Installation Guide
Freedom HW 1000
Inverter/Charger
Freedom HW 1000
Inverter/Charger
Installation Guide
This guide for use by qualified installers only
About Xantrex
the development, manufacturing and marketing of advanced power electronic products and systems for
the renewable and mobile power markets. The company's products convert and control raw electrical
power from any central, distributed, renewable, or backup power source into high-quality power
required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver,
Canada, with facilities in the United States, Germany, Spain, and a joint venture in China.
About Schneider Electric
As a global specialist in energy management with operations in more than 100 countries, Schneider
Electric offers integrated solutions across multiple market segments, including leadership positions in
energy and infrastructure, industrial processes, building automation, and data centres/networks, as well
as a broad presence in residential applications. Focused on making energy safe, reliable, and efficient,
the company's 120,000 employees achieved sales of more than 17.3 billion euros in 2007, through an
active commitment to help individuals and organizations “Make the most of their energy™”.
Trademarks
Xantrex, Freedom, Smart Choice for Power, and Make the most of their energy are trademarks of
Schneider Electric Services International sprl, registered in the U.S. and other countries.
Other trademarks, registered trademarks, and product names are the property of their 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 Technology Inc. reserves the right to revise this document and to periodically
make changes to the content hereof without obligation or organization of such revisions or changes
unless required to do so by prior arrangement.
Exclusion for Documentation
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 LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER
SPECIAL, 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; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH
STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT
BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE
VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
Document Part Number
Product Number
December 2008 Rev A
975-0468-01-01
806-1055
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 408 987 6030 (direct)
Fax:
1 800 994 7828 (toll free North America)
Email:
Web:
This guide for use by qualified installers only
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for setting up and installing a Freedom HW Installation*.
For complete information on how to operate, maintain, and troubleshoot
the Freedom HW unit, see the Freedom HF Inverter/Charger Owner’s
Guide (Doc. Part Number: 975-0467-01-01)
* Recreational or Fleet Vehicle.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, as well as procedures for installing the inverter/charger unit.
It 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 the applicable installation
codes, and awareness of the hazards involved in performing electrical
work and how to reduce those hazards.
Organization
This Guide is organized into two chapters.
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About This Guide
Conventions Used
The following conventions are used in this guide.
WARNING
Warnings identify conditions or practices that could result in personal injury or
loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or
other equipment.
Important: These notes describe things which are important for you to know,
but not as serious as a caution or warning.
Related Information
You can find more information about Xantrex Technology Inc. as well as
its products and services at www.xantrex.com
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Important Safety Instructions
READ AND SAVE THIS INSTALLATION GUIDE FOR FUTURE
REFERENCE.
This chapter contains important safety and operating instructions for the
Freedom HW Inverter/Charger unit.
WARNING: Limitations on use
The Freedom HW is not intended for use in connection with life support systems
or other medical equipment or devices.
1. Before installing and using the Freedom HW, read all instructions and
cautionary markings on the Freedom HW, the batteries, and all
appropriate sections of this guide.
CAUTION: Risk of injury
To reduce the risk of injury, charge only 12 Vdc lead-acid (GEL, AGM, or
Flooded) rechargeable batteries. Other battery types may burst, causing personal
injury and damage.
2. Do not expose the Freedom HW to rain, snow, spray, or bilge water.
To reduce risk of fire hazard, do not cover or obstruct the ventilation
openings. Do not install the Freedom HW in a zero-clearance
compartment. Overheating 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, been
dropped, or otherwise damaged in any way. If the Freedom HW is
damaged, see the Warranty section.
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6. Do not disassemble the Freedom HW. It contains no user-serviceable
parts. See Warranty for instructions on obtaining service. Attempting
to service the Freedom HW yourself may result in a risk of electrical
shock or fire and will void your warranty. 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 Freedom HW before attempting any maintenance or
cleaning or working on any circuits connected to the Freedom HW.
Turning off controls will not reduce this risk.
8. The Freedom HW must be provided with an equipment-grounding
conductor connected to the AC input ground.
WARNING: Explosion hazard
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 install the Freedom HW
in compartments containing batteries or flammable materials, or in
locations that require ignition-protected equipment. This includes any
space containing gasoline-powered machinery, fuel tanks, as well as
joints, fittings, or other connections between components of the fuel
system.
3. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer and the manufacturer of
any unit you intend to use in the vicinity of the battery.
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Personal Precautions When Working With Batteries
WARNING: BATTERIES PRESENT RISK OF ELECTRICAL SHOCK
,
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE OR
EXPLOSION FROM
PRECAUTIONS
VENTED GASES. OBSERVE PROPER
.
