Xantrex Technology Prosine Ps25 User Manual

PS2.5  
PS3.0  
Installation and Operation Guide  
Xantrex  
TM  
Prosine 2.5 and 3.0  
Inverter/Chargers  
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 standalone systems. Xantrex products include inverters, battery  
chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute  
electrical power.  
Trademarks  
Xantrex is a registered trademark of Xantrex International. © 2002 Xantrex International. All rights reserved. Prosine  
is a registered trademark 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  
Installation and Operation Guide © November 2002 Xantrex International.  
Disclaimer  
Xantrex manufactures its products from parts and components that are new or equivalent to new, in accordance with  
industry-standard practices.  
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  
November 2002, Revision 3  
Part number  
445-0096-01-01 Rev 3  
Contact information  
Telephone: 1-800-670-0707 (toll free in North America)  
1-604-422-2777 (outside North America)  
Fax:  
1-604-420-2145 (outside North America)  
www.xantrex.com  
Email:  
Web:  
IMPORTANT SAFETY INSTRUCTIONS  
This manual contains important safety and operating instructions as prescribed by UL and CSA  
specifications for inverter/chargers. This manual covers PS 2.5 and PS 3.0, 12- and 24-volt model  
inverter/chargers.  
General Safety Precautions  
1. READ AND SAVE THESE INSTRUCTIONS. They contain important  
safety and operating information for the Prosine inverter/charger.  
2. Before using the inverter/charger, read all instructions and cautionary markings  
on (1) the inverter/charger, (2) the batteries, and (3) all appropriate sections of  
this instruction manual.  
3. Do not expose the Prosine inverter/charger to rain, snow, spray or bilge water.  
To reduce risk of fire hazard, do not cover or obstruct the ventilation openings.  
Do not install the Prosine inverter/charger in a zero-clearance compartment.  
Overheating may result.  
4. Do not use attachments not recommended or sold by the manufacturer. Doing  
so may result in a risk of fire, electric shock, or injury to persons.  
5. The Prosine 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 proper electrical  
wiring regulations.  
6. To avoid a risk of fire and electric shock, make sure that existing wiring is in  
good electrical condition; and that wire size is not undersized. Do not operate  
the Prosine inverter/charger with damaged or substandard wiring.  
7. Do not operate the Prosine inverter/charger if it has received a sharp blow,  
been dropped, or otherwise damaged in any way. If the Prosine inverter/  
charger is damaged, see the Warranty section of this manual.  
8. Do not disassemble the Prosine inverter/charger. See the Service section of the  
Owner’s Manual for instructions on obtaining service for the Prosine inverter/  
charger. Attempting to service the unit yourself may result in a risk of electrical  
shock or fire. Internal capacitors remain charged long after all power is discon-  
nected.  
9. To reduce risk of electrical shock, disconnect both AC and DC power from the  
Prosine inverter/charger before attempting any maintenance or cleaning or  
working on any circuits connected to the Prosine inverter/charger. Turning off  
controls will not reduce this risk.  
10. Grounding: the Prosine inverter/charger must be provided with an equipment-  
grounding conductor connected to the AC input ground terminal. Grounding  
and all other wiring must comply with local codes and ordinances  
11. For marine applications in the United States, external connections to the Pros-  
ine inverter/charger shall comply with the United States Coast Guard Electrical  
Regulations (33CFR183, Sub part 1).  
Prosine 2.5/3.0 Installation & Operation Guide  
i
     
12. WARNING—RISK OF EXPLOSIVE GASES  
a) WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DAN-  
GEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING  
NORMAL BATTERY OPERATION. BEFORE INSTALLING OR  
USING YOUR INVERTER/CHARGER, READ THIS MANUAL AND  
FOLLOW THE INSTRUCTIONS EXACTLY.  
b) This equipment contains components which tend to produce arcs or sparks.  
To prevent fire or explosion do not install in compartments containing bat-  
teries or flammable materials or in locations which require ignition pro-  
tected equipment. This includes any space containing gasoline-powered  
machinery, fuel tanks, or joints, fittings, or other connection between com-  
ponents of the fuel system.  
c) To reduce the risk of battery explosion, follow these instructions and those  
published by the battery manufacturer and the manufacturer of the equip-  
ment in which the battery is installed.  
13. PRECAUTIONS WHEN WORKING WITH BATTERIES  
a) Someone should be within range of your voice or close enough to come to  
your aid when you work near a lead-acid battery.  
b) Have plenty of fresh water and soap nearby in case battery acid contacts  
skin, clothing, or eyes.  
c) Wear complete eye protection and clothing protection. Avoid touching eyes  
while working near battery.  
d) 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 and get medical attention immediately.  
e) Baking soda neutralizes lead-acid battery electrolyte. Keep a supply on  
hand in the area of the batteries.  
f) NEVER smoke or allow a spark or flame in vicinity of a battery or engine.  
g) Be extra cautious to reduce risk of dropping a metal tool on the battery. It  
might spark or short-circuit the battery or other electrical part that may  
cause an explosion.  
h) Remove personal metal items such as rings, bracelets, necklaces, and  
watches when working with a lead-acid battery. A lead-acid battery pro-  
duces a short-circuit current high enough to weld a ring or the like to metal,  
causing a severe burn.  
i) Use the Prosine inverter/charger for charging a LEAD-ACID battery only.  
Do not use the Prosine inverter/charger to charge nickel-cadmium or dry-  
cell batteries commonly used with home appliances and electronic equip-  
ment. These batteries may burst and cause injury to persons and damage to  
property.  
j) NEVER attempt to charge a frozen battery. Charging a battery when its  
temperature is below 32° F (0° C) is inefficient and ineffective. If possible,  
gradually warm the battery above 32° F (0° C) before charging.  
ii  
Prosine 2.5/3.0 Installation & Operation Guide  
 
Important Safety Instructions  
FCC INFORMATION TO THE USER  
NOTE: This equipment has been tested and found to comply with the limits for a Class A 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 commercial environment. This equipment  
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with  
the instruction manual, may cause harmful interference to radio communications. Operation of this  
equipment in a residential area is likely to cause harmful interference in which case the user will be  
required to correct the interference at his own expense.  
Prosine 2.5/3.0 Installation & Operation Guide  
iii  
 
Materials List  
Your Prosine Inverter/Charger package includes the following items. (See the illustration on  
page vi.)  
1. Prosine inverter/charger  
2. Control panel with fasteners  
3. Control panel communications cable  
4. Red & black DC terminal covers  
5. Installation and Operation Guide  
6. Quick Installation Guide  
7. Mounting brackets with fasteners (PS3.0 only).  
8. Drip cover/vent shield  
9. Battery temperature sensor  
If any of these materials are missing from your package, or if it is unsatisfactory in any manner,  
please call Customer Service:  
Phone: 1-800-670-0707 (toll free) 1-604-422-2777 (direct)  
Fax: 1-604-420-2145  
Web site: http://www.xantrex.com  
Please record the following information:  
Model Number: _____________________________________  
Serial Number: _____________________________________  
Purchased From: ____________________________________  
Purchase Date: _____________________________________  
Comments:  
____________________________________________________________________________  
____________________________________________________________________________  
____________________________________________________________________________  
____________________________________________________________________________  
____________________________________________________________________________  
Thank you for choosing Xantrex to meet your independent power needs.  
iv  
Prosine 2.5/3.0 Installation & Operation Guide  
         
Materials List  
System / Installation Information  
Before you call Customer Service, please record the following information about your system. It will  
help our staff to give you better service.  
Serial Number  
(This is on the side  
of the Prosine).  
Type of installation  
(e.g., RV, Boat,  
Home).  
Date of installation.  
Battery bank size.  
Battery type (e.g.,  
flooded, sealed gel  
cell, AGM.  
AC service setting.  
AC wiring size and  
length.  
DC wiring size and  
length.  
Options installed on  
inverter/charger.  
Charger or Invert  
mode when failure  
occurred.  
Warning, Error, or  
Panel Fault  
message if any.  
Appliance(s)  
operating when  
failure occurred.  
Prosine 2.5/3.0 Installation & Operation Guide  
v
 
Figure 1. Inverter/Charger Components  
vi  
Prosine 2.5/3.0 Installation & Operation Guide  
 
Warranty  
Warranty  
What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc.  
("Xantrex") and covers defects in workmanship and materials in your Xantrex Prosine 2.5/3.0 Inverter/  
Charger. This warranty lasts for a Warranty Period of 24 months from the date of purchase at point of sale  
to you, the original end user customer.  
This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the War-  
ranty Period.  
What will Xantrex do? Xantrex will, at its option, repair or replace the defective product free of  
charge, provided that you notify Xantrex of the product defect within the Warranty Period, and provided  
that Xantrex through inspection establishes the existence of such a defect and that it is covered by this  
Limited Warranty.  
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building  
replacement products. Xantrex reserves the right to use parts or products of original or improved design in  
the repair or replacement. If Xantrex repairs or replaces a product, its warranty continues for the remain-  
ing portion of the original Warranty Period or 90 days from the date of the return shipment to the cus-  
tomer, whichever is greater. All replaced products and all parts removed from repaired products become  
the property of Xantrex.  
Xantrex covers both parts and labor necessary to repair the product, and return shipment to the customer  
via a Xantrex-selected non-expedited surface freight within the contiguous United States and Canada.  
Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on freight policy for return  
shipments outside of the contiguous United States and Canada.  
How do you get service? If your product requires troubleshooting or warranty service, contact your  
merchant. If you are unable to contact your merchant, or the merchant is unable to provide service, contact  
Xantrex directly at:  
Phone: 1-800-670-0707 (toll free) 1-604-422-2777 (direct)  
Fax: 1-604-420-2145  
Direct returns may be performed according to the Xantrex Return Material Authorization Policy described  
in your product manual. For some products, Xantrex maintains a network of regional Authorized Service  
Centers. Call Xantrex or check our website to see if your product can be repaired at one of these facilities.  
In any warranty claim, dated proof of purchase must accompany the product and the product must not  
have been disassembled or modified without prior written authorization by Xantrex.  
Proof of purchase may be in any one of the following forms:  
The dated purchase receipt from the original purchase of the product at point of sale to the end  
user, or  
The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM)  
status, or  
The dated invoice or purchase receipt showing the product exchanged under warranty  
What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of  
the product or costs related to the removal, installation, or troubleshooting of the customer's electrical sys-  
tems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to:  
Prosine 2.5/3.0 Installation & Operation Guide  
vii  
     
