Freedom Inverter Owner's Guide

Inverter Operation Using the Front Panel

Once the inverter/charger is installed, you can operate it in invert mode. To operate in invert mode from the front panel:

1. Press the INVERTER ENABLE button on the Freedom SW on the front panel. The INVERTER ENABLED LED turns on and connected loads will be energized.
2. Note that if AC is present and being passed through, the INVERTER ENABLED LED will still turn on to indicate inverter mode has been enabled. However, AC will continue to be passed through to the loads until conditions exist that cause AC to be disqualified, in which case the unit will transition to invert mode and power up critical loads.
3. Connect AC input power. The charger automatically starts up when qualified AC power is connected. To operate the inverter with the System Control Panel, refer to “Operating the Freedom SW with the SCP”.
4. Disconnect AC power from inverter input by opening the breaker or disconnect.
5. Place a load on the inverter. For example, plug a 100-watt light bulb into an outlet that the inverter is powering. Press the INVERTER ENABLE button on the Freedom SW. The INVERTER ENABLED LED turns on. The inverter should run the load using battery power.
6. To test the charger, reconnect the AC input power to allow AC to the AC input. The AC In/Charging LED should start flashing after a brief delay. Any AC loads previously powered by the inverter will also work at this time. NOTE: On dual input models, only AC Input L1 needs to be powered for the unit to operate.
7. Remove the AC input power. The inverter/charger should transfer to invert mode immediately. (The transfer relay will make a clicking sound and the INVERTER ENABLED LED will turn on.) Loads should continue to operate uninterrupted. If any part of this test fails, determine the cause before using the unit.
8. Monitor the Freedom SW Front Panel. The indicator LEDs on the front panel show you the operating status of the Freedom SW. A description of the LEDs is provided in Table 1. If none of the front panel LEDs are on, see “Troubleshooting”.

Faults and Warnings A fault affects the operation of the unit. A manual fault requires user intervention by clearing the condition and then pressing the CLEAR FAULT RESET button on the inverter/charger’s front panel. See the Xanbus System Control Panel Owner’s Guide for information on clearing faults from the SCP. A warning alerts you to a condition that could possibly affect operation of the unit.

Operating Limits for Inverter Operation

Temperature

The Freedom SW series of inverter/chargers will operate at rated power continuously at 30 °C with some models capable of continuous operation at much higher ambient temperature. However, the continuous power rating at elevated ambient temperature may differ between models. See “Specifications” for full details. In higher ambient temperatures, if the loads draw full power for an extended period of time, the unit may shut down to protect itself against overheating.

The Freedom SW series of inverter chargers feature a surge rating of 200% of rated power for five seconds at 25 °C. Operating the inverter/charger in conditions outside of power and temperature limits, however, will result in thermal shutdown and/or significantly decreased performance. In addition, operation in this range is outside the ratings covered by the regulatory approvals of the product.

Difficulty on starting loads

The inverter/charger should be able to operate all AC loads rated at or below its power rating. Some high horsepower induction motors used in pumps and other motor-operated equipment require very high surge currents to start, and the inverter/charger may have difficulty starting these loads.

If you have problems starting certain loads, ensure that:

• Battery connections are tight and clean.
• DC cabling is no longer than the recommended length. Refer to the Freedom SW Sine Wave Inverter/Chargers Installation Guide for this information.
• AC wiring is of recommended size. Refer to the Freedom SW Sine Wave Inverter/Chargers Installation Guide for this information.
• Battery is of sufficient capacity and is fully charged.

Operating Limits for Charger Operation

By default, the maximum charger output current is the rated charger output current for the particular model. Using the SCP, you can reduce the total output if you change the maximum charge rate (Max Chg Rate) on the Freedom SW Basic Settings menu or Inverter Settings menu under Advanced Settings. The charger can operate within an AC input range of 95–135 volts. The default settings are 95 and 135, which are the ACIn Lo Volt and ACIn Hi Volt respectively. The ACIn Lo Volt setting has a range of 78–115 volts and the ACIn Hi Volt setting has between 125–140 volts.

