Vanner RE24-4500 Owner's manual

4282 Reynolds Drive

Hilliard Ohio, 43026

1(800) ACPOWER

www.vanner.com

RE SERIES

Renewable Energy True Sine Wave

AC Power Inverter/Charger

Owners Manual

RE-4500

RE-4500RE-4500

RE-4500

MULTI-MODE ALTERNATIVE ENERGY INVERTER

AC Power Inverter System

INVERTER

CHARGER

TEMPERATURE

GENERATOR

BATTERY

UTILITY

ON

OFF

CAUTION - Risk of Electric Shock, Do Not Remove Cover. No User Serviceable Parts Inside. Refer Servicing To Qualified Service Personnel.

CAUTION - Risk of Electric Shock, Both AC and DC Voltage Sources Are Terminated Inside This Equipment. Each Circuit Must Be Individually

Disconnected Before Servicing.

Models decribed

RE24-4500

RE48-4500

Part #D99988

07/17/01 12:20 PM

Revision 1.0

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Copyright  2001 Phone: (614) 771-271 RE-4500

Vanner Inc. FAX: 614-771-4904 Installation Manual

4282 Reynolds Dr. www.vanner.com Rev 10d

Hilliard Ohio 43026 RE Owners_Manual_Rev10d D99988

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Notes

Contents

i

Copyright  2001 Phone: (614) 771-271 RE-4500

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Contents

1 Introduction.............................................................................................................1-1

2 Specifications and Features ..................................................................................2-1

Standard Features....................................................................................................2-5

Parts and Accessories..............................................................................................2-6

3 Important Safety Instructions................................................................................3-1

Safety Instructions....................................................................................................3-3

General Precautions.................................................................................................3-4

Explosive Gas Precautions.......................................................................................3-5

Battery Precautions ..................................................................................................3-5

Code Compliance.....................................................................................................3-6

4 Component Identification.......................................................................................4-1

5 System Operation Description...............................................................................5-1

Modes of Operation..................................................................................................5-5

Inverting................................................................................................................................5-5

Load Demand (Load Discover).....................................................................................................5-5

Small Inverting..............................................................................................................................5-6

Normal Inverting...........................................................................................................................5-6

Surging..........................................................................................................................................5-6

Browning Out................................................................................................................................5-6

Low Battery Shutdown..................................................................................................................5-7

Charging...............................................................................................................................5-8

Battery Temperature Sensor................................................................................................5-9

Generator Start Option.......................................................................................................5-10

Grid Interactive...................................................................................................................5-11

Surplus Power....................................................................................................................5-11

Generator Support..............................................................................................................5-12

Generator Start and Grid-Interactive..................................................................................5-12

Set Current.........................................................................................................................5-12

Bypass................................................................................................................................5-13

System Control.......................................................................................................5-13

On/Off Switch .....................................................................................................................5-13

Inverter Charger Control.....................................................................................................5-14

Inverter/Charger Controller......................................................................................................5-14

Display and Key Functions ..........................................................................................................5-15

Moving Around the RE-ICC Menus..............................................................................................5-16

Turning The Inverter / Charger On and Off..................................................................................5-17

Menu Functions ...........................................................................................................................5-18

Display Menu...............................................................................................................................5-24

6 Preventive Maintenance and Trouble Shooting Procedures............................... 6-1

Preventive Maintenance ...........................................................................................6-1

Trouble Shooting Procedures ...................................................................................6-1

Preliminary Checks...................................................................................................6-2

Problem Symptoms and Troubleshooting Checks.....................................................6-3

Appendix A: Warranty........................................................................................................ 1

Appendix B: RE-ICC Menus............................................................................................... 1

Appendix C: Settings ......................................................................................................... 1

Alarm Listing................................................................................................................ 1

Calibration Data........................................................................................................... 2

RE Owners Manual

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Copyright  2001 Phone: (614) 771-271 RE-4500

