RS3000
Installation Guide
RS3000 Sine Wave Inverter/Charger
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RS3000 Sine Wave Inverter/Charger
Installation Guide
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About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from
50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup
power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery
chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute
electrical power.
Trademarks
RS3000 Sine Wave Inverter/Charger is a trademark of Xantrex International. Xantrex and Xanbus are registered
trademarks 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.
Notice of Copyright
RS3000 Sine Wave Inverter/Charger Installation Guide © December 2004 Xantrex International. All rights reserved.
Disclaimer
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.
Date and Revision
December 2004 Rev B
Part Number
975-0171-01-01
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct)
Fax:
1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email:
Web:
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About This Guide
Purpose
The RS3000 Sine Wave Inverter/Charger Installation Guide describes the
procedure for installing the RS3000 Sine Wave Inverter/Charger
(RS3000).
Scope
The Installation Guide provides safety guidelines, detailed planning and
setup information, and procedures for installing the inverter/charger. It
does not provide information on operation, configuration,
troubleshooting, and warranty and product information. Refer to the
RS3000 Sine Wave Inverter/Charger Operation Guide.
This guide does not provide details about particular brands of batteries.
You need to consult individual battery manufacturers for this information.
Audience
The Installation Guide is intended for qualified installers who need to
install the RS3000. Installers should be certified technicians or
electricians.
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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: Important notes provide information that is important for you to
know. They are not as critical as Cautions or Warnings.
Symbols Used
The following symbols are used on the product labels or in this guide.
In this guide: Important information, warnings or cautions.
!
On the product: Important information, warnings or cautions
with further explanation in the product guides.
AC – Alternating current
"
DC – Direct current
#
Warning: Hot surface. Do not touch.
$
DC ground connection point
%
AC safety ground connection point from incoming AC source
&
AC safety ground connection point for AC output (to AC loads)
'
Abbreviations and Acronyms
For a listing of abbreviations and acronyms, refer to the RS3000 Sine
Wave Inverter/Charger Operation Guide.
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About This Guide
Related Information
For related materials on this Xanbus-enabled product and its available
accessories, see also:
RS3000 Sine Wave Inverter/Charger Operation Guide (975-0170-01-01)
Automatic Generator Start Owner’s Guide (975-0082-01-01)
System Control Panel Owner’s Guide (975-0083-01-01)
Xanbus System Installation Guide (975-0136-01-01)
More information about Xantrex Technology Inc. as well as its products
and services, including a complete list of Xanbus-enabled devices, is
available at www.xantrex.com
Contact Information
Telephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct)
Fax:
1 800 994 7828 (toll free North America)
1 360 925 5143 (direct)
Email:
Web:
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Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS
The RS3000 Sine Wave Inverter/Charger Installation Guide contains
important safety instructions.
Before you install and use your RS3000 Sine Wave Inverter/Charger, be
sure to read, understand, and save these safety instructions and those in
the other product guides.
Read all cautionary markings on the inverter/charger, the batteries, and all
appropriate sections of this guide.
WARNING: Risk of injury or loss of life
The RS3000 Sine Wave Inverter/Charger shall not be used in connection with life
support systems or other medical equipment or devices.
WARNING
The following warnings identify conditions or practices that could result in
personal injury or loss of life.
1. Use of accessories not recommended or sold by Xantrex Technology,
Inc. may result in a risk of fire, electric shock, or injury to persons.
2. The inverter/charger 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 application.
3. To avoid a risk of fire and electric shock, make sure that the existing
wiring is in good condition and that the wire is not undersized. Do not
operate the inverter/charger with damaged or substandard wiring.
4. To reduce risk of damage and injury, charge only rechargeable
lead-acid batteries (flooded, gel, or absorbed glass mat (AGM) types).
Other types of batteries may burst causing personal injury and
damage.
5. Do not operate the inverter/charger if it has received a sharp blow,
been dropped, or otherwise damaged in any way. If the unit is
damaged, see the Warranty and Product Information section in the
RS3000 Sine Wave Inverter/Charger Operation Guide.
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Safety
6. Do not disassemble the inverter/charger; it does not contain user
serviceable parts. Take it to a qualified service person when service or
repair is required. Incorrect reassembly may result in a risk of
electrical shock or fire. Internal capacitors remain charged after all
power is disconnected. For instructions on obtaining service, see the
section in the RS3000 Sine Wave Inverter/Charger Operation Guide.
7. Do not expose the inverter/charger to rain, snow, or water.
8. To reduce the risk of electric shock, disconnect all sources of AC and
DC power from the Inverter/Charger before attempting any
maintenance or cleaning. Turning off controls will not reduce this
risk.
9. The inverter/charger must be provided with equipment grounding
conductors connected to the AC input ground and chassis ground
terminals.
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or
other equipment.
To reduce the risk of overheating, keep the ventilation openings clear and
do not install the inverter/charger in a compartment with limited airflow
or inadequate clearances around the unit. The minimum recommended
clearance is 3 inches (76 mm).
vi
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Safety
Explosive Gas Precautions
WARNING: Risk of explosive gases
Working in the vicinity of a lead-acid battery is dangerous. Batteries generate
explosive gases during normal battery operation. For this reason, it is of utmost
importance that each time before servicing equipment in the vicinity of the
battery, you must read this guide and follow the instructions closely.
1. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer and the manufacturer of
any equipment you intend to use in the vicinity of a battery. Review
the cautionary markings on these products and on the engine.
2. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the inverter/charger
in compartments containing batteries or flammable materials or in
locations that require ignition-protected equipment. This includes any
space containing gasoline-power machinery, fuel tanks, as well as
joints, fittings, or other connections between components of the fuel
system.
Personal Precautions When Working With Batteries
1. Someone should be within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid
contacts your skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
4. If battery acid contacts your skin or clothing, wash immediately with
soap and water. If acid enters your eye, immediately flood the eye
with running cold water for at least ten minutes and get medical
attention immediately.
5. Never smoke or allow a spark or flame in the vicinity of the battery or
engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto a
battery. It might spark or short-circuit the battery or other electrical
parts that may cause an explosion.
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Safety
7. Remove personal metal items such as rings, bracelets, necklaces, and
watches when working with a lead-acid battery. A lead-acid battery
can produce a short-circuit current high enough to weld a ring or the
like to metal, causing a severe burn.
8. Never charge a frozen battery.
9. If it is necessary to remove a battery, always remove the grounded
terminal from the battery first. Make sure all the accessories are off,
so as not to cause an arc.
10. Be sure the area around the battery is well ventilated.
11. Clean the battery terminals. Be careful to keep corrosion from coming
in contact with your eyes.
12. Study all battery manufacturer’s specific precautions such as
removing or not removing the cell caps while charging and the
recommended rates of charge.
13. For refillable (flooded) batteries, add distilled water in each cell until
the battery acid reaches the level specified by the battery
manufacturer. This helps to purge excessive gas from cells. Do not
overfill. Carefully follow the manufacturer’s recharging instructions.
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 when the equipment is operated in a residential environment.