AC Frequency

The charger can also be configured to accept and operate from a wide AC source frequency of 40– 68 Hz. Therefore, the Freedom SW can charge your batteries even when incoming AC voltage is less than ideal. The default settings are 45 and 55 Hz, which are the ACIn Lo Freq and ACIn Hi Freq settings respectively.

Power sharing

The Freedom SW charger uses incoming AC or shore power (see following note) to charge the batteries. The charger shares incoming AC power with AC loads on Line 1 only. The AC loads have priority, which means that the charger will reduce its output with large AC loads and increase the output again when the AC load decreases. The regulatory maximum for continuous AC loads is 80% of the breaker rating (see “AC1 Breaker”) that the loads are connected to. The Freedom SW senses passthrough current going to the AC load. The difference between the pass-through (load) and 80% of the AC1 Breaker setting is the current that is available for charging the batteries. For example, if the AC input of the Freedom SW is from an AC panel with a 30-amp breaker, the AC1 Breaker setting on the SCP should be selected as 30 amps. Based on this, the charger will control the charge current so that the total current draw is equal to or less than 24 amps in this case. Should the load current be more than 24 amps, the charger output will reduce to 0 amp, but the Freedom SW will continue to supply the loads. The Freedom SW will continue to pass-through power to the loads, even if the load current exceeds the AC1 Breaker setting. In this case, it will be up to the user to remove/disconnect loads if tripping the AC input breaker supplying the Freedom SW is to be avoided.

Operating the Freedom SW with the SCP

This section contains detailed information and procedures for using your Freedom SW in conjunction with the System Control Panel (SCP). If you’re using the SCP to operate or monitor the status of the unit, you may also refer to the Xanbus System Control Panel Owner’s Guide.

The SCP provides operating, configuration, and monitoring capability for your Xanbus system.

The SCP:

• Monitors activity throughout your onboard power system.
• Displays the latest information about your inverter/ charger, battery voltage level, battery charge output, and generator start and stop activity.
• Displays the settings for each Xanbus-enabled device in the system.
• Enables you to adjust the settings for each Xanbusenabled device in the system.
• Preserves all of its settings if system power is interrupted. After power is restored, you don’t have to reconfigure the SCP or any of the Xanbus-enabled devices connected to it.

This section provides information on operating the Freedom SW with the SCP. Please refer to the System Control Panel Owner’s Guide for complete information on using the System Control Panel.

Using the Xanbus SCP

As shown in Figure 8, the SCP has these important features:

• Display screen: System information is shown on the display screen with an adjustable backlight.
• Indicator LEDs: Four indicator LEDs on the front panel indicate the operating status of the Xanbus system.
• Push buttons: Four push buttons allow you to select device menus and change or display settings. The red STBY/ON Fault Clear button toggles the SCP and Xanbus-enabled devices between Operating mode and Standby (Power Save) mode, if held down for more than five seconds. The button can also be used to clear any active faults or warnings by momentarily depressing the button.

System Control Panel

The Xanbus System Control Panel (SCP) provides configuration and monitoring capability for all Xanbusenabled devices on the network. All changes to the configuration of the Freedom SW are made with the SCP. The front panel of the Freedom SW provides limited control, including reset; charger enable and disable; and inverter enable and disable.

• Enabling a function: When a function is enabled, it is allowed to occur but other conditions may have to be met before the function actually works. For example, the charger function on the Freedom SW may be enabled, but will not charge the battery unless qualified AC power is present.
• Disabling a function: When a function is disabled, it is not allowed to occur and if it is already occurring, it is terminated immediately. Regardless of other conditions, the function will not work. For example, even if AC power is present, if the charger function is disabled, the Freedom SW will not charge the battery.

SCP Navigation

Startup Screen

This screen is shown when the Xanbus SCP first receives power from the Xanbus network.

Viewing the SCP Home Screens The top level screens on the Xanbus SCP are the startup screen, the System Status screen (Figure 10) and the device Home screen. After power is applied and the startup screen appears, the Xanbus SCP displays the System Status screen. You can view the device Home screen for the Freedom SW and other devices in the system by pressing the up and down arrows.