Disclaimer  
a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either  
internally or externally, or damaged from improper use or use in an unsuitable environment;  
b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations, or input  
voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex  
product specifications including high input voltage from generators and lightning strikes;  
c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (here-  
after "ASCs");  
d) the product if it is used as a component part of a product expressly warranted by another manufacturer;  
e) the product if its original identification (trade-mark, serial number) markings have been defaced,  
altered, or removed.  
Disclaimer  
Product  
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY  
XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED  
BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESEN-  
TATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHER-  
WISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY  
CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERA-  
TION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT RESTRIC-  
TION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR  
FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY  
OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICA-  
BLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD  
STIPULATED UNDER THIS LIMITED WARRANTY.  
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDEN-  
TAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING  
WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC  
LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY,  
ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE  
INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT.  
Exclusions  
If this product is a consumer product, federal law does not allow an exclusion of implied warranties. To  
the extent you are entitled to implied warranties under federal law, to the extent permitted by applicable  
law they are limited to the duration of this Limited Warranty. Some states and provinces do not allow lim-  
itations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation  
or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not  
apply to you. This Limited Warranty gives you specific legal rights. You may have other rights which may  
vary from state to state or province to province.  
viii  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Warranty  
Warning: Limitations On Use  
Please refer to your product user manual for limitations on uses of the product. Specifically, please note  
that the Xantrex Prosine 2.5/3.0 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.  
Please note that the Xantrex Prosine 2.5/3.0 Inverter/Charger is not intended for use as an uninterruptible  
power supply and Xantrex makes no warranty or representation in connection with any use of the product  
for such purposes.  
Return Material Authorization Policy  
Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA)  
number and the correct factory "Ship To" address. Products must also be shipped prepaid. Product ship-  
ments will be refused and returned at your expense if they are unauthorized, returned without an RMA  
number clearly marked on the outside of the shipping box, if they are shipped collect, or if they are  
shipped to the wrong location.  
When you contact Xantrex to obtain service, please have your instruction manual ready for reference and  
be prepared to supply:  
The serial number of your product  
Information about the installation and use of the unit  
Information about the failure and/or reason for the return  
A copy of your dated proof of purchase  
Return Procedure  
1. Package the unit safely, preferably using the original box and packing materials. Please ensure that  
your product is shipped fully insured in the original packaging or equivalent. This warranty will not  
apply where the product is damaged due to improper packaging.  
2. Include the following:  
The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the  
box.  
A return address where the unit can be shipped. Post office boxes are not acceptable.  
A contact telephone number where you can be reached during work hours  
A brief description of the problem  
3. Ship the unit prepaid to the address provided by your Xantrex customer service representative.  
If you are returning a product from outside of the USA or Canada In addition to the above you  
MUST include return freight funds and are fully responsible for all documents, duties, tariffs, and depos-  
its.  
If you are returning a product to a Xantrex Authorized Service Center (ASC) A Xantrex  
return material authorization (RMA) number is not required. However, you must contact the ASC prior to  
returning the product or presenting the unit to verify any return procedures that may apply to that particu-  
lar facility.  
Prosine 2.5/3.0 Installation & Operation Guide  
ix  
     
Return Procedure  
x
Prosine 2.5/3.0 Installation & Operation Guide  
Contents  
Section 1: Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Prosine 2.5/3.0 Installation & Operation Guide  
xi  
 
Contents  
xii  
Prosine 2.5/3.0 Installation & Operation Guide  
Contents  
Prosine 2.5/3.0 Installation & Operation Guide  
xiii  
Contents  
xiv  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 1: Features  
Congratulations on your purchase of the Prosine inverter/charger. The Prosine inverter/charger uses  
advanced high-frequency switching technology in the power conversion process. The circuits are  
similar to those used in power supplies for computers and other modern electronic equipment. This  
technology offers several benefits:  
Light weight: for easy installation  
Quiet operation: no transformer buzz  
Clean DC output: filtered output for ideal battery charging  
High surge capability: for hard-to-start AC loads  
All Prosine inverter/chargers are approved for general use including residential, recreational vehicle,  
marine, and photovoltaic applications based upon Canadian Standards Association (CSA),  
Underwriter Laboratories (UL), and other regulatory agency standards. Prosine inverter/chargers meet  
the stringent requirements of CSA 107.1 “General Use Power Supplies,” UL 458 “Power  
Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts,”  
UL1741 “Power Conditioning Units for Use in Residential Photovoltaic Systems,” and other  
standards.  
Battery Charger Features  
Dead Battery Charging Starts recharging batteries even if the battery voltage is near zero.  
Power Factor Correction High power factor charging results in faster battery charging because  
lower AC current is required from your generator or shorepower. When the AC source has limited  
capacity, the charger leaves more current available for other AC loads on the circuit. On a 15-ampere  
shorepower circuit, a Prosine charger delivers as much as 100 amps of DC current to the battery, while  
non power-factor-corrected chargers typically can deliver only about 70 amps.  
Automatic Three-Stage Charging Whenever AC power is supplied to the Prosine inverter/charger,  
the “smart” charging capability of the Prosine provides a three-stage charge to quickly bring back  
deep-cycle batteries to their full charge. Using microprocessor control, the Prosine precisely regulates  
the voltage and current delivered to the battery, accurately charging the battery without risk of  
overcharging and battery damage. Depleted batteries are taken through the recommended “Bulk”,  
“Absorption”, and “Float” stages. The charging algorithm used in the Prosine inverter/charger is based  
on the same charge cycle algorithm used in Xantrex’s proven Truecharge battery charger line.  
Manual Equalization Charging The Prosine inverter/charger enables you to initiate an equalization  
charge to optimize your battery capacity and rejuvenate your batteries. Equalization (for flooded  
batteries only) helps reduce sulfation and extends battery life.  
Battery Temperature Sensor Since battery temperature is a key factor in correct charging, the  
charging formula must be adjusted (automatically and in real time) according to the actual battery  
temperature to ensure that batteries are fully, but not over charged. For this reason, Xantrex has  
included a battery temperature sensor with your Prosine inverter/charger and has temperature-  
compensated the charge algorithm.  
Prosine 2.5/3.0 Installation & Operation Guide  
1
             
Inverter Features  
Battery Temperature Shut Down When using the battery-temperature sensor, the charger will shut  
down if it detects excessively high or low battery temperatures. If battery temperature exceeds 50°C  
(122°F), or falls below -15°C (5°F), the charger will shut down.  
Adjustable Maximum AC Input Current This feature protects against nuisance tripping of AC  
circuit breakers on the utility or generator AC supply. You can set the maximum AC input current to 8,  
12, 16, or 24 amps to prevent 10, 15, 20, and 30-amp (respectively) circuit breakers from  
unnecessarily tripping as AC load demands approach their current rating. You can set the maximum  
AC input current in one (1) amp increments using the ACS control panel. The Prosine automatically  
reduces its charging current to attempt to keep the sum of all loads from exceeding this setting. The  
Prosine has no control over the loads you apply, so if nuisance-tripping still occurs, try removing one  
or more of your AC loads.  
Inverter Features  
Automatic Transfer Switch When utility AC power fails or is disconnected from the unit, or falls  
below 90 volts, the Prosine will automatically begin inverting and provide AC power from your  
batteries within 20 milliseconds; fast enough to keep a computer running. When utility AC is restored,  
the inverter will sample the AC power for about 8 seconds, synchronize to the AC waveform, and  
automatically switch your loads to utility power. It also returns to charging the batteries.  
Automatic Waveform Regulation The Prosine inverter/charger monitors and regulates the AC  
waveform when inverting, delivering a true sinewave with typically only 1% total harmonic distortion  
(THD). This is usually cleaner than generator and utility waveforms.  
High Surge Capacity The Prosine inverter will deliver up to 4000 watts of power for up to five  
seconds to start large motors and other inductive loads that require high power levels to start. The  
Prosine 2.5 will deliver 2500 watts (21-amps RMS) continuously, while the Prosine 3.0 delivers up to  
3000 watts (25-amps RMS) continuously.  
Load Sense Prosine inverters reduce power consumption during idle periods to conserve battery  
capacity by “searching” for loads that exceed a specified threshold. When a load is detected, the  
inverter ‘turns-on’ and delivers full voltage. When no load is detected, the inverter ‘stands-by,’  
consuming less than three watts of power. The threshold can be set at 10, 25, or 50 watts (10 to 1401  
watts using the ACS Control Panel), or disabled by setting it to zero (0).  
Integral Protective Circuitry All Prosine inverter/chargers feature built-in protective circuitry that  
guards against damage to the inverter and your AC equipment due to high battery voltage, low battery  
voltage, AC overload, and high temperature conditions. This protective circuitry includes:  
Automatic Low Battery Shut Down The Prosine inverter protects your batteries from damage by  
over-discharge by shutting down when battery voltage drops to 10.00 volts for 12-volt units, and 20  
volts for 24-volt units. The unit will resume inverting when battery voltage exceeds 12.3 volts for 12-  
volt models, and 24.6-volts for 24-volt models.  
Automatic High Battery Shut Down The Prosine inverter/charger protects itself from damage from  
excessive battery voltages by shutting down when battery voltage reaches 16-volts for 12-volt units,  
and 32-volts for 24-volt units. When battery voltage falls to 15.5-volts for 12-volt units, and 31-volts  
for 24-volt units, the unit will automatically restart.  
2
Prosine 2.5/3.0 Installation & Operation Guide  
                         
Section 1: Features  
Over-Current Protection When the AC loads connected to the Prosine inverter/charger exceed 50  
amps, the inverter will instantaneously reduce the output voltage until the loads on the inverter are  
reduced. If the overload continues, the inverter will shut down. The unit will automatically restart  
after a calculated recovery time.  
High-Temperature Shut Down When the inverter detects a high-temperature condition internally,  
the inverter will shut down. When the internal temperature cools by at least 6°C (11°F) the unit will  
automatically restart.  
Audible Fault Alarm The Prosine inverter/charger features a user-enable audible alarm to alert you  
in the event of a fault condition. The audible alarm is accompanied by blinking LEDs (on the control  
panel) or by a fault code display (on the ACS control panel). There are four fault conditions at which  
the audible alarm will sound:  
Battery high-voltage  
Battery low-voltage  
System over-temperature  
Communication error or temporary fault  
Visual Fault Code Display If an error occurs, the Prosine inverter/charger control panel will display  
an error code that you can use to determine the cause of the error. Three LEDs will flash on the  
standard control panel to describe the error. On the ACS control panel, the error code will be displayed  
on the LCD display. A table of fault codes and likely causes, along with corrective measures to take, is  
Prosine 2.5/3.0 Installation & Operation Guide  
3
         
Inverter Features  
4
Prosine 2.5/3.0 Installation & Operation Guide  
Section 2: Controls and Indicators  
Prosine 2.5 inverter/chargers feature DC input and output connectors, an AC terminal block, a DIP  
switch panel for custom configuration, three accessory jacks, an LED control panel for the PS2.5 and  
an ACS panel for PS3.0, an LCD control panel, a cover for the AC connector block. The LCD control  
panel is optional on the PS2.5 and standard on the PS3.0. DC terminal covers come standard with both  
units. A replacement AC cover with a GFCI outlet is available as an accessory option for both the  
PS2.5 and PS3.0.  
Figure 2. Prosine Chassis Side and Bottom Views  
DIP Switch Panel  
The DIP switch panel consists of two small, eight-  
position up-down switches located under a cover on the  
side of the Prosine inverter/charger: SW1 and SW2.  
These switches are used to configure the Battery Type, Battery Temperature, Load Sensing, Audible  
Signal, AC Service Rating, and Battery Size user-selectable options. See “Section 3: Configuration”  
on page 25 for configuration instructions.  
Accessory Jacks  
Three accessory jacks are provided on the side of Prosine  
inverter/charger: a battery temperature sensor jack (labeled  
BATT TEMP) and two Remote Output jacks. The battery  
temperature sensor reports battery temperature to the charger to  
Prosine 2.5/3.0 Installation & Operation Guide  
5
                       
AC Bypass Selector  
optimize the charging profile. The remote output jacks enable you to remotely mount the standard  
and/or the ACS control panels, described later in this section of this manual.  
AC Bypass Selector  
The small slide switch located between the Batt Temp jack and the Remote Output jacks is the AC  
Bypass selector switch. The default position of this switch is On. In the On position, the inverter/  
charger operates as programmed. When the switch is in the Bypass position, the inverter/charger is  
Off, and AC current bypasses the inverter/charger to supply  
the AC loads directly.  
DC Terminals & Covers  
The DC cabling connectors are located on the  
bottom of the Prosine inverter/charger. Each  
connector is an M10 x 1.5 stainless steel stud  
and nut. The studs are about 1-inch long and  
approximately 3/8-inch in diameter. Use a 17mm (~11/16-inch) wrench. Two color-  
coded covers, a red one for the positive terminal and a black one for the negative  
terminal, are provided for preventing accidental contact with these connectors after  
installation.  
Adjacent to the DC terminals is the chassis ground lug. The chassis ground lug provides a ground path  
for DC fault current from the inverter/charger chassis to ensure your battery fuse opens in the event of  
a fault.  
AC Terminals & Covers  
On the bottom of the Prosine inverter/charger,  
alongside the DC connectors, a nine-position  
terminal block is provided for attaching AC cabling  
to the unit. The terminal block is divided into AC-  
Input and AC-Output sections. One terminal each is  
provided for the AC Line-In (Hot) cable, the AC Neutral-In cable, and the AC Ground-In (GND)  
cable. Two terminals each are provided for the AC Line-Out cable, the AC Neutral-Out cable, and the  
AC Ground-Out cable. All are clearly labeled. The AC Line  
cable usually has a black insulator, the AC Neutral generally  
has a white insulator, and the AC Ground cable generally has  
either a green insulator, or no insulator at all.  
Adjacent to the AC terminal block is a black bracket with two  
1-inch diameter holes in it. This bracket is provided for  
attaching cable clamps (strain reliefs) or conduit. A cover is  
provided that slides into the end plate of the inverter and  
attaches to the strain-relief bracket. This cover is also  
available with an optional AC duplex GFCI outlet and 15-amp  
circuit protector.  
6
Prosine 2.5/3.0 Installation & Operation Guide  
                           
