02D Gen Start Exercise Run YES NO Read Only YES NO Read Only
02E Gen Start Run Time YES NO Read Only YES NO Read Only
02F Days left to Gen Exercise 00 to 255 Read Only 00 to 255 Read Only
03 Time of Day (00:00:00) See “03 Time Of Day Menu” on page 8–20 for details.
SWPlus
Revision 2.01
Info.
Displayed
Read Only Info.
Displayed
Read Only
2.5 KVA ** 120 VAC 60 HZ **24 Vdc Read Only **48 VDC Read Only
Xantrex Tech Inc
5916 195th St NE
Info.
Displayed
Read Only Info.
Displayed
Read Only
Arlington, WA
98223 USA
User Menu Settings
976-0043-01-02 B–3
Ph 1-800-446-6180
www.xantrex.com
Press reset for factory defaults Press to refresh the LCD display.
04 Meters Menu See “04 Meters Menu” on page 8–22 for details.
04A Battery Actual VDC 13.2 to 35.5 Read Only 20.0 to 71.0 Read Only
04B Battery Comp VDC 13.2 to 35.5 Read Only 20.0 to 71.0 Read Only
04C Inv/Chr Amps AC -63 to 63 Read Only -63 to 63 Read Only
04D Input Amps AC 00 to 63 Read Only 00 to 63 Read Only
04E Load Amps AC 00 to 63 Read Only 00 to 63 Read Only
04F Inverter Volts AC 00 to 163 Read Only 00 to 163 Read Only
04G Grid (AC1) Volts AC 00 to 163 Read Only 00 to163 Read Only
04H Gen (AC2) Volts AC 00 to 163 Read Only 00 to 163 Read Only
04I Frequency Hertz 52 to 68 Read Only 52 to 68 Read Only
04J Max Bulk/EQ Time h:m 00:00 to
23:50
Read Only 00:00 to
23:50
Read Only
04K Battery Temp Degrees C -28 to 60, OL Read Only -28 to 60, OL Read Only
04L Fan Speed 00, 01, 02,
03, 04
Read Only 00, 01, 02,
03, 04
Read Only
05 Error Causes Menu See “05 Error Causes Menu” on page 8–25 for details.
05A Over Current NO YES Read Only NO YES Read Only
05B Transformer overtemp NO YES Read Only NO YES Read Only
05C Heatsink overtemp NO YES Read Only NO YES Read Only
05D Low Battery Voltage NO YES Read Only NO YES Read Only
05E High Battery Voltage NO YES Read Only NO YES Read Only
05F External err (stacked) NO YES Read Only NO YES Read Only
05G Input Relay Failure NO YES Read Only NO YES Read Only
05H Gen Failed to Start NO YES Read Only NO YES Read Only
05I Gen Stopped due to V/F NO YES Read Only NO YES Read Only
Table B-1
User Menu Default and User Settings
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548, 4048, and 5548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Configuration Settings
B–4 976-0043-01-02
06 Status Menu See “06 Status Menu” on page 8–28 for details.
06A Bypass Mode Selected NO YES Read Only NO YES Read Only
06B CHR Selected (No Backup) NO YES Read Only NO YES Read Only
06C Gen Signalled to Run NO YES Read Only NO YES Read Only
06D Gen in Cooldown NO YES Read Only NO YES Read Only
06E EQ Charge Selected NO YES Read Only NO YES Read Only
06F Battery Vdc < LBCO NO YES Read Only NO YES Read Only
06G Battery Vdc > HBCO NO YES Read Only NO YES Read Only
06H EPO shutdown NO YES Read Only NO YES Read Only
07 GSM/ALM Menu See “07 GSM/ALM Options Menu” on page 8–30 for details.
07A RY7 (GSM) Energized NO YES Read Only NO YES Read Only
07B RY8 (GSM) Energized NO YES Read Only NO YES Read Only
07C RY9 (ALM) Energized NO YES Read Only NO YES Read Only
07D RY9 DeEngz. Time Minute 00 to 255 Read Only 00 to 255 Read Only
07E RY10 (ALM) Energized NO YES Read Only NO YES Read Only
07F RY10 Engz. Time Minute 00 to 255 Read Only 00 to 255 Read Only
07G RY11 Energized NO YES Read Only NO YES Read Only
Table B-1
User Menu Default and User Settings
User Menus
Sine Wave Plus
2524 and 4024
Sine Wave Plus
2548, 4048, and 5548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Basic Setup Menu
976-0043-01-02 B–5
Basic Setup Menu
Table B-2 provides a list of Basic Setup Menu headings and menu items,
with available set points. This table also provides the default settings for
each menu item as programmed in the factory. The last column “User
Settings” is provided for you to write in the settings specific to your
installation.
Table B-2
Basic Setup Default and User Settings for the Sine Wave Plus 2524 and 2548 Models
Sine Wave Plus 2524 Sine Wave Plus 2548
User
SettingsBasic Setup Menus
Range/
Display Default
Range/
Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00 00:00:00 to
23:50:00
00:00:00
10B Set Minute 00:00:00 to
00:09:00
00:00:00 00:00:00 to
00:09:00
00:00:00
10C Set Second 00 to 59 00:00:00 00 to 59 00:00:00
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 16.1 to 34.0 32.0 32.2 to 68.0 64.0
11B Low Battery Cut In Vdc 16.1 to 33.9 26.0 32.2 to 67.8 52.0
11C Low Battery Cut Out Vdc 11.0 to 33.9 22.0 32.0 to 67.8 44.0
11D LBCO Delay Minutes 01 to 255 15 01 to 255 15
11E Search Watts (SRCH) 00 to 248 08 00 to 248 08
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT
FLOAT
FLOAT SILENT
FLOAT
FLOAT
12B Bulk Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6
12C Float Volts DC 20.0 to 32.0 26.8 40.0 to 64.0 53.6
12D Equalize Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6
12E Max Charge Amps AC 01 to 20 20 01 to 20 20
12F Bulk Done Amps AC 00 to 45 10 00 to 45 10
12G EQ Vdc Done Timer 00:00 to
23:50
02:00 00:00 to
23:50
02:00
12H Max Bulk/EQ Timer 00:00 to
23:50
05:00 00:00 to
23:50
05:00
Configuration Settings
B–6 976-0043-01-02
12I Temp Comp LeadAcid
NiCad
LeadAcid LeadAcid
NiCad
LeadAcid
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60 00 to 60 60
13B Gen (AC2) Amps AC 00 to 60 30 00 to 60 30
13C Input Upper Limit Vac 125 to 150 130 125 to 150 130
13D Input Lower Limit Vac 80 to 115 110 80 to 115 110
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
14A Push INV now to save
settings
Push INV now to Save Settings
14B Push GEN to restore settings Push GEN to restore settings
14C Push GEN for factory
defaults
Push GEN for factory defaults
Table B-3
Basic Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models
Sine Wave Plus 4024 Sine Wave Plus 4048
User
SettingsBasic Setup Menus
Range/
Display Default
Range/
Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00 00:00:00 to
23:50:00
00:00:00
10B Set Minute 00:00:00 to
00:09:00
00:00:00 00:00:00 to
00:09:00
00:00:00
10C Set Second 00 to 59 00:00:00 00 to 59 00:00:00
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 16.1 to 34.0 32.0 32.2 to 68.0 64.0
11B Low Battery Cut In Vdc 16.1 to 33.9 26.0 32.2 to 67.8 52.0
11C Low Battery Cut Out Vdc 11.0 to 33.9 22.0 32.0 to 67.8 44.0
11D LBCO Delay Minutes 01 to 255 15 01 to 255 15
11E Search Watts (SRCH) 00 to 248 08 00 to 248 08
Table B-2
Basic Setup Default and User Settings for the Sine Wave Plus 2524 and 2548 Models
Sine Wave Plus 2524 Sine Wave Plus 2548
User
SettingsBasic Setup Menus
Range/
Display Default
Range/
Display Default
Basic Setup Menu
976-0043-01-02 B–7
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT
FLOAT
FLOAT SILENT
FLOAT
FLOAT
12B Bulk Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6
12C Float Volts DC 20.0 to 32.0 26.8 40.0 to 64.0 53.6
12D Equalize Volts DC 20.0 to 32.0 28.8 40.0 to 64.0 57.6
12E Max Charge Amps AC 01 to 30 30 01 to 30 30
12F Bulk Done Amps AC 00 to 30 10 00 to 30 10
12G EQ Vdc Done Timer 00:00 to
23:50
02:00 00:00 to
23:50
02:00
12H Max Bulk/EQ Timer 00:00 to
23:50
05:00 00:00 to
23:50
05:00
12I Temp Comp LeadAcid
NiCad
LeadAcid LeadAcid
NiCad
LeadAcid
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60 00 to 60 60
13B Gen (AC2) Amps AC 00 to 60 30 00 to 60 30
13C Input Upper Limit Vac 125 to 150 130 125 to 150 130
13D Input Lower Limit Vac 80 to 115 110 80 to 115 110
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
14A Push INV now to save
settings
Push INV now to Save Settings
14B Push GEN to restore settings Push GEN to restore settings
14C Push GEN for factory
defaults
Push GEN for factory defaults
Table B-3
Basic Setup Default and User Settings for the Sine Wave Plus 4024 and 4048 Models
Sine Wave Plus 4024 Sine Wave Plus 4048
User
SettingsBasic Setup Menus
Range/
Display Default
Range/
Display Default
Configuration Settings
B–8 976-0043-01-02
Table B-4
Basic Setup Default and User Settings for the Sine Wave Plus 5548 Model
Sine Wave Plus 5548
User SettingsBasic Setup Menus Range/Display Default
10 Time of Day Setup Menu See “10 Time of Day Setup Menu” on page 6–11 for details.
10A Set Hour 00:00:00 to
23:50:00
00:00:00
10B Set Minute 00:00:00 to
00:09:00
00:00:00
10C Set Second 00 to 59 00:00:00
11 Inverter Setup Menu See “11 Inverter Setup Menu” on page 6–12 for details.
11A High Battery Cut Out Vdc 32.2 to 68.0 64.0
11B Low Battery Cut In Vdc 32.2 to 67.8 52.0
11C Low Battery Cut Out Vdc 32.0 to 67.8 44.0
11D LBCO Delay Minutes 01 to 255 15
11E Search Watts (SRCH) 00 to 248 08
12 Battery Charging Menu See “12 Battery Charging Menu” on page 6–19 for details.
12A Finish Stage SILENT FLOAT FLOAT
12B Bulk Volts DC 40.0 to 64.0 57.6
12C Float Volts DC 40.0 to 64.0 53.6
12D Equalize Volts DC 40.0 to 64.0 57.6
12E Max Charge Amps AC 01 to 45 40
12F Bulk Done Amps AC 00 to 20 10
12G EQ Vdc Done Timer 00:00 to 23:50 02:00
12H Max Bulk/EQ Timer 00:00 to 23:50 05:00
12I Temp Comp LeadAcid NiCad LeadAcid
13 AC Inputs Menu See “13 AC Inputs Menu” on page 6–26 for details.
13A Grid (AC1) Amps AC 00 to 60 60
13B Gen (AC2) Amps AC 00 to 60 30
13C Input Upper Limit Vac 125 to 150 130
13D Input Lower Limit Vac 80 to 115 110
14 Save/Restore Settings Menu See “14 Save/Restore Settings Menu” on page 6–29 for details.
Basic Setup Menu
976-0043-01-02 B–9
14A Push INV now to save
settings
Push INV now to Save Settings
14B Push GEN to restore settings Push GEN to restore settings
14C Push GEN for factory
defaults
Push GEN for factory defaults
Table B-4
Basic Setup Default and User Settings for the Sine Wave Plus 5548 Model
Sine Wave Plus 5548
User SettingsBasic Setup Menus Range/Display Default
Configuration Settings
B–10 976-0043-01-02
Advanced Setup Menu
Table B-5 provides a list of Advanced Setup Menu headings and menu
items, with available set points. This table also provides the default
settings for each menu item as programmed in the factory. The last
column “User Settings” is provided for you to write in the settings
specific to your installation.
