Xantrex Technology Freedom 458 manual

Xantrex Freedom 458 Series Inverter/Charger Owner's Manual Freedom 458 10 15 20 25 30[...]

2 SAFETY SUMMAR Y Safety information for installation and operation is contained throughout this manual where it applies and is not included in this summary . Definitions: W arning statements identify conditions or practices which could result in personal injury , loss of life, damage to equipment or other property . Fuse Replacement For continued [...]

3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4 Things Y ou Should Know . . . . . . . . . . . . . 5 Circuit Breaker Protection Thermostat Controlled Cooling Inverter Idle Circuit Low and High Battery Shutdown Power Sharing T emperature Sensitive Charging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Optional Rem[...]

4 This owner ’s manual describes the Freedom 458 Series Inverter/Chargers from Xantrex. These units perform three distinct functions: 1. DC to AC power inverting. 2. Automatic transfer switching between inverter power and incoming AC power . 3. Automatic three-stage battery charging plus manual battery equalizing. • The inverter provides regula[...]

5 Circuit Breaker Protection The Freedom Inverter/Charger is supplemental breaker protected. The INVERT/CHARGE breaker on the front of the unit protects against sustained inverter/ charger over-current conditions. These breakers are reset by pushing the button back in. The output circuit breakers protect the output AC circuits. Models are available[...]

6 T emperature Sensitive Charging When the supplied battery temperature sensor is connected to the unit and the batteries, the charge voltage is controlled based on battery temperature. The charger adjusts the charge voltage to the best level, minimizing water loss in wet cell batteries. Charge voltage regulation optimizes the bat- tery life cycle.[...]

7 OPERA TION The Freedom 458 Inverter/Charger pro vides 120 volt AC power from auxiliary DC bat teries, automatic battery charging and automatic AC transfer switching between an external AC source and inverter mode. External AC Power When external AC power is available, the three-stage battery charger , transfer switching, and Power Sharing automat[...]

8 ST A TUS LEDs Each Status LED performs two functions, providing battery type selection and operation status. OPERA TION Operation Status INVERT - Green LED The INVERT push-button switch is located on the front of the unit. • When the LED is solid green, the unit is in invert mode. This occurs by pressing the INVERT switch for (three to five sec[...]

9 OPERA TION • When the LED is blinking slowly (once per second), an over-current condition or a short circuit has occured. The system has shut OFF and will not automatically restart. Correct the fault condition and manually restart the system. LOW BA TTER Y AND OVERTEMP/OVER- LOAD - Red LEDs • When both LEDs are blinking, an AC backfeed has be[...]

10 LINK 2000 The Link 2000 has the same features as the Link 1000, providing inverter/charger control and complete battery state of charge information. It monitors two battery banks. OPTIONAL REMOTE CONTROL P ANELS Freedom Remote Control Panel An optional remote control panel is available. The LED bar graphs on the remote control panel show battery[...]

11 BA TTERIES BA TTERY TYPES Use only deep-cycle batteries with your Freedom Inverter/Charger . These fall into three broad categories: wet cell, gel cell and Advanced AGM (Absorbed Glass Mat) batteries. Wet Cell Batteries T rue deep-cycle wet cell batteries are characterized by relatively thick internal plates that are alloyed with antimony . Comm[...]

12 Beware of so-called maintenance-free batteries. These batteries have calcium alloyed with the lead and hold the liquid electrolyte in a sponge-like material. They are sealed and water cannot be added. Do not confuse them with true gel cell or AGM batteries—they will not hold up well to deep discharging and repeated cycling. Gel Cell Batteries [...]

13 Parallel Connecting two batteries in parallel will double the amp-hour rating of the battery bank, while the voltage will be the same as each individual battery . For example, two 12-volt 105 amp-hour batteries in parallel will produce one 12-volt 210 amp-hour battery bank. BA TTERIES Parallel Parallel Increase Amp-Hour Capacity EACH BA TTERY CA[...]

14 T o achieve 50% cycling you should calculate your amp-hour consumption between charging cycles and use a battery bank with twice that capacity**. Each AC appliance or tool has a rating plate on it and will be rated in either AC amps or watts or AC V A (volt-amps) apparent power . T o calculate amp- hour consumption, use one of the formulas to th[...]