Section 2: Controls and Indicators  
Standard LED Control Panel  
The Prosine inverter/charger is supplied with a control panel that can be mounted into an instrument  
panel, bulkhead or wall. The standard control panel is used to report information about Prosine  
operating parameters and the external AC and DC power sources connected to it. The standard control  
panel has five separate functional divisions: the Battery Status LED display, the Faults Display and  
Reset Button, the Inverter Status Indicator and On/Off Control Button, the Shorepower Indicator, and  
the Charger Status Display and On/Off Control. These functional divisions are shown in the following  
illustration.  
Figure 3. Standard LED Control Panel Display  
Prosine 2.5/3.0 Installation & Operation Guide  
7
       
Standard LED Control Panel  
Battery Status Indicator  
The Battery Status LED Display includes two vertical series of LEDs that indicate the battery voltage  
and current. A conversion table enables you to estimate the AC output from the inverter by the DC  
current.  
Battery Voltage Indicator This indicator reports the battery voltage at the input terminals of the  
Prosine inverter/charger. At low currents, the indicator is very accurate. At high currents, the indicated  
voltage will be somewhat lower than the actual battery voltage due to voltage drop across the cables  
between battery and inverter. The range of the battery voltage indicator is from 10.0 to 16.75 volts  
DC. The LEDs do not light until the voltage level exceeds the value printed alongside the LED.  
Battery Current Indicator This indicator reports the current drawn by the Prosine inverter/charger  
from the batteries. It does not indicate current drawn by other loads connected to the batteries. High  
current loads (over 200A) are displayed by yellow LEDs. The LEDs do not light until the current level  
exceeds the value printed alongside the LED.  
Error Code Display When an error occurs,  
either the Warning, the Fault, or the Temp  
LED will be lighted, as well as one of the  
Battery Voltage LEDs, and one of the Battery  
Current LEDs. These three LEDs indicate an  
error code that you can look up on the Error.  
to assist in determining the nature of the error  
In the example at right, the Warning, 10V, and  
100A LEDs are flashing, and the error code  
indicated is derived from the value shown in  
parenthesis, in this case: 206. Look in the  
determine the meaning of the code.  
Faults Indicators & Reset Button  
Warning LED This LED flashes on-and-off for the duration of  
any error condition, accompanied by an audible alarm if the  
alarm is enabled.  
8
Prosine 2.5/3.0 Installation & Operation Guide  
                       
Section 2: Controls and Indicators  
Fault LED This LED flashes on-and-off during an error condition from which the unit will  
automatically recover and restart when the condition is remedied. The FAULT LED will be lighted  
steadily when any error occurs from which the inverter/charger cannot automatically recover. It is  
usually necessary to disconnect the AC or DC supply to recover from this type of error. An error  
condition is accompanied by an audible alarm if the alarm is enabled.  
Temp LED This LED flashes on-and-off to indicate that the internal temperature of the Prosine  
inverter/charger is too high and the unit has shutdown. When the internal temperature of the unit cools  
sufficiently, the inverter/charger will automatically restart. The audible alarm that accompanies this  
condition (if enabled) will also be silenced upon auto-restart.  
Reset Button The RESET button on the Faults panel has two functions: pressed and released, it  
will silence the audible alarm which, if enabled, will sound an insistent intermittent tone anytime an  
error condition occurs, which can be looked up in a table to determine the nature of the error. Press  
and hold the RESET button to display error codes. Error codes are listed in an Appendix to this  
manual.  
Inverter Status Indicators and On/Off Button  
Invert LED When the green LED labeled INVERT is flashing,  
shorepower is not present, Load Sense is enabled, and no AC  
loads exceed the Load Sense threshold. The inverter is not  
producing AC power from the batteries. When the INVERT  
LED is lighted steadily, shorepower is not present and the  
inverter is producing AC power from the batteries. The INVERT LED is not lighted when shorepower  
is present.  
Standby LED When the amber LED labeled STANDBY is lighted steadily, shorepower is present  
and the inverter will pass AC power through to any AC loads that may be present.  
If shorepower should fail or be removed while the inverter is in Standby mode, the inverter will  
automatically begin to produce AC power from the batteries, and the INVERT LED will be lighted.  
On/Off Button. A button labeled ON/OFF is provided adjacent to the INVERT and STANDBY  
LEDs. When pressed, this button switches the inverter from On to Standby mode. Use in conjunction  
with the charger’s ON/OFF button to set the startup inverter/charger mode. See “Section 3:  
Configuration‚” on page 25 for instructions on how to set the startup inverter/charger mode.  
Prosine 2.5/3.0 Installation & Operation Guide  
9
                       
Standard LED Control Panel  
Power Indicator  
A green LED labeled UTILITY/SHOREPOWER (INCOMING) lights  
whenever AC power is supplied to the AC INPUT connectors on the  
inverter/charger. Throughout this manual, the term “shorepower” refers to  
the presence of AC power at the AC INPUT connectors, regardless of the  
source of the power: from the utility grid (power company), a generator,  
or any other source.  
Charger Status Indicator and On/Off  
Button  
The Charger Status Indicator includes four LEDs: a green  
LED labeled CHARGE; a green LED labeled READY; an  
amber LED labeled STANDBY; and an amber LED labeled  
EQUALIZE. A charger ON/OFF button is also provided.  
Charge LED The green CHARGE LED lights when the Prosine charger is in Bulk or Absorption  
charging mode. A discussion of the Prosine three-stage charging profile is found in the “Charging  
Profile” section of this manual (see page 59).  
Ready LED The green READY LED lights when the charging cycle has been completed, and the  
charger is in Float charging mode.  
Standby LED The amber STANDBY LED lights when the charger is enabled awaiting AC power.  
When shorepower becomes available, the charger will begin charging, the STANDBY LED will be  
extinguished, and the CHARGE LED will be lighted.  
Equalize LED The amber EQUALIZE LED lights when the battery equalization has been requested,  
and the Prosine is in Charge mode. An equalization charge cycle will commence after fully charging  
the batteries, and both the EQUALIZE LED and the CHARGE LED will flash on-and-off. See  
“Section 6: Multistage Charging” on page 59 for more information about equalization.  
On/Off Button The charger ON/OFF button switches the charger between charger standby mode,  
On, and Off. In standby mode, the charger begins charging automatically when AC shorepower is  
available. In charge mode, press and hold this button for 5 seconds to request an equalize charge.  
Equalize mode will not begin until the batteries are fully charged.  
CAUTION Disconnect DC loads on the batteries during equalization to prevent damage to them by  
the high voltages encountered during equalization. Equalization must be monitored to prevent battery  
damage. Refer to “Section 6: Multistage Charging” for more details.  
10  
Prosine 2.5/3.0 Installation & Operation Guide  
                         
Section 2: Controls and Indicators  
Mounting and Installing the LED Control Panel  
You can install the LED Control Panel in a convenient location up to 50-feet from the Prosine inverter/  
charger unit. This can be extended up to 100-feet with an appropriate extension cable of the same type.  
For flush mount installation onto a wall, bulkhead, or panel, the remote panel requires an opening with  
the measurements of 4 1/8 inches by 4 1/8 inches (10.5cm by 10.5cm). Be sure that there is no wiring  
or other obstruction within the wall before making an opening. The LED Control Panel requires  
approximately 2 inches (5cm) of free space within the wall to accommodate its depth. Follow the steps  
shown below:  
1. Select an appropriate location that is dry, not subject to corrosive or explosive fumes,  
and otherwise appropriate for mounting an electronic device.  
2. Hold the control panel faceplate flush against the wall, bulkhead or panel and mark  
around the outside edge of the faceplate with a pencil.  
3. Mark the location of the four mounting holes at each corner.  
4. Remove the faceplate and mark a line 7/16-inch inside each of the four perimeter lines  
that you marked previously.  
5. Drill an access hole at each corner of the resulting small square, large enough to allow  
you to insert a jigsaw blade. Place your drill bit so that the finished hole will not extend  
beyond the 4 1/8-inch by 4 1/8-inch square you marked on the bulkhead.  
6. Use your jigsaw to cut between the holes you just drilled, and remove the material you  
just cut out. Blow out any waste residue from the cutting and drilling.  
7. Route the telephone-type connector cable from your inverter/charger and the control  
panel and plug it into the control panel only.  
8. Insert the control panel into the bulkhead and secure with appropriate fasteners.  
9. Insert the other end of the connector cable it one of the RJ-11 connectors marked  
“Remote Output.”  
10. Secure the EMI bead attached to the communications cable to a location close to the  
inverter/charger. The EMI bead reduces interference from the inverter on the control  
panel. Securing it prevents accidental disconnect of the remote panel.  
If you purchased the ACS Panel as an accessory to be used with your Prosine 2.5, the ACS Panel and  
standard supplied panel can both be used at the same time. Either connect the standard panel to the  
OUTPUT jack on the back of the ACS Panel, or connect the standard panel to the REMOTE output  
connector jack on the side of the Prosine inverter/charger. The standard panel can then be mounted  
close by the Prosine unit for system monitoring in that location and the ACS Panel can be mounted  
remotely in some other area where you want more detailed operating information and control  
capability.  
Prosine 2.5/3.0 Installation & Operation Guide  
11  
           
ACS Control Panel  
ACS Control Panel  
The Advanced Control System (ACS) panel features a two-line 16-character liquid crystal display  
(LCD) that enables you to monitor and control your Prosine inverter/charger from a remote location. It  
comes standard with a 50-foot (15-metre) four-conductor telephone cord. The ACS control panel  
provides you with a finer degree of both monitoring and operating control over the standard control  
panel. If you purchased a Prosine 3.0, it comes with the ACS panel in place of the standard panel. The  
digital readout of the ACS gives you a detailed display of many parameters for the system, while the  
menu structure allows advanced configuration as well as the convenience to change system settings  
when you need to.  
CAUTION Configuration settings made with the ACS panel will override settings made by  
configuring the DIP switches on the side of the chassis.  
The ACS Panel has a backlight to facilitate reading. The backlight for the LCD panel illuminates  
when any key on the ACS is pressed. The backlight will remain on for one minute after the last key  
press, or after a warning has been displayed.  
12  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Section 2: Controls and Indicators  
Liquid Crystal Display  
You can cycle the LCD panel through a menu tree of items that provide both system display  
information and adjustable parameters. Some display screens allow you to set configuration  
parameters. The following diagram and tables will help you get familiar with the buttons and LEDs on  
the ACS Panel and their functionality.  
The top level screen for the ACS panel displays battery  
voltage and current flow, either from the batteries to the  
inverter (a “–” in front of the current reading) or to the  
–PROSINE–  
BAT: 12.9V +0.5A  
batteries from the charger (a “+” in front of the current  
reading). The “–” indicates that the inverter/charger is in  
inverter mode while the “+” indicates charger mode. In the example shown, the battery voltage is at  
12.9 volts and the battery is being charged at the rate of 0.5 amps.  
Control Buttons  
The ACS LCD display panel includes four menu control keys, an ESCAPE key, an Up arrow key, a  
Down arrow key, and an ENTER key. The function of each key is described below.  
Button Purpose  
Comments  
Moves up one level in the menu tree.  
Does not change values.  
Moves up one option in the selected menu, or  
This button is shown as S in  
the following instructions.  
For some menus, if you hold  
the button down, it will scroll  
rapidly through the numerical  
values.  
Selects the next higher value (or previous  
choice) in a screen that allows the user or  
installer to scroll through selectable values.  
Moves down one option in the selected menu,  
or  
This button is shown as T in  
the following instructions.  
Selects the next lower value (or next choice) in For some menus, if you hold  
a screen that allows the user or installer to  
scroll through selectable values.  
the button down, it will scroll  
rapidly through the numerical  
values.  
Selects the menu level, or is used to enter your  
choice. If editing of the displayed value is  
permitted, this key places the value in edit  
mode, allowing you to scroll through the  
allowed values, then when pressed again, the  
current value displayed will be the new value  
for that menu item.  
You can then use the S or T  
buttons to move through the  
screens at that level.  
If the screen has editable  
options, you can then use the  
S or T buttons to move  
through the options.  
Prosine 2.5/3.0 Installation & Operation Guide  
13  
             