Table B-5
Advanced Setup Default and User Settings for the Sine Wave Plus 2524 and
2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 16.1 to 33.9 28.4 32.2 to 67.8 56.8
20B Refloat Low Volts DC 16.1 to 33.8 25.0 32.2 to 67.8 50.0
20C Float Done Amps AC 00 to 40 10 00 to 40 10
20D Must Float Time Min 00 to 255 05 00 to 255 05
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB BX SB SB BX SB
21B Grid Usage Begin h:m 00:00 to
23:50
21:00 00:00 to
23:50
21:00
21C Grid Usage End h:m 00:00 to
23:50
21:00 00:00 to
23:50
21:00
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 16.1 to 33.9 27.0 32.2 to 67.8 54.0
22B Low Xfer (LBX) Vdc 16.1 to 33.8 23.0 32.2 to 67.8 46.0
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
23A RY9 Vdc Energized 22.1 to 35.5 26.0 44.2 to 71.0 52.0
23B RY9 Vdc DeEnergized 20.0 to 35.5 22.0 40.0 to 71.0 44.0
23C RY9 Delay at DeEngz. Min 00 to 255 10 00 to 255 10
23D RY10 VDC Energized 10.0 to 32.0 28.8 20.0 to 64.0 57.6
23E RY10 VDC DeEnergized 10.0 to 32.0 26.8 20.0 to 64.0 53.6
23F RY10 Delay at DeEngz. Min 00 to 255 10 00 to 255 10
23G RY11 Mode Cooldown
Error
Error Cooldown
Error
Error
Advanced Setup Menu
976-0043-01-02 B–11
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to
23:50
08:00 00:00 to
23:50
08:00
24B Gen Run Time Stop h:m 00:00 to
23:50
08:00 00:00 to
23:50
08:00
24C Quiet Time Begin h:m 00:00 to
23:50
08:00 00:00 to
23:50
08:00
24D Quiet Time End h:m 00:00 to
23:50
08:00 00:00 to
23:50
08:00
24E Gen Exercise Period Days 00 to 255 30 00 to 255 30
24F Gen Exercise Timer Min 00 to 255 15 00 to 255 15
24G Gen Cooldown Timer Min 00 to 255 02 00 to 255 02
24H RN2/Gen Run h:m 00:00 to
23:50
08:00 00:00 to
23:50
08:00
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
25A RY7 Mode GS RN1 RN2 GS GS RN1 RN2 GS
25B Gen Warmup
Second/Minute
0 to 127
/0 to 127
10 Seconds 0 to 127
/0 to 127
10 Seconds
25C Pre Crank Seconds 00 to 255 10 0 to 255 10
25D Max Crank Seconds 01 to 15 10 01to15 10
25E Post Crank Seconds 00 to 255 30 00 to 255 30
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
26A Load Start Amps AC 00 to 63 20 00 to 63 20
26B Load Start Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0
26C Load Stop Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0
26D 24-hr Start Volts DC 10.0 to 35.5 24.6 20.0 to 71.0 49.2
26E 2-hr Start Volts DC 10.0 to 35.5 23.6 20.0 to 71.0 47.2
26F 15-min Start Volts DC 10.0 to 35.5 22.6 20.0 to 71.0 45.2
Table B-5
Advanced Setup Default and User Settings for the Sine Wave Plus 2524 and
2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Configuration Settings
B–12 976-0043-01-02
26G Read LBCO 30 sec Start LBCO
setting (11C)
22.0 LBCO
setting (11C)
44.0
27 Save/Restore Setup Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
27A Push INV now to save
Settings
Push INV now to save Settings
27B Push GEN to restore settings Push GEN to restore settings
27C Push GEN for Factory
Defaults
PUSH GEN for Factory Defaults
Table B-5
Advanced Setup Default and User Settings for the Sine Wave Plus 2524 and
2548 Models
Advanced Setup Menus
Sine Wave Plus 2524 Sine Wave Plus 2548
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Table B-6
Advanced Setup Default and User Settings for the Sine Wave Plus 4024 and
4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 16.1 to 33.9 28.4 32.2 to 67.8 56.8
20B Refloat Low Volts DC 16.1 to 33.8 25.0 32.2 to 67.8 50.0
20C Float Done Amps AC 00 to 40 10 00 to 40 10
20D Must Float Time Min 00 to 255 05 00 to 255 05
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB BX SB SB BX SB
21B Grid Usage Begin h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00
21C Grid Usage End h:m 00:00 to 23:50 21:00 00:00 to 23:50 21:00
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 16.1 to 33.9 27.0 32.2 to 67.8 54.0
22B Low Xfer (LBX) Vdc 16.1 to 33.8 23.0 32.2 to 67.8 46.0
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
Advanced Setup Menu
976-0043-01-02 B–13
23A RY9 Vdc Energized 22.1 to 35.5 26.0 44.2 to 71.0 52.0
23B RY9 Vdc DeEnergized 20.0 to 35.5 22.0 40.0 to 71.0 44.0
23C RY9 Delay at DeEngz. Min 00 to 255 10 00 to 255 10
23D RY10 VDC Energized 10.0 to 32.0 28.8 20.0 to 64.0 57.6
23E RY10 VDC DeEnergized 10.0 to 32.0 26.8 20.0 to 64.0 53.6
23F RY10 Delay at DeEngz. Min 00 to 255 10 00 to 255 10
23G RY11 Mode Cooldown
Error
Error Cooldown
Error
Error
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00
24B Gen Run Time Stop h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00
24C Quiet Time Begin h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00
24D Quiet Time End h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00
24E Gen Exercise Period Days 00 to 255 30 00 to 255 30
24F Gen Exercise Timer Min 00 to 255 15 00 to 255 15
24G Gen Cooldown Timer Min 00 to 255 02 00 to 255 02
24H RN2/Gen Run h:m 00:00 to 23:50 08:00 00:00 to 23:50 08:00
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
25A RY7 Mode GS RN1 RN2 GS GS RN1 RN2 GS
25B Gen Warmup
Second/Minute
0 to 127
/0 to 127
10
Seconds
0 to 127
/0 to 127
10
Seconds
25C Pre Crank Seconds 00 to 255 10 0 to 255 10
25D Max Crank Seconds 01 to 15 10 01to15 10
25E Post Crank Seconds 00 to 255 30 00 to 255 30
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
26A Load Start Amps AC 00 to 63 33 00 to 63 33
26B Load Start Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0
26C Load Stop Delay Min 00.0 to 25.5 05.0 00.0 to 25.5 05.0
Table B-6
Advanced Setup Default and User Settings for the Sine Wave Plus 4024 and
4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Configuration Settings
B–14 976-0043-01-02
26D 24-hr Start Volts DC 10.0 to 35.5 24.6 20.0 to 71.0 49.2
26E 2-hr Start Volts DC 10.0 to 35.5 23.6 20.0 to 71.0 47.2
26F 15-min Start Volts DC 10.0 to 35.5 22.6 20.0 to 71.0 45.2
26G Read LBCO 30 sec Start LBCO setting
(11C)
22.0 LBCO setting
(11C)
