Xantrex FREEDOM HW 1000, Installation Manual

Page 1: ...Freedom HW 1000 Inverter Charger Installation Guide ...

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Page 3: ...This guide for use by qualified installers only Freedom HW 1000 Inverter Charger Installation Guide ...

Page 4: ...heir respective owners and are used herein for identification purposes only Notice of Copyright Xantrex Freedom HW Inverter Charger Installation Guide December 2008 Xantrex Technology Inc All rights reserved No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of Xantrex Technology Inc 5917 195th St NE Arlington WA 98223 Xantrex T...

Page 5: ... does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience The Guide is intended for qualified installers who need to install and configure the Freedom HW Inverter Charger The installer should be a qualified technician or electrician with knowledge and experience in installing electrical equipment knowledge of t...

Page 6: ...Xantrex Technology Inc as well as its products and services at www xantrex com WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or ...

Page 7: ...ng may result 3 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 Freedom HW with damaged or substandard wiring 4 The use of any attachments not recommended or sold by Xantrex may result in risk of fire electric shock or injury to persons 5 Do not operate the Freedom HW if it has received a sharp blow b...

Page 8: ...ground 1 Working in the vicinity of batteries is dangerous Batteries generate explosive gases during normal operation Therefore it is of utmost importance that each time before servicing the unit in the vicinity of the battery that you read this manual and follow the instructions exactly 2 This equipment contains components which tend to produce arcs or sparks To prevent fire or explosion do not i...

Page 9: ...plosion 6 Remove all metal items like rings bracelets and watches when working with batteries Batteries can produce a short circuit current high enough to weld metal to skin causing a severe burn 7 Have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery 8 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothin...

Page 10: ...t directly above batteries gases from a battery will corrode and damage the unit 16 Never allow battery acid to drip on the unit when reading gravity or filling battery 17 Do not operate the unit in a closed in area or restrict the ventilation in any way DC CONNECTION PRECAUTION 18 Connect and disconnect DC output connections only after setting any recreational vehicle unit switches to off positio...

Page 11: ...ation 1 6 Step 2 Choosing a Location for the Freedom HW 1 12 Step 3 Mounting the Freedom HW 1 13 Connecting the Equipment Ground 1 14 Grounding Locations 1 14 Step 4 Connecting the AC Input Wires 1 15 General AC Wiring Considerations 1 15 AC Input Connections 1 16 Step 5 Connecting AC Output to an Existing AC Circuit 1 18 Step 6 Connecting the DC Cables 1 23 DC Grounding 1 26 Step 7 Mounting the D...

Page 12: ...verter Mode 2 2 Electrical Specifications Charge Mode 2 3 Environmental Specifications 2 4 System Specifications 2 4 Physical Specifications 2 4 Regulatory Approvals 2 5 Inverter Overload Operation 2 5 Invert Power Derating vs Ambient Temperature 2 6 Charger Output Current vs AC Input Voltage 2 7 ...

Page 13: ...ion It covers the following Materials list Safety instructions and various installation codes that may be applicable to your installation Sample installation tools and materials High level overview of installation steps Installation procedures starting on page 1 5 including mounting and connecting the equipment ground AC cabling DC cabling and grounding steps ...

Page 14: ...nt cover p n 210 0738 01 01 two reference materials an Owner s Guide and an Installation Guide p n 975 0468 01 01 and 975 0467 01 01 one set of lock washers and nuts already connected to the bolts p n 061 2002 and 062 0030 Figure 1 1 What s In The Box Owner s Guide Mounting Template Freedom HW unit Installation Guide Display panel is already mounted on the unit and connected to the remote panel po...

Page 15: ...allation Codes Governing installation codes vary depending on the specific location and application of the installation Some examples include the following The U S National Electrical Code NEC The Canadian Electrical Code CEC The U S Code of Federal Regulations CFRs Canadian Standards Association CSA and the RV Industry Association RVIA for installations in RVs It is the installer s responsibility...