ACS Control Panel  
Menu Navigation Procedure  
To navigate through the menu and select parameters:  
1. Press the S or T keys to scroll up or down through the menu;  
2. Press the ENTER key to enter a menu;  
3. Press the S or T key to scroll to the desire menu item;  
4. If the menu item you select includes a value that you can change, you can press  
ENTER again, then the S or T button to scroll (up or down) through the available  
choices. To select a displayed value, press ENTER again. Then press ESCAPE  
repeatedly to return to the battery status display.  
ACS Menu Tree  
The ACS menus include system status and configuration parameters. All menus fall into one of six  
categories: AC Information, Battery, Inverter, Charger, System Information, and Version Information.  
This section describes each menu display and configuration parameter.  
The battery status display is the top of the ACS menu tree. When it is displayed, press any key to  
display the AC Information menu. Press the T to scroll through the remaining menus, or press  
ENTER to display the menu items.  
—PROSINE—  
BAT: 12.9V +0.05A  
Select From:  
AC  
Select From:  
BATTERY  
Select From:  
INVERTER  
Select From:  
CHARGER  
Select From:  
SYSTEM INFO  
Select From:  
VERSION INFO  
14  
Prosine 2.5/3.0 Installation & Operation Guide  
             
Section 2: Controls and Indicators  
AC Information Menu  
AC Information menus include AC input and output voltage, AC input and output current (amperage),  
and one configuration parameter: breaker size. The menu flow is shown below:  
AC  
Select From:  
AC  
ENTER  
INFORMATION:  
AC  
INFORMATION:  
AC  
INFORMATION:  
AC  
INFORMATION:  
Breaker size is a user configuration  
item. Press the ENTER key and then  
an arrow key to change this setting.  
Values range from 5 to 30 amps.  
Press ENTER to set, and ESCAPE  
to exit. Set at or below the  
shorepower circuit-breaker size to  
prevent nuisance circuit-breaker  
tripping.  
BREAKER SIZE:  
SET AT:XXA  
BREAKER SIZE:  
SET AT:  
ENTER  
Prosine 2.5/3.0 Installation & Operation Guide  
15  
           
ACS Control Panel  
Battery Information Menu  
This menu displays the current configuration settings associated with the battery system. These  
parameters include battery type, size, and temperature. See “Section 3: Configuration” for detailed  
information about these configuration parameters.  
SELECT FROM:  
BATTERY  
BATTERY INFO:  
TYPE: FLOODED  
ENTER  
BATTERY INFO:  
SIZE: 75Ah  
BATTERY INFO:  
TEMP:WARM  
Inverter Information Menu  
The Inverter menu displays configuration information about the inverter section of the Prosine  
inverter/charger. All of these parameters are user-configured. See “Section 3: Configuration”  
(page 25) for information about setting these parameters.  
LOAD SENSE  
TURN-ON  
SELECT FROM:  
INVERTER  
ENTER  
POWER: 00  
W
LOAD SENSE  
INTERVAL: 00.0s  
DC INPUT  
RANGE:  
DC INPUT  
RANGE:  
DC INPUT  
RANGE:  
DC INPUT  
RANGE:  
16  
Prosine 2.5/3.0 Installation & Operation Guide  
           
Section 2: Controls and Indicators  
Charger Information Menu  
The Charger menu displays the charging status and enables you to determine if an equalization request  
is enabled. A charger override request is also available at this menu.  
SELECT FROM:  
CHARGER  
CHARGER  
STATE:  
ENTER  
CHARGER STATE  
OF  
EQUALIZE IS  
ENTER  
NOW:  
EQUALIZE IS  
NOW:  
OVERRIDE  
CHARGER  
Table 1: Charger Status  
DESCRIPTION  
STAGE  
Charger has been disabled or is on standby.  
Not Charging  
The first phase of the three-phase charging cycle has started.  
Bulk Charging  
Absorption Charging  
Bulk charging has completed and the second phase of the  
charging cycle has begun.  
Absorption charging has completed and the charger is  
‘topping-off’ and maintaining the batteries.  
Float Charging  
Equalization  
The charger has started the special “equalization” stage.  
See “Section 6: Multistage Charging” (page 59) for a detailed description of the charging regime, and  
a discussion of equalization in general. See “ACS Configuration‚” on page 28 for detailed instructions  
on setting configuration parameters using the ACS panel.  
See “ACS Configuration‚” on page 28 for details on the Equalization Request and Override Charger  
Operating Mode procedure.  
Prosine 2.5/3.0 Installation & Operation Guide  
17  
       
ACS Control Panel  
System Information Menu  
The System Information menu displays the current system startup mode, audible alarm mode, last  
system fault number, chassis temperature at four areas in the inverter/charger, and the system buss  
voltage. All except the system startup mode and audible alarm mode settings are troubleshooting aids.  
All the system information configuration parameters can be reset to the factory configuration by  
entering a special key sequence in this menu. See “ACS Configuration‚” on page 28 for configuration  
instructions.  
SELECT FROM:  
SYSTEM INFO  
SYSTEM INFO:  
DEFAULT INV/  
ENTER  
SYSTEM INFO:  
ALARM  
SYSTEM INFO:  
LAST FAULT #  
CHASSIS TEMP.  
T1:  
CHASSIS TEMP:  
T2:  
CHASSIS TEMP:  
T3:  
CHASSIS TEMP:  
T4:  
SYSTEM INFO:  
DC BUS: 220Vdc  
*This menu is seen in Installer mode  
page 28”.  
*SYSTEM INFO:  
RESET TO  
18  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Section 2: Controls and Indicators  
Version Information Menu  
The Version Information menu displays the version number of the software used in the ACS, and the  
version number of the two main internal microprocessors used in the Prosine inverter/charger.  
SELECT FROM:  
VERSION INFO  
VERSION No. OF  
THIS DISPLAY: X  
ENTER  
VERSION No. OF  
MASTER IC:X  
VERSION No. OF  
ISOLATED IC:X  
Prosine 2.5/3.0 Installation & Operation Guide  
19  
   
Faults Display & Reset Button  
Faults Display & Reset Button  
Fault LED This LED flashes on-and-off during an error  
condition from which the unit will automatically recover and  
restart when the condition is remedied. The FAULT LED will  
be lighted steadily when any error occurs from which the  
inverter/charger cannot automatically recover. It is usually  
necessary to disconnect the AC or DC supply to recover from  
this type of error. An error condition is accompanied by an  
audible alarm if the alarm is enabled. All error messages, their meanings, and the appropriate action to  
take are listed in a table in “Appendix C: Troubleshooting”.  
Temp LED This LED flashes on-and-off to indicate excessive internal temperature of the Prosine  
inverter/charger and the unit has shutdown. When the internal temperature of the unit cools  
sufficiently, the inverter/charger will automatically restart. The audible alarm that accompanies this  
condition (if enabled) will also be silenced upon auto-restart.  
Reset Button The RESET button on the Faults panel has two functions: silencing the audible  
alarm; and displaying error codes. Pressed and released, it will silence the audible alarm which, if  
enabled, will sound an irritating intermittent tone anytime an error condition occurs. Pressed and held,  
the RESET button causes the LCD screen to display error codes.  
Inverter Status Indicators and On/Off Button  
Invert LED When the green INVERT LED is flashing,  
shorepower is not present, Load Sense is enabled, and no  
AC loads exceed the Load Sense threshold. The inverter is  
not producing AC power from the batteries. When the  
Invert LED is lighted steadily, shorepower is not present  
and the inverter is producing AC power from the batteries.  
The INVERT LED is not lighted when shorepower is present.  
Standby LED When the amber LED labeled STANDBY is lighted steadily, shorepower is present  
and the inverter will pass AC power through to any AC loads that may be present.  
If shorepower should fail or be removed while the inverter is in Standby mode, the inverter will  
automatically begin to produce AC power from the batteries, and the INVERT LED will be lighted.  
ON/OFF Button When pressed, this button switches the inverter from On to Standby mode.  
20  
Prosine 2.5/3.0 Installation & Operation Guide  
                       
Section 2: Controls and Indicators  
Power Indicator  
A green LED labeled “UTILITY/SHOREPOWER (INCOMING)” lights  
whenever AC power is supplied to the AC INPUT connectors on the  
inverter/charger. Throughout this manual, the term “shorepower” refers to  
the presence of AC power at the AC INPUT connectors, regardless of the  
source of the power: from the utility grid (power company), a generator,  
or any other source.  
Charger Status Indicator and On/Off Button  
The Charger Status Display includes four LEDs:  
a green LED labeled CHARGE; a green LED  
labeled READY; an amber LED labeled  
STANDBY; and an amber LED labeled  
EQUALIZE. A charger On/Off button is also  
provided.  
Charge LED The green CHARGE LED lights when the Prosine charger is in Bulk or Absorption  
charging mode. A discussion of the Prosine multi-stage charging profile is found in “Section 6:  
Ready LED. The green READY LED lights when the charging regime has been completed, and the  
charger is in Float charging mode.  
Standby LED. The amber “STANDBY” LED lights when the charger is enabled awaiting AC  
power. When shorepower becomes available, the charger will begin charging, the Standby LED will  
be extinguished, and the Charge LED will be lighted.  
Equalize LED The amber “EQUALIZE” LED lights when the battery equalization has been  
requested, and the Prosine is in Charge mode. An equalization charge cycle will commence after fully  
charging the batteries, and both the EQUALIZE LED and the CHARGE LED will flash on-and-off.  
See “Section 6: Multistage Charging” on page 59 for more information about equalization.  
On/Off Button The charger ON/OFF button switches the charger between charger standby mode,  
On, and Off. In standby mode, the charger begins charging automatically when AC shorepower is  
available. In charge mode, press and hold this button for 5 seconds to request an equalize charge.  
Equalize mode will not begin until the batteries are fully charged.  
CAUTION Disconnect DC loads on the batteries during equalization to prevent damage to them by  
the high voltages encountered during equalization. Equalization must be monitored to prevent battery  
damage. Refer to “Section 6: Multistage Charging” for more details.  
Prosine 2.5/3.0 Installation & Operation Guide  
21  
                             