44.0
27 Save/Restore Setup Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
27A Push INV now to save
Settings
Push INV now to save Settings
27B Push GEN to restore settings Push GEN to restore settings
27C Push GEN for Factory
Defaults
PUSH GEN for Factory Defaults
Table B-7
Advanced Setup Default and User Settings for the Sine Wave Plus 5548 Model
Advanced Setup Menus
Sine Wave Plus 5548
User Settings
Range/
Display
Default
Settings
20 Silent Setup Menu See “20 Silent Setup Menu” on page 7–13 for details.
20A Refloat High Volts DC 32.2 to 67.8 56.8
20B Refloat Low Volts DC 32.2 to 67.8 50.0
20C Float Done Amps AC 00 to 40 10
20D Must Float Time Min 00 to 255 05
21 Grid AC1 Usage Menu See “21 Grid (AC1) Usage Menu” on page 7–16 for details.
21A Grid Usage SB BX SB BX SB
21B Grid Usage Begin h:m 00:00 to 23:50 21:00
21C Grid Usage End h:m 00:00 to 23:50 21:00
22 Battery Xfer (BX) Menu See “22 Battery Xfer (BX) Menu” on page 7–18 for details.
22A High Xfer (HBX) Vdc 32.2 to 67.8 54.0
Table B-6
Advanced Setup Default and User Settings for the Sine Wave Plus 4024 and
4048 Models
Advanced Setup Menus
Sine Wave Plus 4024 Sine Wave Plus 4048
User
Settings
Range/
Display
Default
Settings
Range/
Display
Default
Settings
Advanced Setup Menu
976-0043-01-02 B–15
22B Low Xfer (LBX) Vdc 32.2 to 67.8 46.0
23 ALM Relays Menu See “23 ALM Relays Menu” on page 7–19 for details.
23A RY9 Vdc Energized 44.2 to 71.0 52.0
23B RY9 Vdc DeEnergized 40.0 to 71.0 44.0
23C RY9 Delay at DeEngz. Min 00 to 255 10
23D RY10 VDC Energized 20.0 to 64.0 57.6
23E RY10 VDC DeEnergized 20.0 to 64.0 53.6
23F RY10 Delay at DeEngz. Min 00 to 255 10
23G RY11 Mode Cooldown
Error
Error
24 Generator Timers Menu See “24 Generator Timers Menu” on page 7–26 for details.
24A Gen Run Time Start h:m 00:00 to 23:50 08:00
24B Gen Run Time Stop h:m 00:00 to 23:50 08:00
24C Quiet Time Begin h:m 00:00 to 23:50 08:00
24D Quiet Time End h:m 00:00 to 23:50 08:00
24E Gen Exercise Period Days 00 to 255 30
24F Gen Exercise Timer Min 00 to 255 15
24G Gen Cooldown Timer Min 00 to 255 02
24H RN2/Gen Run h:m 00:00 to 23:50 08:00
25 Gen Starting Details Menu See “25 Gen Starting Details Menu” on page 7–29 for details.
25A RY7 Mode GS RN1 RN2 GS
25B Gen Warmup
Second/Minute
0 to 127
/0 to 127
10 Seconds
25C Pre Crank Seconds 00 to 255 10
25D Max Crank Seconds 01 to 15 10
25E Post Crank Seconds 00 to 255 30
26 Gen Auto Run Setup Menu See “26 Gen Auto Run Setup Menu” on page 7–38 for details.
26A Load Start Amps AC 00 to 63 45
Table B-7
Advanced Setup Default and User Settings for the Sine Wave Plus 5548 Model
Advanced Setup Menus
Sine Wave Plus 5548
User Settings
Range/
Display
Default
Settings
Configuration Settings
B–16 976-0043-01-02
26B Load Start Delay Min 00.0 to 25.5 05.0
26C Load Stop Delay Min 00.0 to 25.5 05.0
26D 24-hr Start Volts DC 20.0 to 71.0 49.2
26E 2-hr Start Volts DC 20.0 to 71.0 47.2
26F 15-min Start Volts DC 20.0 to 71.0 45.2
26G Read LBCO 30 sec Start LBCO setting
(11C)
44.0
27 Save/Restore Setup Menu See “27 Save/Restore Settings Menu” on page 7–39 for details.
27A Push INV now to save
Settings
Push INV now to save
Settings
27B Push GEN to restore settings Push GEN to restore settings
27C Push GEN for Factory
Defaults
PUSH GEN for Factory
Defaults
Table B-7
Advanced Setup Default and User Settings for the Sine Wave Plus 5548 Model
Advanced Setup Menus
Sine Wave Plus 5548
User Settings
Range/
Display
Default
Settings
C Battery Information
Appendix C, “Battery Information” supplies general
information about batteries such as battery types, battery bank
sizing, battery configurations, and battery care. For detailed
information, see your battery manufacturer or your system
designer.
Battery Information
C–2 976-0043-01-02
Introduction
Batteries Batteries are available in different sizes, amp-hour ratings, voltage, liquid
or gel, vented or non-vented, chemistries, etc. They are also available for
starting applications (such as an automobile starting battery) and deep
discharge applications.
Recommendations Consider the following recommendations for battery use.
• Use only the deep discharge types for inverter applications.
• Use the same battery type for all batteries in the bank.
• Use only batteries from the same lot and date in your battery bank.
This information is usually printed on a label located on the battery.
Battery Types
There are two principal types of batteries: starting and deep-discharge
(with several different types of chemistries). Batteries can be either sealed
or non-sealed (vented).
Deep discharge The battery types recommended for use in an inverter system are: Flooded
Lead Acid (FLA), Sealed Gel Cells (GEL), Sealed Absorbed Glass Mat
(AGM); and alkaline types Nickel-iron (NiFe) and Nickel-Cadmium
(NiCad).
Starting Automotive (starting) batteries are designed to provide high starting
current for short periods of time and are not appropriate for inverter
applications.
Deep-cycle Flooded Lead Acid (FLA)
Description A flooded lead acid battery is designed to be deep-discharged before
being recharged, making it suitable for inverter applications. Flooded
batteries require periodic maintenance consisting mainly of adding
distilled water to the cells.
Attributes
Types of FLA Batteries Attributes
Golf Cart • Popular for smaller off-grid home
systems
• Many medium sized inverter
systems use “L16” batteries
• Rugged, long lasting
• Typically rated at 6 volts
(220 to 350 amp hours)
Battery Types
976-0043-01-02 C–3
Sealed Batteries (Gel and AGM)
Description Gel Cell and absorbed glass mat (AGM) batteries are sealed and do not
require the addition of distilled water. Since these batteries are valve
regulated, over-charging can cause irreversible damage.
Attributes Attributes of sealed batteries are:
NiCad and NiFe Batteries
Disadvantages These types of batteries can be used but are not optimized for the Sine
Wave Plus for the following reasons:
• Alkaline batteries, such as NiCad and NiFe types, have a nominal cell
voltage of 1.2 volts per cell.
Xantrex inverters and battery chargers are optimized for use with lead
acid batteries having a nominal 2.0 volts per cell (that is, 12 cells for a
24-volt system and 24 cells for a 48-volt system).
The number of cells required in a battery bank for alkaline batteries
must, therefore, be adjusted for a 24- and 48-volt system
(i.e, 20 cells for a 24-volt system and 40 cells for a 48-volt system).
• Alkaline batteries require a higher charge voltage to fully recharge,
and drop to a lower voltage during discharge compared to a similarly
sized lead-acid type battery.
Industrial (electric forklift) • Popular in large inverter systems
• Extremely rugged - lasts up to 10
years or more in an inverter system
• Typically 2 volt cells
(1,000 amp hours or more)
Types of FLA Batteries Attributes
Types of Sealed Batteries Attributes
Gel Cell • Gelled electrolyte instead of
liquid
• Long life (up to 1500 cycles,
typical)
• Low self-discharge
Absorbed Glass Mat • Electrolyte is contained in glass-
fibre mats between battery plates
• Similar to gel cells in
characteristics
• Good low temperature
performance
Battery Information
C–4 976-0043-01-02
Other options Another option for 24 volt (only) alkaline battery banks is to use only
19 cells instead of 20. Fewer cells allow the battery charger to operate
more closely to the settings used for lead-acid batteries. However, the
battery voltage will drop to as low as 18 volts when discharging the
batteries.
Consult the battery manufacturer or supplier regarding system
requirements and battery charger settings for alkaline type batteries.
Understanding Battery Capacity Ratings
Discharge rate Deep cycle batteries have their amp-hour rating expressed as “at the x-
hour rate”. The hour rating refers to the time it takes to discharge the
batteries. A faster hour rate (6 hour rate) means more current is
withdrawn from the batteries during their discharge period. There is an
inevitable amount of heat associated with the flow of current through a
battery and the higher amount of current the greater the amount of heat
will be generated. The heat is energy which is no longer available to the
battery to power loads. a relatively long discharge rate (72 hour rate) will
result in a larger number of amp-hours being available for electrical loads.
Calculation This calculation shows how to determine the level of current drawn from
a battery at any given hour rate—battery capacity divided by the hour rate
equals the current drawn from the battery. For example, a battery rated
220 Ah at a 6 hour rate would be discharged at 36 amps (220/6).
For most residential applications of the Sine Wave Plus the 72 hour rate is
appropriate because on average a household uses low amounts of current
(lights, TV, radio for example) with occasional bursts or higher
consumption appliances like toasters or washing machines. For those
installations where high continuous electrical consumption rates are
anticipated it is more appropriate to use the 20 hour rate.
CCA rating The CCA rating (cold cranking amps) shown on starting batteries
expresses battery capacity in terms of its ability to provide large amounts
of current for intervals measured in minutes, not hours. This is why
starting batteries are not appropriate for inverter systems.
Battery Bank Sizing
Running time and
size The battery bank’s size determines the length of time the inverter can
supply AC output power. The larger the bank, the longer the inverter can
run.
Battery Bank Sizing
976-0043-01-02 C–5
Depth of discharge In general, the battery bank should be designed so the batteries do not
discharge more than 60% of their capacity on a regular basis. Discharging
up to 80% is acceptable on a limited basis, such as a prolonged utility
outage. Totally discharging a battery can reduce its effective life or
permanently damage it.
Days of autonomy For off-grid, stand-alone applications, design a battery bank that can
power the loads for three to five days without requiring recharging. This
design calculation assumes a worst case scenario where there is no
recharging taking place during these days of autonomy.
Days of autonomy may vary depending upon the availability of other
charging sources, the critical nature of the load and other factors. If the
system is to be powered by renewable energy sources such as solar, wind,
and micro-hydro, determine the appropriate number of days of autonomy
by allowing for cloudy or calm weather as well as other seasonal
variations in available energy.
If an engine generator is part of the system design, the days of autonomy
can be determined by simply deciding how often you are prepared to run
the generator. Significant battery cost reductions can be achieved by
shortening the days of autonomy and allowing a generator to run for a
schedule time period daily.
Back up power systems which use utility power for recharging should use
the estimated number of days of maximum power outage for determining
days of autonomy.
Understanding Amp-hour Requirements
Amp-hours To estimate the battery bank requirements, you must first calculate the
amount of power you will draw from the batteries during your period of
autonomy. This power draw is then translated into amp hours (Ah)—the
unit of measure to express deep-cycle battery capacity.
Amp hours are calculated multiplying the current drawn by the load by
the length of time it will operate.
Watts to amps To calculate amps when the power consumption is expressed in watts, use
the following equation:
A = W/V
where W = watts and V = volts AC
For example:
A 100 watt light bulb will draw approximately 0.83 amps
0.83 = 100 /120
If the light runs for three hours it will consume (0.83 x 3) or 2.5 Ah of
power.
Battery Information
C–6 976-0043-01-02
Time and power The length of time a load is operated will affect the power draw. In some
cases, an appliance which draws a large wattage may not consume as
many amp hours as a load drawing fewer watts but running for a longer
period of time.
For Example:
A circular saw draws 1500 watts or 12.5 amps. It takes 5 seconds to
complete a cross cut. Twelve such cuts would take a minute and you
would consume 12.5 A x 0.016* hour = 0.2 Ah
*1/60 = 0.016
Observation The circular saw, while it draws more power, consumed
fewer amp hours of electricity because it ran for a short period of time.
Calculating Amp Hours
Calculations To determine the amp hours you will consume, you need to list your
anticipated loads and the length of time you will operate each one.
Determine the number of hours per day and the number of days during the
week you will use the appliance. For example, you use the microwave
every day, but a breadmaker only once a week. If you use an appliance for
less than an hour, express the time as a decimal portion of an hour.
Amps to watts All electrical appliances have labels which state their energy
consumption. Look for an amps rating on motors and a watts rating on
other appliances.