Page 16: ...devices High Level Overview of Installation Steps Installing the Freedom HW includes the following steps 1 Ensure that AC and DC power are both OFF 2 Mount the inverter securely and permanently in one of the acceptable orientations 3 Connect the Equipment Grounding Terminal to the equipment ground bus 4 Connect the AC input wiring to the AC source panel 5 Connect the AC output wiring to the AC loa...

Page 17: ...tion For your convenience the overall procedure is divided into ten main steps Step 1 Designing an installation Start on page 1 6 Step 2 Choosing a location for the Freedom HW Start on page 1 12 Step 3 Mounting the Freedom HW Start on page 1 13 Step 4 Connecting the AC input wires Start on page 1 15 Step 5 Connecting the AC output wires Start on page 1 18 Step 6 Connecting the DC cables Start on p...

Page 18: ...nents and their relationship to each other in a typical recreational vehicle or fleet vehicle installation Figure 1 2 Typical Recreational Vehicle and Fleet Vehicle Installation l to engine DC Fuse Disconnect or Circuit Breaker AC Load Panel AC Source Panel Shorepower Generator Automatic or Manual AC Source Select or Switch F R E E D O M H F 1000 12V Deep Cycle Battery Vehicle Starting Battery Equ...

Page 19: ...ominal 120 Vac 60Hz sine wave AC power Since the DC charging current limit of the Freedom HW may be configured to provide as little as 7 A it is possible to use very small generators with the Freedom HW to charge batteries The Freedom HW has been tested with generators of various sizes including some as small as 700W AC Disconnect and Over Current Protection Device Most safety requirements and ele...

Page 20: ...er current protection and as a disconnect for the AC shore power supply line Additional circuit breakers serve individual circuits one of which serves the Freedom HW The AC load panel can incorporate an AC output circuit breaker and breakers for individual load circuits AC Cabling AC cabling includes all the wires and connectors between the AC source and the Freedom HW as well as all cabling betwe...

Page 21: ...to National Electrical Code which requires that separately derived AC sources such as inverters and generators to have their neutral conductors tied to ground in the same way that the neutral conductor from the utility is tied to ground in only one place Check the regulations for your specific application to ensure that the installation will comply with the necessary requirements In other words th...

Page 22: ...the DC current that the Freedom HW converts to AC Table 1 2 Recommended Cable Sizes Inverter Charger Cable Length Battery to Inverter one way Minimum Cable Size Maximum battery Fuse Size Freedom HW Less than 5 feet 1 5 meters No 2 AWG 150 Adc Note Xantrex recommends not using a cable longer than 5 feet 1 5 meters in each direction Cable sizes above are based on the US National Electrical Code Tabl...

Page 23: ...in wet or damp locations Installations in recreational vehicles require GFCI protection of branch circuits connected to the AC output of the Freedom HW The modified sine wave output of the Freedom HW is not equivalent to the waveform provided by electric utilities and compliance with UL and CSA standards requires that Xantrex test and recommend specific GFCIs that will work correctly with the Free...

Page 24: ...C source and load panels Avoid excessive cable lengths which reduce input and output power due to wire resistance Use the recommended cable lengths and sizes especially between the battery banks and the Freedom HW Protected from battery acid and gases Never allow battery acid to drip on the Freedom HW or its wiring when reading specific gravity or filling the battery Also do not mount the unit whe...

Page 25: ...irements for use in on land applications the Freedom HW must be mounted in one of the following orientations Under a horizontal surface see 1 In a horizontal position on a vertical surface see 2 On a horizontal surface see 3 3 Look for the mounting template and unfold Tape it to the mounting surface and pilot drill the desired number of mounting holes Remove the template 4 Fasten the Freedom HW to...

Page 26: ...more yellow stripes or larger For recommended equipment ground cable size see below In general the equipment ground cable size must not be smaller than one AWG size than the supply cable WARNING Fire hazard Never operate the Freedom HW without properly connecting the equipment ground A fire hazard could result from improper grounding Figure 1 4 DC Panel Connections Equipment ground stud Table 1 3 ...