1. Study and follow all of the battery manufacturer's specific
precautions, such as removing or not removing cell caps while
charging, and recommended rates of charge.
2. Add distilled water in each cell until battery acid reaches the level
specified by the battery manufacturer. This helps to purge excessive
gas from cells. Do not overfill. For a battery without cell caps,
carefully follow manufacturer's recharging instructions.
3. Make sure the area around the battery is well ventilated.
4. Never smoke or allow a spark or flame near the engine or batteries.
5. Use extra caution to reduce the risk or dropping a metal tool on the
battery. It could spark or short circuit the battery or other electrical
parts and could cause an explosion.
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, clothing, or eyes.
9. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
10. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.
11. If you need to remove a battery, always remove the ground terminal
from the battery first. Make sure all accessories are off so you don’t
cause an arc.
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12. Never charge a frozen battery.
13. Clean battery terminals. Be careful to keep corrosion from coming
into contact with your eyes.
14. Locate the Freedom HW unit away from batteries in a separate, well
ventilated compartment.
15. Never place the Freedom HW unit 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 position and opening AC
disconnect.
19. Proper disposal of batteries is required. Refer to your local codes for
disposal requirements.
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Contents
Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
Materials List- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Basic Installation Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Step 1: Designing the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Step 2: Choosing a Location for the Freedom HW - - - - - - - - - - - - - - - - - - - - 1–12
Step 3: Mounting the Freedom HW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
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Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Charger Output Current vs. AC Input Voltage- - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
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1
Installation
Chapter 1 provides information to help in installing a
Freedom HW Inverter/Charger Installation.
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.
including mounting and connecting the equipment
ground, AC cabling, DC cabling, and grounding
steps.
1–1
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Materials List
Your Freedom HW Inverter/Charger package includes the items listed
below.
•
•
Freedom HW Inverter/Charger unit
display panel (p/n: 808-9557) with
7-inch (0.17 m) display panel cable (p/n: 053-0049-02)
•
•
•
•
•
display panel mounting plate (p/n: 808-9555)
display panel mounting template (p/n: 531-0081-01-01)
display panel compartment cover (p/n: 808-9556)
AC wiring compartment 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)
Freedom HW unit
Display panel is already mounted on the
unit and connected to the remote panel
port using the 7-inch display panel cable.
Underneath is the display panel
compartment that houses the remote
panel port and the remote dip switch.
Wiring compartment
cover
Display panel
compartment cover
Display panel
mounting plate
Figure 1-1 What’s In The Box
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Safety Instructions
Safety Instructions
WARNING: Shock hazard
Xantrex Technology recommends that all wiring be done by a certified technician
or electrician to ensure adherence to the applicable electrical safety wiring
regulations.
•
•
Before you begin the installation, review the “Important Safety
you can plan your installation from beginning to end.
Disconnect all AC and DC power sources to prevent accidental
shock. Disable and secure all AC and DC disconnect devices and
automatic generator starting devices.
Installation 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 to ensure that all applicable installation
requirements are met.
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Installation Tools and Materials
You will need the following to install the Freedom HW:
❐ Wire stripper
❐ Mounting screws or bolts
❐ #2 Phillips screwdriver
❐ Wrench for DC terminals (1/2 inch or 13mm or adjustable)
❐ AC cable (i.e. 2-conductor-plus-ground cable), sized appropriately
for load and application
❐ Wire nuts or crimp connectors for AC wire and appropriate tools
❐ DC cable, sized appropriately for load and application
❐ Lugs for DC cables to fit 8 mm (5/16 in.) DC stud terminals) as well
as appropriate tools (e.g. crimping tool)
❐ AC and DC disconnects and over-current protective 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 load panel.
6. Connect one end of the DC negative cable to the negative of the
battery, and the other to the negative terminal of the unit.
7. Install an appropriately sized fuse and DC disconnect in the positive
cable.
8. Connect the DC positive cable to the positive of the battery, and to the
positive terminal of the unit.
9. Close the DC disconnect switch.
Do not proceed with installation until you have read “Safety Instructions”
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Basic Installation Procedures
Basic Installation Procedures
Xantrex recommends that you have your installation performed by a
qualified technician or electrician.
This section provides sample installation information as a guide for your
installation. For your convenience, the overall procedure is divided into
ten main steps:
❐ Step 2: Choosing a location for the Freedom HW.
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Step 1: Designing the Installation
Most Freedom HW installations share common components, and
components and their relationship to each other in a typical
recreational vehicle or fleet vehicle installation.