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Appendix D: Application Notes..........................................................................................1

Application Notes..........................................................................................................1

Applicable Documents..................................................................................................1

List of Tables

Table 2-1: RE-4500 Inverter/Charger Specifications.......................................................... 2-1

Table 4-1: Relay Configurations for Relay A...................................................................... 4-7

Table 4-2: Relay Configurations for Relay B...................................................................... 4-7

Table 4-3: Relay Configurations for Relay C......................................................................4-8

Table 4-4: Relay Configurations for Relay D......................................................................4-8

List of Charts

Chart 2-1: Inverter Power De-Rating Chart* ...................................................................... 2-3

Chart 2-2: Output Current Surge Fault Response Time @ 25°C*...................................... 2-3

Chart 2-3: Current Regulation (Brownout) Mode Shutdown Time...................................... 2-4

Chart 5-1: Output Current Surge Fault Response Time @ 25°C*......................................5-6

Chart 5-2: Current Regulation (Brownout) Mode Shutdown Time......................................5-7

List of Figures

Figure 4-1: Inverter/Charger Front and Side View............................................................. 4-1

Figure 4-2: Inverter/Charger Front Panel Indicators........................................................... 4-3

Figure 4-3: DC Raceway Terminations..............................................................................4-6

Figure 4-4: AC Raceway Terminations.............................................................................. 4-6

Figure 5-1: Block Diagram.................................................................................................5-2

Figure 5-2: Inverter/Charger Controller............................................................................5-15

Figure 5-3: RE-ICC Menus.............................................................................................. 5-19

Figure 5-4: Main Menu.................................................................................................... 5-20

Figure 5-5: Inverter Menu................................................................................................ 5-21

Figure 5-6: Display Menu ................................................................................................ 5-25

Introduction

1-1

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1 Introduction

Thank you for purchasing a Vanner RE-4500 Renewable

Energy Inverter System. We are confident that you will be

satisfied with its performance and its many features. With

proper installation and care, you can look forward to years of

service from this high performance product.

“RE-4500” stands for Renewable Energy 4500 Watt, Inverter

System. The specific model numbers covered in this document

are the “RE48-4500” and “RE24-4500” which designate

48VDC or 24VDC respectively.

The RE SERIES is a family of dependable inverters designed

to meet the service requirements of the Renewable Energy

market and produce true sine wave AC output power.

This document will describe the operation and technical

specifications of the RE24-4500 and accessories offered in this

product family. We suggest that you acquaint yourself with this

model inverter/charger and any optional accessories that you

have purchased before proceeding with this manual. If you

require additional information please contact your dealer, or

contact us directly at 1-800-227-6937 (800 AC POWER).

WARNING: Before you install and use your RE SERIES Inverter/Charger be sure

to read and save these safety instructions.

WARNING: The RE-4500 is not designed to be a part of Life Supporting or Life

Sustaining Equipment. If the Unit is to be used in such an

application, please contact Vanner Inc. at 1-800-ACPOWER.

The RE SERIES product line is designed to meet the

requirements of a variety of applications.

RE Owners Manual

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Save these instructions!

Please note your model and serial number here for future

reference.

Model No.

Serial No.

Date of Installation

This document describes the operation, technical specifications

and installation procedures for the RE-4500 Inverter/Charger

System. If you require additional information please contact

your dealer or contact Vanner at 1-800-AC POWER (1-800-

227-6937).