If the label plate has expressed power consumption in amps, multiply by
volts for the watts required. (watts = volts x amps)
Considerations When calculating battery bank size, consider the following:
• Motors typically require 3 to 6 times their running current when
starting. Check the manufacturer’s data sheets for their starting
current requirements. If you will be starting large motors from the
inverter, increase the battery bank size to allow for the higher start-up
current.
• Refrigerators and ice-makers typically run only about 1/3 of the time,
therefore, the running wattage is 1/3 of the total wattage of the
appliance. Divide the total wattage of the appliance by 3 when
determining the battery requirements.
Battery Bank Sizing
976-0043-01-02 C–7
Amp Hour Example Worksheet
Complete the following steps to calculate the amp-hour requirements per
day for your system. Use and Table C-2 as examples to complete your
own.
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. Enter this figure in the Hours column.
3. Determine the number of days the appliance will be used during the
week. Enter this figure in the Days column.
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 watt/hours per day.
6. Divide the total average per day by the DC nominal voltage.
This figure represents the average amp-hours per day that you will
use.
Table C-1
Determining Average Daily Load in Amp-hours
Load Watts Hours per Day
Days per
week used
Weekly
watt-hours
5 lights: 15 W CFL 75 W 5 7 2625
Breadmaker 1200 0.75 2 1800
Energy-efficient
refrigerator
200 x 0.3 24 10080
Laptop computer 50 6 5 1500
Total weekly watt-hours of AC load 16005 Wh
Divided by days per week 7
Average total watt-hours per day 2286
Divided by DC nominal voltage 24
Average amp-hours per day (Ah/d) 95
Battery Information
C–8 976-0043-01-02
Battery bank size worksheet
Calculation To calculate the battery bank size, use the average amp-hours per day that
you calculated using Table C-1, then make the other calculation shown in
Table C-2 to calculate the battery bank size you need to support your
loads.
Worksheets Table C-1 and Table C-2 are examples only. Use the specifications noted
on the label of each AC appliance and fill in the values specific for the
appliances used in this installation on the a work sheet.
Table C-3 provides a typical wattage for selected appliances. However,
you should try to find the exact wattage on the appliance label.
Table C-2
Determining Battery Bank Size
Average amp hours per day 95
Divided by inverter efficiency (90%) for Sine Wave Plus 0.9
Divided by battery efficiency (usually 0.75) 0.75
Adjusted hours per day 140
Divided by Depth of Discharge (usually 60%) 0.6
Multiplied by days of autonomy 5
Battery bank size required 1173 Ah
Table C-3
Typical Appliance Wattage
Appliance Watts Appliance Watts
Fluorescent Type Light 10 Blender 400
Computer 200-300 Toaster 1000
Microwave (compact) 600-800 Hot Plate 1800
Microwave (full-size) 1500 Washer/Dryer 375-1000
Stereo or VCR 50 3/8" Drill 500
Color Television (19") 150 Hair Dryer or Iron 1000
Refrigerator (3 cu ft) 180 Vacuum Cleaner 1200
Refrigerator (12 cu ft) 480 Coffee Maker 1200
Battery Configurations
976-0043-01-02 C–9
Battery Configurations
The battery bank must be wired to match the inverter’s DC input voltage
specifications (24 or 48 Vdc). In addition, the batteries can be wired to
provide additional run time. The various wiring configurations are:
Series Wiring batteries in series increases the total bank output voltage. This
voltage MUST match the DC requirements of the inverter or inverter and/
or battery damage may occur.
Parallel Wiring the batteries in parallel increases the total run time the batteries
can operate the AC loads. The more batteries connected in parallel the
longer the loads can be powered from the inverter.
Series-Parallel Series-parallel configurations increase both the battery voltage (to match
the inverter’s DC requirements) and run-time for operating the AC loads.
This voltage must match the DC requirements of the inverter.
Batteries with more than two or three series strings in parallel often
exhibit poor performance characteristics and shortened life.
Wiring Batteries in Series
Effect Wiring the batteries in a series configuration increases the voltage of the
battery string. Six-volt batteries can be combined to form 24-volt or 48-
volt battery banks. In the same way, 12-volt batteries connected in series
form 24-volt and 48-volt battery banks. The total current capacity of the
bank does not increase and remains the same amp-hour rating as it does
for a single battery.
Important The voltage must match the DC requirements of the inverter.
Figure C-1
6-volt Battery Wiring - “Series” Configuration
+-+-
6 V 6 V
+-
24 V INVERTER
(T otal batt ery ca pacity = 100 Ah)
+-+
6 V 6 V
-
+-+-
6 V 6 V
+-
48 V INVERTER
(Total battery capacity = 100 Ah)
+-+-
6 V 6 V
+-+-
6 V 6 V
+-+-
6 V 6 V
Battery Information
C–10 976-0043-01-02
Wiring Batteries in Parallel
Effect Wiring the batteries in a parallel configuration increases the current of the
battery string. The voltage of the battery bank remains the same as an
individual battery. “Parallel” configurations extend the run times of the
AC loads by providing increased current for the inverter to draw from. In
a parallel configuration, all the negative battery terminals are connected
together and all the positive battery terminals are connected together.
Wiring example Figure C-4 is an example only of how to wire batteries in a parallel
configuration. The Sine Wave Plus is not available in a 12-volt unit.
Figure C-2
12-volt Battery Wiring - “Series” Configuration
+-+-
12 V 12 V
+-
48 V INVERTER
(Total battery capacity = 100 Ah)
+-+-
12 V 12 V
+-+-
12 V 12 V
+-
24 V INVERTER
(Total battery capacity = 100 Ah)
SHUNT
SHUNT
DC Disconnect
(either a circuit
breaker or a
fuse with a
disconnect)
DC Disconnect
(either a circuit
breaker or a
fuse with a
disconnect)
Each battery's amp-hou
r
rating is 100 Ah.
Each battery's amp-hou
r
rating is 100 Ah.
Figure C-3
Battery Wiring in Parallel (Example Only)
12-volt
Inverter
+
–
+
–
+
–
12-volt
Battery
12-volt
Battery
Battery Wiring configured in Parallel
SHUNT
DC Disconnect
(either a circuit
breaker or a
fuse with a
disconnect)
Total battery
capacity of 200 Ah
Each battery is rate
d
at 100 Ah.
Battery Configurations
976-0043-01-02 C–11
Wiring Batteries in Series-Parallel
Effect Wiring the batteries in a series-parallel configuration increases the current
and voltage of the battery bank. “Series-parallel” wiring is more
complicated and care should be taken when wiring these banks.
Steps It is done in three steps; wiring the batteries in series, wiring them in
parallel, then wiring the string to the inverter.
Series wiring To wire in series:
1. First wire the batteries in “series” (voltage adds) with the positive
terminal of one battery connected to the negative terminal of the next
battery to meet the inverter’s DC input requirements (24 volts shown
in Figure C-4 and Figure C-5.)
2. Repeat this step for the next battery string.
Two identical strings of batteries are now wired in series.
Parallel wiring To wire the batteries in parallel:
1. Connect the positive terminal of the first battery string to the positive
terminal of the second battery string.
2. Connect the negative terminal of the first battery string to the
negative terminal of the second battery string.
Figure C-4
Step 1 - Wiring Batteries in “Series”
+–+–
12 V 12 V
+–+–
12 V 12 V
+–+–
12 V 12 V
+–+–
12 V 12 V
Series String 1
Series String 2
Each battery's amp-ho
ur
rating is 100 Ah.
666 6
66 6 6
350
Figure C-5
Step 2 - Two series strings wiring in “Parallel”
–+–
12 V 12 V
+–+–
12 V 12 V
+–+–
12 V 12 V
+–+–
12 V 12 V
+
Parallel
Connection
Series String
1
Series String
2
Parallel
Connection
E
ach battery's amp-hour
rating is 100 Ah.
6666
66 6 6
350
Battery Information
C–12 976-0043-01-02
Connect to inverter To connect to the inverter:
1. Connect a cable from the positive terminal of the first battery string to
the inverter’s positive DC terminal (via a fused device).
2. Connect the negative terminal of the last battery string to the negative
terminal of inverter’s DC terminal.
Battery Connections for Stacked Inverters
When using inverters in a stacked configuration, the same battery bank
must be used for both inverters. To ensure even charging of the batteries,
each inverter must be connected to both strings (i.e., positive cable to
string two, and negative cable to string one for inverter 1, and positive
cable to string one and negative cable to string two for inverter 2) as
shown in the diagram below.
Figure C-6
“Series-Parallel” Configuration Wired to the Inverter
–+–
12 V 12 V
+–+–
12 V 12 V
+
12 V 12 V
–
12 V 12 V
+–
48 V INVERTER
(Total battery capacity = 200 Ah)
–+–+–+
+
Connection from Series String 2
to
inverter's negative (–) terminal
Series String 2
Series String 1
C
onnection from Series String 1
t
o inverter's positive (+) terminal
Each battery's amp-hour
rating is 100 Ah.
SHUNT
DC Disconnect (can be
either a circuit breaker or a
fuse with a disconnect)
66 6 6
66 6 6
24 700
350
Figure C-7
Example of Battery Connections for Stacked Inverters
(24 Vdc shown)
DC CONDUIT
FOR
IN VERTER 1
–+
12 Volt
Battery
200 Ah
–+
12 Volt
Battery
200 Ah
+–
12 Volt
Battery
200 Ah
Series String 1
Series String 2
DC CONDUIT
FOR
INVERTER 2
24 VD C/20 0 Ah
24 VD C/20 0 Ah
–+
12 Volt
Battery
200 Ah
Shunt
Batteries in
Parallel
24 VDC 400 Ah
Battery Maintenance
976-0043-01-02 C–13
Battery Maintenance
Maintenance
strategy
To get the best performance from an inverter system, the batteries must be
properly setup and maintained. This includes setting the proper voltages
for Bulk and Float charging. See the “CAUTIONS” in the section on
Equalization Charging that follows. In addition, the battery terminals
should be inspected, cleaned, and re-torqued if necessary.
Neglecting any of these items may result in poor inverter performance
and greatly reduce battery life.
Battery charging
Charge Rate The maximum safe charge rate is related to the size and type of the
batteries. Flooded lead acid batteries (with removable caps) can be
charged at a high rate. Small batteries may require a lower charge rate.
Check with your battery vendor for the proper battery charging rate for
the batteries used in the system.
Bulk Voltage This is the maximum voltage the batteries will be charged to during a
normal charge cycle. Gel cell batteries are set to a lower value and non-
sealed batteries are set to a higher voltage setting.
Float Voltage The Float voltage is set lower than the Bulk voltage and provides a
maintenance charge on the batteries to keep them in a ready state.