Equipment Ground
DC Fuse /
Disconnect or
Circuit Breaker
12V Deep Cycle
Battery
AC Load Panel
+
to engine
–
l
AC Source Panel
Vehicle Starting
Battery
Equipment Ground
Automatic or Manual AC
Source Select or Switch
Shorepower
Generator
Figure 1-2 Typical Recreational Vehicle and Fleet Vehicle Installation
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Basic Installation Procedures
AC shore power
A source of 120 V, 60Hz sine wave alternating current is needed to
provide energy to charge batteries and pass power through to AC loads.
This source is usually the utility grid (power company) or an AC
generator. An automatic or manual AC source selector switch can be used
to switch between the multiple sources of shore power to the Freedom
HW system.
The AC source feeding the Freedom HW must have the neutral conductor
bonded to ground. When the inverter passes shore power through, it will
lift the bonding relay on the output and will rely on the input being
bonded in order to ensure that the power delivered to a sub panel is
properly bonded. See “AC Output Neutral Bonding” on page 1–9 for
more information on bonding relay operation.
Important: Throughout this manual, the term “shore power” refers to AC
input power from a utility grid, generator, or other AC source.
Generator
The Freedom HW is compatible with most generators which produce
nominal 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
Most safety requirements and electrical codes require the Freedom HW’s
AC and DC inputs and outputs to be provided with over-current
protection (such as circuit breakers or fuses) and disconnect devices.
Protection
Device
AC Input: The circuit breaker or fuse (connected through hard
wiring) that is used to supply the Freedom HW must be rated at no
more than 30A and must be approved for use on 120 Vac branch
circuits. The wire used between the breaker and the Freedom HW
input must be sized adequately to carry current up to the rating of the
input breaker and in accordance with the electrical codes or
regulations applicable to your installation.
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AC Output: The circuit breaker or fuse must be rated at no more than
the rating of the input breaker in the installation and must be
approved for use on 120 Vac branch circuits. The wire used between
the Freedom HW and the AC output breaker must be of adequate size
to match the AC input circuit breaker’s rating. The wiring from each
AC output breaker to each of the loads must be adequately sized to
carry the current rating of the individual AC output breaker.
Disconnect Devices: Each system requires a method of
disconnecting the AC circuits. If the over-current protection devices
are circuit breakers, they will also serve as the disconnects. If fuses
are used, separate AC disconnect switches will be needed ahead of
the fuses. These will have to be a branch circuit rated for 120 Vac and
have an appropriate current rating.
AC Distribution
Panels
Most systems incorporate distribution centers both ahead of the Freedom
HW (the AC source panel) and between the Freedom HW and the loads
(the AC load panel). An AC source panel includes a main circuit breaker,
which serves as over-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.
CAUTION: Equipment damage
Do not connect the output of the Freedom HW to what is known as a “multi-wire
branch circuit”. These are four-wire circuits consisting of a ground, neutral, and
two lines that are 180 degrees out of phase with each other (from a standard 120/
240V “split phase” circuit). These circuits are commonly used in kitchens to
power “split receptacles” where the top and bottom halves of a duplex receptacle
are connected to different lines.
AC Cabling
AC cabling includes all the wires and connectors between the AC source
and the Freedom HW, as well as all cabling between the Freedom HW
and the AC output panels, circuit breakers, and loads. The type and size of
the wiring varies with the installation and load. For example, in high
vibration environments, such as RV applications, wire nuts may not be
acceptable, so crimp splices would be required. In other applications,
flexible multiple-strand wire may be required. Installation codes usually
specify solid or stranded, overall size of the conductors, and type and
temperature rating of the insulation around the wire.
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Basic Installation Procedures
AC breakers and fuses must be sized to adequately protect the wiring that
is installed on the input and output AC circuits of the Freedom HW. All
breakers and wiring must be sized and connected in accordance with the
electrical codes or regulations applicable to your installation. Table 1-1
gives some examples of wiring sizes based on the U.S. National Electrical
Code and the Canadian Electrical Code. These examples are based on
using a 2-conductor-plus-ground cable rated at 75 °C, and assuming an
ambient temperature of up to 30 °C. Ensure that your breakers, and fuses
have suitable temperature ratings for your wiring. Other codes and
regulations may also be applicable to your installation.
Table 1-1 Required AC Wire Size vs Breaker Rating
15A
20A
30A
Breaker Size
14AWG
12AWG
10AWG
Minimum Wire Size
AC Output
Neutral
Bonding
The neutral conductor of the Freedom HW’s AC output circuit (i.e., AC
Output Neutral) is automatically connected to the safety ground during
inverter operation. When the Freedom HW is using AC shore power, this
connection is not present, so that the utility neutral (i.e., AC Input
Neutral) is only connected to utility ground at your source. This conforms
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, the AC Input Neutral and Output Neutral
must be isolated from each other.