Specifications and Features

2-1

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2 Specifications and Features

AC Power Output (Inverter Output)

Rated Output Watts (-40 to +25°C) 4500 Watts

Continuous Output at 25°C (77°F) 4500 Watts

Continuous Output at 40°C (104°F) 3650 Watts

Continuous Output at 50°C (122°F) 3250 Watts

Continuous Output at 60°C (140°F) 3200 Watts

Max Continuous Output on L1 or L2 26.5 Amps (Electronically current

limited)

3 Second Surge Output (at 24 VDC input, and 25ºC) 10000 VA

AC Maximum Output Fault Current 56.25 Arms

(Inverter shuts down in 1/60 sec)

Output Waveform True Sine Wave

Output Voltage, Single Phase, 3 Wire 120/240 Vrms ±5.0%

Output Frequency 60 Hz ± 0.01 Hz

Power Factor -1 to 1

Charging or Grid Interactive Power Factor Unity

% of Rated Charger Current Available at Full Charger

Voltage 100%

Total Harmonic Distortion (THD) 5% Maximum

AC Output Wiring Method Hardwire Terminal Strip

AC Transfer Switch

Amperage Rating 30 Amp 240 Volt

Transfer Speed (a function of load) 16 milliseconds to 0.5 second

(approx.)

From Inverter to Utility Power 16 ms

From Utility Power to Inverter w/ Grid Tie Enabled 1 second

From Utility Power to Inverter w/ Grid Tie Disabled 40 ms

Table 2-1: RE-4500 Inverter/Charger Specifications

RE Owners Manual

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AC Operating Ratings

AC Operating Voltage (Utility Interactive) 211.8 to 264 Vrms

AC Operating Voltage (Stand-alone) 211.8 to 264 Vrms

AC Maximum Output Current 18.75 Arms

AC Maximum Output Fault Current

(Measured when L1 is shorted to L2.) 56.25 Arms

AC Maximum Input Current

(From grid when charging) 30 amp APM rating

18.75 Arms for Inverter/Charger

AC Operating Frequency Range 59.75 Hz to 60.25 Hz

Output Neutral to Ground Not Bonded

(Good AC wiring practice dictates

that bonding between neutral and

ground should take place in the AC

distribution panel only.)

Charger

Maximum Charge Current Supported 100 ADC

Types of Charge supported Bulk, Absorption, Float, and Equalize

Types of Batteries Supported Lead Acid: Flooded-Cell, GEL, or

AGM

DC Input Voltage (Inverter Input)

DC Input Voltage Range 21.0 to 31.0 VDC - RE24-4500

41.0 to 62.0 VDC - RE48-4500

DC Input Current at 24VDC (Inverter Input)

Inverter OFF 1 ma

Inverter in Load Demand (No AC load) 0.5 amps

Inverter ON with no AC load 2.0 amps

Inverter with full load at 22VDC (4500W @ 25°)225 amps

System

Generator Start & Low Battery Warning Control Relays

Rating 2 Amps 120 VAC / 2 Amps up to

100VDC

Efficiency 80% Nominal (at 22VDC for 24V

System, full load, at 44VDC for 48V

System, full load)

90% peak

Ambient Operating Temperature -40° to +40°C (-40 to +104°F) (to

+60°C (+140°F) with de-rated

output)

Cooling Air Thermostatically Controlled Fan

Enclosure Powder-Coated Aluminum / Wall

Mounting

Dimensions 29½ H x 20½ W x 9¼ D

Unit Weight 95 pounds

Specifications and Features

2-3

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Temperature in Degrees C

5000

4500

4000

3500

3000

2500

2000

1500

1000

500

Watts (Output)

Operating Range

-50 -40-30 -20 -10 0 10 20 30 40 50 60 70 80

18.75 Arms

28.13 Arms

37.50 Arms

56.25 Arms

79.55 Arms

0.0000514

Seconds

10

Seconds 3

Seconds 1 Second .01667

seconds

Indefinitely

*Note: The RE-4500 Inverter will try to power the load as per the chart

above. When the load exceeds the inverter's rated output the

Inverter/Charger Indicator LED will turn Orange. The current limit

circuit will operate in the manner indicated above, and will reduce the

AC Output Voltage as needed to keep the AC Output Current from

exceeding specifications. If the output voltage is outside the limits

shown in Chart 2-3, the inverter will shut off and the Inverter/Charger

LED will turn Red.