System Status Screen

• The System Status screen appears after the startup screen. It displays aggregated status information for the entire power system. For example, a single system might have two Xanbus network-connected Freedom SWs, one Xanbus AGS module, and one Xanbus SCP all connected to a single battery bank. The System Status screen always features a menu arrow pointing to the Enter button. Pressing Enter takes you to the Select Device menu screen. For more information, see “Reading the System Status Screen”. 

Select Device Screen

• As mentioned, this screen appears when the Enter button is pressed from the System Status screen. It lists all Xanbus-enabled devices including options to select System Settings and Clock.

To display the Select Device menu:

• While viewing the System Status screen, press Enter.

Device Setup Screen: The Device Setup screen is shown when a Xanbus-enabled component is selected from the Select Device screen. For example, below is an example of a Device screen for the Freedom SW 3012 inverter/charger. Device Setup menus display status information and changeable settings. Changeable settings are identified by the square brackets [ ] around values in the right-hand column.

To display the Setup menu for a device:

• Highlight the device name on the Select Device menu screen and press Enter. -Or, from the device Home screen, press Enter.

Soft Key Navigation

Soft keys are the objects on the fifth line of the System Status screen. The soft keys have arrows that point to a corresponding physical button such as the Enter, Up arrow, Down arrow, and Func buttons. They are called as such because they perform functions in conjunction with pressing the corresponding SCP button that each arrow points to.

In the next page, it will show how to navigate the soft keys to:

• Enable/disable inverter function (EnInv/DsInv)
• Enable/disable charger function (EnChg/DsChg)
• Change shore breaker ratings (Shr) - see also “AC In Breaker” 
• Select AGS trigger modes (AGS)

Viewing the Firmware Revision Number

You may need to view the firmware revision number (F/W Rev.) of the Freedom SW when troubleshooting the unit with authorized service personnel.

To view the firmware revision number:

1. From the System Status screen, press the Enter button. The Select Device menu screen appears.
2. From the Select Device screen, press the Enter button. The System Settings menu screen appears.
3. From the System Settings screen, press the down arrow button to highlight View Device Info
4. Press Enter. The Device Info screen appears.
5. Read the displayed information. The series of numbers and letters opposite F/W Rev. is the firmware revision number.
6. Press Func (3x) to return to the System Settings menu.

Setting the Time and Date

Freedom SW advanced features such as time-stamped events (faults, warnings, and logged historical data) require that the system be set to the correct time. The Xanbus SCP has an internal clock that controls the time for all Xanbus-enabled devices in the system. You can set the time, time format, and date on the Clock menu. The Clock menu is accessible on the Select Device menu.

Using the STBY/ON Fault Clear Button

The STBY/ON Fault Clear button has two functions. The STBY/ON Fault Clear is used to clear active faults on the system if pressed momentarily. It also toggles all Xanbus enabled devices on the system between Operating and Standby (Power Save) mode when held down for more than five seconds.

Reading the System Status Screen

The System Status screen displays:

• Battery-related information (see Line 2)
• Battery level and inverter/charger operating state (see Line 3)
• Load information (see Line 4)
• AC Input information (see Line 5)

Configuring the Freedom SW using the SCP

This section contains information about all configurable settings and procedures for the Freedom SW. It provides information on using the SCP to configure the Freedom SW settings for optimal performance. Please refer to the Xanbus System Control Panel Owner’s Guide for detailed information on how to use the SCP.

System Menu Map

Figure 16 provides a map of how the SCP screens and menus are organized. The order of devices appearing on the SCP will vary, depending on the order in which they’ve been connected to the network.

Viewing the System Status Screen

The System Status screen displays system activity. The information appearing on the System screen varies with the status of the inverter/charger. See “Reading the System Status Screen”. Go back to “Reading the Freedom SW Device Setup Screen” for an explanation of the different states of the inverter/charger. For example, Figure 17 shows the Freedom SW in the bulk stage of charging.

You cannot select or change any of the information on the System Status screen. If you would like to view more detailed information, press the Enter button (indicated by the menu arrow) to go to the Select Device menu.