Page 27: ...he Freedom HW AC input and output to an existing AC installation read this section AC wiring includes all the wires and connectors between the AC source and the Freedom HW and all wiring between the inverter the AC panels circuit breakers and the GFCIs The type and size of the wiring varies with the installation and load For some RV applications flexible multiple strand wire is required AC wiring ...

Page 28: ...t hand side AC wiring knockout from the front panel of the unit see Figure 1 5 on page 1 17 5 Locate the terminal block The two input terminals are labeled as follows AC Input L AC Input N A separate screw is provided to connect the AC input ground see Figure 1 5 on page 1 17 Table 1 4 Required AC wire size vs required breaker rating Required Breaker Size Required Wire Size Freedom HW 30 A maximum...

Page 29: ...ert the Line and Neutral wires into the corresponding terminals 12 Tighten the wire attachment screws to a torque of 15 6 21 6 in lbf 1 76 2 44 N m Leave some wiring slack inside the wiring compartment 13 Reinstall the AC wiring compartment cover Figure 1 5 Freedom HW AC Wiring Compartment Sel ec t U til ity B a tte ry Fault S TATUS Inpu t Voltag e V Inpu t Current A Outpu t Pow er W AC INPUT N L ...

Page 30: ...sted and approved the following GFCIs for use with the Freedom HW For more information about GFCIs see the application note Using GFCI Receptacles on Xantrex Inverters and Inverter Chargers in the Document Library at www xantrex com WARNING Shock fire and energy hazards Make sure wiring is disconnected from all electrical sources before handling All wiring must be done in accordance with applicabl...

Page 31: ... be either solid or stranded as required but must have three conductors and sized as in Table 1 4 on page 1 16 The AC terminal block accepts wire sizes up to No 10 AWG 6 Strip approximately 3 8 inch 10 mm off the insulation of each conductor 7 Remove the AC wiring compartment cover 8 Run the AC cable through the left hand side knockout and into the wiring compartment 9 Fasten the Ground wire to th...

Page 32: ...ompartment Ensure you have maintained correct polarity and that there are no loose strands of wire 13 Reinstall the AC wiring compartment cover 14 Connect the outgoing AC wires to the AC load panel CAUTION Reverse polarity Improper connections connecting a line conductor to a neutral conductor for example will cause the Freedom HW to malfunction and may permanently damage the inverter Damage cause...

Page 33: ... OUTLETS with GFCI MAIN AC PANEL TRANSFER SWITCH GENERATOR SHORE POWER INVERTER LOADS See Important note below See Important note below See Important note below CAUTION Equipment damage Do NOT connect the AC OUT Neutral and Line to the AC IN Neutral and Line Important The generator must have its neutral bonded to ground If it is not bonded a bonding jumper must be installed between the neutral and...

Page 34: ...anel SHORE POWER GENERATOR TRANSFER SWITCH MAIN AC PANEL AC OUTLETS with GFCI INVERTER LOADS Input breakers must be provided by installers See Important note below See Important note below CAUTION Equipment damage Do NOT connect the AC OUT Neutral and Line to the AC IN Neutral and Line Important The generator must have its neutral bonded to ground If it is not bonded a bonding jumper must be insta...

Page 35: ... not route your DC cables through an electrical distribution panel battery isolator or other device that will cause additional voltage drops Figure 1 8 shows the DC end for your reference CAUTION Before making the final DC connection check cable polarity at both the battery and the Freedom HW Positive must be connected to positive negative must be connected to negative Reversing the positive and n...

Page 36: ...ke sure no stray wires protrude from the connector or terminal You may find it more convenient to have the crimp connectors attached by the company that sells you the cable and or connectors 5 For each cable end that will be connected to the inverter strip 1 2 inch 13 mm to 3 4 inch 19 mm of insulation from the cable The amount stripped off will depend on the terminals chosen 6 Attach the connecto...

Page 37: ...al of the inverter CAUTION Loose connections cause excessive voltage drop and may cause overheated wires and melted insulation CAUTION Do not over tighten the nut on the DC input terminals Damage to the DC input terminals may result The maximum torque setting is 120 in lbf 13 6 N m CAUTION Reverse polarity DC power connections to the Freedom HW must be positive to positive and negative to negative...