Chart 2-1: Inverter Power De-Rating Chart*

Chart 2-2: Output Current Surge Fault Response Time @ 25°C*

RE Owners Manual

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254 Vrms

330 Vrms

420 Vrms

Indefinitely 10

Seconds .033

Second .01667

Second

211 Vrms

120 Vrms

60 Vrms

10

Seconds

.033

Second

.01667

Second

Chart 2-3: Current Regulation (Brownout) Mode Shutdown Time

Specifications and Features

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Standard Features • True sine wave single phase 3 wire 240 VRMS output.

• Unity Power Factor Corrected Battery Charger for less AC

Input Distortion, accommodating Lead Acid, Flooded-Cell,

GEL, and AGM types of batteries.

• True single phase three wire 240VRMS output that can be

used with Multiwire branch circuits, without needing the

load rewiring (required by many single phase inverters).

• Total harmonic distortion less than 5% for all loads up to

the Surge Output Rating.

• Reliable electronic protection designed to handle output

short-circuits and output overloads.

• Terminal block for hardwiring the AC outputs.

• Automatic shutoff for low or high battery voltage,

overload, or over-temperature.

• Relay Output circuits, providing Normally Open (NO) and

Normally Closed (NC) control for activating external

devices and alarms.

• Indicator lights for Inverter, Temperature, Battery,

Generator, and Utility status.

• Thermostatically controlled cooling fan.

RE Owners Manual

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Parts and Accessories

Part

Number Name Description

RE-ICC/LCD Remote Display Inverter/Charger Controller – changes and

displays the programmable settings inside the

RE-4500.

RE24-4500S 24V RE-4500 with a

Small Inverter Board This option enables greater efficiency when the

inverter is providing power for a light load (less

than 75 watts).

RE-ACM AC Control Module Includes most requirements for utility, load,

bypass, and AC generator connections, breakers,

and switches in a convenient assembly.

RE-DCM

Models:

RE48-DCM

RE24-DCM

DC Control Module Includes most requirements Solar, Battery,

Auxiliary DC Loads, Charge Controllers,

Disconnects, and connections for the DC source

and loads in a convenient assembly.

RE-BTS1 B/T Sensor Battery Temperature Sensor – an optional sensor

available to more accurately monitor the

condition of batteries in the system.

RE-SLM

Model:

RE48-SLM

Sun Lynx Module Configures the system for “battery-less

operation”. This module is used to connect to

the Solar Array instead of the RE-DCM used in

a Battery populated system.

Important Safety Instructions

3-1

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3 Important Safety Instructions

WARNING: Before you install and use your RE-SERIES AC Power Inverter, read

and save these safety instructions!

This manual contains important safety and operating

instructions for the Vanner Incorporated RE-4500 Power

Inverter that shall be followed during installation and

maintenance of the inverter as prescribed by Underwriters

Laboratories (UL). The RE-4500 inverter is listed as compliant

with UL 1741 Power Conditioning Units for use in Residential

Photovoltaic Power Systems.

Warning Labels

Please READ ME

It should be noted that hazardous voltages are associated with

this product. This unit has connections to both DC at lethal

amperages and AC at lethal amperages and voltages.

Installation should only be done by qualified personnel and in

compliance with local regulations and codes.

Special care must be taken in working around the RE-4500

Inverter/Charger System in order to avoid hazardous voltages

and currents.

NOTE: In order to reduce the risk of damage to personnel or equipment,

please read all instructions in this manual, particularly warnings

noted by the following symbols.

RE Owners Manual

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These symbols are used to note procedures that if not closely

followed could lead to loss of life or damage to equipment or

property due to electrocution.

Electrocution hazard exists

Fire hazard exists

A potentially dangerous

condition

Explosive hazard exists

Corrosive hazard exists

The following are additional symbols used in identifying other

aspects of the RE-4500.