This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction guide,
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 and the 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 radio/TV technician for help.
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Contents
Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii
Personal Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - vii
Installation Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Before You Begin the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
About the Xanbus System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Xanbus Enabled - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
System Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Planning the Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Two Key Performance Factors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Size and Length of DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
AC, DC, and Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
AC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
AC Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
AC Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Distribution Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
AC Output Neutral Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
DC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
DC Cabling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Unpacking and Inspecting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
Installing the Inverter/Charger- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
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Contents
Step 2: Mounting the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Connecting AC Input Wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
DC Connection Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Preparing the Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
Mounting Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
Step 6: Connecting to the Network - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
Step 7: Performing Checks Prior to Initial Start-Up - - - - - - - - - - - - - - - - - - - - - - - - 35
Battery Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Battery Bank Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Restrictions on Motor Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
Cabling and Hook-up Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
Parallel Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
Series Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
Series-Parallel Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
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Figures
RS3000 Hardware Materials as Shipped - - - - - - - - - - - - - - - - - - - - - - - - - 15
RS3000 Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
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Installation
The Installation Guide provides detailed information for installing the
RS3000 Sine Wave Inverter/Charger and the battery temperature
sensor, wiring the inverter/charger to the AC and DC circuits, and
connecting the inverter/charger to the Xanbus® system.
The RS3000 is a Xanbus-enabled device that typically powers the
Xanbus system. For information on installing the Xanbus system, see
the Xanbus System Installation Guide which is available for download
This Installation Guide provides:
•
•
•
•
•
•
•
safety instructions that must be observed during installation
a typical Xanbus system diagram
information on additional AC and DC components required
a list of installation tools and materials
detailed procedures for a typical installation
installation testing procedures
battery information
For information on operating the RS3000, see the RS3000 Sine Wave
Inverter/Charger Operation Guide.
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Installation
Installation Information
Before You Begin the Installation
Before beginning your installation:
•
Read the entire Installation Guide so you can plan the installation from
beginning to end.
•
Read the Xanbus System Installation Guide to plan your network
requirements.
•
•
•
Assemble all the tools and materials you require for the installation.
Review the Important Safety Instructions on page v.
Be aware of all safety and electrical codes which must be met.
WARNING: Electrical shock and fire hazards
Xantrex® recommends all wiring be done by qualified personnel. 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.
It is the installer’s responsibility to ensure compliance with all applicable installation
codes and regulations.
Installation Codes
Applicable installation codes vary depending on the specific location and
application of the installation. Some examples are:
•
The U.S. National Electrical Code (NEC)
The Canadian Electrical Code (CEC)
•
•
Canadian Standards Association (CSA) and RV Industry Association (RVIA)
for installation in RVs.
2
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Installation
About the Xanbus System
The Xanbus system includes the RS3000 Sine Wave Inverter/Charger and other
Xanbus-enabled devices, as shown in Figure 1, “Typical Xanbus System
Diagram”. Each Xanbus-enabled device interacts and communicates with the
other devices on the network, creating a power system that can be precisely
configured to your needs.
The RS3000 is the device that typically provides power in a Xanbus system. The
System Control Panel provides configuration and monitoring capability for each
device connected to the Xanbus system, such as the Automatic Generator Start
and the RS3000.
electrical connections are represented by solid lines. Your system requirements
may be more complex than the basic installation shown in Figure 1. Xantrex
recommends that you consult a qualified installer or electrican to customize your
installation to meet your requirements.
AC Out
AC In
Figure 1 Typical Xanbus System Diagram
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Installation
Xanbus Enabled
The Xanbus-enabled designation means that this product will work on a Xanbus
network. Xanbus-enabled products are:
•
Easy to use. The Xanbus network simplifies operation and automates routine
tasks.
•
•
•
Reliable. Software control eliminates analog signalling errors.
Accurate. Digital information is less susceptible to interference and line loss.
Upgradeable. Firmware upgrades mean your purchase will remain up to date.
For detailed instructions and a complete list of Xanbus-enabled devices, visit the
System Accessories
System accessories currently available which are Xanbus-enabled include the
System Control Panel and Automatic Generator Start. These system accessories
provide the part number of the accessory to the dealer.
Other Xanbus-enabled devices will become available in the future.
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Installation
Planning the Installation
This section provides information to help you plan for a basic installation of the
RS3000.
As your system configuration is determined, record the details in Information
About Your System on page WA-4 of the RS3000 Sine Wave Inverter/Charger
Operation Guide.
Two Key Performance Factors
Two key factors in particular will have a major impact on system performance.
Size and Length of DC Cables
To select the appropriate size and length of DC cables, see “DC Cabling” on
The DC 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. If there are long battery cables which are in excess of 10 feet
each and not of sufficient size, the voltage drop across the cables will have a
negative impact on overall system performance.
Mounting Location of the RS3000
To choose an appropriate location for mounting the inverter/charger, see
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Installation
Planning
AC, DC, and Network Components
For a successful installation, you need to plan for AC, DC, and network
components of the power system. The AC and DC components are described in
this section and illustrated in Figure 2 on page 7.
AC components include:
•
•
•
•
•
•
DC components include:
•
•
•
•
Network considerations include:
•
Cables, connectors, network connectors, and terminators for the System
Control Panel and Automatic Generator Start, if installing.
Detailed information on planning and installing your network is available in
the Xanbus System Installation Guide. Refer to the system guide to determine
the type of network layout to install, as well as guidelines for installing the
network. This guide is available for download at www.xantrex.com
6
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Installation
Sine Wave Inverter/Charger
Automatic Generator Start
System Control Panel
AC Out
AC In
DC +
DC Fuse
DC -
House Battery
AC Main Panel
Battery Temperature
Sensor
Isolator
Engine Battery
Non-Inverter Loads
R
T
ESETR E S
E
T
TESTT E S
Inverter AC Panel
Transfer Switch
UtilityPower
Xanbus-enabled
Devices
Alternator
Generator
Sensing and
control
Figure 2 Typical Recreational Vehicle Electrical System
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Installation
AC Components
AC Input
AC input to the RS3000 can be supplied from a split-phase or dual-input AC
source such as the utility grid (power company), a generator, or the output of a
transfer switch. The RS3000 can be operated from the following types of 120 volt
60 Hz AC sources:
•
Split phase: This source type has two lines, one neutral, and one ground. The
two 120 VAC lines are 180 degrees out of phase with each other, so that the
two voltages total to 240 VAC. The voltage between each line and neutral is
still 120 VAC, and the voltage between the neutral and ground is
approximately zero.
Because the two lines are out of phase, the currents from each line subtract in
the neutral, and the neutral current will be approximately zero if the loads are
equal. For example, if Line 1 is supplying 20A and Line 2 is supplying 15A,
the current in the neutral will be 5A.
•
Dual input: This source type has two line inputs, one neutral, and one ground.
Unlike the split-phase type, the two lines are in phase (not out of phase), and
must come from the same source. The voltage between the two lines is zero.
The voltage between each line and the neutral is 120 VAC, and the voltage
between the neutral and ground is approximately zero.