Viewing the Select Device Menu

The Select Device menu is where you can view a list of all the Xanbus-enabled devices in your power system. At least two devices are sure to appear together with System Settings and Clock – the Freedom SW Inverter/Charger and the Xanbus SCP. Other devices such as the Xanbus AGS and the Freedom Sequence Intelligent Power Manager appear only when they are connected and installed.

Selecting the Freedom SW from the Select Device Menu

To view the Freedom SW Setup menu screen:

• Follow the procedures on “To view the Freedom SW Setup menu screen:”

You can view and change Freedom SW settings from the Setup menu screen. The Basic Settings and Advanced Settings bring up their menu screens for which other configurable settings can be found.

Changing Configurable Settings From The Device Setup Menu Screen

The Freedom SW can only be configured using the Xanbus SCP. Follow the procedure in “To view the Freedom SW Setup menu screen:” to bring up the device setup screen for the Freedom SW inverter/charger.

As discussed in “Reading the Freedom SW Device Setup Screen” the Freedom SW Device Setup menu screen has two segments. The first segment (lines 2 to 5) displays status information and appears first in the screen’s initial four lines. The second segment (lines 6 to 15) contains selectable fields which are configurable settings.

These configurable settings are:

• Advanced settings
• Inverter
• Search mode
• Charger
• Force charge
• Equalize
• Desired mode
• Clear fault settings
• View device info
• Basic settings

Only nine of these settings are displayed at a time. The Advanced Settings (Line 6) is not initially listed and only lines 7 through 15 appear. When the Advanced Settings is listed, it will appear on top of the list for configurable settings and the setup screen will display lines 6 through 14. See Table 5, “Configurable Settings” for information on each setting.

To select and change a configurable setting:

1. On the setup menu, press the Down arrow (or Up arrow) button to highlight the setting you want to change.
2. Press Enter to highlight the current value of the setting.
3. Press the Up arrow or the Down arrow button to change the value. Hold down the button to scroll through a large range of values quickly. The previously set value (or default value) appears with an asterisk (*) beside it.
4. Press Enter to select and confirm the value.
5. If you have another setting to change, return to step 1. -OrIf you have no more settings to change, press Func until the Xanbus SCP displays the desired screen or menu.

Using Search Mode

Why use Search mode?

• Search mode allows the inverter to selectively power only items that draw more than a certain amount of power, which can result in power savings. The Freedom SW has a no-load power draw of about 28 watts. Enabling search mode reduces this power draw to less than 8 watts. Search mode operates differently in single-unit and multi-unit installations.

Single units

• When a single Freedom SW has search mode enabled, the inverter sends electrical search pulses through its AC output. These search pulses look for connected AC loads. The delay between search pulses is set using the Search Delay setting. After a load larger than the Search Watts setting is detected, the inverter starts producing AC output.

Double units

• When configured for 120/240-volt series stacking, each inverter/charger operates independently in search mode and attempts to detect loads connected to its terminals only. To use search mode in parallel stacking, the Master unit must have Search Mode disabled. The Slave unit must have Search Mode enabled.

When to set up Search mode

• The search mode feature is only valuable if the inverter can spend a fair amount of time “sleeping” each day. Therefore, if search mode is to be used it must be adjusted properly. The initial adjustment should be made so that the inverter comes on only when needed. Certain types of loads can cause search mode to work unexpectedly. These types of loads are described in “Inverter Applications” on page 88. If these kinds of loads are in the system, follow the suggestions given to eliminate the problem.

If the problem loads cannot be eliminated, there are two work-around solutions:

1. Disable search mode from the main Freedom SW Setup menu, causing the inverter to always remain at full output voltage.
2. Use a search-friendly companion load whose only purpose is to be switched on to wake up the inverter to power the load that is unable to bring the inverter out of search mode.

Equalization Procedure

To start equalizing the batteries, do one of the following:

• Apply AC voltage and ensure that the inverter/charger transfers AC and starts charging.
• On the Xanbus Setup menu, highlight Equalize and select Enable. The unit will proceed and execute a complete bulk and absorption charge before transitioning to equalize. IMPORTANT: The inverter/charger will not perform equalization if AC is not present, the charger is disabled, or the selected battery type does not support equalization. If any of these cases happen, a warning is issued.