Mounting and Installing the ACS Control Panel  
Mounting and Installing the ACS Control Panel  
You can install the ACS Control Panel in a convenient location up to 50 feet from the Prosine inverter/  
charger unit.  
For flush mount installation onto a wall, bulkhead, or panel, the remote panel requires an opening with  
the measurements of 4-1/8 inches by 4-1/8 inches (10.5cm by 10.5cm). Be sure that there is no wiring  
or other obstruction within the wall before making an opening. The LCD Control Panel requires  
approximately 2 inches (5cm) of free space within the wall to accommodate its depth. Follow the  
steps shown below:  
1. Select an appropriate location that is dry, not subject to corrosive or explosive fumes,  
and otherwise appropriate for mounting an electronic device.  
2. Hold the control panel faceplate flush against the wall, bulkhead or panel and mark  
around the outside edge of the faceplate with a pencil.  
3. Mark the location of the four mounting holes at each corner.  
4. Remove the faceplate and mark a line 7/16-inch inside each of the four perimeter lines  
that you marked previously.  
5. Drill an access hole at each corner of the resulting small square large enough to allow  
you to insert a jigsaw blade. Place your drill bit so that the finished hole will not extend  
beyond the 4 1/8-inch by 4 1/8-inch square you marked on the bulkhead.  
6. Use your jigsaw to cut between the holes you just drilled, and remove the material you  
just cut out. Blow out any waste residue from the cutting and drilling.  
7. Route the telephone-type connector cable from your inverter/charger and the control  
panel and plug it into the receptacle labeled “INPUT” on the back of the control panel.  
You can add another ACS panel in series to the first ACS panel by plugging the second  
ACS panel into the receptacle labeled “OUTPUT” on the back of the first ACS panel.  
8. Insert the control panel into the bulkhead and secure with appropriate fasteners.  
9. Insert the other end of the connector cable into the one of the RJ-11 connectors marked  
“Remote Output” on the Prosine inverter/charger. You can connect another control  
panel to the other output connector on the inverter/charger if you desire.  
10. Secure the EMI bead attached to the communications cable to a location close to the  
inverter/charger. The EMI bead reduces interference from the inverter on the control  
panel. Securing it prevents accidental disconnect of the remote panel.  
If you purchased the ACS Panel as an accessory to be used with your Prosine 2.5, the ACS Panel and  
standard supplied panel can both be used at the same time. Either connect the standard panel to the  
OUTPUT jack on the back of the ACS Panel, or connect the standard panel to the REMOTE output  
connector jack on the side of the Prosine inverter/charger. The standard panel can then be mounted  
close by the Prosine unit for system monitoring in that location and the ACS Panel can be mounted  
remotely in some other area where you want more detailed operating information and control  
capability.  
22  
Prosine 2.5/3.0 Installation & Operation Guide  
         
Section 2: Controls and Indicators  
Battery Temperature Sensor  
The temperature sensor continuously measures the temperature of the battery and adjusts charger  
output for a more accurate, temperature-compensated charge.  
!
"
#
Figure 4. Battery Temperature Sensor  
Feature Description  
Mounting plate. Connects to the negative battery terminal.  
!
Sensor. Reverse side has peel-off backing and self-adhesive strip so  
you can attach the sensor to the side of the battery case.  
"
Sensor cable (25ft; 8m).  
#
NOTE: The battery temperature sensor is electrically isolated from the  
mounting plate.  
Prosine 2.5/3.0 Installation & Operation Guide  
23  
   
Battery Temperature Sensor  
24  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 3: Configuration  
This section explains how to configure the Prosine inverter/charger to best meet your electrical system  
requirements and get maximum performance using the DIP switches located on the side of the unit.  
You will need a pen or other fine-pointed instrument to adjust the switches. Each switch has two  
positions: Up and Down.  
DIP Switch Settings  
Each configuration parameter is defined in the list  
below. DIP switch settings are described in the tables on  
the next two pages. An asterisk () indicates the factory  
default settings.  
WARNING Risk of battery damage and fire or explosion: “Installer settable” configuration items  
are meant to be configured by a professional installer who is not only familiar with the system settings  
of the inverter, but also the ramifications of changing those system settings. Setting these parameters  
incorrectly can cause damage to your equipment or severely affect the performance of your system.  
NOTE After configuring the inverter/charger using the DIP switches, make sure you replace the DIP  
switch cover.  
This is an “Installer-only” configuration item. Note the preceding Warning.  
Settings are available for either flooded or gel electrolyte. Sealed batteries should  
be charged as gel batteries even though they may have a liquid electrolyte. For fur-  
ther details, see “Section 7: Batteries”.  
Battery Type  
With the battery temperature sensor installed, leave the switches in the WARM  
position; they are ignored unless battery temperature falls below 5°C. Between  
5ºC and -10ºC, the charger stops. If the temperature is below –10ºC, the tempera-  
ture sensor is not detected, and the inverter/charger responds to the manual  
defaults. With the battery temperature set to the average ambient temperature the  
manual defaults are:  
Battery  
Temperature  
COLD: < 50ºF (10ºC),  
WARM: between 50º F to 80º F (10ºC to 27ºC), and  
HOT: > 80ºF (27ºC).  
.
This setting determines what power level the inverter has to detect before it will  
auto start. Setting this value to 0 will cause the inverter to remain on all the time.  
Note that extremely low power loads (e.g. digital clocks on microwaves) may  
require the 0 setting in order for the inverter to stay on.  
Load Sense  
This switch turns the audible alarm On or Off.  
Audible Alarm  
The maximum AC current that the Prosine inverter/charger will draw from shore-  
power is determined by this value. If you find that the Prosine inverter/charger  
keeps tripping the utility power breaker, set this value to a lower level. This value  
may limit the maximum charging current to your batteries, depending also upon  
battery capacity.  
AC Service  
Rating  
This is an “Installer-only” configuration item. The capacity of the battery or bat-  
tery bank in amp-hours. Note the preceding Warning: charging at a rate too high  
for your batteries can damage and/or destroy them.  
Battery Size  
Prosine 2.5/3.0 Installation & Operation Guide  
25  
                             
DIP Switch Settings  
SWITCH BANK 1 (SW1)  
Battery Type  
Switch 1 UP  
DOWN  
Flooded  
Gel  
Not used  
Switch 2  
Switch 3  
Switch 4  
Battery Temperature  
Switch 5 and Switch 6  
UP UP  
Warm, usually 50–80 °F / 10–27 °C  
Cold, usually below 50 °F / 10 °C  
Hot, usually above 80 °F / 27 °C  
Warm, usually 50–80 °F / 10–27 °C  
DOWN UP  
UP DOWN  
DOWN DOWN  
Load Sense  
Switch 7 and Switch 8  
UP  
DOWN  
UP  
UP 0 Watts. Load sense is disabled  
UP 10 Watts  
DOWN 25 Watts  
DOWN  
DOWN 50 Watts  
26  
Prosine 2.5/3.0 Installation & Operation Guide  
             
Section 3: Configuration  
SWITCH BANK 2 (SW2)  
Audible Alarm  
Switch 1  
UP Audible signals enabled  
DOWN Audible signals disabled  
Switch 2 Not Used  
Maximum DC  
Charging Amps  
AC service rating  
PS 2.5  
12V  
PS 3.0  
Switch 3  
Switch  
4
24V  
12V 24V  
UP  
DOWN  
UP  
UP 10 A  
8 A  
12A  
16A  
24A  
55  
30  
45  
55  
55  
55  
90  
30  
45  
UP 15 A  
DOWN 20 A  
DOWN 30 A  
90  
100  
100  
100 60  
120 60  
DOWN  
Battery Size  
Switch 5, 6, 7, 8  
Max DC charging current (amps)  
Prosine 2.5 Prosine 3.0  
Battery  
Capacity  
UP 50 Ah  
#5  
UP  
DOWN  
#6  
#7  
#8  
12V  
24V  
12V  
24V  
UP  
UP  
UP  
UP  
11A  
11A  
25A  
33A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
50A  
11A  
11A  
25A  
33A  
50A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
60A  
UP 75 Ah  
UP 100 Ah  
25A  
25A  
UP DOWN  
UP  
33A  
33A  
DOWN DOWN  
UP  
UP 150 Ah  
50A  
50A  
UP  
UP  
UP  
DOWN  
DOWN  
DOWN  
DOWN  
UP  
UP 200Ah  
67A  
67A  
DOWN  
UP 300 Ah  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
100A  
120A  
120A  
120A  
120A  
120A  
120A  
120A  
120A  
120A  
120A  
UP DOWN  
UP 400 Ah  
DOWN DOWN  
UP 500 Ah  
UP  
UP  
UP  
DOWN 600 Ah  
DOWN 700 Ah  
DOWN 800 Ah  
DOWN 1000 Ah  
DOWN 1200 Ah  
DOWN 1400 Ah  
DOWN 1700 Ah  
DOWN  
UP  
UP DOWN  
UP  
DOWN DOWN  
UP  
UP  
UP  
UP  
DOWN  
DOWN  
DOWN  
DOWN  
DOWN  
UP DOWN  
DOWN DOWN  
DOWN 2000 Ah  
or greater  
Prosine 2.5/3.0 Installation & Operation Guide  
27  
           
ACS Configuration  
ACS Configuration  
The ACS Control Panel enables you to configure the Prosine inverter/charger to your particular  
installation. All of the ACS Control Panel menus (except Version Information) contain one or more  
configurable parameters. Each configuration parameter is discussed in the appropriate menu section  
that follows.  
User Configuration Items  
CAUTION Do not change the configuration of your Prosine if you are uncertain of your changes. If  
you are uncertain of the effects of your changes, read the entire manual, then consult a qualified  
installer or call Xantrex Customer Assistance.  
For User Configuration items, press ENTER to select the parameter you want to change, and then an  
arrow key to change the value. Set the value by pressing ENTER.  
Installer Configuration Items  
WARNING Risk of battery damage and fire or explosion: An “installer settable” configuration  
item is meant to be configured by a professional installer who is familiar not only with the system  
settings of the inverter, but also the ramifications of changing those system settings. Setting these  
parameters incorrectly can cause damage to your equipment or severely affect the performance of  
your system.  
To enter Installer Mode:  
1. Scroll the display until the parameter to be changed is visible.  
2. Press and hold down the ESCAPE and DOWN ARROW keys until the panel beeps.  
3. Press ENTER.  
4. Use the UP and DOWN ARROW keys to change the parameter as appropriate.  
5. To store the change, press ENTER.  
After a change is stored, the inverter/charger will remain in Installer Mode. To change additional  
parameters, select the parameter and repeat steps 3, 4 and 5.  
To exit Installer Mode:  
Press the ESCAPE key repeatedly until you reach the main menu.  
If you want to change another installer-settable parameter after reaching the main menu, follow the  
keypress sequence (steps 1, 2 and 3) to enter Installer Mode again.  
28  
Prosine 2.5/3.0 Installation & Operation Guide  
           
Section 3: Configuration  
ACS Configuration Considerations  
ACS Configuration settings override the DIP switch settings discussed above. If your unit has been  
configured using the ACS control panel, it will retain these configuration settings even after the ACS  
has been disconnected. The physical position of the DIP switches does not necessarily indicate the  
setting. To reset the configuration settings to the DIP switch settings, perform these actions:  
Change all the DIP switches to the alternate setting.  
Wait at least 20 seconds for the Prosine to recognize the new setting.  
Change the DIP switches to the desired setting.  
Wait at least another 20 seconds for the desired setting to be recognized.  
Prosine 2.5/3.0 Installation & Operation Guide  
29  
 
ACS Configuration Considerations  
AC (Shorepower) Configuration  
Only one configurable parameter is found in the AC Information menu: breaker size. An AC circuit  
breaker must be installed in the AC supply circuit (shorepower) leading to the Prosine inverter/  
charger. Specifying the size of the breaker in the AC Information menu reduces ‘nuisance’ tripping of  
the supply breaker by preventing the charger from attempting to draw more current than is available  
through the supply circuit breaker.  
Example: when the breaker size parameter is set to 10 amps and AC loads are operating while the  
charger is also charging the batteries, the Prosine automatically reduces charging current to help keep  
the sum of all AC loads (including the charger) at or below 8 amps. As AC loads fluctuate, the Prosine  
automatically adjusts charging current up to the maximum allowed by this setting.  
For RV, marine, and mobile installations, the available shorepower circuit breaker size may vary  
frequently. Marinas and RV parks often supply shorepower with from 15- to 50-amp service. By  
adjusting the breaker size parameter in the AC Information menu, you can increase the maximum  
current available for more rapid charging, or prevent nuisance circuit-breaker tripping when  
shorepower current is limited.  
To adjust the breaker size parameter, enter the AC Information menu by pressing the Enter key, as  
shown below. Use the arrow key to scroll through the menu to the Breaker Size screen. Press  
ENTER to enter the menu, followed by an arrow key to scroll to the desired value. Press ENTER  
again to accept the value, then press ESCAPE to exit the menu.  
Select From:  
AC INFORMATION  
BREAKER SIZE:  
SET AT: 5  
ENTER  
ENTER  
A
A
BREAKER SIZE:  
SET AT: 30  
ENTER  
Select From:  
ESCAPE  
AC INFORMATION  
30  
Prosine 2.5/3.0 Installation & Operation Guide  
           