Because the two lines are in phase, the currents from each line add together in
the neutral. For example, if Line 1 is supplying 20A and Line 2 is supplying
15A, the current in the neutral will be 35A.
Important: Single-phase input (where only one of the AC inputs (L1 or L2) is
energized) is not supported because the RS3000 is designed for inputs that energize both
lines (L1 and L2). This may be accomplished with an appropriate transfer switch ahead of
the RS3000. Consult a qualified installer.
AC Output
AC Loads
AC output from the RS3000 is 120 VAC, and can be wired as single output or dual
output.
The RS3000 is intended to power loads consisting of 120 VAC appliances.
In Invert mode, the RS3000 connects L1 and L2 output lines together to provided
120 VAC to loads on either line. In AC Bypass mode, the source connected to the
AC input is passed through to the load. Because of the way invert mode operates,
only 120 VAC appliances can be connected to the RS3000 output.
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WARNING: Shock Hazard
Do not connect 240 VAC loads to the RS3000 outputs. Doing so may result in
120 VAC on exposed parts of the appliance.
AC Disconnect and Over-Current Protection Device
To meet CSA, UL, and electrical code requirements, and to protect system wiring,
the AC inputs and outputs of the inverter/charger must be provided with over-
current protection on both the AC input and output. This protection may be a
circuit breaker or a fuse with a disconnect device (for simplicity the following
refers to breakers). Refer to your applicable installation codes and the following
requirements:
AC Input Protection
The breakers protecting the AC input of the RS3000 must be approved for use on
120 VAC branch circuits, and must be located in each Line. The breakers must be
rated as shown below, so that the 50A maximum current that the inverter/charger
and its transfer relay can handle is not exceeded:
•
•
Split-phase input: No more than 50 amps max in each line.
Dual input: The neutral current in a dual-input system is the sum of the two
line currents, and must be limited to 50A max to protect the transfer relay.
Each breaker must not exceed 50A, and the total (sum) of the ratings of the
two breakers must not exceed 50A. For example, if Line 1 has a 30A breaker,
the Line 2 breaker cannot exceed 20A. The sum of the breakers can exceed
50A if both are fed from a common feeder line protected at no more than 50A
(for example a 50A breaker feeding a pair of 30A breakers).
AC Output Protection
The breaker between the RS3000 AC output and the AC loads must be rated to
protect the AC output wire size used. If the AC output wiring is based on the full
50A pass-through rating, then a 50A output breaker is acceptable. If the AC
output wiring is smaller, then the breaker size will have to be smaller as well, in
accordance with applicable electrical installation codes.
GFCI Requirements
A GFCI (ground fault circuit interrupter) is a device that deenergizes a circuit
when a current to ground exceeds a specified value that is less than that required
to open the circuit breaker. GFCIs are intended to protect people from electric
shocks and are usually required in wet or damp locations.
Installation in recreational vehicles requires GFCI protection of certain branch
circuits. Consult all applicable codes.
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Tested GFCIs
Compliance with UL standards requires that Xantrex test and recommend specific
tested and will function properly when connected to the AC output of the RS3000.
Table 1 Tested GFCI Models
Manufacturer
Hubbell
Model Number
GFR5252WA
8599-GY
Leviton
Pass & Seymour
1594-W
Disconnect Devices
Each system requires a method of disconnecting the AC circuits. If the over-
current protection device is a circuit breaker, it will also serve as the disconnect. If
fuses are used, separate AC disconnect switches will be needed between the
source and the fuses.
Distribution Panels
Some systems incorporate distribution panels both ahead of the inverter/charger
(the AC source panel) and between the inverter/charger and the loads (the AC
load panel). The AC source panel includes a main circuit breaker, which serves as
over-current protection for the panel. Additional circuit breakers serve individual
circuits, one of which serves the inverter/charger.
AC Wiring
Definition
AC wiring includes input wiring (all the wires and connectors between the AC
source and the inverter/charger input) and output wiring (all the wires between the
inverter/charger and the AC load panels, circuit breakers, and loads).
Type
The type of wiring required varies according to the electrical codes or regulations
applicable to your installation. For RV applications, this may be solid wire in
multi-conductor cables, but stranded wire is required if single conductors are
used. All wiring must be rated 90 °C or higher.
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Size of Input Wiring
Wire size must be coordinated with the overcurrent protection provided ahead of
the wire involved, in accordance with the electrical codes or regulations
applicable to your installation.
Therefore, the wiring used between the AC input circuit breaker and the inverter/
charger input must be sized to match the input breaker rating.
Table 2 AC Wire Size In and Out of the Inverter/Charger
Split phase
50 A
Dual input
25 A
Breaker Size Used
Wire Size
No. 8 AWG
No. 8 AWG
Color Coding
L1: black:
N: white
L2: red
L1: red or black
N: white
L2: red or black
Gnd: green
Gnd: green
For dual input, the wire may be red or black; consult the documentation provided
by the manufacturer of the power source (that is, the generator).
Size of Output
Wiring
Wire size must be coordinated with the current the wiring will carry. This may be
determined by the 25 A maximum inverter current, or by the bypass current,
which is determined by the overcurrent protection provided ahead of the RS3000
•
If the input wiring is split-phase, the output wiring must be sized to coordinate
with the breakers used on the input. Refer to your applicable installation
codes. For a 50 A input breaker, the output wiring is usually No. 8 AWG.
•
If the input wiring is dual-input and the output wiring is single-input, the
following rules apply: If the input breaker on L1 is greater than 25 A, the wire
size must be coordinated for that amperage. If the input breaker on L1 is less
than 25 A, the wire size must be coordinated for 25 A. The wire size must not
be sized for anything lower than 25 A.
•
If both the input and the output wiring are dual-input, the output wiring for
each line (L1 and L2) must be calculated separately, following these rules: If
the input breaker on the specific line is greater than 25 A, the wire size for that
line and its neutral must be coordinated for that amperage. If the input breaker
on the specific line is less than 25 A, the wire size for that line and its neutral
must be coordinated for 25 A. The wire size must not be sized for anything
lower than 25 A.
Size of Wiring
Downstream of the
AC Output Breaker
The wiring used between the AC output breaker and your loads must be sized to
match the output breaker.
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AC Output Neutral Bonding
The AC source must have its neutral conductor bonded to ground.
Bonding system
The RS3000 provides a system that automatically connects the neutral conductor
of the inverter’s AC output circuit to safety ground (“bonding” it) while the
inverter/charger is inverting, and disconnects it (“unbonding” it) when the
inverter/charger is connected to external AC power. This system is designed to
conform to installation codes that require AC sources such as inverters and
generators to have their neutral conductors tied to ground at the source of power in
the same way that the neutral conductor from the utility is tied to ground. These
same codes specify that the neutral can only be connected to ground in one place
at any one time.
Suitability
This automatic neutral-to-ground bonding system requires AC input sources with
bonded neutral. This will be the case in most situations: in a utility feed, at an
external AC hook-up, or a generator with a bonded neutral. If not, have an
electrician look into bonding the source’s neutral to ground. See also “AC Input
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DC Components
Batteries
The RS3000 system requires a 12 volt, lead-acid deep-cycle battery or group of
batteries to provide the DC current that the inverter/charger converts to AC power.