DC Cabling
This includes all the cables and connectors between the batteries, the DC
disconnect and over-current protection device, and the Freedom HW.
Most mobile installations require multi-strand insulated cables for
flexibility and durability in high vibration environments and require
disconnects and over-current devices. Electrical wiring sizes are indicated
by AWG notation. Under the AWG standard, a larger gauge number
indicates a smaller wire diameter. Wire size is usually marked on the
cable size and maximum fuse size for the Freedom HW. The DC cables
must be copper and must be rated 75 °C minimum. The cables should
be terminated with lugs that fit the DC stud terminals snugly (8 mm or
5/16 in. hole size).
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Table 1-2 Recommended Cable Sizes
Cable Length: Battery
to Inverter (one way) Minimum Cable Size
Maximum battery Fuse
Size
Inverter/Charger
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 Table 310.17 - 75C cables, assuming an
ambient temperature of 30 °C cables.
Important: Using the correct cable size is critical to achieving the rated
performance of the Freedom HW unit. When starting a heavy load the Freedom
HW can draw current surges from the battery of up to 400A. If the DC wiring is
too small the voltage drop from this surge will result in a voltage at the Freedom
HW terminals that is too low for the Freedom HW to operate correctly. The
Freedom HW may appear to operate correctly with smaller cables until a heavy
load such as a microwave or refrigerator attempts to start - then the unit may
work correctly sometimes and not work correctly other times.
DCDisconnects
and Over-
Current Devices
The DC circuit from the battery to the Freedom HW must be equipped
with a disconnect and over-current device. This usually consists of a
circuit breaker, a “fused-disconnect,” or a separate fuse and DC
disconnect. Do not confuse AC circuit breakers with DC circuit breakers.
They are not interchangeable. The rating of the fuse or breaker must be
matched to the size of cables used in accordance with the applicable
installation codes. The breaker or disconnect and fuse should be located
as close as possible to the battery, in the positive cable. Applicable codes
may limit how far the protection can be from the battery.
Batteries
The Freedom HW uses 12-volt battery banks. Every Freedom HW system
requires a deep-cycle battery or group of batteries that provide the DC
current that the Freedom HW converts to AC.
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Basic Installation Procedures
Ground Fault
Circuit
Interrupters
(GFCIs)
A GFCI is a device that de-energizes a circuit when a current to ground
exceeds a specified value that is less than that required to blow the circuit
breaker. GFCIs are intended to protect people from electric shocks and
are usually required 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 Freedom HW.
For more information about GFCIs, see the application note "Using GFCI
Receptacles on Xantrex Inverters and Inverter/Chargers" in the Document
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Step 2: Choosing a Location for the Freedom HW
WARNING: Fire and explosion hazard
This equipment contains components that tend to produce arcs or sparks. To
prevent fire or explosion, do not install the Freedom HW in compartments
containing batteries or flammable materials, or in locations that require ignition-
protected equipment. This includes any space containing gasoline-powered
machinery, fuel tanks, or joints, fittings, or other connections between
components of the fuel system.
WARNING: Fire hazard
To reduce the risk of fire, do not cover or obstruct the ventilation openings. Do
not install the Freedom HW in a zero-clearance compartment. Overheating may
result.
The Freedom HW should only be installed in locations that meet the
following requirements:
❐ Dry. Do not allow water or other fluids to drip or splash on the
Freedom HW. Do not mount the Freedom HW in an area subject
to splashing water or bilge water.
❐ Cool. Normal air temperature should be between 21 °F and 165 °F
(–20 °C and 60 °C)—the cooler the better.
❐ Ventilated. Allow at least 5 in. (13cm) of clearance at the DC end of
the Freedom HW for air flow, 1 in. (2.5cm) on each side, and 2 in.
(5cm) at the AC end. The more clearance for ventilation around the
unit, the better the performance. Do not allow the ventilation
openings on the ends of the unit to become obstructed.
❐ Safe. Do not install the Freedom HW in the same compartment as
batteries or in any compartment capable of storing flammable liquids
like gasoline.
❐ Close to the battery compartment and the AC 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 where it will be
exposed to gases produced by the batteries. These gases are very
corrosive, and prolonged exposure will damage the Freedom HW.
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Basic Installation Procedures
Step 3: Mounting the Freedom HW
To mount the Freedom HW:
1. Remove the Freedom HW from its shipping container, verify that all
components are present, and record relevant product information on
Freedom HF Inverter/Charger Owner’s Guide (Doc. Part Number:
975-0467-01-01) Warranty section.