Section 3: Configuration  
Battery Configuration  
The Battery Information menu has three configuration parameters: Battery Type, Battery Size, and  
Battery Temperature. All of these parameters have an effect upon the optimal charging regime. For a  
comprehensive discussion about batteries, see “Section 7: Batteries”.  
WARNING Risk of battery damage and fire or explosion if using the wrong battery type or size  
setting.  
Battery Type  
NOTE: This is an “Installer-only” configuration item. There are two types of batteries appropriate for  
use with the Prosine inverter/charger: flooded lead-acid batteries, and gel-cell lead-acid batteries. The  
factory default setting for this parameter is flooded. When using sealed or gel lead-acid batteries,  
change the setting of this parameter to Gel.  
Battery Size  
NOTE: This is an “Installer-only” configuration item. You can use one battery with a capacity of only  
50 amp hours (Ah) or a group of batteries with a combined capacity of over 2000Ah to provide DC  
power to the inverter/charger. The amount of current used to recharge the batteries will vary with the  
combined capacity of the batteries. Setting this parameter too high (larger than your batteries’ actual  
capacity) can result in damage to your batteries or cause them to produce excessive amounts of  
corrosive and explosive gasses. Setting this parameter too low can result in under-charged batteries, or  
excessively long charging periods. Consult with your battery supplier to determine the type and  
capacity of your batteries.  
Battery Temperature  
The amount of current your batteries can absorb while charging is directly related to their temperature.  
The ambient temperature affects the amount of current that will pass into and out of the batteries. You  
can set the battery temperature to optimize the Prosine charging regime for cold, warm, or hot ambient  
temperatures. Xantrex strongly recommends use of the included Battery Temperature Sensor that  
enables the Prosine inverter/charger to automatically adjust the charging regime for temperature.  
When the temperature sensor is installed, the Battery Temperature setting is ignored. You can switch  
between the Celsius (C) and Fahrenheit scales by pressing ENTER and then or but use of the  
battery temperature sensor is preferred.  
Cold = <10°C (50°F), Warm = 10°C to 27°C (50°F to 80°F), Hot = >27°C (80°F)  
Battery temperature can be set in the usual way: by entering the menu, scrolling to the desired value,  
and accepting the value by pressing ENTER.  
BATTERY INFO:  
TEMP: WARM  
BATTERY INFO:  
TEMP: HOT  
ENTER  
ENTER  
Battery type and size parameters are installer configuration items. Enter Installer Mode, then enter  
the menu, and set the value as above. Press ENTER to accept the value and ESCAPE to exit the  
menu.  
Prosine 2.5/3.0 Installation & Operation Guide  
31  
                   
ACS Configuration Considerations  
BATTERY INFO:  
TYPE: FLOODED  
BATTERY INFO:  
TYPE: GEL  
ENTER  
ENTER  
BATTERY INFO:  
SIZE: 75Ah  
BATTERY INFO:  
SIZE: 2000Ah  
32  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 3: Configuration  
Inverter Configuration  
All the items on the Inverter menu are configuration parameters. The first two items are Load Sense  
parameters. The remaining items are high- and low-voltage alarms and cut-off settings. See “Prosine  
Inverter Load Sense Mode‚” on page 56 for a complete discussion of the Load Sense feature.  
Load Sense Parameters. You can define a minimum load at which the inverter will provide AC  
power. Any load that draws less than the minimum current, adjustable from 1 to 1401 watts, will not  
activate the inverter. Loads that draw more than the minimum current will activate the inverter from  
Standby mode to Invert mode. A minimum setting of zero will disable Load Sense altogether. Power  
consumption by the inverter when it is not on Standby is about 60 watts. When Load Sense is enabled  
and the inverter is in Standby mode, power consumption is about three watts, conserving your  
batteries.  
LOAD SENSE TURN-  
ON POWER:00 W  
LOAD SENSE TURN-  
ON POWER:1401 W  
ENTER  
ENTER  
When Load Sense mode is active (turn-on power >0), the inverter tests for loads connected to it by  
sending a pulse signal. You can define the interval between these pulse signals. A longer interval  
between pulse signals consumes less energy than a shorter interval, thus reducing idle current  
requirements. You can set the interval between signals from two to 26.5 seconds.  
LOAD SENSE  
INTERVAL:2.0s  
LOAD SENSE  
INTERVAL:26.5s  
ENTER  
ENTER  
High and Low Voltage Alarms & Cutoffs. The Prosine inverter/charger features integrated  
circuitry to protect excessive charging and discharging of your batteries, and an audible warning alarm  
to alert you to when high- and low-voltage conditions occur. You can use the ACS Control Panel to  
specify the levels at which the alarms will sound, and at which the inverter/charger unit will cut off  
and shut down. Alarm values cannot be outside the cutoff range. Ex: Low Cutoff Range = 11.0V; Low  
Alarm must be 11.0V or higher.  
DC INPUT RANGE:  
LO ALARM:10.0V  
DC INPUT RANGE:  
LO ALARM:12.0V  
ESCAPE  
DC INPUT RANGE:  
HI ALARM:14.0V  
DC INPUT RANGE:  
HI ALARM:16.0V  
ESCAPE  
ESCAPE  
DC INPUT RANGE:  
LO CUTOFF:10.0V  
DC INPUT RANGE:  
LO CUTOFF:12.0V  
DC INPUT RANGE:  
HI CUTOFF:14.0V  
DC INPUT RANGE:  
HI CUTOFF:16.0V  
ESCAPE  
Prosine 2.5/3.0 Installation & Operation Guide  
33  
               
ACS Configuration Considerations  
The voltage range for these alarms and cutoffs is generally set at the factory at the absolute minimum  
and maximum, as shown in the illustration above for 12-volt systems. Example: Lo Cutoff = 10.0V, Hi  
Cutoff = 16.0V, Range = 10.0 to 16.0 volts DC. The table below illustrates the factory settings and the  
min–max range for both 12-volt and 24-volt systems.  
High and Low Voltage Alarms and Cutoffs  
ALARM OR CUTOFF  
12-VOLT MIN-  
MAX RANGE  
Factory  
Default  
24-VOLT MIN-  
MAX RANGE  
Factory  
Default  
LO ALARM  
HI ALARM  
10.0V - 12.0V  
14.0V - 16.0V  
10.0V - 12.0V  
14.0V - 16.0V  
10.5V  
15.5V  
10.0V  
16.0V  
20.0V - 24.0V  
28.0V - 32.0V  
20.0V -24.0V  
28.0V - 32.0V  
21.0V  
31.0V  
10.0V  
16.0V  
LO CUTOFF  
HI CUTOFF  
Charger Configuration  
The ACS Charger menu displays the current status of the charger and enables you to begin an  
equalization charge, or to override the current charger status and force the charger into Float or  
Equalization mode.  
Override Charger Operating Mode The charger will not begin an equalization charge until it has  
completed a Bulk or Absorption charge. It may be desirable to force an equalization charge in some  
instances. Forcing the charger into Float or Equalization mode is usually performed only during an  
installation, and should not be lightly considered. Consult your installer or call Xantrex Customer  
Service before attempting to override the charger mode. Overriding the charger operating mode is an  
installer-configuration item. The menu procedure is illustrated below.  
Enter “Installer Mode, and then:  
SELECT FROM:  
CHARGER  
OVERRIDE CHARGER  
OPERATING MODE  
ENTER  
ENTER  
FORCE CHARGER TO  
FLOAT CHARGE  
FORCE CHARGER TO  
EQUALIZE CHARGE  
ENTER  
Equalization Request For some batteries, equalization is a regular maintenance activity; for  
others, equalization is damaging. Read “Section 6: Multistage Charging” (page 59) before attempting  
to initiate an equalization charge. Inappropriate equalization charging can ruin your batteries. An  
equalization request is a user-configuration item: press ENTER at the menu and follow the prompts  
shown below to initiate an equalization request. When you press ENTER at the YES prompt,  
equalization will begin immediately if the batteries are fully charged, and AC power is available.  
Since equalization voltage is usually above the range of the High Voltage Alarm, an audible alarm will  
sound briefly when it is enabled. The Faults and Charger LEDs will also flash as a visual alarm. This  
34  
Prosine 2.5/3.0 Installation & Operation Guide  
           
Section 3: Configuration  
is normal. The audible alarm will be silenced after a few moments, the LEDs will stop flashing, and  
the EQUALIZE LED will be lighted.  
EQUALIZE IS NOW:  
DISABLED  
EQUALIZE IS NOW:  
ENABLED  
ENTER  
HIT AN ARROW KEY  
system will ...  
HIT AN ARROW KEY  
now receive ...  
HIT AN ARROW KEY  
high voltage...  
HIT AN ARROW KEY  
unplug all ....  
HIT AN ARROW KEY  
delicate devices  
HIT AN ARROW KEY  
enter to proceed  
ENTER  
PROCEED WITH EQ?  
NO  
NOTE: When Battery Type is set to  
GEL, the “Equalize is Now: Disabled”  
message will be displayed following an  
equalization request, which is denied.  
PROCEED WITH EQ?  
YES  
ENTER  
Prosine 2.5/3.0 Installation & Operation Guide  
35  
ACS Configuration Considerations  
System Configuration  
The System Information menu contains two configuration items: System Startup Default and Audible  
Alarm. Both are user configuration items and are selected by pressing ENTER.  
System Startup Default You can set the initial power-up configuration when AC shorepower is  
provided to the Prosine inverter/charger so that the inverter and charger are either both On, both Off,  
or one is On and the other is Off. This is a User configuration item set by pressing ENTER, scrolling  
to the desired value by pressing an arrow key, pressing ENTER to select the value, and pressing  
ESCAPE to exit the menu. The indicates the current selection.  
SELECT FROM:  
SYSTEM INFO  
SYSTEM INFO:  
DEFAULT INV/CHG  
ENTER  
ENTER  
DEFAULT INV/CHG  
INV ON/CHG ON  
DEFAULT INV/CHG  
INV OFF/CHG OFF  
DEFAULT INV/CHG  
INV OFF/CHG ON  
DEFAULT INV/CHG  
INV ON/CHG OFF  
ENTER  
Audible Alarm The System Info menu also allows you to turn the audible alarm Off or On. The  
audible alarm sounds any time there is an inverter/charger fault, or when the DC high- or low-voltage  
range is exceeded. If equipped with a battery temperature sensor, the audible alarm will also sound  
when battery temperature is less than -15°C (5°F) or more than 50°C (122°F). The audible alarm is  
always accompanied by flashing LEDs and an error code display. The alarm is ENABLED at the  
factory.  
SELECT FROM:  
SYSTEM INFO  
SELECT FROM:  
ALARM AUDIBLE  
ENTER  
ENTER  
AUDIBLE ALARM:  
ENABLED  
AUDIBLE ALARM:  
ENTER  
DISABLED  
36  
Prosine 2.5/3.0 Installation & Operation Guide  
             