The battery may be a flooded, gel, or AGM type.
See “Battery Information” on page 40 for information on:
•
•
•
Estimating the battery size that will meet your requirements.
Designing battery banks.
Restrictions on the size of appliances.
For information on cabling and hooking up batteries, see “Cabling and Hook-up
For detailed information about specific brands of batteries, you’ll need to consult
individual battery manufacturers for this information.
DC Disconnects and Over-Current Devices
The DC circuit from the battery to the inverter/charger must be equipped with a
disconnect and over-current protection device. (Refer to your applicable
installation code.)
Type
This device 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.
Rating
The rating of the fuse or breaker must be matched to the size of cables used in
accordance with the applicable installation codes.
Location
The breaker or fuse and disconnect 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.
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DC Cabling
Definition
DC cabling includes all of the cables and connectors between the batteries, the DC
disconnect and over-current protection device, and the inverter/charger.
Type
All installations require multi-strand insulated cables. The DC cables must be
copper and must be rated 105 °C minimum.
Size and Length
See Table 3 for required DC cable length, cable size and required fuse size for the
RS3000. Wire size is usually marked on the cables.
Important: Using a smaller gauge cable or a longer cable may cause the inverter to
shut down under heavy load.
Table 3 Recommended DC Input Cable and Fuse Size
Maximum DC Cable
Length: Battery to
RS3000 (one way)
Total Length
(two way)
Minimum
Recommended
Cable Size
Maximum
Battery Fuse or
Breaker
10 feet (3 meters)
20 feet (6 meters) No. 4/0 AWG
400A class T
DC Grounding
The inverter/charger DC (chassis) ground terminal needs to be connected to the
vehicle chassis by a minimum No. 8 AWG copper conductor that is either
insulated (green) wire rated 90 °C or bare copper.
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Unpacking and Inspecting the Inverter/Charger
WARNING: Heavy load
The RS3000 Sine Wave Inverter/Charger is heavy (see “Inverter/Charger Physical
Xantrex recommends that two people lift and mount the unit. Always use proper lifting
techniques during installation to prevent personal injury.
Materials List
Contents
The following materials are in the shipping box:
•
•
•
RS3000 Sine Wave Inverter/Charger
DC terminal covers (one red, one black) and four screws
Bag containing DC terminal hardware:
•
•
•
Two flat washers
Two lock washers
Two 3/8" bolts
•
•
•
Battery temperature sensor
RS3000 Sine Wave Inverter/Charger Installation Guide
RS3000 Sine Wave Inverter/Charger Operation Guide
Figure 3 RS3000 Hardware Materials as Shipped
To unpack and inspect:
1. Unpack the unit and check the materials list. If anything is missing from the
shipping box, contact Xantrex Customer Service. See “Contact Information”
2. Record the serial number of the RS3000 and other purchase information in the
“Warranty and Product Information” section of the RS3000 Sine Wave
Inverter/Charger Operation Guide. You will be asked for this product
information if you need to call Xantrex Customer Service.
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3. Save your purchase receipt to use as proof-of-purchase. This is required if the
inverter/charger should need warranty service.
4. Save the original shipping carton and packing materials. If the inverter/
charger needs to be returned for service, it should be shipped in the original
carton. This is also a good way to protect the inverter/charger if it ever needs
to be moved.
Installation Tools and Materials
Tools
You will need the following tools to install the RS3000 and the battery
temperature sensor.
p
p
p
p
p
p
Wire stripper
Crimping tools for fastening lugs and terminals on DC cables
Phillips screwdriver: #2
Slot screwdriver (¼" wide blade max.)
Needle-nose pliers
Wrench for DC terminals: 9/16"
Materials
You will need the following materials to complete your installation:
p
p
p
p
p
p
Strain-relief clamp(s) for AC cables: 3/4" and/or 1"
DC battery cables sized according to Table 3 on page 14
Terminals and/or crimp connectors for DC cables (for 3/8" stud size)
Terminal or crimp connector for DC grounding cable (for 1/4" stud size)
AC and DC disconnect switches and over-current protective devices and
p
p
p
AC output and input wire. See Figure 2 on page 11
If the AC ground wire is stranded, each ground wire requires a ring terminal
Six 1/4"–20 1.25" length steel screws or bolts to mount the RS3000
For a list of tools and materials required to install the network, refer to the Xanbus
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Installing the Inverter/Charger
Overview
This section provides detailed information on installing the RS3000. The overall
procedure is divided into eight steps:
Step 1: Choosing a Location for the Inverter/Charger
WARNING: Risk of fire or explosion
This equipment contains components that could produce arcs or sparks. To reduce the risk
of fire or explosion, do not install this equipment 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
Do not cover or obstruct the ventilation openings. Do not install this equipment in a
compartment with limited airflow. Overheating may result.
The location of the inverter/charger is a key factor in system performance.
Allow sufficient clearance around the unit (recommended minimum 3 inches
(76 mm)) and install in a well-ventilated compartment to prevent overheating and
premature shutdown of the inverter/charger.
The inverter should only be installed in a location that meets the following
requirements:
Ventilated
Do not operate the inverter/charger in a closed-in area or restrict
ventilation in any way. The inverter/charger requires air circulation
to maintain optimum operating temperature and provide best
performance. If the unit has inadequate ventilation, it may shut down
due to overheating.
The air vented through the openings should also have a path to
circulate away from the inverter/charger.
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Dry
Do not allow water or other fluids to drip or splash on the inverter.
Do not expose to rain, snow or water.
Cool
Normal air temperature should be between 32 °F and 122 °F
(0 °C and 50 °C)—the cooler the better within this range.
Clearance
Allow as much space around the inverter/charger as possible.
Xantrex recommends that other objects and surfaces be at least
3 inches (76 mm) away from the ventilation openings for best
performance.
Safe
Locate the inverter/charger away from battery in a separate well
ventilated compartment. Do not install the inverter/charger in any
compartment containing flammable gases or liquids like gasoline.
Close to
battery
compartment
The length and size of your DC cables will affect performance. Use
not be installed in the battery compartment due to the possible
presence of explosive hydrogen gas from the batteries.
Protected
from battery
Never place the inverter/charger directly above the batteries—gases
from battery will corrode and damage the inverter/charger. If the
acid and gases inverter/charger is installed in a compartment above the batteries,
make sure there is a solid, gas-impermeable wall dividing the two
compartments.
Never allow battery acid to drip on the inverter/charger or its wiring
when filling the batteries or reading their specific gravity.
Orientation
To meet regulatory requirements, the RS3000 must be mounted in
WARNING: Fire Hazard
Mount the RS3000 only in an approved orientation.
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Step 2: Mounting the Inverter/Charger
Considerations
Before mounting the RS3000, take the following two factors into account.
1. The weight of the inverter/charger requires two people to install it.
WARNING: Heavy load
The RS3000 Sine Wave Inverter/Charger is heavy (see “Inverter/Charger Physical
Xantrex recommends that two people lift and mount the unit. Always use proper lifting
techniques during installation to prevent personal injury.