1-3 below.) To meet regulatory requirements, 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)
1
2
3
Figure 1-3 Approved Mounting Orientations
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 the mounting surface. If you are mounting
the unit on a wall or bulkhead, use #12 or #14 pan-head wood or sheet
metal screws to secure it to the framing behind the wall or bulkhead.
Alternatively, use nut inserts and 1/4-20 machine screws.
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Connecting the Equipment Ground
WARNING: Fire hazard
Never operate the Freedom HW without properly connecting the equipment
ground. A fire hazard could result from improper grounding.
The Freedom HW has a ground stud on the side of the unit as shown in
the inverter’s chassis to the ground.
Equipment
ground stud
Figure 1-4 DC Panel Connections
Grounding Locations
You must connect the equipment ground stud to a grounding point—
usually the vehicle’s chassis or DC negative bus ground—using
recommended copper wire (if insulated then green insulation with or
without one or more yellow stripes) or larger.
For recommended equipment ground cable size, see below.
Table 1-3 Recommended Equipment Ground Cable size
Minimum equipment ground cable size
Application
(Stranded cable is recommended)
a
No. 8 AWG
Recreational Vehicle
Note: There are no restrictions on length for the equipment ground cable.
a.Based on US National Electrical Code NFPA70, Article 551, par. 551-20c 2005
version.
In general, the equipment ground cable size must not be smaller than one
AWG size than the supply cable.
1–14
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Basic Installation Procedures
Step 4: Connecting the AC Input Wires
WARNING: Fire, Shock and Energy hazards
Make sure wiring is disconnected from all electrical sources before handling. All
wiring must be done in accordance with local and national electrical wiring
codes. Do not connect the output terminals of the Freedom HW to any incoming
AC source.
General AC Wiring Considerations
AC cable size
The AC input cable may be either solid or stranded (as required), but must
AC Wiring
Connectors
Connect AC wires with crimp-on splice connectors.
The amount of insulation you strip off individual wires will be specified
by the connector manufacturer and is different for different types of
connectors.
AC and DC
Wiring
Separation
Do not mix AC and DC wiring in the same conduit or panel. Where DC
and AC wires must cross, make sure they do so at 90° to one another.
Consult applicable codes for details about DC and AC wiring in close
proximity to each other.
AC Wiring
For your reference, the AC Wiring Compartment is shown in Figure 1-5.
Compartment
AC Wiring
To hard wire the 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 must be sized appropriately to carry full load current on the
input and output AC circuits in accordance with the electrical codes or
National Electrical Code, 2003 Ed. and the Canadian Electrical Code,
assuming 2-conductor-plus-ground cable, using 75 °C wiring, at an
ambient temperature of 30 °C. Other codes and regulations may be
applicable to your installation.
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Table 1-4 Required AC wire size vs. required breaker rating
Required Breaker Size Required Wire Size
30 A maximum
10 AWG
Freedom HW
There are two knockouts on the front panel for AC input and output
wiring.
CAUTION: Equipment damage
The AC wiring terminal block is split into input and output sections. Damage to
the inverter will occur if the unit is wired incorrectly.
When making the AC input and AC output connections, observe the
correct color code for the appropriate AC wire, as described in Table 1-5.
Table 1-5 Color codes for typical AC wiring
Color
AC Wire
Line
Black or Brown
White or Blue
Neutral
Green, Green/Yellow, Ground
or bare copper
AC Input Connections
1. Ensure that AC and DC power are both OFF.
2. Install the required circuit breaker in the AC output panel supplying
3. Remove the AC wiring compartment cover.
4. Remove the left-hand side AC wiring knockout from the front panel
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
1–16
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Basic Installation Procedures
AC input
AC output
STATUS
Util ity
Ba tte ry
Fault
ground screw
ground screw
Inpu
Inpu
t
t
Voltag
Cu rre nt (A)
Powe r (W )
e
(V )
Select
Outpu
t
HW
FREEDOM HW 1000
AC knockout
AC knockout
Figure 1-5 Freedom HW AC Wiring Compartment
6. Strip about 2 inches (50 mm) from the jacket of the AC input cable.
The AC input cable may be either solid or stranded (as required), but
(The AC terminal block accepts wire sizes up to No. 10 AWG.)
7. Strip approximately 3/8 inch (10 mm) from the insulation of each
conductor.
8. Run the AC cable through the right-hand side knockout and into the
wiring compartment.
9. Fasten the Ground wire to the grounding screw.
10. Using the 1/8 inch slot screwdriver, loosen the wire attachment
screws on the terminals.
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 caused by a reverse polarity connection is not
covered by your warranty.