Page 38: ...int as required by electrical regulations Use copper wire that is either bare or provided with green insulation Do not use the DC Ground Lug for your AC grounding See the AC wiring instructions in this section Follow the guidelines below that correspond to the specific type of installation These guidelines assume you are using the DC supply cable and fuse sizes recommended in this manual If you ar...

Page 39: ...orner holes using the display panel mounting template and cut out the hole in which the display panel will be inserted 4 Position the display panel mounting plate over the hole and fasten it to the wall using all four screws in all the corners of the mounting plate 5 Route the communications cable s inside the wall and through the mounting plate opening 6 Insert the cable s connector the one throu...

Page 40: ...re shore power is not present 2 Press the Inverter button to turn the inverter on The status LED on the display panel glows yellow and the LED display illuminates 3 Plug an appliance within the power rating of the inverter into the AC outlet hard wired to the Freedom HW 4 Turn the appliance on to verify that it operates If the appliance operates your installation is successful If your installation...

Page 41: ... will change from yellow to a ten second flashing yellow and then green If the appliance operates your installation is successful Note If the Inverter button on the Freedom HW is set to Standby the Freedom HW will automatically supply the appliances with inverter power if the shore power source fails or becomes disconnected or the shore power voltage is too low less than 95 volts AC WARNING Shock ...

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Page 43: ...2 1 2 Specifications Chapter 2 contains electrical performance information and product specifications Note Specifications are subject to change without notice ...

Page 44: ...ting 11 8 12 3 V 12 6 V Safe non operating voltage range 0 16 Vdc Normal voltage 12 5V Nominal current at full load 100A AC Output Output voltage 120 Vac Continuous power 1 0kW 25 C Surge power 17A 2kW for 200 ms Max short circuit current 55A peak Frequency 60 Hz Wave shape Modified Sinewave Power derating above 40 C ambient temp See Invert Power Derating vs Ambient Temperature on page 2 6 Peak ef...

Page 45: ...Min battery voltage for charging 0 0 Vdc Max output voltage 14 4 Vdc Nominal output current User selectable 5 A 15 A 35 A 55 A Charger current derating Automatically reduce charger current as internal temperature exceeds 80 C and input Vac approaches low transfer Efficiency at nominal output 78 Other Battery type settings Flooded default Gel AGM or Fixed 13 5V Charge algorithms Three stages Bulk A...

Page 46: ...ity Operation Storage 5 95 RH non condensing Pass through 120 Vac 60 Hz 30 A 3 hr Max 24 A continuous Transfer relay rating 30A 2 0hp Transfer time 30ms milliseconds Transfer on bad voltage 90 100V for low AC and 130 140 for high AC Cooling Fan activated by any of the following High internal temperature High AC output power Unit Dimensions and Weight Length 15 5 39 3cm Width 9 5 24 1cm Height 4 2 ...

Page 47: ...s graph shows how long measured in seconds the Freedom HW will operate for a given output current measured in Amps The graph illustrates inverter operation at 25 C ETL approved to CSA 107 1 UL458 10 12 14 16 18 20 30 40 50 Time sec 1600 1400 1200 1000 800 600 400 200 0 Output Current Amps 4000 ...

Page 48: ... the unit is in inverter mode and in elevated ambient temperature above 25 C you will have to reduce power draw according to the following chart to avoid over temperature shutdown 0 Watts 50 C 25 30 35 40 45 1000 900 750 33 C 30 C 900 W 850 W 800 W 750 W 12 5 V 11 5 V ...

Page 49: ... fall as the Freedom HW draws current To reduce the chance of the shore power voltage collapsing below the configured transfer level the Freedom HW will reduce the charging current at low shore power voltage according to the following graph Table 2 1 Charging Voltage Battery Type Bulk Absorption Volts Float Volts Flooded 14 4 13 5 GEL 14 2 13 8 AGM 14 3 13 4 Fixed 13 5 13 5 95V 105V 135V 55A 35A ...

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Page 52: ...Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free NA customerservice xantrex com www xantrex com 975 0468 01 01 Printed in China ...