The RS3000 dimensions and location of the mounting holes are provided in
Mount your inverter/charger before you connect any wires or cables.
To mount the inverter/charger:
1. Remove the inverter/charger from its shipping container.
2. Verify that all components are present, and record relevant product
information on form WA-4 in the RS3000 Sine Wave Inverter/Charger
Operation Guide.
3. Select an appropriate mounting location and orientation. To meet regulatory
requirements, the RS3000 must be mounted in one of the orientations shown
5. Pilot drill the six mounting holes.
6. Fasten the inverter/charger to the mounting surface with six 1/4"–20 steel
screws or bolts.
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Figure 4 Mounting Orientations
Approved Mounting
Orientation?
Orientation
Comment
Desktop Mount
Yes
Upside-down
Mount
Maybe
Suitable only for applications with
no risk of condensation or dripping
water.
Wall Mount DC on
Left
Yes
On a vertical surface with DC
terminals facing left.
Wall Mount DC on
Right
Maybe
On a vertical surface with DC
terminals facing down. This
orientation is suitable only for
applications with no risk of
condensation or dripping water.
Wall Mount DC
Up
Maybe
On vertical surface with DC
terminals facing up. This
orientation is suitable only for
applications with no risk of
condensation or dripping water.
Wall Mount DC
Down
No
Not acceptable.
This orientation does not meet
regulatory requirements.
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Step 3: Connecting the AC Input and AC Output Wires
WARNING: Fire, shock, and energy hazards
Make sure wiring being connected to the inverter/charger is disconnected (physically or
by opening the breaker) from all electrical sources before handling. All wiring must be
done in accordance with local and national electrical wiring codes.
General AC Wiring Considerations
AC and DC Wiring Separation Do not mix AC and DC wiring in the same
conduit or panel. Consult the applicable installation code for details about DC
wiring and AC wiring in vicinity to each other.
AC Input and Output Isolation The AC input and output circuits of this
inverter/charger are isolated from each other when in invert mode to ensure safe
operation. This isolation must be maintained in the installation, by being sure not
to connect AC input and output wiring to a common point. For example, do not
route the AC input and output neutrals to a common neutral bus.
AC Wiring Compartment For your reference, the AC wiring compartment is
AC Knockouts There are two 3/4" trade-size knockouts on the front panel for
AC wiring. For easier wiring access, there are also 1" trade-size knockouts on
either side of the unit (not shown). Use the same trade size of strain relief as the
trade size of the knockout(s) you are using.
AC Wiring Terminals The AC wiring terminals accept cables of a specific
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Connecting AC Input Wires
Figure 5 shows the wiring compartment, which contains a grounding bus (used to
wire the AC input and output gound wires) and a terminal block (used to wire the
AC input and AC output connections).
Grounding bus
Terminal block
Figure 5 AC Wiring Compartment
CAUTION: Equipment damage
The terminal block is split into INPUT and OUTPUT sections. Damage may occur if the
unit is wired incorrectly.
Do not remove or loosen factory installed wiring.
When making the AC input and AC output connections, observe the correct color
To make the AC input connections:
1. Locate the wiring compartment cover panel and remove the four screws.
2. Remove the cover panel from the unit to access the wiring compartment.
3. Remove one of the AC knockouts from the front or side of the unit. Do not
leave the knockout inside the wiring compartment.
4. Install a strain-relief clamp in the AC knockout.
5. Run the AC wiring through the strain-relief clamp.
6. Strip approximately 2 inches (50 mm) off the jacket from the AC cable and
separate the wires.
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7. Using a 1/4" blade slot screwdriver, loosen the terminal screws on the
terminals. Do not remove the screws.
8. Connect the line and neutral wires to the input terminals (labeled AC Input on
Line 2 to L2.
9. Tighten the terminal screws. Leave some slack wire inside the wiring box.
10. Connect the ground wires to a free position on the ground bus, Figure 5 on
page 22. If solid ground wire is being used, the wire can be connected directly
under the screw heads. If stranded ground wire is being used, ring terminals
must also be used.
11. Secure the strain-relief clamp on the AC input cable jacket.
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Connecting the AC Output Wires
CAUTION: Risk of equipment damage
Do not connect the output of the inverter to any incoming AC source.
To make the AC output wiring connections:
1. Remove one of the AC knockouts from the front or side of the unit. Do not
leave the knockout inside the wiring compartment.
Important: The applicable installation code may not allow you to run the AC
input and AC output wiring through the same AC knockout.
2. Install a strain-relief clamp in the AC knockout and run the AC wiring
through the strain-relief clamp.
3. Strip approximately 2 inches (50 mm) off the jacket from the AC cable and
separate the wires.
4. Using a 1/4" blade slot screwdriver, loosen the terminal screws on the AC
output terminals. Do not remove the screws.
5. Connect the line and neutral wires to the output terminals (labeled AC
Line for Dual
Output
Lines for Single
Output
Terminals
N
Neutral 2
Line 2
Unused
Unused
Neutral
Line
L2
N
Neutral 1
Line 1
L1
6. Tighten the terminal screws. Leave some slack wire inside the wiring box.
page 22. If solid ground wire is being used, the wire can be connected directly
under the screw heads. If stranded ground wire is being used, ring terminals
must also be used.
8. Secure the strain-relief clamp on the AC output cable jacket.
9. Attach the wiring compartment cover panel and tighten the four screws.
10. Connect the outgoing AC wires to an AC load panel equipped with circuit
breakers.
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Step 4: Connecting the DC Cables
DC Connection Precautions
WARNING: Energy hazard
Connect and disconnect DC wiring only after opening the disconnect switches or breakers
at all AC and DC sources.
Recommended Cable Sizes and Lengths and Fuse Size
Preparing the Cables
To prepare the DC cables:
1. Cut the negative and positive cables to the required length. Strip off enough
insulation so you can install the terminals you will be using.
Xantrex recommends the use of crimp connectors. The connector should be
designed for a 3/8" stud size to connect to the RS3000. If a crimp connector is
used, it should be crimped using the tool indicated by the connector
manufacturer.
2. Cut the DC ground cable to the required length. Strip off enough insulation so
you can install the terminals you will be using.
Xantrex recommends the use of crimp connectors. The connector should be
designed for a 1/4" stud size to connect to the RS3000. If a crimp connector is
used, it should be crimped using the tool indicated by the connector
manufacturer.
3. Attach the connectors to the ends of both cables. Make sure no stray wire
strands protrude from the connectors.
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Guidelines for Routing the DC Cables
Follow these guidelines to ensure maximum performance.
WARNING: Fire and shock hazard
Route the cables away from sharp edges that might damage the insulation. Avoid sharp
bends in the cable.
•
•
•
Do not attempt to use the chassis in place of the battery negative connection
for grounding. The inverter requires a reliable return path directly to the
battery.
To reduce the chance of radio frequency interference, keep the positive and
negative cables close together—ideally, held together by straps, loom, or
insulated clamps at regular intervals.