If the Freedom SW will not perform the equalization, see“Detected Warning Types and Behavior".

Charge Algorithm Stages

Three-Stage charging

If three-stage charging is enabled, the Freedom SW will charge batteries in a sequence known as three-stage charging. Whenever qualified AC power is present at the inverter’s input, it passes power through to the connected load and begins charging the batteries. The charging voltage delivered to the battery depends on the battery’s:

• Type setting
• Temperature (by switch setting or battery temperature sensor)
• State of charge

The three automatic stages are:

• Bulk
• Absorption
• Float

See Figure 35 for a graph of the three-stage charging profile. There is a fourth stage, equalization, which is initialized manually as it is only performed occasionally and only on flooded (or wet) batteries.

The charging cycle is a multistage (three-stage) process. Whenever qualified AC power is present at the inverter’s input, it passes power through to the connected load and begins charging the batteries.

Bulk Stage

Bulk charge is the first stage in the charging process and provides the batteries with a controlled, constant current. Once the battery voltage rises to the absorption voltage threshold, the charger switches to the absorption stage.

Absorption Stage

Absorption charge is the second stage of battery charging and provides the batteries with a controlled, constant voltage. During this stage, the current drawn by the batteries slowly decreases. When this current falls below 2% of the battery capacity, or when the configurable Absorb Time expires, the charger switches to the Float or NoFloat stage, depending on the selected charge cycle. The timer begins when the battery voltage is above the bulk termination voltage for three minutes.

The Freedom SW transitions to the float stage if either one of the following two conditions are met:

1. The charge current allowed by the batteries falls below the exit current threshold, which is equal to 2% of the programmed battery capacity (for a 500 amp-hour battery bank, this would be 10 amps), for three minutes.
2. The Freedom SW has been in absorption for the programmed maximum absorption time limit. The default is 3 hours, but the time limit is programmable from 1 minute to 8 hours.

Float Stage

Float charge maintains the batteries slightly above the self discharge voltage of the batteries. The charge current in float is the current necessary to maintain the batteries at the Float Voltage setting, limited only by the inverter's capability or other settings that limit the inverter's maximum charge rate. Float charging reduces battery gassing, minimizes watering requirements (for flooded batteries), and makes sure the batteries are in a constant state of readiness. When three-stage charging is selected, the charger automatically switches to the float stage after the batteries have received a bulk and absorption charge (see Figure 35). The batteries are maintained at the default float voltage level for the selected battery type or the voltage selected under Float Voltage on the Custom Battery Settings menu.

Two-Stage Charging Process

Two-stage (or no float) mode differs from an ordinary three-stage charge mode in that it does not continuously maintain the battery at float voltage. Instead, the Freedom SW begins charging the battery in bulk mode whenever the battery voltage drops below the recharge level. While the battery voltage is above the recharge level the inverter’s AC transfer switch continues to pass power through from the utility grid to the loads, but does not actively charge the batteries. Two-stage mode increases efficiency of utility connected systems by reducing the amount of power consumed by the inverter and batteries compared to when the battery is continuously maintained at Float Voltage. This feature can extend the life of most batteries.

Equalize Charging

Many battery manufacturers recommend periodic equalize charging to counter cell charge imbalance and capacity-robbing electrolyte stratification. Equalizing helps to improve battery performance and lifespan by encouraging more of the battery material to become active. Battery equalization is a controlled overcharging method that mixes up stratified electrolyte and reactivates unused areas of the plate material. Periodic equalizing can help to regularly restore batteries to a full and healthy state of charge. Consult the battery manufacturer's recommendation for equalize charging settings. Sealed batteries should never be equalized. Consult the battery manufacturer for optimal charging procedures when using sealed batteries. When Equalize mode is enabled, the battery is charged from bulk to absorption, and then to the equalize phase. The Freedom SW will transition from the absorption phase to equalize if:

• the DC charge current is below 2% of the configured battery capacity (for example, 8.8A for 440Ah)
• the absorption time is exceeded (for example, 180 min)

After absorption, the maximum charge DC current is set to 10% of battery capacity (for example, 44A for 440Ah). See Figure 37. This constant current charge will continue until the voltage has increased to the equalize voltage at which point the battery will be regulated at the temperature-compensated equalize voltage. If the battery capacity is set to zero (Ah=0 effectively disables the exit current criteria for the absorption charge stage making the absorption stage defined by time only), the equalize charge current is fixed at maximum 100% of the charge rate. Equalization duration is fixed at one hour.