Temperature
Compensation For optimal battery charging, the Bulk and Float charge rates should be
adjusted according to the temperature of the battery. This can be
accomplished automatically by using a BTS. The sensor attaches directly
to the side of one of the batteries in the bank and provides precise battery
temperature information.
When battery charging voltages are compensated based on temperature,
the charge voltage will vary depending on the temperature around the
batteries. The following table describes approximately how much the
voltage may vary depending on the temperature of the batteries.
If you have liquid lead acid batteries (non-sealed), you may need to
periodically equalize your batteries. Check the water level monthly to
maintain it at the appropriate level.
Battery Information
C–14 976-0043-01-02
Temperature compensation is based on battery type—5 mv/cell for lead
acid type batteries and 2 mv/cell for alkaline type batteries (NiCad or
NiFe). The temperature compensation calculations are derived from
Table C-5.
Table C-4
Variances in Charging Voltage based on Battery Temperature
Temperature
(around the BTS) 24-volt units 48-volt units
Celsiu
s
Fahrenhei
t
Lead
Acid NiCad
Lead
Acid NiCad
60 140 -2.10 -1.40 -4.20 -2.80
55 131 -1.80 -1.20 -3.60 -2.40
50 122 -1.50 -1.00 -3.00 -2.00
45 113 -1.20 -0.80 -2.40 -1.60
40 104 -0.90 -0.60 -1.80 -1.20
35 95 -0.60 -0.40 -1.20 -0.80
30 86 -0.30 -0.20 -0.60 -0.40
25 77 0.00 0.00 0.00 0.00
20 68 0.30 0.20 0.60 0.40
15 59 0.60 0.40 1.20 0.80
10 50 0.90 0.60 1.80 1.20
5 41 1.20 0.80 2.40 1.60
0 32 1.50 1.00 3.00 2.00
-5 23 1.80 1.20 3.60 2.40
-10 14 2.10 1.40 4.20 2.80
-15 5 2.40 1.60 4.80 3.20
-20 -4 2.70 1.80 5.40 3.60
-25 -13 3.00 2.00 6.00 4.00
-30 -22 3.30 2.20 6.60 4.40
-35 -31 3.60 2.40 7.20 4.80
-40 -40 3.90 2.60 7.80 5.20
Table C-5
Temperature Compensation Calculation
Battery Type
24-volt
Systems 48-volt Systems
Lead Acid 0.060 volts (60 mV)
per degree Celsius
0.120 Volts (120 mV)
per degree Celsius
NiCad 0.040 volts (40 mV)
per degree Celsius
0.080 volts (80 mV)
per degree Celsius
Battery Maintenance
976-0043-01-02 C–15
Equalization Charging
Purpose An equalize charge helps to remove sulfate buildup on the battery plates
and balances the charge of individual cells.
Effect Equalize charging also produces gassing which stirs up the electrolyte
mixture and helps distribute the acid more evenly.
Non-equalized
batteries Batteries that are not equalize charged can be damaged by sulfate
accumulation, thus sealing off a percentage of the plates and reducing
battery capacity. They may also have sulfuric acid accumulate at the
bottom of the battery, potentially damaging the plates. At the same time,
the electrolyte at the top of the battery gets watery. This effect is called
stratification.
Frequency Every month or two the batteries should be equalize charged.
Note: If the battery temperature is allowed to fall to extremely cold
temperatures, the inverter with a BTS may not be able to properly recharge cold
batteries due to maximum voltage limits of the inverter. Ensure the batteries are
protected from extreme temperatures.
CAUTION: Damage to DC Loads
The high voltages reached during an equalize charge may damage DC loads that
are connected to the inverter. Disconnect any DC loads from the inverter before
running an equalize charge.
CAUTION: Damage to Batteries
Equalization should be done for standard electrolyte vented batteries only. Sealed
or GEL cell batteries should not be equalize charged. Consult your battery
supplier for details on equalize charging for the battery type in your system.
Battery Information
C–16 976-0043-01-02
General Maintenance
Water Levels Flooded lead acid batteries require periodic water refills in each battery
cell. Only distilled water should be used in a battery, as tap or mineral
water may contain contaminants which will upset the battery chemistry
and may damage the battery.
When filling the battery, clean the surface first to prevent dirt from
entering the cell. Fill the cell to just above the plates or to the bottom of
the internal collar inside the battery. Never fill the cells to the top or acid
will leak out during charging.
Check the water level in the batteries frequently when performing an
equalize charge and add water if necessary. Always follow the safety
steps covered in the front of the manual.
Battery Cables and
Posts Battery posts must be clean to reduce the resistance between the battery
post and cable connection. A buildup of dirt or oxidation may eventually
lead to the cable terminal overheating during periods of high current draw.
Use a stiff wire brush and remove all dirt and corrosion from the battery
terminals and cables. Use an alkaline solution of baking soda and water to
clean the terminals and neutralize any battery acid on the terminals or
cable lugs.
Torque Battery
Connections After the terminals are clean, reassemble the cable to the battery terminal
and torque the connections to the battery manufacturer’s
recommendations.
Coat the battery terminals with an antioxidant compound.
WARNING: Shock Hazard
Before attempting to clean the battery posts, turn off the DC circuit breaker. Use
only insulated tools and remove all jewellery.
CAUTION: Damage to Batteries
Never let a baking soda solution get into the battery as it will neutralize the acid
resulting in permanent damage.
Battery Maintenance
976-0043-01-02 C–17
State of Charge The battery’s state-of-charge should be checked often and only when the
battery at a state of rest (when the battery is not powering loads or
actively being charged). First thing in the morning is usually the best time
to check the state of charge. If the batteries are readily accessible,
measure the voltage across the individual battery terminals. There should
be less than a 0.2 volt difference between each battery.
To determine the individual cell voltage, divide the voltage by the number
of cells in the battery (25.2 volts divided by 12 cells = 2.1 volts per cell).
If a greater difference is measured, the batteries may need to be equalized
(liquid lead-acid types only) or replaced.
All batteries in the bank should measure the same voltage (this is not an
accurate measurement for cross-tied batteries’ as each battery is in
parallel with another battery making individual battery measurements
impossible).
The voltage should match the following table for the entire battery bank
output. These values indicate the overall battery’s state of charge for the
entire bank. Individual cell voltages (if available) are also shown as a
percentage of charge.
The values given are for a temperature of 77 °F (25 °C). Cooler
temperatures produce lower voltage measurements.
Table C-6
Battery State-of-Charge
System Voltage
Percent of Full
Charge 12 Volt 24 Volt 48 Volt
Individual
Cell
Voltage
100% 12.7 25.4 50.8 2.12
90% 12.6 25.2 50.4 2.10
80% 12.5 25.0 50.0 2.08
70% 12.3 24.6 49.2 2.05
60% 12.2 24.4 48.8 2.03
50% 12.1 24.2 48.4 2.02
40% 12.0 24.0 48.0 2.00
30% 11.8 23.6 47.2 1.97
20% 11.7 23.4 46.8 1.95
10% 11.6 23.2 46.4 1.93
0% < 11.6 < 23.2 < 46.4 < 1.93
C–18
D Generators
Appendix D, “Generators” supplies information about
generator starting.
This information is provided for basic reference only. Because
of the wide variety of generator circuits available, Xantrex
cannot be held responsible for the accuracy of the information
provided. Always refer to the manufacturer’s recommendation
for specific operating instructions.
Generators
D–2 976-0043-01-02
Two-Wire Start Circuits
Two-wire starting generators are the easiest to control and are highly
recommended for this type of application. A contact closure starts the
generator and opening the contacts stops the generator. These types of
generators also provide their own cranking control circuit, possibly oil
pressure and overtemp protection circuits, and are designed for
unattended operation applications.
Three-Wire Start Circuits
The common term “three-wire start” may be misleading, as the actual
number of wires required may be four or more. Control of the starter
motor is separate in these systems and the protection circuits found in
two-wire start systems may not be present. This could lead to the
generator running when it is in an over-temperature or low oil condition,
etc. Since these generators are not designed for unattended operation, the
generator supplier should be consulted regarding additional safety/
protection components that may be required.
Two well-known manufacturers of three-wire starting generators are
Honda and Onan. Each uses a different starting sequence and must be
wired accordingly.
Honda™ 3-Wire Type Generators
Honda 3-wire type generators incorporate a starting sequence similar to
an automotive starting system, the switch is first placed in the RUN
position then momentarily held in the START position. When the
generator has started, the switch is returned to the RUN position. To
STOP the generator, the switch is placed in the OFF position.
In this starting configuration, relay RY7 (in the RN1 mode) duplicates the
“RUN” position and RY8 duplicates the “START” position cranking the
starter motor.
Three-Wire Start Circuits
976-0043-01-02 D–3
Onan™ 3-Wire Type Generators
Most Onan 3-wire type generators use a three-position, momentary type
switch to control their operation. To start the generator, the switch is held
in the “START” position, energizing the ignition system and cranking the
starter motor. Once the engine starts, the switch is released and returns to
a center off position. The starter motor stops cranking but the ignition
system remains energized. To shut down the generator, the switch is held
in the “STOP” position until the engine dies. When the switch is released,
it returns to the center position.
In this system, RY8 duplicates the “START” position and relay RY7 (in
the “GS” mode) duplicates the “STOP” position. Some generators use a
similar system with two push-button switches, one to start and one to stop
the generator. For diesel engines, select GS.
Many diesel generators are controlled like the Onan 3-wire type with the
exception that they also require glow plugs to be operated before a
generator start is attempted. The inverter’s automatic generator start
system allows for glow plug control. The addition of a relay between the
GSM and the generator may be required to operate the glow plugs (due to
the amperage) and to separate the stop signal circuit.
3-2 Wire Converters
Another option for three-wire start type generators is to use a 3-to-2 wire
converter. These vary from very simple relay types to very advanced
microprocessor types. Onan offers a simple 3-to-2 wire converter for
some of their generators that are known to work well for many
installations. Universal 3-to-2 wire converters can be used with virtually
any generator and can control glow plugs for diesel engines as well.
These can allow additional system components to signal the generator
start system to start.
For more information on these or additional generator hookup
information, consult your generator supplier or manufacturer.
D–4
E Over-Charge
Protection
Appendix E, “Over-Charge Protection” supplies information
about options for over-charge protection.
This information is provided for basic reference only. Because
of the wide variety of over-charge protection available,
Xantrex cannot be held responsible for the accuracy of the
information provided. Always refer to the manufacturer’s
recommendation for specific operating instructions.