To ensure maximum performance from the inverter/charger, do not route your
DC cables through a DC distribution panel, battery isolator, or other device
that will cause additional voltage drops. The exception is the DC fuse and
Disconnect or the DC circuit breaker which is required at the battery to
protect the DC wiring.
•
To help avoid damage caused by reverse polarity battery connection, it is a
good idea to mark each end of each cable to identify it as a positive (red) or
negative (black) cable before routing the wiring.
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Connecting the DC Cables to the Inverter/Charger
WARNING: Fire hazard
Use only appropriately sized copper cable. Loose connections or improper connections
will overheat. Make sure the bolts supplied by Xantrex on the inverter/charger are
tightened to a torque of 15–16 ft-lbs (20.4–21.7 Nm). Torque all other connections to the
manufacturer’s specifications. Make sure the DC cable, washers, and bolt are assembled
in the order shown in Figure 6.
CAUTION: Reverse polarity damage
Before making the final DC connection or closing the DC breaker or disconnect, check
cable polarity at both the battery and the inverter/charger. Positive (+) must be connected
to positive (+). Negative (–) must be connected to negative (–).
To connect the DC cables:
1. Route the DC cables from the battery bank to the inverter/charger. Observe
2. Install a DC fuse and disconnect switch or a DC circuit breaker between the
inverter/charger and the battery. It must be installed in the positive side of the
DC circuit, as close as possible to the battery.
This protects your battery and wiring in case of accidental shorting. See
Table 3 on page 14 for required fuse or breaker size.
3. Open the DC disconnect switch or turn off the DC circuit breaker.
4. Connect one connector on the POSITIVE (+) cable to the POSITIVE DC
first, then the flat washer (steel), lock washer (steel), and 3/8" bolt (brass).
5. Connect the other connector to the POSITIVE (+) terminal on the fuse or
breaker. Observe polarity carefully while completing the installation.
Use a wrench to tighten the bolt to a torque of 15–16 ft-lbs (20.4–21.7 Nm) at
the inverter/charger end. Observe the fuseholder or breaker manufacturer’s
recommendation at the other end.
6. Connect one connector on the NEGATIVE (–) cable to the NEGATIVE (–)
DC terminal on the inverter/charger, as shown in Figure 6. The connector
goes on first, then the flat washer (steel), lock washer (steel), and 3/8" bolt
(brass).
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Figure 6 DC Cable Connections
7. Before proceeding, check that the cable polarity is correct: POSITIVE (+) on
the inverter/charger is connected to the POSITIVE (+) on the battery, and
NEGATIVE (–) cable is connected to the NEGATIVE (–) terminal on the
inverter/charger.
Important: The next step is the last cable connection you need to make. A spark is
normal when this connection is made.
8. Connect the other end of the cable to the NEGATIVE (–) terminal on the
battery.
9. Use a wrench to tighten the bolt to a torque of 15–16 ft-lbs (20.4–21.7 Nm) at
the inverter/charger end.
10. To protect the DC terminals, attach the DC terminal covers (Figure 7) to the
inverter/charger, using the screws provided.
Figure 7 DC Terminal Covers
The completed DC terminal wiring with covers is shown in Figure 8.
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DC Grounding
The Chassis Ground point on the inverter/charger is used to connect the chassis of
the inverter/charger to your system’s DC grounding point, as required by
regulations for some installations. Use copper wire that is either bare or provided
with green insulation.
The grounding guideline given below assumes you are using the code-compliant
sizes, refer to the applicable code for DC grounding detail.
To connect the chassis ground:
1. Using the appropriate wrench, loosen the bolt on the chassis ground point
and the DC grounding point for your system.
In an RV or vehicle installation, the DC grounding point will usually be the
vehicle chassis or a dedicated chassis ground bus.
3. Tighten the screw to a torque of 1.0–1.25 ft-lbs (1.47–1.7 Nm).
!
Chassis ground point
Figure 8 Completed DC Wiring and DC Grounding
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Installation
Step 5: Connecting the Battery Temperature Sensor (BTS)
Installing a battery temperature sensor (BTS) extends the life of a battery by
preventing overcharging in warm temperatures and undercharging in cold
temperatures. With a BTS monitoring the battery temperature, the voltage
delivered to the battery is adjusted according to the battery’s actual temperature.
The BTS has a self-adhesive backing and attaches to the side of the battery. A
25-foot (7.6 m) cable is supplied with the BTS, as shown in Figure 9.
Figure 9 BTS with Cable
WARNING: Energy and explosion hazard
Review the “Important Safety Instructions” on page v.
Mounting Options
You can mount the BTS in one of two ways:
•
Mounting the sensor to the negative battery post allows the internal battery
temperature to be sensed and provides the most accurate results.
•
Attaching the sensor to the side of the battery using the self-adhesive backing
also provides good results in most situations.
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Mounting to the Negative Battery Terminal
To mount the sensor on the negative battery terminal:
Figure 10 BTS Mounted on the Negative Battery Terminal
1. Select the battery to be monitored. The BTS should be connected to the
battery bank that is directly connected to the inverter/charger.
2. Switch off all devices operating from the battery, or open the battery switch (if
present) to disconnect the battery.
3. Wait 10 minutes for any explosive battery gases to dissipate.
4. Remove the nut that connects existing wiring ring terminals to the battery
negative terminal stud.
5. Move or reorient the existing wiring ring terminals on the battery negative
terminal stud, so there is a flat surface on which to seat the BTS mounting
plate.
You may need to bend the ring terminal crimp and/or wires slightly downward
to allow the sensor to seat flush to the top surface of the upper ring terminal.
and firmly tighten the terminal nut.
WARNING: Fire hazard
In this procedure, you must install the DC wire on the battery terminal, then install the
sensor on top of the DC wire. This sequence is required to provide the best connection to
the battery and to ensure correct performance of the sensor.
7. Check to ensure that the sensor and all wires are held firmly and cannot be
moved.
8. Turn the battery switch on again (if you opened it in Step 2.)
9. Route the sensor cable to the inverter/charger and plug it into the Battery
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Installation
Mounting to the Side of the Battery Case
To mount the sensor on the battery case:
Figure 12 BTS Mounted on the Battery Case
1. Select the battery to be monitored.
The BTS should be connected to the battery bank that is directly connected to
the inverter/charger.
2. Select a side suitable for attaching the sensor.
The surface where the sensor is to be mounted must be flat and free from
reinforcing ribs or other raised features. This surface must be in direct internal
contact with the battery electrolyte. Do not install the sensor near the top of
the battery or on the battery’s top surface.
3. Clean the selected area thoroughly to remove any oil or grease that could
prevent the sensor from adhering to the battery case. Allow the battery case to
dry thoroughly.
4. Peel the protective backing from the self-adhesive strip on the rear of the
sensor.
5. Press the sensor firmly against the clean side of the battery to fix it in place, as
6. Route the sensor cable to the inverter/charger and plug it into the Battery
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Installation
Step 6: Connecting to the Network
the RS3000.