AC

This symbol denotes AC Voltage is

potentially present on this termination.

DC Voltage

This symbol denotes DC Voltage is

potentially present on this termination.

L1 Phase 1

This symbol denotes that this termination

is used for the upper phase of a 240 Vrms

3 wire system consisting of Phase 1

(Black wire), Neutral (White wire), and

Phase 2 (Red wire).

Important Safety Instructions

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NNeutral

This symbol denotes that this termination

is used for the middle wire of a 240 Vrms

3 wire system consisting of Phase 1

(Black wire), Neutral (White wire), and

Phase 2 (Red wire).

L2 Phase 2

This symbol denotes that this termination

is used for the lower phase of a 240 Vrms

3 wire system consisting of Phase 1

(Black wire), Neutral (White wire), and

Phase 2 (Red wire).

GND Ground

This symbol denotes that this termination

is used for a ground connection (Green

wire).

Safety Instructions

Caution

Read owners manual BEFORE wiring or powering up the RE-4500.

Caution

DO NOT cover or obstruct ventilation openings. DO NOT mount in

a zero-clearance compartment. Overheating may result.

Warning

Under high ambient temperature / high-power-output conditions

some parts of the inverter may become hot enough to cause

burns. The unit should be installed so that it is not to be contacted

by personnel.

Warning

This equipment employs components that tend to produce arcs

and sparks. To prevent fire or explosion, DO NOT install in

confined areas or compartments that contain batteries or

flammable gases and materials.

Warning

Improper use of this product may result in risk of electrical shock.

Both AC and DC voltage sources are terminated inside this

equipment.

RE Owners Manual

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Battery connections are for disconnection only, NOT for current

interruption.

General Precautions Do not expose the inverter/charger to direct water spray, rain, or

snow.

To reduce the risk of a fire hazard, do not cover or obstruct the

ventilation openings.

Do not install the inverter in a zero clearance compartment. This

may result in overheating and/or diminished performance.

To avoid the risk of fire, electrical shock, or injury to persons, do

not use attachments not recommended or sold by Vanner

Incorporated.

Vanner recommends that all AC and DC electrical wiring be

performed by a licensed electrician or a qualified technician to

ensure compliance with all applicable national and local wiring

regulations.

To avoid a risk of fire and/or electrical shock, always verify wiring

connections are in good electrical condition. All external

conductors must use proper wire size to avoid dangerous

overheating and/or diminished performance.

If the inverter has been dropped or damaged in any way, do not

operate the inverter until it has been verified to be safe by a

qualified technician.

To reduce the risk of electrical shock, always disconnect the AC

and DC connections using the code required AC and DC

disconnects. The On/Off switch only turns off the Inverter

electronics. Dangerous AC and DC Voltages Are Still Present!

The inverter must be properly grounded in accordance with local

and national codes and ordinances before operation. For most

installations, the negative (ground) conductor should be bonded

to the grounding system at one and only one point in the system.

For optimum inverter/charger performance, battery temperature

should be above 32 degrees Fahrenheit.

Important Safety Instructions

3-5

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Do not disassemble the inverter/charger. See the service section

of this manual for instructions on obtaining service. Attempting

to service the inverter yourself may result in a risk of electrical

shock, fire and/or loss of warranty.

Always use service disconnects to break the circuit before

attempting any kind of servicing of the RE-4500. DO NOT attempt

to service the unit while still actively connected to a power

source of any kind.

Explosive Gas Precautions

This equipment contains components, which tend to produce arcs

or sparks. To prevent fire or explosion, do not install 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.

To reduce the risk of battery explosion, follow these instructions,

the battery manufacturer instructions, and the instructions of the

manufacturer of the equipment in which the battery is installed.

Working near a lead-acid battery is dangerous. Batteries generate

explosive gases during normal battery operation.

Battery Precautions

Always have someone within range of your voice to come to your

aid when you work near a lead-acid battery.