Over-Charge Protection
E–2 976-0043-01-02
Overvoltage Protection using a Charge Controller
When using a renewable energy source to charge the batteries, a charge
controller prevents the batteries from exceeding a user-specified voltage
level. This preserves and extends the life of the battery by preventing the
damage caused by overcharging. The charge controller can also take over
the functions of bulk and equalize charging, and many charge controllers
provide the functions of multi-stage charging.
Figure E-1
Overvoltage using a C-Series Charge Controller
Diversion Load Control
976-0043-01-02 E–3
Diversion Load Control
DC generator devices, such as wind turbines and hydro-electric
generators, may be damaged by over-spinning if the DC loads are
suddenly removed from them. This can happen if the DC disconnect
should open (trip) or the batteries are fully charged and no other DC loads
are connected in the system. A diversion load controller prevents
damage to the generator system by diverting the power from the generator
to a diversion load device. This keeps a load on the generator and controls
over-spin if the batteries should be disconnected. Refer to the controller
manual for proper types of diversion load devices.
Figure E-2
Diversion Load Control
E–4
F Multi-wire Branch
Circuit Wiring
Appendix F, “Multi-wire Branch Circuit Wiring” supplies
information about Multi-wire Branch Circuit Wiring
Precautions when using stand-alone 120 Vac inverters or
generators.
WARNING
A possible fire hazard can exist if 120 Vac only sources (such as inverters and
generators) are wired incorrectly into 120/240 Vac panels containing multi-wire
branch circuits. This section describes how to check for multi-wire branch
circuits in the load center and presents some possible solutions to this wiring
method.
Multi-wire Branch Circuit Wiring
F–2 976-0043-01-02
Multi-wire Branch Circuits
Problem A potential safety problem exists when installing stand-alone 120 Vac
inverters into existing 120/240 Vac wired panels where multi-wire branch
circuit wiring methods were used.
Legacy situation Multi-wire branch circuits are wired differently from “home run” type
wiring (Figure F-1) in that only one neutral wire is used to provide the
neutral-return path for each circuit connected to both phases of the AC
grid. This method has been employed by electricians in recent years to
keep construction costs down by saving copper and labor costs involved
in running a separate Romex™ for each circuit.
Normal condition Under normal conditions, this technique is quite safe and meets code
requirements. When used as originally installed, the current for each
circuit is 180° out-of-phase with each other, so the neutral wire never
receives more current than it was designed to handle as the current from
each circuit subtracts (or cancels out, leaving only the difference current
between the two circuits). Refer to Figure F-2.
Safety issue A safety problem occurs when a stand-alone 120 Vac inverter is installed
to power these circuits, causing the one neutral wire to now carry the in-
phase currents for both circuits. Since the current is in-phase, the two
circuits add instead of subtract, potentially doubling the current flow in
the neutral return wire! Refer to Figure F-3. The branch circuit breakers
do not protect the neutral wire from overload under this condition. This
excess current will overheat the neutral wire, potentially creating a fire
hazard.
Figure F-1
Conventional Home-type Wiring
Load Center
L1
L2
Neutral
Ground
120 Vac
15 A
Breaker 15 A
Breaker
240 Vac
from Grid
Bare - Ground
White - Neutral
(Current Flow 15 A)
Black - Hot
(Current Flow 15A)
120 Vac
Black - Hot
(Current Flow 15A)
White - Neutral
(Current Flow 15 A)
Bare - Ground
Multi-wire Branch Circuits
976-0043-01-02 F–3
Figure F-2
Multi-wire Branch Circuit Wiring and Current Flow
Figure F-3
120 Vac Inverter Incorrectly Wired in a Multi-wire Branch Circuit
Load Center
L1
L2
Neutral
Ground
120 Vac 120 Vac
15 A
Breaker
(Ganged)
2
40 Vac
fr
om Grid
Bare - Ground
Single White - Neutral
(Current Flow 0 A)
Black - Hot
(Current Flow 15 A)
Red - Hot
(Current Flow 15 A)
Bare - Ground Splice
White - Neutral Splice
(Current Flow 15 A)
Out-of-Phase current
subtract at this point
(Current Flow 0 A)
15 A
Breaker
(Ganged)
Load Center
L1
L2
Neutral
Ground
120 Vac 120 Vac
15 A
Breaker
(Ganged)
240 Vac
from Grid
Bare - Ground
Single White - Neutral
(Current Flow 10 A)
Black - Hot
(Current Flow 5 A)
Red - Hot
(Current Flow 15 A
)
White - Neutral Splice
(Current Flow 15 A)
When unbalanced
current flows through
each leg, only the
difference current
flows through the
neutral return wire.
15 A
Breaker
(Ganged)
Load Center
L1
L2
Neutral
Ground
120 Vac 120 Vac
15 A
Breaker
(Ganged)
Bare - Ground
Single White - Neutral
(Current Flow 30 A)
Black - Hot
(Current Flow 15 A)
Red - Hot
(Current Flow 15
A
White - Neutral Splice
(Current Flow 15 A)
WARNING: FIRE HAZARD
The in-phase currents ADDS
at this point exceeding wire
capacity!
15 A
Breaker
(Ganged)
120 Vac
Inverter or Generator
Multi-wire Branch Circuit Wiring
F–4 976-0043-01-02
Identifying Multi-wire Branch Circuits
Identifying
characteristic Multi-wire branch circuits can be identified by removing the cover on the
load center and inspecting the wiring. Conventional 120 Vac circuits are
identified by a 2-wire-plus-ground (black, white, and copper) “romex” for
each circuit. Multi-wire branch circuits use a 3-wire-plus-ground
arrangement (black, red, white and copper) for each circuit run.
If this arrangement exists in the panel and it is being powered by a stand-
alone 120 Vac inverter, a potential fire hazard exists! For safety, these
circuits must be rewired to meet code.
WARNING: Shock Hazard
The next step involves opening the load center, exposing live circuits. This
procedure should only be performed by qualified persons or electricians.
Figure F-4
Multi-wire Branch Circuit Wiring
Ground Bare
Copper
S
ingle Neutral
White
Red From L2
Breaker
Red From L1
Breaker
To Branch Circuits
Correcting Multi-wire Branch Circuit Wiring
976-0043-01-02 F–5
Correcting Multi-wire Branch Circuit Wiring
Acceptable options Correcting multi-wire branch circuit wiring is not easy. Two options
which will correct multi wiring branch circuit wiring are:
• Rewire existing multi-wire branch circuits to conventional “home
run” wiring. This requires a qualified electrician (knowledgeable
about multi-wire branch circuit wiring) and is expensive. There may
be multiple multi-wire branch circuits located throughout the
structure, requiring complete rewiring.
• Add a second inverter in a “series stacked” arrangement. This is an
expensive solution, but would restore the original 240 Vac split-phase
configuration. This solution may actually be less expensive than
having an electrician re-wire the multi-wire branch circuits. It also
provides increased power backup protection and can power 240 Vac
loads.
Recommended
option Add a step-down autotransformer to the output of the inverter to restore
the split-phase configuration. This is the least expensive and easiest
method to correct for multi-wire branch circuit wiring. Refer to Figure F-
5. Using this method, half of the current is supplied to one leg of the
circuit and half to the other in a split-phase arrangement (180° out-of-
phase). This will restore the original functionality and safety to the multi-
wire branch circuit.
WARNING: Fire Hazard
Until one of the solutions above is implemented, a stand-alone 120 Vac inverter
(or generator) must not be installed where multi-wire branch circuits exist.
Multi-wire Branch Circuit Wiring
F–6 976-0043-01-02
Figure F-5
Using a Step-down Autotransformer in Multi-wire Branch Circuit Wiring
Load Center
L1
L2
Neutral
Ground
120 Vac 120 Vac
15 A
Breaker
(Ganged)
Bare - Ground
Single White - Neutral
(Current Flow 0 A)
Black - Hot
(Current Flow 15 A)
Red - Hot
(Current Flow 15
A
White - Neutral Splice
(Current Flow 15 A)
15 A
Breaker
(Ganged)
T240
AutoTransformer
White - Neutral
HOT - L2
HOT - L1
HOT
NEUTRAL
The out-of-phase
current SUBTRACTS
at this point.
120 Vac
Inverter or Generator
G Emergency Power Off
Switches
Appendix G, “Emergency Power Off Switches” supplies
information about the requirements for installing an
Emergency Power Off Switch.
Emergency Power Off Switches
G–2 976-0043-01-02
The Purpose of an EPO switch
In the event an emergency situation, the first priority is to remove power
from the house by removing the power meter. However, systems with
battery backups can run in inverter mode (i.e., no utility power) for hours
providing AC output to the household loads. The inverter can also have
several other sources of input power such as AC (generators) or DC
sources from wind turbines or photo voltaic arrays. In these situations, if
the meter was pulled to remove power, the inverter would continue to
provide power to the residence. This can cause a potential hazard to the
emergency response crew and possibly hinder rescue or salvage efforts.
To provide a shutdown solution, the Sine Wave Plus includes a feature
that when utilized with a properly marked switch, can disable and
shutdown the system.
The Sine Wave Plus is one of the first renewable energy inverters that
include this feature. It is designed to provide an emergency power off
function that disables the inverter function, output, and power transfer.
The unit will then require manual intervention to physically turn the unit
back on using the display buttons in the 01 Inverter ON/OFF menu.
This provides a secondary shutdown feature when DC shunt trip circuit
breakers are not available, or the local authority having jurisdiction
requires some form of externally mounted switched shutdown. This is
classified as a shutdown control and does not physically disconnect any
circuit breakers.
Figure G-1
Emergency Power OFF Disconnect Switch
Power
Meter
Emergency
Power OFF
Disconnect
Switch
The Purpose of an EPO switch
976-0043-01-02 G–3
The intent of this feature is to provide three options:
• Inverter shutdown using an externally mounted switch as described in
the 2002 NEC Article 230-70 (a) (no physical disconnect required),
• Inverter shutdown and physical disconnect by using a 2-pole EPO
switch, one set of contacts open the AC output breaker, the other set
turn off the inverter (Physical shunt trip breaker required), or
• DC and AC circuit shunt trip breakers physical disconnect required
(very expensive and not necessary).
During discussion with industry experts, their opinion was that if the DC
battery bank was within the vicinity of the unit and the EPO control
provided a clear, repeatable shutdown, tested and verified by agency
approval, then the control signal shutdown would be allowed and the
expensive physical DC disconnect would not be required.
In the case where AC service subpanels are located in separate locations,
away for the inverter, other buildings, or unknown wire running through
walls, you may be required to install a shunt trip type “physical
disconnect” added between the inverter output and the sub “essential
loads” panel. When the EPO switch is activated, as described above, the
inverter shuts down, and a separate set of contacts provides the signal to
trip the shunt trip circuit breaker.