15 Battery Charging Completely charging wet cell deep-cycle batteries requires the battery voltage to be raised beyond what is known as the gassing point. This is the voltage at which the battery begins to bubble and gas is given off. If charging stops short of this point, sulfate is left on the plates and deterioration of the battery begins. The g[...]

16 BA TTER Y CHARGING NOTE: Freedom battery chargers are ON whenever AC power is connected to the charger input. The charger can be turned OFF using the CHARGE switch on the front of the unit. This sequence will occur each time external AC power is available. The charger can be turned ON/OFF using the Remote Control Panel or Link Instrumentation. E[...]

17 Gel cell and Advanced AGM batteries can accept a higher rate of charge. Consult the manufacturer for specifications. Stage 2 - Acceptance Charge The acceptance stage immediately follows the bulk charge stage. During this stage the battery voltage is held constant at the bulk charge voltage limit and the current gradually ramps down. During this [...]

18 BA TTER Y CHARGING The equalizing charge is a timed, eight- hour cycle. The cycle can be ended early by interrupting the AC power to the charger at any time during the cycle. Equalizing should only be engaged after the batteries have been fully charged by a normal battery charging cycle. During this equalizing stage, the battery voltage will inc[...]

19 BA TTER Y CHARGING 1. Do not equalize gel cell batteries. Check remote default settings. 2. Always monitor the equalize charge cycle. Provide proper ventilation for battery fumes. Do not allow any sparks during equalizing. If one or more cells begin to overflow , terminate the equalize cycle. 3. Check the battery electrolyte both before and afte[...]

20 BA TTER Y CHARGER VOL T AGE SETTINGS P M E T 0 E P Y T 1 E P Y T 2 E P Y T 3 E P Y T l l e C t e W * 1 l e G * 2 l e G M G A F ° C °T P E C C AT A O L FT P E C C AT A O L FT P E C C AT A O L FT P E C C AT A O L F 0 2 1 9 45 . 2 15 . 2 10 . 3 10 . 3 10 . 3 10 . 3 19 . 2 19 . 2 1 0 1 1 3 46 . 3 17 . 2 15 . 3 10 . 3 10 . 4 14 . 3 19 . 3 19 . 2 1 [...]

21 CAUTION This equipment is not ignition protected and employs components that can produce arcs or sparks. T o reduce the risk of fire or explosions, do not install in unvented compartments containing batteries or flammable gasses or areas in which ignition-protected equipment is required. INST ALLA TION PRECAUTIONS For continued protection agains[...]

22 CAUTION Risk of electrical shock. Do not remove cover , no user serviceable parts inside. Refer servicing to qualified service personnel. The Freedom 458 Inverter/Charger is appropriate for installation in recreational v e hicles (RV) and other applications. It is recommended that installation be completed by an authorized Xantrex technical deal[...]

23 9. Do not backfeed the AC output of the in- verter with incoming AC power . A backfeed occurs when AC power from shorepower or generator is connected to the output of the in verter . This will damage the inverter and void the warranty . Remember that incoming AC must be fed only to the AC input and never the AC output. Always check for AC voltag[...]

24 Do not connect incoming AC from any source to the AC output of the inverter/ charger . This is known as backfeeding and will damage the unit and void the warranty . The Over T emp/Overload and Low Battery LEDs will be blinking rapidly if this condition exists. W ARNING Grounding For safety purposes, the chassis of the inverter/charger must be co[...]

25 AC Wiring The AC wires route through the strain relief mounted in holes on the front of the unit. Use a screwdriver to remove the screws which secure the AC wiring compartment cover plate. Depending upon which model you have, there can be one or two AC inputs and one or two AC outputs within the AC wiring compartment. The labeling for the pigtai[...]

26 DC Wiring DC wiring is generally very simple, the positive (+, may be red for identification) and negative (-, may be black or yellow for identification) cables from the inverter/charger terminal posts are connected to the house or auxiliary battery . Connection to the engine starter battery is not recommended. High current will pass through the[...]

27 • Remove the positive (+) battery cable terminal cover from the unit and attach the battery cable. T ighten the battery terminal bolts to a torque value between 160 inch-pounds and 180 inch-pounds. Replace the cover for the positive terminal. The negative (-) cable should be connected directly to the negative post of the house or auxiliary bat[...]