Section 4: Inverter/Charger Installation  
This section describes the tools and materials required, the appropriate location and environment for  
mounting the inverter/charger, AC and DC cabling, and step-by-step instructions to install the unit. A  
number of diagrams for various types of installations are provided. These instructions are intended to  
be used as a guide only. It is the installer’s responsibility to observe all safety and appropriate  
installation regulations and to proceed accordingly.  
Read the entire chapter first before commencing the installation to ensure you have all the materials  
necessary to install the PS2.5/3.0 and that is is being installed in an appropriate environment.  
WARNING: FIRE, SHOCK, AND ENERGY HAZARD Installation should be performed by  
certified and experienced technicians familiar with inverter/charger installations and the applicable  
installation codes.  
Governing installation codes will vary depending upon the specific location and application of the  
inverter/charger installation. Installations may be governed by the Code of Federal Regulations  
(CFRs), the American Boat and Yacht Council, (ABYC), National Electrical Code (NEC), Canadian  
Standards Association (CSA), Canadian Electrical Code (CEC), RV Industry Association (RVIA) or  
others. For complete and authoritative installation regulations contact the appropriate regulatory  
agency.  
Safety Instructions  
Before beginning the installation of the Prosine inverter/charger, review the safety instructions at the  
beginning of this manual, and read this entire section. Disconnect all sources of AC and DC power to  
prevent accidental shock. Disable and secure all AC and DC disconnect devices and automatic  
generator starting devices. Use the DIP switches to configure the inverter/charger after reading  
”Section 3: Configuration” page 25. If you have the ACS Control panel, you can configure the unit  
after installation, but before operating.  
Installation Overview  
Experienced and licensed installers familiar with inverter/charger installations may follow the steps  
listed below to install the Prosine 2.5/3.0 inverter/charger. For system component recommendations  
and requirements, refer to each specific section in this manual. For instance, the ”AC Cabling” section  
describes AC wiring guidelines, while the ”DC Cabling” section describes DC wiring guidelines.  
This is an overview only. If you are unsure of any aspect of inverter/charger installation, read the  
entire manual, cover to cover, before attempting to perform an installation.  
1. Before beginning any installation, disconnect all sources of power, both AC and DC.  
2. Remove the Prosine inverter/charger from the shipping container and verify that all  
components are present. Record the model and serial number on the packaging page of  
this manual.  
3. Slide the BYPASS/ON switch on the side of the Prosine inverter/charger to BYPASS.  
Prosine Installation & Operation Guide  
37  
     
Installation Overview  
4. Select an appropriate mounting location. The Prosine must be mounted vertically on a  
bulkhead or wall with the AC and DC connectors on the bottom. The Prosine is a solid-  
state electronic device and must be located in an appropriate environment. (Refer to  
5. Configure the Prosine inverter/charger using the DIP switches on the side of the unit.  
See “Section 3: Configuration‚” on page 25 and following for details.  
6. Remove the cover over the AC connector block. Install two, one-inch cable clamps  
(strain reliefs) in the holes in the cover mounting bracket.  
7. Locate the mounting screw locations and pre-drill a pilot hole for each location. For the  
Prosine 3.0, locate the mounting holes using the mounting brackets provided with the  
unit, then install the mounting brackets on the Prosine using the fasteners provided.  
8. Attach the Prosine inverter/charger to the bulkhead or wall. Use #12 or #14 pan-head  
wood or sheet metal screws to secure the inverter/charger to the framing behind the wall  
or bulkhead. Alternatively, use nut inserts and 1/4-20 machine screws.  
9. Route the AC input cable through the left cable clamp on the bottom of the inverter/  
charger. Strip about two inches of the exterior insulation from the AC cable and separate  
the three wires. Strip 5/16-inch of insulation from each of the three AC conductors  
within the AC cable.  
10. Insert the AC Line (HOT)  
conductor (black insulation) into  
the opening at the top of the AC  
input connector labeled LINE;  
insert the Ground conductor  
(green insulation or bare) into the  
AC Input connector labeled GND;  
and insert the Neutral conductor  
(white insulation) into the AC  
Input connector labeled NEUTRAL. Tighten the screw in the connectors to min. 21  
inch-pounds.  
11. Route the AC Output cable through the right cable clamp on the bottom of the inverter.  
Strip about three-inches of the outside insulator from the AC cable and separate the  
three wires inside. Strip 5/16-inch of insulation from each wire in the AC output cable.  
12. Insert the AC Output line,  
ground, and neutral  
conductors into the top  
openings of the AC output  
connector block labeled  
LINE, GND, and NEUTRAL  
respectively. There are two  
each connectors on the AC  
OUTPUT connector block  
6
/1  
5
labeled LINE, GND, and  
NEUTRAL. The two LINE  
output connectors are bonded  
together; as are the two GND output connectors, and the two NEUTRAL output  
connectors. The second set is for the GFCI receptacle option. Tighten the screw in each  
connector to min. 21 inch-pounds.  
38  
Prosine Installation & Operation Guide  
Section 4: Inverter/Charger Installation  
13. Tighten the cable clamps and secure the cables to the wall or bulkhead to prevent  
unnecessary strain on the connections. Replace the cover over the AC connection block.  
14. Connect a cable from the Chassis GND terminal on the inverter to earth ground for on-  
shore installations, to the vehicle chassis for RV installations, or to the engine negative  
terminal for marine installations. DO NOT connect this conductor to the AC input  
ground wire or directly to the negative pole of the battery. Refer to “DC Grounding,”  
below.  
15. For residential installations, a DC wiring enclosure is required to cover DC  
connections and cables. Contact Xantrex or your distributor for this part.  
16. Route your DC supply cables from the battery bank to your inverter/charger. Provide  
an anti-chaffing device around the cables where they pass through a bulkhead or  
partition. Seal around the cables where they pass through the bulkhead or partition to  
prevent gasses from passing through them.  
17. An inline fuse is recommended between the inverter/charger and the battery and is  
required by regulations for some installations. This protects your wiring in case of  
accidental shorting. The fuse and fuse holder need to be installed in the positive side of  
the DC circuit, as close as possible to the batteries. Attach the cable from the positive  
(+) terminal on the fuse to the positive DC connector post on the inverter/charger.  
Tighten the hex nut on the inverter/charger connector to 216–240 inch-pounds (24–  
27Nm). Secure the cable to the bulkhead or partition to prevent unnecessary strain on  
the connector.  
18. Attach the cable to the negative (–) terminal on the battery first, and then connect it to  
the negative DC connector post on the inverter/charger. There will be a “snap” or spark  
as electrical current jumps from the cable to the connector post. This is normal. Tighten  
the hex nut on the DC terminal to 216–240 inch pounds.  
19. Attach the DC terminal covers and the vent cover/drip shield.  
20. Connect the standard or ACS control panel by inserting the RJ-11 telephone-type  
connector plug into one of the jacks labeled “Remote Output” on the inverter/charger.  
Secure the EMI bulb on the control panel cable to the wall or bulkhead adjacent to the  
inverter/charger to prevent unnecessary strain on the cable connector.  
21. Reconnect your AC shorepower supply.  
22. Slide the BYPASS/ON switch on the side of the inverter/charger to the ON position.  
23. Verify that you have configured the unit correctly, and that it is operating correctly.  
Prosine Installation & Operation Guide  
39  
Designing the Installation  
Designing the Installation  
All installations of the Prosine inverter/charger system share many common components, described  
briefly in this section. AC & DC cabling, circuit breakers, fuses, and distribution panels are more fully  
described in following sections. The figure below diagrams a typical residential installation showing  
these components and their relationship to each other in a typical installation.  
AC Shorepower A source of 120-volt, 60-Hz alternating current is necessary to provide a source of  
energy for charging batteries, and to pass-through to AC loads. This source could be the utility grid or  
power company, or a gasoline-, diesel-, or natural gas-powered AC generator. Multiple sources of  
shorepower may also be available.  
AC Disconnect and Overload Device Every system requires a method of disconnecting the AC  
power source, and an overload protection device (circuit breaker or fuse). These two components are  
often integrated into an AC circuit breaker, which provides a disconnect and protects against overload  
at the same time. These devices are usually installed within a protective box. Some provide a method  
of selecting between multiple AC sources as well as circuit protection and disconnect. You can use up  
to a 30-amp circuit breaker in the AC supply line feeding the inverter/charger. The current rating of  
the breaker or fuse must be matched to the wire size(s) involved, in accordance with the applicable  
installation codes.  
AC Distribution Center The AC distribution center is often called a ‘main panel,’ or a ‘sub panel.’  
A main panel includes a main circuit breaker, which serves as a disconnect for the AC power supply  
line. Additional circuit breakers serve individual circuits, one of which may serve the inverter/charger.  
Some systems route all AC service through the inverter/charger, in which the main AC distribution  
panel is fed by the inverter/charger AC output. In all systems, both the inverter/charger and the AC  
loads on the inverter/charger must be protected with circuit breakers.  
AC Cabling AC cabling includes all of the  
wires and connectors between the AC source  
and the inverter/charger; and between the  
DC Fuse or  
inverter/charger and the AC distribution  
Circuit Breaker  
panels, circuit breakers, and loads. The type  
and size of the wiring varies with the  
installation and the load. For marine and some  
RV applications, flexible multiple-strand wire  
known as ‘boat cable’ is required. For  
residential installations, solid ‘ROMEX’ cable  
is often used. Your installation code may  
AC Sub-panel  
specify the number of strands, the overall size  
of the conductors, and the type and  
temperature rating of the insulation around the  
wire.  
120Vac from  
Utility Grid  
DC Cabling DC cabling includes all of the  
wires and connectors between the batteries,  
the DC disconnect and over-current protection  
device, and the inverter/charger. All  
AC Main Panel  
installations require multi-strand insulated  
cables as well as disconnect and over-current devices. DC cables come in a large assortment of sizes,  
indicated by the AWG notation or the kcmil (MCM) notation. AWG refers to the American Wire  
Gauge standard, while kcmil refers to thousands of circular mils. Under the AWG standard, a larger  
40  
Prosine Installation & Operation Guide  
     
Section 4: Inverter/Charger Installation  
gauge number indicates a smaller wire diameter (for example: a 2 AWG cable is smaller than a 00  
AWG cable). Under the MCM standard, a larger number indicates a larger cable (example: a 350  
MCM cable is larger than a 250 MCM cable). Wire size is usually marked on the cables for sizes this  
large.  
DC Disconnect and Over-Current Device The DC power supply leading to the inverter/charger  
must also be equipped with a disconnect and over-current device. These usually consist of a circuit  
breaker or a fuse and disconnect. Do not confuse AC circuit breakers with DC circuit breakers. They  
are not interchangeable. The Prosine inverter/charger requires a DC over-current device rated at least  
300-amps. This can be a fuse in the positive DC cable, or a DC breaker in the same line.  
Batteries Every Prosine inverter/charger system requires a deep-cycle battery or group of batteries  
that provide the DC current that the inverter/charger converts to AC current. There are different types  
and sizes of batteries, many of which are discussed in ”Section 7: Batteries”. Automotive-type  
batteries are not recommended for use with the Prosine inverter/charger, except for temporary  
emergency use only. The Prosine inverter/charger utilizes 12-volt or 24-volt battery banks, depending  
upon the model purchased. Read the label on the side of the inverter/charger to determine the correct  
battery voltage to use.  
Generator When a generator is included as a secondary AC power source, a manual or automatic  
AC source selector switch must be installed ahead of the circuit breaker in the line leading to the  
inverter/charger. In marine and RV applications, the AC cabling from the generator to the circuit  
breaker must be composed of stranded cable. Both the Line (Hot) conductor and the Neutral  
conductor must be protected by circuit breakers. If the generator is the only AC shorepower source, no  
source selector switch is needed.  
Ground Fault Circuit Interrupters (GFCIs) A GFCI is a device that de-energizes a circuit when  
a current to ground exceeds a specified value that is less than that required to blow the circuit breaker.  
GFCIs are intended to protect people from electric shocks.  
Installations in marine and recreational vehicles may require GFCI protection of branch circuits  
connected to the AC output of the inverter/charger. In addition, electrical codes require GFCI  
protection of certain receptacles in residential installations.  
While the true sine wave output of the Prosine inverter/charger is equivalent to the waveform  
provided by utilities, compliance with UL standards requires that Xantrex test and recommend  
specific GFCIs. Xantrex has tested the GFCI-protected 15A receptacles listed in Table 2 and found  
that they function properly when connected to the AC output of the Prosine 2.0.  
Table 2: GFCI Models  
Manufacturer  
Model Number  
Leviton  
Leviton  
Eagle  
6599/701  
6598/722 (with polarity check and indicator light)  
Shock Sentry  
1591-WCN  
GF252GYA  
GFR52FTI  
GFR82FTI  
Pass & Seymore  
Hubbell  
Bryant  
Bryant  
Prosine Installation & Operation Guide  
41  
 