The disconnect mounted on the outside of the house should be at or near
the utility meter. The label on the EPO switch should be labeled
“EMERGENCY POWER OFF OF SECONDARY SOURCES OF
POWER”. See Figure G-1, “Emergency Power OFF Disconnect Switch”
on page G–2.
See the 2002 NEC Section 3, as shown below.
SECTION 3. MODIFICATION TO ARTICLE 230 OF THE
NATIONAL ELECTRIC CODE, 1999 EDITION
Article 230 of the National Electric Code is hereby modified by
amending Subsection 230-70(a) to read as follows:
230-70(a) Location.
The service disconnecting means shall be installed at a readily
accessible location either outside of a building or structure or inside
nearest the point of entrance of the service conductors.
Except in one and two family dwellings, the service disconnecting
means shall be installed at the exterior of the building or structure in
close proximity to the meter location.
Exception: The service disconnecting means can be installed inside
the building or structure nearest the point of entrance of the service
conductors provided a shunt trip switch is installed at the exterior of
Emergency Power Off Switches
G–4 976-0043-01-02
the building at a readily accessible location. The shunt trip switch,
when installed should be between six (6) feet and six feet seven
inches (6'7") above finish grade. A sign constructed of permanent
materials with no less than 1½" high letters designating "Shunt Trip -
Main Disconnect" shall be located on the exterior of the building or
structure, and approximately one foot (1') above and one foot (1') to
one side of the shunt trip mechanism. Service disconnecting means
shall not be installed in bathrooms.
How to use the EPO Port for an EPO Switch
The following diagram shows how to modify a 6-conductor cable to
connect the Sine Wave Plus for an Emergency Power Off Switch.
Figure G-2
Modifying a 6-conductor Cable to connect to the EPO Port
976-0043-01-02 H–1
Glossary
“Glossary” contains a glossary of technical terms used in this manual. The
glossary also defines some common electrical terms.
“Glossary” also defines abbreviations and acronyms associated with the Sine
Wave Plus and this manual.
Glossary of Terms
The second stage of three-stage battery charging. Voltage
remains constant and current tapers as internal battery
resistance increases during charging. This ensures complete
charging.
The type of electrical power supplied by the power utility.
The unique characteristic of this form of electricity is that it
reverses direction at regular intervals. For example, 120 Vac
60 Hz power reverses flow 60 times a second, hence the
rating 60 Hz (cycles).
A measurement of the flow of electrical current. One amp is
equal to the electric force of one volt acting across the
resistance of one ohm.
One amp of electrical current flowing for one hour. Expresses
the relationship between current (amps) and time. (Ohm’s
law: A = V/R)
A group of solar electric modules wired together.
The first stage of three-stage battery charging. Current is sent
to batteries at the maximum rate they will accept while
voltage rises to full charge level.
The rate of flow of electrical charge. The flow of amps is
often expressed as current.
The type of electricity stored in batteries and generated by
solar electric devices. Current flows in a single direction.
H–2 976-0043-01-02
A conductive medium in which the flow of electricity takes
place; this is the liquid found inside storage batteries.
The third stage of three-stage battery charging. After batteries
reach full charge, charging voltage is reduced to a lower level
to reduce gassing (boiling of electrolyte) and prolong battery
life. This is often referred to as a maintenance charge, since
rather than charging a battery it keeps an already-charged
battery from self-discharging.
When used in reference to utility power, it refers to a system
of electrical transmission and distribution lines.
A circuit protection device that prevents the flow of electrical
current to earth if a short circuit is present. Usually required in
wet locations—for example, for outdoor, kitchen, and
bathroom circuits.
The frequency, or number of times per second, that the flow
of AC electricity reverses itself. Also referred to as cycles
(see alternating current).
A control circuit that disconnects charge current flowing to
batteries when voltage reaches a dangerously high threshold.
Prevents damage created by excess gassing (or boiling) of
electrolyte.
A simple device that measures the specific gravity of battery
electrolyte. Specific gravity readings express state of charge/
discharge of battery.
The amount of electrical power required to keep an inverter
ready to produce electricity on demand.
The peak power that a load will draw at the instant that it
starts up.
One thousand watts of electricity. Ten 100-watt light bulbs
use one Kilowatt of electrical power.
One kW of electrical power used for one hour. The most
common measurement of electrical consumption, most grid
connected electrical meters measure kWh for billing
purposes.
A device used to display various status functions.
976-0043-01-02 H–3
A voltage drop caused by resistance in wire during
transmission of electrical power over distance.
An electrical system that is connected to a utility distribution
grid. For example, Xantrex SW line tie inverters are designed
to connect to and interact with utility power.
Any device that consumes electricity in order to operate.
Appliances, tools, and lights are examples of electrical loads.
A control circuit that stops the flow of electricity from
batteries to loads when battery voltage drops to dangerously
low levels.
Every PV (solar electric) device has a point where maximum
current is delivered. MPPT electronically adjusts the output of
a PV device to the maximum power point.
An AC wave form (generated by many inverters) that is a
pulse width modified square wave.
The electrical wiring and installation standards used in the
United States.
An electrical system that is not connected to a utility
distribution grid.
A device that displays the wave form created by an electrical
generating device such as a generator, inverter, or utility.
A control circuit designed to protect an inverter or similar
device from loads exceeding its output capacity. (A fuse, for
example, is an overcurrent protection device.) All Xantrex
inverters have internal circuitry to protect themselves from
overload/overcurrent conditions.
A group of electrical devices, such as batteries or PV
modules, wired together to increase ampacity, while voltage
remains constant. Two 100 amp hour 12 VDC batteries wired
in parallel will form a 200 amp-hour 12 VDC battery bank.
The components that form a solar electric generating system,
usually consisting of PV modules, charge controller, circuit
protectors (fuses or breakers) and batteries.
H–4 976-0043-01-02
A group of electrical devices, such as batteries or PV
modules, wired together to increase voltage, while ampacity
remains constant. Two 100 amp hour 12 Vdc batteries wired
in series form a 100 amp hour 24 Vdc battery bank.
The output wave form of an electric generator or utility. A
smooth wave going above and below zero is created.
The amount of current an inverter can deliver for short
periods of time. Most electric motors draw up to three times
their rated current when starting. An inverter will “surge” to
meet these motor-starting requirements. Most Xantrex
inverters have surge capacities at least three times their
continuous ratings.
A switch designed to transfer electricity being supplied to
loads (appliances, for example) from one source of power to
another. A transfer switch may be used to designate whether
power to a distribution panel will come from a generator or
inverter.
A unit of measure of the pressure in an electrical circuit. Volts
are a measure of electric potential. Voltage is often explained
using a liquid analogy, comparing water pressure to voltage: a
high pressure hose would be considered high voltage, while a
slow-moving stream could be compared to low voltage.
A quantitative measurement of electrical power. Watts are
calculated by multiplying volts times amps. Using a liquid
analogy, watts are similar to liquid flow such as litres or
gallons. (watts = volts × amps)
Electrical power measured in terms of time. One watt hour of
electricity is equal to one watt of power being consumed for
one hour. A one-watt light operated for one hour would
consume one watt hour of electricity.
976-0043-01-02 H–5
Abbreviations and Acronyms
AC Alternating Current
ACCB AC Conduit Box
Ah amp hour
ALM Auxiliary Load Module
ASC Authorized Service Center
AUX Auxiliary
AWG American Wire Gauge
BTS Battery Temperature Sensor
BX Battery Transfer
CSA Canadian Standards Association
DC Direct Current
DCCB DC Conduit Box
EMI Electro-Magnetic Interference
EPO Emergency Power Off
FLT Float (relates to battery charging)
FCC Federal Communications Commission
GEN Generator
GFP Ground Fault Protection
GSM Generator Start Module
HBCI High-Battery Cut In
HBCO High-Battery Cut Out
Hz Hertz
ICA Inverter Communications Adapter
ICM Inverter Control Module
ISC-S Inverter Stacking Control – Series
LBCI Low-Battery Cut In
LBCO Low-Battery Cut Out
LBX Low-Battery Transfer
H–6 976-0043-01-02
LCD Liquid Crystal Display
LED Light Emitting Diode
NEC National Electric Code
NEU Neutral
OEM Original Equipment Manufacturer
PC Personal Computer
PV Photovoltaic (solar electric panels)
PVGFP PV Ground Fault Protection
RE Renewable Energy
RFI Radio Frequency Interference
RMA Return Material Authorization
SB Stand By
SLT Silent (relates to battery charging)
TOU Time Of Use
UL Underwriters Laboratory
Vac Volts AC
Vdc Volts DC
Xfer Transfer
976-0043-01-02 I–1
Warranty and Product
Information
Warranty
What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc.
("Xantrex") and covers defects in workmanship and materials in your Sine Wave Plus Inverter/
Charger. This warranty lasts for a Warranty Period of two years from the date of purchase at point of
sale to you, the original end user customer.
This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the
Warranty Period.
What will Xantrex do? Xantrex will, at its option, repair or replace the defective product free of
charge, provided that you notify Xantrex of the product defect within the Warranty Period, and
provided that Xantrex through inspection establishes the existence of such a defect and that it is
covered by this Limited Warranty.
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and
building replacement products. Xantrex reserves the right to use parts or products of original or
improved design in the repair or replacement. If Xantrex repairs or replaces a product, its warranty
continues for the remaining portion of the original Warranty Period or 90 days from the date of the
return shipment to the customer, whichever is greater. All replaced products and all parts removed
from repaired products become the property of Xantrex.
Xantrex covers both parts and labor necessary to repair this product, and return shipment to the
customer via a Xantrex-selected non-expedited surface freight within the contiguous United States
and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on
freight policy for return shipments outside of the contiguous United States and Canada.
How do you get service? If your product requires troubleshooting or warranty service, contact
your merchant. If you are unable to contact your merchant, or the merchant is unable to provide
service, contact Xantrex directly at:
Phone: 1-800-670-0707 (toll free)
1-360-925-5097 (direct)
Fax: 1-800-994-7828 (toll free)
Fax: 1-360-925-5143 (direct)
Email: customerservice@xantrex.com
I–2 976-0043-01-02
Direct returns may be performed according to the Xantrex Return Material Authorization Policy
described in your product manual. For some products, Xantrex maintains a network of regional
Authorized Service Centers. Call Xantrex or check our website to see if your product can be
repaired at one of these facilities.
In any warranty claim, dated proof of purchase must accompany the product and the product must
not have been disassembled or modified without prior written authorization by Xantrex.