28 COMPRESSION / RING TERMINAL INST ALLA TION Improper stack up of hardware will cause excessive heat and fuse failure. Stack up as shown. W ARNING Battery Cable Fusing A fuse is required by the NEC to protect the battery and cables. A UL Listed DC rated slow blow fuse must be installed in the positive (+) battery cable, within 18 inches of the bat[...]

29 INST ALLA TION Follow these instructions to ensure proper start up and confirm that the installation is correct. 1. Check to make sure Invert and Charge are OFF . The INVERT LED should not be illuminated, the CHARGE LED should be blinking (charger ready but no external AC power available). If using a Remote Control Panel or a Link Instrument, ma[...]

30 NOTE: For low power system shutdown mode, both the INVERT and CHARGE LEDs must be OFF . • T esting for backfeed. If a backfeed condition is indicated, disconnect from shorepower and disconnect the AC output wires on the inverter . Make sure the inverter is OFF . Apply shorepower and measure for voltage between the black and white wires that we[...]

31 TROUBLESHOOTING LED ST A TUS s u t a t S D E Ls u t a t S n o i t a r e p Os e t o N T R E V N IE G R A H CY R E T T A B W O LP M E T R E V O D A O L R E V O n e e r G d i l o Sn e e r G g n i k n i l BF F OF F Oo n t u b y d a e r r e g r a h C . g n i t r e v n I . e l b a l i a v a C A l a n r e t x e l a m r o N g n i k n i l B n e e r G n e[...]

32[...]

33 Alternating Current (AC) An electric current that reverses direction at regular intervals. Sources of alternating current are shore power , generator power , inverter power or household current. Ampere (Amp, A) The unit of measure of electron flow rate of current through a circuit. Ampere-hour (Amp-Hr ., Ah) A unit of measure for a battery’s e[...]

34 Equalize Charge A controlled overcharge of the batteries which brings all cells up to the same voltage potential, extends the battery life, restores capacity and mixes the electrolyte. This can only be done using the Freedom Remote Control Panel or a Link Instrument. Gel Cell Battery A type of battery that uses a gelled electrolyte solution. The[...]

35 SPECIFICA TIONS l e d o M) s e i r e S 8 5 4 ( 0 1) s e i r e S 8 5 4 ( * D 5 1 d n a 5 1) s e i r e S 8 5 4 ( * D 0 2 d n a 0 2s e i r e S 8 5 4 ( 5 2) s e i r e S 8 5 4 ( 0 3 r e b m u N t r a P 2 1 - 0 1 0 1 - 1 8- 0 2 5 1 - 1 8 d n a 2 1 - 0 1 5 1 - 1 8 2 1 - 0 2 0 2 - 1 8 d n a 2 1 - 0 1 0 2 - 1 8 2 1 2 1 - 0 1 5 2 - 1 82 1 - 0 1 0 3 - 1 8 [...]

36 W ARRANTY What does this warranty cover? This Limited W arranty is provided by Xantrex T echnology , Inc. (“Xantrex”) and covers defects in workmanship and materials in your Xantrex Freedom 458 Inverter/Charger . This warranty lasts for a W arranty Period of 30 months from the date of purchase at point of sale to you, the original end user c[...]

37 W ARRANTY What does this warranty not cover? This Limited W arranty does not cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer ’ s electrical systems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to: a ) the product if i[...]

38 Warning: Limitations On Use Please refer to your product user manual for limitations on uses of the product. Specifically , please note that the Freedom 458 Inverter/Charger is not intended for use in connection with life support systems and Xantrex makes no warranty or representation in connection with any use of the product for such purposes. [...]

39 INST ALLA TION EXAMPLES Installation examples for the new Freedom 458 Series Inverter/Chargers Shorepower configurations: Systems with one 30 Amp single-phase shorepower source with optional generator Systems with two 30 Amp shorepower sources with optional generator Systems with a 50 Amp 120 V olt single-phase (3 wire) shorepower source with op[...]

40 Installation Option #1 for Freedom 10, 15, 20, 25, and 30 The inverter is used in a Single Input / Single Output mode. Up to 30 Amps is transferred through the Freedom unit with the charger sharing power with all of the AC loads. In this installation example, a single 30 Amp shorepower source is available and all AC loads are supplied power thro[...]