Inverter Applications

The Freedom SW performs differently depending on the AC loads connected to it. If you are having problems with any of your loads, read this section.

Resistive Loads

Resistive loads are the easiest and most efficient to drive. Voltage and current are in phase, which means they are in step with one another. Resistive loads generate heat in order to accomplish their tasks. Toasters, coffee pots, and incandescent lights are typical resistive loads. It is usually impractical to run larger resistive loads—such as electric stoves and water heaters—from an inverter due to their high current requirements. Even though the inverter may be able to accommodate the load, the size of battery bank will limit inverter run time.

Motor Loads

Induction motors (AC motors without brushes) require up to six times their running current on startup. The most demanding are those that start under load (for example, compressors and pumps). Of the capacitor start motors (typical in drill presses and band saws, for example), the largest you can expect to run is one horsepower. Universal motors are generally easier to start. Check that the Locked Rotor Amps (LRA) rating of the motor load does not exceed the maximum surge current rating of the inverter. Since motor characteristics vary, only testing will determine whether a specific load can be started and how long it can be run. If a motor fails to start within a few seconds or loses power after running for a time, it should be turned off. When the inverter attempts to start a load that is greater than it can handle, the inverter may shut down from an AC overload fault.

Problem Loads

Very Small Loads If the power consumed by a device is less than the threshold of the search mode circuitry, and search mode is enabled, the inverter will not run. Most likely the solution will be to disable Search mode or lower the sense threshold.

Fluorescent Lights and Power Supplies

• Some devices cannot be detected when scanned by search mode circuitry. Small fluorescent lights are the most common example. Some computers and sophisticated electronics have power supplies that do not present a load until line voltage is available. When this occurs, each unit waits for the other to begin. To drive these loads, either a small companion load like a light bulb rated for more than the Search Watts setting must be used to bring the inverter out of search mode, or the inverter may be programmed to remain on by disabling Search mode. (See “Using Search Mode” on page 45.)

Clocks

• You may notice that your clocks are not accurate. Some of the clocks on your appliances may reset when the Freedom SW is in search mode.

Searching

• When the inverter is in search mode, it may fail to start some loads even though the rated wattage on the load is more than the Search Watts setting. Disable Search or apply an additional load (companion load) to make the inverter exit search mode.

Troubleshooting the Freedom SW via the SCP

The Freedom SW is designed with a number of protection features to provide efficient operation. If, however, you have any problems operating your inverter/charger read this troubleshooting chapter. If you cannot resolve the problem, record the information about your system. This information will help your dealer or customer service to assist you better when you contact them.

When a detected fault or warning message appears, you can acknowledge the message to clear the screen. To acknowledge a fault or warning message, press the Enter button on the SCP. This action does not clear the fault or warning condition, so you should consult “Detected Fault Messages” and “Detected Warning Messages” for suggested actions after you have acknowledged the message. Refer to the Xanbus System Control Panel Owner’s Guide for more information on detected faults and warnings.

Detected Fault Types

There are three types of detected fault messages: automatic faults, manual faults, and escalating automatic faults. Table 1 describes how they differ in their behavior and how you can respond to them when they appear on the SCP.

To view a fault list:

1. On the Select Device menu, highlight System and press Enter.
2. On the System Settings menu, highlight View Fault List.
3. Press Enter.

Detected Warning Types

There are two types of detected warnings: automatic and manual. When the Freedom SW detects a warning condition, it displays a warning message on the SCP. Table 2 describes how they differ in their behavior and in how you can respond to them when they appear on the SCP.

To view a warning list:

1. On the Select Device menu, highlight System and press Enter.
2. On the System Settings menu, highlight View Warning List.
3. Press Enter.