Proof of purchase may be in any one of the following forms:
• The dated purchase receipt from the original purchase of the product at point of sale to the end
user, or
• The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM)
status, or
• The dated invoice or purchase receipt showing the product exchanged under warranty
What does this warranty not cover? This Limited Warranty does not cover normal wear and tear
of the product or costs related to the removal, installation, or troubleshooting of the customer's
electrical systems. This warranty does not apply to and Xantrex will not be responsible for any
defect in or damage to:
a) the product if it has been misused, neglected, improperly installed, physically damaged or
altered, either internally or externally, or damaged from improper use or use in an unsuitable
environment;
b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations,
or input voltage that creates operating conditions beyond the maximum or minimum limits
listed in the Xantrex product specifications including high input voltage from generators and
lightning strikes;
c) the product if repairs have been done to it other than by Xantrex or its authorized service centers
(hereafter "ASCs");
d) the product if it is used as a component part of a product expressly warranted by another manu-
facturer;
e) the product if its original identification (trade-mark, serial number) markings have been
defaced, altered, or removed.
Disclaimer
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION
WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES,
CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED,
STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT,
TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR
OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY,
Return Material Authorization Policy
976-0043-01-02 I–3
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE
PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING
WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY
PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE
INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT.
Exclusions
If this product is a consumer product, federal law does not allow an exclusion of implied warranties.
To the extent you are entitled to implied warranties under federal law, to the extent permitted by
applicable law they are limited to the duration of this Limited Warranty. Some states and provinces
do not allow limitations or exclusions on implied warranties or on the duration of an implied
warranty or on the limitation or exclusion of incidental or consequential damages, so the above
limitation(s) or exclusion(s) may not apply to you. This Limited Warranty gives you specific legal
rights. You may have other rights which may vary from state to state or province to province.
Warning: Limitations On Use
Please refer to your product manual for limitations on uses of the product.
SPECIFICALLY, PLEASE NOTE THAT THE SINE WAVE PLUS INVERTER/CHARGER SHOULD NOT BE USED IN
CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING
THE GENERALITY OF THE FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE
USE OF THE XANTREX SINE WAVE PLUS INVERTER/CHARGER IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR
OTHER MEDICAL EQUIPMENT OR DEVICES.
Please note that the Sine Wave Plus Inverter/Charger is not intended for use as an uninterruptible
power supply and Xantrex makes no warranty or representation in connection with any use of the
product for such purposes.
Return Material Authorization Policy
Before returning a product directly to Xantrex you must obtain a Return Material Authorization
(RMA) number and the correct factory "Ship To" address. Products must also be shipped prepaid.
Product shipments will be refused and returned at your expense if they are unauthorized, returned
without an RMA number clearly marked on the outside of the shipping box, if they are shipped
collect, or if they are shipped to the wrong location.
When you contact Xantrex to obtain service, please have your instruction manual ready for
reference and be prepared to supply:
• The serial number of your product
• Information about the installation and use of the unit
• Information about the failure and/or reason for the return
• A copy of your dated proof of purchase
Record these details in on page I–5.
I–4 976-0043-01-02
Return Procedure
1. Package the unit safely, preferably using the original box and packing materials. Please ensure
that your product is shipped fully insured in the original packaging or equivalent. This warranty
will not apply where the product is damaged due to improper packaging.
2. Include the following:
• The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the
box.
• A return address where the unit can be shipped. Post office boxes are not acceptable.
• A contact telephone number where you can be reached during work hours.
• A brief description of the problem.
3. Ship the unit prepaid to the address provided by your Xantrex customer service representative.
If you are returning a product from outside of the USA or Canada In addition to the above,
you MUST include return freight funds and are fully responsible for all documents, duties, tariffs,
and deposits.
If you are returning a product to a Xantrex Authorized Service Center (ASC) A Xantrex
return material authorization (RMA) number is not required. However, you must contact the ASC
prior to returning the product or presenting the unit to verify any return procedures that may apply to
that particular facility.
Out of Warranty Service
If the warranty period for your Sine Wave Plus Inverter/Charger has expired, if the unit was
damaged by misuse or incorrect installation, if other conditions of the warranty have not been met,
or if no dated proof of purchase is available, your inverter may be serviced or replaced for a flat fee.
To return your Sine Wave Plus Inverter/Charger for out of warranty service, contact Xantrex
Customer Service for a Return Material Authorization (RMA) number and follow the other steps
outlined in “Return Procedure” on page I–4.
Payment options such as credit card or money order will be explained by the Customer Service
Representative. In cases where the minimum flat fee does not apply, as with incomplete units or
units with excessive damage, an additional fee will be charged. If applicable, you will be contacted
by Customer Service once your unit has been received.
Information About Your System
976-0043-01-02 I–5
Information About Your System
As soon as you open your Sine Wave Plus Inverter/Charger package, record the following
information and be sure to keep your proof of purchase.
If you need to contact Customer Service, please record the following details before calling. This
information will help our representatives give you better service.
❐Serial Number ______________________________
❐Purchased From ______________________________
❐Purchase Date ______________________________
❐Type of installation (e.g. RV, truck) ________________________________
❐Length of time inverter has been installed ________________________________
❐Battery/battery bank size ________________________________
❐Battery type (e.g. flooded, sealed gel cell, AGM) ________________________________
❐DC wiring size and length ________________________________
❐Alarm sounding? ________________________________
❐Description of indicators on front panel ________________________________
❐Appliances operating when problem occurred ________________________________
❐Description of problem ________________________________
______________________________________________________________________________
_____________________________________________________________________________
I–6
Index
976-0043-01-02 IX–1
3-to-2 Wire Converters D–3
AC 3–26
AC output requirements, determining 2–4
AC side feature 1–4
ACCB, purpose of 2–22
Accessing the AC Terminal Block and Ground Bar
3–26
ALM, purpose of 2–28
Automatic Generator Control Mode
Generator Exercising 7–25
Generator Starting Scenarios 7–23
Auto-start generators 2–21
Auxiliary 3–42
Auxilliary Load Module see ALM
Batteries
Battery Care and Maintenance
Equalization Charging C–15
Temperature Compensation C–13
Battery Types
Absorbed Glass Mat C–3
Flooded Lead Acid (FLA) C–2
Gel Cell C–3
Golf Cart C–3
Industrial (electric forklift) C–3
NiCad and NiFe C–3
Charging
Bulk Voltage C–13
Charge Rates C–13
Float Voltage C–13
batteries
accessibility to 2–11
Battery 3–4, C–13
battery banks, determining size 2–12
battery cable lugs 2–14
battery cables
importance of correct size 2–13
length requirements 2–13
battery enclosures, safety requirements for 2–11
battery status meter, features of 2–25
battery temperature sensor
location 1–6
purpose 1–7
battery temperature sensor, purpose of 2–17
bonding, guidelines for 2–11
certification label, how to interpret 1–5
charge controller, purpose of 2–30
chassis ground lug
location 1–6
chassis grounding, reason for 2–9
circuit breaker
location 1–8
circuit breakers, Xantrex products 2–14
conductor size for inverter grounding 2–8
conduit boxes
ACCB 2–22
DCCB 2–23
Customer Service
email I–1
fax number I–1
phone number I–1
preparing to call I–5
DC 3–18
DC side features 1–6
DC system grounding 2–7
Diversion load control, purpose of 2–30
email, contacting Customer Service by I–1
enclosures,safety requirements for battery 2–11
energy managment, features which allow 2–44
EPO
purpose 1–5
Exercise Period 7–25
fax number for Customer Service I–1
FCC information to the user ii–viii
front panel features 1–3
functional test 4–2
fuse block, purpose of 2–24
Index
IX–2 976-0043-01-02
Generator
Exercising 7–25
Generator Start Module see GSM
generator start types 2–20
generator, as only source of AC power 2–36
generator, starting requirements 2–21
ground and neutral bonding guidelines 2–10
ground rod
purpose 2–9
size 2–9
Grounding 3–15
grounding electrode see ground rod 2–9
grounding system, definition 2–10
grounding, methods of 2–7
GSM, purpose of 2–28
Hardware 3–3
Honda 3-Wire Type Generators D–2
ICA, purpose of 2–27
ICM, purpose of 2–27
Information about Your System form I–5
input requirements
determining 2–4
Install 3–38
inverter
mounting considerations 2–6
purchase date I–5
serial number I–5
Inverter Capacity vs. Temperature A–12
Inverter Communications Adapter see ICA
Inverter Control Module see ICM
inverter grounding
conductor size 2–8
inverter location considerations 2–4
Inverter Mode
Theory of Operation
Output Waveform A–7
Inverter Panel Mounting 3–33
Inverter Stacking Control-Series Cable see ISC-S
ISC-S, purpose of 2–29
LED Status Indicators
Inverting 4–3
lightning strikes,effect on warranty 2–9
locating the inverter 2–4
lugs, battery cable 2–14
Manual 3–30
Mounting 3–8
negative ground
bonding 2–7
definition 2–7
off-grid
applications 2–32–2–39
definition 2–2
on-grid
applications 2–40–2–47
definition 2–2
overcurrent protection, requirements 2–14
Over-voltage Protection using a Charge Controller
E–2
peak load management, applications of 2–44
positive ground, definition 2–7
Power Vs. Efficiency A–8
Prepare 3–4
proof of purchase I–5
purchase date I–5
PVGFP, purpose of 2–31
Remote 3–41
remote monitors, available options 2–26
renewable energy input sources, considerations 2–
30
renewable energy systems, bonding location 2–10
residential systems, bonding location 2–10
Index
976-0043-01-02 IX–3
safety instructions ii–vii–??
serial number I–5
series stacking, operation requirements 2–16
stacking, considerations for 2–15
system input requirements 2–4
system output requirements 2–4
T240 Autotransformer, purpose of 2–29
telephone number for Customer Service I–1
temperature, effect on batteries 2–17
Theory of Operation
Output Waveform A–7
Three-Wire Start Circuits D–2
Time-of-Use (TOU )metering, applications of 2–45
TM500A, features 2–25
Tools 3–2
Two-Wire Start Circuits B–1, D–2, E–2
utility grid, ground and neutral bonding
considerations 2–11
vented enclosures, importance to batteries 2–11
ventilation, requirements for 2–6
warranty
out of warranty service I–4
terms and conditions I–1
warranty and lightning strikes 2–9
web site i–vi
Xantrex
web site i–vi
Xantrex circuit breaker 2–14
Index
IX–4 976-0043-01-02
Xantrex Technology Inc.
8999 Nelson Way
Burnaby, British Columbia
Canada V5A 4B5
800 670 0707 Tel Toll Free in North America
360 925 5097 Tel direct
800 994 7828 Fax Toll Free in North America
360 925 5143 Fax direct
customerservice@xantrex.com
www.xantrex.com
976-0043-01-02 Rev B PC Printed in USA

Navigation menu