Have close access to plenty of fresh water and soap in case

battery acid contacts skin, clothing, or eyes.

Always wear complete eye protection and clothing protection.

Avoid touching eyes while working near batteries.

If battery acid contacts skin or clothing, wash immediately with

soap and water. If acid enters eye, immediately flood eye with

running cold water for at least 20 minutes. Get medical attention

immediately.

NEVER smoke or allow a spark or flame near a battery. Gases

produced by batteries are explosive.

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Be careful when working with metal tools around batteries.

Potentials exist for sparks or short-circuit of the battery or other

electrical part which could cause an explosion.

Before attempting any sort of wiring for the DC supply to the

Inverter, turnoff the DC disconnect associated with the Batteries.

For Safety, ALWAYS check the operation of the disconnect with a

voltmeter!

In addition to the lethal current associated with the batteries, care

must be taken to avoid any potential problems or explosions from

the batteries. ALWAYS comply with the battery manufacturer’s

and local code requirements/guidelines for the installed battery

system.

Code Compliance Vanner Model RE-4500 is certified by Underwriter’s

Laboratory to meet UL listing 1741 for Photovoltaic Systems,

and complies with IEEE 929 and the National Electric Code

Article 690, Solar Photovoltaic Systems.

Component Identification

4-1

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4 Component Identification

This section will give the reader an idea as to location and

description of various features of the RE-4500.

Note that at the top of the unit there is a parallel raceway with

terminations for connecting DC Power and Control Wiring.

The bottom of the unit contains another parallel raceway for

AC Power Wiring connections.

Left View Right View

3

12

1 2

28 28

Front View

RE-4500

RE-4500RE-4500

RE-4500

MULTI-MODE ALTERNATIVE ENERGY INVERTER

AC Power Inverter System

INVERTER

CHARGER

TEMPERATURE

GENERATOR

BATTERY

UTILITY

ON

OFF

CAUTION - Risk of Electric Shock, Do Not Remove Cover. No User Serviceable Parts Inside. Refer Servicing To Qualified Service Personnel.

CAUTION - Risk of Electric Shock, Both AC and DC Voltage Sources Are Terminated Inside This Equipment. Each Circuit Must Be Individually

Disconnected Before Servicing.

8910

12

14

28

29 11

467 5

13

11

Figure 4-1: Inverter/Charger Front and Side View

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(1) Knockout for High Current DC Wiring

This knockout provides for the routing and termination of high

capacity DC cables from batteries, RE-SLM, RE-DCM to the

RE-4500 Inverter/Charger.

This knockout provides access (from either the right side or the

left side of the inverter) to the DC Wiring Raceway.

This knockout matches up with the high capacity DC knockout

on Vanner accessories such as the DC Control Module (RE-

DCM), the RE48-SLM (Sun Lynx Module), and the AC

Control Module (RE-ACM). This is a standard size 2 ½”

conduit knockout.

(2) Knockout for Low Current DC Control Wiring

These knockouts provide for the routing and termination of

low capacity DC Control Wiring.

These knockouts provide access (from either the right side or

the left side of the inverter) to the DC Wiring Raceway.

These knockouts match up with the low current DC/Control

knockouts on Vanner accessories such as the DC Control

Module (RE-DCM), the RE-SLM (Sun Lynx Module), and the

AC Control Module (RE-ACM). This is a standard size ¾”

conduit knockout.

(3) Knockout for AC Wiring This knockout provides for the routing and termination of AC

Wiring.

This knockout provides access (from either the right side or the

left side of the inverter) to the AC Wiring Raceway.

This knockout matches up with the AC knockout on Vanner

accessories such as the AC Control Module (RE24-ACM), the

RE48-SLM (Sun Lynx Module), and the DC Control Module

(RE24-DCM). This is a standard size 1 ¼ “ conduit knockout.

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Vanner RE24-4500, RE Series, RE48-4500, TSC24-4500 Owner's manual

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