11. Insert 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.
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Step 5: Connecting AC Output to an Existing AC Circuit
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 applicable local and national electrical
wiring codes.
WARNING: Shock hazard and equipment damage
Do not connect any AC source (such as a generator or utility power) to the
AC wiring output of the Freedom HW.
The Freedom HW will not operate if its output is connected to AC voltage from
another source, and potentially hazardous or damaging conditions may occur.
These conditions can occur even if the inverter is off.
Do not connect the Freedom HW to an AC branch circuit that has
high-power consumption loads.
The Freedom HW will not operate electric heaters, air conditioners,
stoves, and other electrical appliances that consume more than 1000
watts.
A Xantrex-tested and approved GFCI must be connected to the Freedom
HW AC output, and on every receptacle connected to the AC hard wired
installation. Other types may fail to operate properly when connected to
the Freedom HW. Although you can reuse the factory-installed GFCI,
Xantrex has also tested and approved the following GFCIs for use with
the Freedom HW.
Make
Model
Hubbell
Leviton
GFR5252
6598, 8598
For more information about GFCIs, see the application note “Using GFCI
Receptacles on Xantrex Inverters and Inverter/Chargers” in the Document
1–18
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Basic Installation Procedures
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 applicable local and national electrical
wiring codes. Do not connect the output leads of the inverter to any incoming AC
source.
To make a permanent connection to existing AC wiring (continuing
1. Ensure that AC and DC power are both OFF.
2. Install the required value of circuit breaker in the AC load panel (see
3. Remove the left-hand side AC wiring knockout from the front of the
unit.
Important: The applicable installation code may not allow you to run the AC
IN and AC OUT wiring through the same AC knockout.
4. Locate the terminal block.
The two output terminals are labeled as follows:
•
•
AC Output (L)
AC Output (N)
A separate screw is provided to connect the AC output ground.
5. Strip about 2 inches (50 mm) from the jacket of the AC output cable.
The AC output cable may 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 the grounding screw.
10. Using the 1/8 inch slot screwdriver, loosen the wire attachment
screws on the terminals.
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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 caused by a reverse polarity connection is not
covered by your warranty.
11. Insert 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.
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.
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Basic Installation Procedures
CAUTION: Equipment damage
Do NOT connect the AC OUT Neutral and Line
to the AC IN Neutral and Line.
See Important note below.
See Important
note below.
GENERATOR
INVERTER SUBPANEL
See Important
note below.
TRANSFER SWITCH
SHORE POWER
AC OUTLETS (with GFCI)
MAIN AC PANEL
INVERTER LOADS
Figure 1-6 AC Wiring Diagram with an Inverter Subpanel
In this wiring diagram, the AC input to the Freedom HW comes from the
main AC panel which contains the input circuit breaker. The AC output
wiring is routed to a separate inverter subpanel with a dedicated circuit
breaker.
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 ground at
the generator’s output or at the generator side of the transfer switch.
Also, both the main AC panel and the inverter subpanel must not have a
permanent neutral to ground bonds installed.
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CAUTION: Equipment damage
Do NOT connect the AC OUT Neutral and Line
to the AC IN Neutral and Line.
See Important note below.
GENERATOR
See Important
note below.
TRANSFER SWITCH
MAIN AC PANEL
SHORE POWER
Input breakers must
be provided by
installers.
AC OUTLETS (with GFCI)
INVERTER LOADS
Figure 1-7 AC Wiring Diagram without an Inverter Subpanel
In this wiring diagram, the AC input to the Freedom HW comes directly
from an AC source. The AC source input wiring must be protected by an
AC breaker of 30 A max. The output wiring is routed to the main AC
panel which is also protected by AC breakers or circuit breakers.
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 ground at
the generator’s output or at the generator side of the transfer switch.
Also, the main AC panel must not have a permanent neutral to ground bond
installed.
1–22
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Basic Installation Procedures
Step 6: Connecting the DC Cables
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 negative battery cables will damage the Freedom HW
and void your warranty. This type of damage is easily detected.
WARNING: Fire hazard
Use only copper wire rated 75 °C minimum. Make sure all DC connections are
tight to a torque of 108–120 in-lbf (12.2–13.6 N-m). Loose connections will
overheat.
Follow the procedure given below to connect the battery leads to the
terminals on the DC end. The cables should be as short as possible and
large enough to handle the required current, in accordance with the
electrical codes or regulations applicable to your installation. Table 1-2
on page 1–10 specifies the minimum DC cable size and maximum fuse
size for the Freedom HW.
Do 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.
Figure 1-8 DC End
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To make the DC connections
Refer to Figure 1-9.