41 Freedom 458 Installation Option 1 Freedom 458 Model 10, 15, 20, 25, 30 AC O utp ut AC I nput G roun d Bus Neu tra l B us In ve rt er AC Su b Pa ne l To In vert e r AC Lo ads 12 V D C B at t er y B ank Op tio nal Ge ner ator 30 A M ain B r eak er T r ans f er S w i tc h 30 A S hor ep ow er Cl a ss T Fu s e S ingl e In put / Sin gl e Ou t put 30 A[...]

42 Installation Option #2 for Freedom 10, 15, 20, 25, and 30 The inverter is used in Single Input / Single Output mode. The AC loads are split be- tween main loads and ‘inverter loads’. The external sources of AC power can be a single 30 Amp shorepower source or a 30 Amp breaker from a panel fed by a 50 Amp 120 V olt single phase (3 wire) shore[...]

43 AC O utp ut A C In pu t G roun d Bus Ne u t ral Bus I n ve rt er A C S u b P a ne l To In ve r t e r AC Lo ads 12 V D C B at t er y B ank Cl a ss T Fu se S ingl e In put / Sin gle Ou tput 30 A mp T r an sf er S w i t ch P ower Sh a r es w i t h C harger. . * * Al ways co n s ult L o c a l an d Na ti o n al E l ec t ric al Co des fo r pr ope r w [...]

44 Installation Option #3 for Freedom 20 D/D, 25 D/D and 30 D/D The inverter is used in Dual Input / Single Output mode. The AC loads are split between main loads and ‘inverter loads’. The external sources of AC power can be two different 30 Amp shorepower sources (both neutrals and both “Hots” must be kept separate) or two 30 Amp breakers [...]

45 AC O utp ut 2 AC O utp ut 1 AC I nput 2 AC I nput 1 Gr o u n d Bu s Ne u t ral Bus C ap* O f f eac h w i re s ep ara te l y In ve rt e r AC Su b Pa n el To In ve r t e r AC Lo ads 1 2 VD C Ba tte r y Ba nk Cl a ss T Fu se Fr eed om 458 I ns ta ll at i on Op t i on 3 F r eed om 458 M o del 2 0 D/ D, 2 5 D/ D, 3 0 D/ D D ual Inpu t / S ing l e O u[...]

46 Installation Option #4 for Freedom 20 D/D, 25 D/D and 30 D/D The inverter is used in Dual Input / Dual Output mode. The AC loads are split between main loads and ‘inverter loads’. The external sources of AC power can be two different 30 Amp shorepower sources (both neutrals and both “Hots” must be kept separate) or two 30 A breakers from[...]

47 AC O utp ut 2 AC O utp ut 1 AC In put 2 AC In put 1 Gr ou nd B us N eut ral 2 Bu s In vert e r AC Sub Pa n e l L2 L1 1 2 VDC Ba tte r y Ba n k Cl a ss T Fu s e F re e do m 4 5 8 In st a l la tio n Op tio n 4 F r eed om 458 Mo del 2 0 D/ D, 2 5 D/ D, 3 0 D/ D D ual I npu t/ D ual Ou tput 30 Amp T r an sf e r o f t wo Le gs of pow er (60 Amps t ot[...]

48 Installation Option #5 for Freedom 15 S/D and 20 S/D The inverter is used in Single Input / Dual Output mode. The AC loads are split between main loads and two branch circuits containing ‘inverter loads’ (AC output 1 and AC out- put 2). The external sources of AC power can be a single 30 Amp shorepower source or a 30 Amp breaker from a panel[...]

49 AC O utp ut 2 AC O utp ut 1 AC I nput 1 1 2 VD C Batte r y Ba nk Cla ss T Fu se F re e d o m 4 5 8 Inst al la tio n O p tio n 5 F r eed om 458 M o del 1 5 S/D , 20 S/ D S i n gl e I n put/ Du al O utp ut 30 Amp T r a n sfer t hat P ower Shar es wi t h t he C har ger . 1 5 o r 20 S / D M odels a vai l able w i th 15/ 15, 15/ 20 or 20/ 20 Am p b r[...]

Xantrex T echnology Inc. T oll Free 1 800 670 0707 Direct 1 604 422 2777 Fax 1 604 420 2145 CustomerService@xantrex.com www .xantrex.com 445-0193-01-01 Rev . 2 Printed in the U .S .A.[...]