To connect the RS3000 to the Xanbus network:
u
Plug a network cable connected to the Xanbus network into either one of the
two network jacks on the RS3000.
CAUTION: Equipment damage
Connect the RS3000 only to other Xanbus compatible devices.
Although the cabling and connectors used in this network system are the same as Ethernet
connectors, this network is not an Ethernet system. Equipment damage may result from
attempting to connect two different systems.
Detailed information on planning and installing your network is available in the
Xanbus System Installation Guide. Refer to the this guide to determine the type of
network layout to install, as well as guidelines for installing the network.
The Xanbus System Installation Guide is available for download at
Figure 13 Connecting to a Network Jack
34
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Installation
Step 7: Performing Checks Prior to Initial Start-Up
Before testing your installation, ensure these conditions are met:
Chassis and AC grounds are properly installed.
p
p
AC input connections and AC output connections are wired correctly on the
terminal block and not reversed.
p
Positive (+) battery cable is connected to the positive (+) battery terminal
through the DC fuse and disconnect switch or DC circuit breaker.
p
p
Negative (–) battery cable is connected to the negative (–) battery terminal.
Battery voltage is within the proper range for this unit
(10.3–15.3 volts DC).
p
p
p
DC disconnect switch or breaker is turned off.
AC input and output breakers are turned off.
All connections are tight.
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Installation
Step 8: Testing Your Installation
WARNING: Shock hazard
The Inverter Enable button on the RS3000 and the optional accessories do not disconnect
DC or AC input power to the RS3000.
There are several tests to be performed for testing your installation. These tests
will verify that:
•
•
•
The RS3000 works in invert mode
The RS3000 works in charge mode
The RS3000 works in AC bypass mode
Up” on page 35 and go through the checklist again to check the installation. Then
perform the test again. If the test fails again, see the troubleshooting section in the
RS3000 Sine Wave Inverter/Charger Operation Guide.
Figure 14 RS3000 Front Panel
Testing in Invert Mode
To test the RS3000 in invert mode, using a 100 watt light bulb as the test load:
1. Close the DC disconnect switch or the DC circuit breaker to supply DC power
to the RS3000.
Wait for all the lights on the front panel to flash on and off, indicating that the
unit has successfully initialized (10 to 30 seconds).
If the light does not come on, make sure the voltage at the DC terminals on the
RS3000 is correct, as described in “Step 7: Performing Checks Prior to Initial
2. After the initial flash, verify that the lights on the front panel illuminate as
follows:
•
•
•
The Charger Enable button light is illuminated
The Network light is illuminated
All other lights are not illuminated
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3. Press the Inverter Enable button. Verify that:
•
•
The Inverter Enable button light illuminates
The Invert On light illuminates
4. Connect the RS3000 to the test load by closing the AC breaker that controls
the circuit that the test load is connected to.
If the light bulb illuminates, the Invert mode is working.
5. Press the Inverter Enable button to disable the inverter. The Invert On light
and Inverter Enable button light are off.
Testing in Charge Mode and AC Bypass Mode
1. Close the AC supply breaker to supply AC power to the unit.
To verify that the RS3000 starts charging:
2. After a few seconds, verify that the Bulk light illuminates. Over a period of
time, the Absorption or Float light illuminates as charging progresses.
•
In three-stage charging, the Bulk, Absorption and Float lights illuminate
in sequence.
•
In two-stage charging, the Bulk and Absorption lights illuminate in
sequence.
To verify that RS3000 correctly switches to Bypass mode:
3. Press the Charger Enable button to disable the charger. Verify that:
•
•
The Charger On light and Charger Enable button light turn off.
The AC load is still powered.
Installation Complete
Your installation is now complete. The inverter/charger is ready for use.
The preceding tests use a light load (a light bulb) as a test case. If you encounter
problems when using a load over 1000 W (for example, a hairdryer or
microwave), see the troubleshooting information in the RS3000 Sine Wave
Inverter/Charger Operation Guide.
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Installation
Inverter/Charger Physical Specifications
For complete inverter/charger specifications, refer to the RS3000 Sine Wave
Inverter/Charger Operation Guide.
described in Table 4.
Table 4 RS3000 Physical Specifications
Length
Width
16.19 inches (411 mm)
14.20 inches (361 mm)
8.1 inches (208 mm)
75 lb (34 kg)
Height
Weight
38
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Installation
Battery Information
Battery Bank Sizing
Battery capacity
Battery size or capacity is just as important as the battery type selected for use
with the RS3000. The batteries are the most important part of your system, so
Xantrex recommends that you purchase as much battery capacity as possible. A
large battery will extend running time and ensure that your inverter/charger
delivers full rated surge.
Xantrex recommends a minimum battery size of 200 amp-hours (Ah) for
moderate loads (<1000W) and greater than 400 Ah for heavy loads.
calculation.
About Amp-hours
A number of different standards are used to rate battery energy storage capacity.
Automotive and marine starting batteries are normally rated in cranking amps.
This is not a relevant rating for continuous loads like an inverter. Deep-cycle
batteries use a more suitable rating system such as amp-hours (Ah).
Amp-hour capacity is the number of amps a battery can continuously deliver
during a specified number of hours. It is represented by the product of the two —
amps multipled by hours.
A typical marine or RV battery rated for 100 Ah can deliver 5 amps for 20 hours
(5A × 20 hours = 100 Ah). This same battery can deliver a higher or lower current
for less or more time, limited approximately by the 100 Ah figure (50 A for 2
hours or 200 A for 1/2 hour), but usually the capacity figure given is only accurate
for the specified duration (20 hours).
Estimating Battery Requirements
Calculating Battery Size
Step1: Compute
Amp-hours
For each appliance, compute the number of amp-hours that will be used between
charging cycles, as follows:
1. Obtain the wattage. If the wattage is marked on the nameplate rating, use that.
Otherwise, multiply the marked voltage and amperage:
WATTS = VOLTS × AMPS.
2. Obtain the Watt-hours by multiplying that amount by the hours the appliance
will be used:
WATT-HOURS = WATTS × HOURS.
3. Obtain the amp-hours that the appliance requires by dividing that amount by
10 (the factor for the RS3000, which is a 12-volt system):
BATTERY AMP-HOURS USED = AC WATT-HOURS/10
For example, a 100 W light bulb that is used for 4 hours will use 400 watt-hours
(Wh) and the inverter will consume approximately 40 Ah from a 12 volt battery.
40
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Step 2: Calculate
Battery Size
on page 41 for an example.
Size the batteries at approximately twice the estimated total amp-hour usage.
Doubling the expected amp-hour usage ensures that the batteries will not be
overly discharged and extends battery life.
Resist the temptation to skip this doubling step. More capacity is better since you
will have more reserve capacity, be better able to handle large loads and surge
loads, and your battery won’t be discharged as deeply. Battery life is directly
dependent on how deeply the battery is discharged. The deeper the discharge, the
shorter the battery life.
Troubleshooting
If you find that the system shuts down when appliances with large motors are
started, the problem may be that this motor is too much for the battery. Even
though you calculated the amp-hour requirements appropriately, the startup of a
large motor makes high demands on the battery. You may find that adding more
amp-hours (in the form of extra batteries or replacement with a bigger battery)
solves the problem.