1. Make sure the inverter is off and no AC or DC is connected to the
unit.
2. Remove the nuts and washers from the Freedom HW positive and
negative DC terminals.
3. Strip 1/2 inch (13 mm) to 3/4 inch (19 mm) insulation from one end
of each cable. The amount stripped off will depend on the terminals
chosen.
4. Attach the connectors that will secure the cables to the battery, to the
disconnect/battery selector switch, and the fuse block. The connectors
you use must create a permanent, low-resistance connection.
If crimp connectors are required, Xantrex recommends using
approved and certified connectors, and to use the tool recommended
by the terminal manufacturer. Make 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 connector that will join the cable to the inverter DC
terminal.
7. Install a fuse and fuse holder in the cable that will be used for the
positive side of the DC circuit.
The fuse must:
•
•
•
be as close to the battery positive terminal as possible,
be rated for DC circuits,
have an Ampere Interrupting Capacity (AIC) that exceeds the
short-circuit current available from the battery (i.e., Class T fuse).
8. To prevent sparking when making the connection, ensure the
disconnect/battery selector switch is off.
9. Attach the connector on the positive cable to the positive DC terminal
on the inverter.
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Basic Installation Procedures
10. Install the lock washer and nut that are supplied with the inverter.
Tighten the nut to a torque of 108–120 in-lbf (12.2–13.6 N-m). Make
the connection snug enough so the ring terminal does not move
around on the DC terminal, but do not overtighten. See Figure 1-9,
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.
A reverse polarity connection (positive to negative) will blow a fuse in the
inverter and may permanently damage the inverter. The fuse is not user
replaceable and the inverter may need to be returned for servicing.
Damage caused by a reverse polarity connection is not covered by your warranty.
11. Before proceeding, double check that the cable you have just installed
connects the positive DC terminal of the inverter to the disconnect/
battery selector switch, fuse holder, and that the other end of the fuse
holder is connected to the positive terminal of the battery.
.
WARNING: Explosion or fire
Do not complete the next step if flammable fumes are present. Explosion or fire
may result if the disconnect/battery selector switch is not in the off position.
Thoroughly ventilate the battery compartment before making this connection.
12. Connect the cable from the negative post of the battery to the negative
DC terminal of the inverter.
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13. Install the lock washer and nut that are supplied. Tighten the nut to a
torque of 108–120 in-lbf (12.2–13.6 N-m). Make the connection snug
enough so the ring terminal does not move around on the DC
terminal, but do not overtighten.
Figure 1-9 DC Cable Connections
DC Grounding
To connect the DC ground:
The equipment grounding lug on the DC end of the Freedom HW is used
to connect the chassis of the Freedom HW to your system’s DC negative
connection or grounding bus point 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 are using different
sizes, refer to the applicable installation code for DC grounding details.
Recreational
Vehicle
Use 8AWG copper wire and connect it between the Chassis Ground lug
and the vehicle’s DC grounding point (usually the vehicle chassis or a
dedicated DC ground bus).
1–26
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Basic Installation Procedures
Step 7: Mounting the Display Panel
Xantrex has three communications cables of different lengths available
for purchase. Choose a 25-foot cable (p/n: 31-6257-00), 50-foot cable
(p/n: 31-6262-00), or a 70-foot cable (p/n: 31-6275-00).
Flush mounting the panel on a wall or bulkhead requires an opening
specified in the display panel mounting template. About 1.5 inches (3.8
cm) of free space is required within the wall to accommodate the depth of
the panel. Be sure there is no wiring or other obstructions within the wall
before you make an opening.
To mount the display panel:
1. Choose a location that is dry, out of direct sunlight, free from
corrosive or explosive fumes, and otherwise appropriate for mounting
an electronic device.
2. Remove the display panel from Freedom HW.
3. Pilot-drill the corner 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 through the opening) in the jack
on the backside of the display panel.
7. Place the display panel through the opening of the mounting plate and
secure it with two screws – one for each side.
8. Route the communications cable to the Freedom HW’s display panel
compartment and insert the other connector in the jack located near
the battery select dip switch.
9. Install the display panel compartment cover over the compartment
and secure it with two screws – one for each side.
Important: Do not route the communications cable in parallel and in conduit
with the AC and DC wires. In situations where the cable must cross with the AC
and DC wires, make sure they cross at a 90° angle to each other.
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Step 8: Testing Your Installation
WARNING: Shock hazard
Pressing the Inverter button to turn OFF the Freedom HW inverter function on
display panel does not disconnect DC or AC input power to the Freedom HW. If
shore power is present at AC input terminals, it will pass through to the AC
output.