Table 1-1 Battery Sizing Example
Daily watt-hours needed
for this appliance
(= A × B)
(A) Power
(B) Operating Time
Appliance
Consumption (Watts) per Day (Hours)
TV & VCR
200 W
800 W
2 hours
400 Wh
200 Wh
Small microwave
oven
15 min = 1/4 hour
3 lamps, 60 W
each
180 W
4 hours
720 Wh
Coffee maker
Hair dryer
600 W
15 min = 1/4 hour
6 min = 1/10 hour
150 Wh
150 Wh
1620 Wh
1500 W
Total daily watt-hours of AC load
× Number of days between charges
3
= Total watt-hours of AC load between charges
4860 Wh
486 Ah
Battery Ah used between charges (divide by 10 for 12 volt system;
divide by 20 for 24 volt system)
Recommended Battery Bank Size in Ah (multiply by 2)
972 Ah
This example illustrates how quickly your battery needs can escalate. To reduce
the required battery bank size, you can either conserve energy by eliminating or
reducing the use of some loads, or recharge more frequently.
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Battery Banks
As your power requirements increase, you may need to use more than one battery
to obtain sufficient capacity. Batteries can be connected in parallel, in series, or in
series-parallel to create higher capacity systems.
See “Cabling and Hook-up Configurations” on page 44 for more information
about battery inter-connection schemes.
Mixing Batteries
Batteries connected in parallel should be of the same type and amp-hour rating
and from the same manufacturer.
It is not recommended to connect batteries of different types, amp-hour ratings or
manufacturers. Improper charging and decreased battery life will result.
Battery Bank Sizing Worksheet
The following worksheet is a guide to help you determine your battery needs. Be
generous in estimating the time for which you will run each of the loads to ensure
sufficient battery capacity.
Restrictions on Motor Size
An appliance may require three to six times its normal running current in order to
start. The RS3000 can handle surges to 7500 VA for 5 seconds, which translates to
a locked rotor amp on the motor of no more than 60 A. The locked rotor amp may
be specified on the motor nameplate as “LRA” or “LRI”.
When considering appliances with large motors, follow these guidelines:
•
Make sure that the motor’s LRA rating is no more than 60 A. The RS3000
may not be able to start a motor with a higher LRA, and the RS3000 will shut
down if the attempt is made.
•
Make sure the battery bank, DC cables and DC fuses are capable of handling
up to 750 A DC for five seconds. A weaker circuit may not be able to provide
sufficient power to the RS3000 to allow the RS3000 to start up the appliance.
Again if the circuit cannot deliver the required current, the system may shut
down or the fuse may open.
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Table 1-2 Battery Sizing Worksheet
Daily watt-hours needed
for this appliance
(= A × B)
(A) Power
(B) Operating Time
Appliance
Consumption (Watts) per Day (Hours)
W
W
W
W
W
W
W
W
hours
hours
hours
hours
hours
hours
hours
hours
Wh
Wh
Wh
Wh
Wh
Wh
Wh
Wh
Wh
Total daily watt-hours of AC load
× Number of days between charges
= Total watt-hours of AC load between charges
Wh
Ah
Battery Ah used between charges (divide by 10 for 12 volt system;
divide by 20 for 24 volt system)
Recommended Battery Bank Size in Ah (multiply by 2)
Ah
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Cabling and Hook-up Configurations
Several smaller batteries can be connected to create a battery bank of substantial
size. You can connect batteries in three ways: in parallel, series, or series-parallel.
To make a larger battery bank, connect individual batteries with heavy cables. The
actual size of the cable depends on whether the batteries are connected in parallel
or series. Generally, the cable should not be smaller than the inverter cables—if
the main cables are 4/0 AWG, the battery interconnects should be 4/0 AWG.
The best configuration is to connect the batteries in series and parallel. This
requires additional cables, but reduces imbalances in the battery bank and can
improve the overall performance. Consult your battery supplier for more
information regarding the hook-up configuration required for your system.
Parallel Connection
Batteries are connected in parallel when all the positive terminals of a group of
batteries are connected and then, separately, all the negative terminals are
connected. In a parallel configuration, the battery bank has the same voltage as a
single battery, but an Ah rating equal to the sum of the individual batteries. See
Figure 16 Batteries Connected in Parallel
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Series Connection
When batteries are connected with the positive terminal of one battery to the
negative terminal of the next battery, they are connected in series. In a series
configuration, the battery bank has the same Ah rating of a single battery, but an
Figure 17 Batteries Connected in Series
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Series-Parallel Connections
As the name series-parallel implies, both the series and parallel configurations are
used in combination. The result is an increase in both the voltage and the capacity
of the total battery bank. This is common with all battery-inverter system
voltages. The smaller, lower voltage batteries are first connected in series to
obtain the necessary voltage, and then these “batteries connected in series” sets
are connected in parallel to increase the battery bank capacity. See Figure 18.
Figure 18 Batteries in Series-Parallel Connections
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Index
A
G
AC and DC wiring separation 21
AC input wiring connections 22
AC input, defined 8
gases, hydrogen 18
GFCI 9
GFCI models, tested 10
ground fault circuit interrupter. See GFCI. 9
AC knockout dimensions 21
AC output neutral bonding 12
AC output wiring connections 24
AC wiring
I
installation
defined 10
approved mounting orientations 19
approved mounting orientations, illustrated 20
choosing a location for inverter/charger 17
connecting AC input wires 21
connecting AC output wires 21
connecting BTS cable to BTS jack 33
connecting cables to inverter/charger 27
connecting DC cables 25
size 11
type 10
AC wiring compartment, illustrated 21
AC wiring considerations 21
AC wiring terminal, illustrated 21
B
batteries 13
connecting the battery temperature sensor (BTS) 30
DC grounding 29
battery temperature sensor
cable length 30
function of 30
mounted on negative battery terminal 31
mounted to battery case 33
two mounting options 30
BTS. See battery temperature sensor 30
mounting the inverter/charger 19
performing checks prior to initial start-up 35
routing DC cables 26
testing in charge mode 37
testing in invert mode 36
tests 36
installation codes
Canadian Electrical Code (CEC) 2
Canadian Standards Association (CSA) 2
RV Industry Association (RVIA) 2
U.S. National Electrical Code (NEC) 2
inverter/charger, heavy load precaution 19
C
connecting to the network, precaution 34
Customer Service
email iii
fax number iii
phone number iii
M
materials list 15
materials, installation 16
D
DC cable, required size and length 14
DC cabling, required 14
DC disconnect device 13
DC fuse size, required 14
DC grounding 14
R
related product literature iii
S
DC over-current device 13
specifications
inverter 38
F
physical 38
strain relief, size of 21
FCC, regulations viii
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Xantrex Technology Inc.
1 800 670 0707 Tel toll free NA
1 360 925 5097 Tel direct
1 800 994 7828 Fax toll free NA
1 360 925 5143 Fax direct
customerservice@xantrex.com
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