There are two tests to be performed. The first test verifies that the
Freedom HW is inverting DC battery power and delivering AC power to
its output.
The second test is intended for installations where AC input and output is
hard wired to the Freedom HW. This test verifies that the Freedom HW
transfers from inverter power to shore power when shore power is
present.
Note: Shore power (pass-through) refers to the AC input power from a utility
grid, generator or external AC source.
When you are ready to test your installation and operate the Freedom
HW, close the DC fuse and Disconnect or the DC circuit breaker to
supply DC power to the Freedom HW.
Testing in Invert Mode
To test the Freedom HW in invert mode:
1. For hard wired installations, ensure 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 has AC input hard wired to the Freedom HW, proceed to
If the status LED on the display panel glows red, see the Troubleshooting
chapter.
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Basic Installation Procedures
Testing in Shore Power Mode
To test the Freedom HW in shore power mode:
◆ With the appliance from the previous test still connected and
operating, connect the shore power source.
The Freedom HW transfers the appliances to shore power. The status
LED on the display panel 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 hazard
Whether or not the Inverter button is turned ON, shore power will pass through
the Freedom HW to the output when shore power is within normal operating
range.
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1–30
2
Specifications
Chapter 2 contains electrical performance information
and product specifications.
Note: Specifications are subject to change without notice.
2–1
Electrical Specifications: Inverter Mode
DC Input
Low operating voltage range
“SdL” setting
10.5–15.5 V
11.8–15.5 V
High operating voltage range
“SdH” setting
Under voltage alarm/shutdown
Under voltage recovery
“SdL” setting
10.5/11.0 V
12.0 V
Under voltage alarm/shutdown
Under voltage recovery
“SdH” setting
11.8/12.3 V
12.6 V
Safe non-operating voltage range
Normal voltage
0–16 Vdc
12.5V
Nominal current at full load
AC Output
100A
Output voltage
120 Vac
Continuous power
Surge power
1.0kW @ 25 °C
17A
(2kW for 200 ms)
Max short-circuit current
Frequency
55A peak
60 Hz
Wave shape
Modified Sinewave
temp
Peak efficiency
Full load efficiency
Other
≥88%
≥85%
No load input power (producing
output voltage)
≤10W
Off mode current draw
≤3mA
2–2
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Electrical Specifications: Charge Mode
Electrical Specifications: Charge Mode
AC Input
Operating voltage range
Nominal current
95–135 Vac
12Aac at 55A charge, 120 Vac in
60 Hz
Nominal frequency
DC Output
Nominal voltage
12.0 Vdc
0.0 Vdc
Min battery voltage for charging
Max output voltage
Nominal output current
14.4 Vdc
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
Other
≥78%
Battery type settings
Flooded (default), Gel, AGM, or
Fixed (13.5V)
Charge algorithms
Three stages (Bulk, Absorption,
and Float)
Independent battery banks
1
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2–3
Environmental Specifications
Operating Temperature Range
32–104 ºF (0–40 ºC),
with output derated above 77 ºF (25 °C)
Storage Temperature Range
Humidity: Operation/Storage
-40–158 ºF (-40–70 ºC)
5–95% RH, non-condensing
System Specifications
Pass-through
120 Vac, 60 Hz, 30 A,
3-hr Max, 24 A continuous
Transfer relay rating
Transfer time
30A, 2.0hp
<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
Physical Specifications
Unit Dimensions and Weight
Length
Width
15.5” (39.3cm)
9.5” (24.1cm)
4.2” (10.6cm)
10.3 lbs (4.7 kg)
Height
Weight
2–4
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Regulatory Approvals
Regulatory Approvals
ETL approved to CSA 107.1, UL458
Inverter Overload Operation
This 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.
Time (sec)
4000
.
.
.
1600
1400
1200
1000
800
600
400
200
0
10
12
14
16
18
20
30
40
50
Output Current (Amps)
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2–5
Invert Power Derating vs. Ambient Temperature
If 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.
Watts
30 °C
@ 12.5 V
1000
900 W
850 W
800 W
750 W
@ 11.5 V
900
750
~33 °C
0
25 30 35 40 45 50 °C
2–6
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Charger Output Current vs. AC Input Voltage
Charger Output Current vs. AC Input Voltage
When the Freedom HW is charging batteries from a weak shore power
source the AC voltage may 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:
55A
35A
95V
105V
135V
Table 2-1 Charging Voltage
Battery Type
Flooded
GEL
Bulk/Absorption (Volts)
Float (Volts)
13.5
14.4
14.2
14.3
13.5
13.8
AGM
13.4
Fixed
13.5
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2–8
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
Printed in China
975-0468-01-01
|