Tools and Materials Required  
Tools and Materials Required  
You will need the following tools and materials to properly install the Prosine inverter/charger:  
Wire insulation stripper  
Mounting screws or bolts (#12 or #14)  
#2 (¼-inch) flat blade screwdriver  
Small Phillips screwdriver  
17mm or adjustable wrench for DC terminals  
AC cable sized appropriate for load and application  
Two one-inch AC cable strain-relief clamps  
DC cable, sized appropriate for load and application  
Lugs or terminals for your DC cables and appropriate tools  
AC and DC disconnects and overcurrent protective devices  
Where to Install the Prosine Inverter/Charger  
Install the Prosine inverter/charger only in locations that are dry, cool, well ventilated, close to  
batteries and loads, and protected from the weather. These terms are described below:  
Dry—Do not allow water or other fluids to drip or splash on the Prosine  
inverter/charger. Do not mount the Prosine inverter/charger in an area  
subject to splashing water or bilge water.  
Cool—Normal ambient air temperature should be between 32°F (0°C) and  
77°F (25°C)—the cooler the better.  
Ventilated—For the Prosine 2.5, allow at least 5 inches (13cm) clearance at  
the bottom of the unit for air flow, 3 inches (8cm) on each side, and 1.5 inches  
(4cm) at the top. For cooling purposes, the volume of the enclosure is not as  
important as the overall supply of air. Do not allow the ventilation openings on  
the back and top of the unit to become obstructed. When mounting in a closed  
compartment, provide a fresh-air intake opening directly to the fans (located  
behind the unit) to assure a good supply of cooling air. The Prosine 3.0 must be  
mounted on top of the brackets that are provided with it to allow adequate  
airflow to the cooling fans.  
The figure below illustrates the effect of inadequate ventilation on the output  
power of the Prosine 2.5 and 3.0 inverter/chargers. As with all inverters, the  
amount of continuous power that the Prosine inverter/chargers can deliver  
without overheating is limited by the ambient temperature. They will operate  
and deliver their continuous power ratings at higher temperatures, but the  
ambient temperature as well as the input voltage from the battery limits the  
extent to which they can do this. The following curve illustrates the  
relationship between rated power output and ambient temperature. Operating  
the unit in conditions outside the power and temperature limits 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 products.  
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Prosine Installation & Operation Guide  
   
Section 4: Inverter/Charger Installation  
Prosine  
Output Power De-rating at Elevated Temperature  
4000  
3000  
2000
1000  
0
PS 2.5  
PS 3.0  
0
20  
40  
60  
80  
Ambient temperature (deg. C)  
WARNING Explosion hazard: This equipment contains components which tend to produce arcs  
or sparks. To prevent fire or explosion do not install the Prosine inverter/charger in compartments  
containing batteries or flammable materials or in locations which require ignition protected  
equipment. This includes any space containing gasoline-powered machinery, fuel tanks, or joints,  
fittings, or other connection between components of the fuel system.  
Safe—Do not install the inverter/charger in the same compartment as vented  
(non-sealed) batteries or in any compartment capable of storing flammable  
liquids such as gasoline. The Prosine inverter/charger is not ignition protected.  
Do not install it an engine or gas tank compartment or any other location where  
ignition protected equipment is required. These gases are very corrosive and  
prolonged exposure will damage the Prosine inverter/charger.  
Close to batteries and the AC distribution box—Avoid excessive cable  
lengths, which reduce input and output power due to wire resistance. Use the  
recommended wire lengths and sizes.  
Protected from battery acid—Never allow battery acid to drip on the Prosine  
inverter/charger or its wiring when reading specific gravity or filling the  
battery.  
Prosine Installation & Operation Guide  
43  
Mounting the Prosine Inverter/Charger  
Mounting the Prosine Inverter/Charger  
The inverter must be mounted on a vertical surface as  
shown. Before mounting the Prosine inverter/charger,  
test the chosen location for adequate space around the  
unit to allow for connections, ventilation and access to  
configuration DIP switches. Mounting hardware  
should be corrosion resistant and #12 or #14. Your  
mounting system should be able to support three times  
the weight of the Prosine inverter/charger, which  
weighs 32 pounds (14.5kg).  
The more clearance for ventilation around the unit, the  
better the performance. Allow at least 5 inches at the  
bottom, 3 inches on each side, and 1.5 inches at the top  
for ventilation. For better ventilation, route a fresh-air  
supply through the bulkhead near the fans. This fresh-  
air supply must be baffled or otherwise constructed to  
prevent rain or spray from entering the unit.  
Mount the Prosine inverter/charger on a vertical  
surface (such as a wall or bulkhead) using the mounting holes provided, with the DC and AC wiring  
connections at the bottom. Mark the location of the holes on the mounting surface. Use all six  
mounting holes. If you are installing a Prosine 3.0, you must use the mounting brackets provided with  
the unit to allow for sufficient air circulation. The mounting holes on these brackets are spaced 16  
inches apart to align with wall-stud spacing.  
Attach the vent cover/drip shield to the top of the Prosine inverter/charger after securing the unit. The  
screws for attaching this cover can be found already in the bracket holes. Remove the screws, place  
cover in the slots and align holes, then replace the screws.  
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Prosine Installation & Operation Guide  
 
Section 4: Inverter/Charger Installation  
AC Cabling  
AC wiring must be sized to match the current rating of the AC breakers you provide on the input and  
output AC circuits in accordance with the electrical codes or regulations applicable to your  
installation. The input and output circuits to and from the inverter/charger must be protected with a  
maximum 30-amp circuit breaker. The output branch circuit breaker size is determined by the load  
that will be placed on the circuit. Determine the output load, then select the appropriate circuit breaker  
size, the appropriate wire size and type. The following table is based on the U.S. National Electrical  
Code and the Canadian Electrical Code. There may be other codes and regulations applicable to your  
installation.  
Recommended Wire Size vs Breaker Rating  
Breaker Size  
Min Wire Size  
10A  
15A  
20A  
30A  
14AWG  
14AWG  
12AWG  
10AWG  
AC and DC Wiring Separation  
Do not mix AC and DC wiring in the same conduit or panel. Where DC wiring must cross AC or vice-  
versa, make the wires at the crossing point 90° to one another. Consult code for details of DC and AC  
wiring in vicinity to one another.  
AC Output Neutral-to-Ground Bonding  
The neutral (common) conductor of the AC output circuit of the Prosine inverter/charger is  
automatically connected (bonded) to the input safety ground during inverter operation. This conforms  
to National Electrical Code requirements that separately derived AC sources (such as inverter and  
generators) have their neutral conductors tied to ground in the same way that the neutral conductor  
from the utility is tied to ground at the AC breaker panel. When AC utility power is present and the  
Prosine inverter/charger is in charger mode, this connection (neutral of the Prosine inverter/charger’s  
AC output to input safety ground) is not present so that the utility neutral is only connected to ground  
in one place, at your AC input breaker panel, as required. Your AC load distribution panel must not  
bond the neutral to ground. Many sub-panels have a bonding screw designed to allow the installer to  
bond or un-bond the panel’s neutral.  
AC Disconnect and Overload Protection  
AC Input: The circuit breaker or fuse used to protect the inverter/charger must be rated max. 30A,  
and must be approved for use on 120VAC branch circuits. The wire size used between the breaker and  
the Prosine inverter/charger input must be sized to match the circuit breaker, in accordance with the  
electrical codes or regulations applicable to your installation. The "AC Service Rating" setting of the  
Prosine inverter/charger must also be set to match the size of the breaker provided.  
AC Output: The circuit breaker or fuse used must be rated max. 30-amp, and must be approved for  
use on 120V AC branch circuits. The wire size used between the Prosine inverter/charger output and  
the breaker, and between the breaker and your loads, must be sized to match the circuit breaker’s  
rating, in accordance with the electrical codes or regulations applicable to your installation.  
Disconnect Devices: Since circuit breakers can be turned off, they will also meet the requirement  
for a disconnect device. As an alternate, use separate fuses and disconnect switches. Note that the  
required disconnect device is not intended for disconnection under load, it is only meant to be a way to  
isolate the Prosine inverter/charger from the input and output circuits.  
Prosine Installation & Operation Guide  
45  
         
DC Cabling  
DC Cabling  
DC wiring includes the positive and negative conductors from the battery(s) as well as a disconnect  
device and over-current protection. Locate your battery(s) as close as possible to your inverter (or  
vice-versa) to reduce energy losses caused by cable resistance. Cables should be as short as possible  
(5-10 feet) and large enough to handle the required current, in accordance with the electrical codes or  
regulations applicable to your installation. The connectors on the inverter/charger are designed to fit  
up to 500 MCM crimp-on ring terminals (either AMP or ILSCO) or box connectors.  
Do not route your DC wiring through an electrical distribution panel, battery isolator, or other device  
that will add additional voltage drops.  
DC Over-Current Protection  
Installation codes require over-current protection for battery cables, installed as close as possible to  
the battery, in the positive side of the circuit. The current rating of this DC fuse or circuit breaker must  
be large enough to allow the Prosine inverter/charger to operate your loads, but if the rating is too  
high, electrical codes will require you to use larger DC cables than you would otherwise have to. The  
fuse or circuit breaker must be rated for use on DC circuits. Fuses or circuit breakers rated only for AC  
service are not suitable for use on DC circuits and may pose a hazard. The wire size used between the  
inverter/charger and the fuse or circuit breaker must be sized to match the fuse or circuit breaker's  
current rating, in accordance with the electrical codes or regulations applicable to your installation.  
The following table outlines the minimum DC cable size and maximum fuse size required for some  
common installation codes. There may be other codes and regulations applicable to your installation.  
Marine Installation  
See footnote a.  
RV Installation  
See footnote b.  
Residential Installation  
See footnote c.  
Model  
Wire Size  
Fuse Size  
Wire Size  
Fuse Size  
Wire Size  
Fuse Size  
Prosine 2.5/12  
Prosine 2.5/24  
Prosine 3.0/12  
Prosine 3.0/24  
# 2/0 AWG  
# 4AWG  
350A  
175A  
450A  
250A  
# 3/0 AWG  
# 3 AWG  
350A  
175A  
450A  
200A  
350 MCM  
# 2/0 AWG  
500 MCM  
# 3/0 AWG  
350A  
175A  
400A  
200A  
# 3/0AWG  
# 2AWG  
# 4/0 AWG  
# 2 AWG  
a. Based on ABYC Recommended Practice E-9, 75C wire, no conduit.  
b. Based on the NEC, NFPA 70, Article 551, 90C wire.  
c. Based on NFPA 70, Article 240 and 310, 75C wire, wire in conduit. If your installation code allows you to wire  
in free air, then the following table applies. NOTE: This table applies to residential installations only.  
Model  
Wire Size  
Fuse Size  
(Amps DC)  
350A  
Prosine 2.5/12  
Prosine 2.5/24  
Prosine 3.0/12  
Prosine 3.0/24  
# 3/0 AWG  
# 2 AWG  
250 MCM  
# 1 AWG  
175A  
450A  
200A  
What the above tables do not take into account, however, is voltage drop associated with greater cable  
lengths. It is always best to use oversize cables to reduce voltage drop and improve inverter  
performance.  
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Prosine Installation & Operation Guide  
   
Section 4: Inverter/Charger Installation  
For best performance, the wire sizes shown in the table below will allow the Prosine to operate  
properly. Please note that regulatory requirements may not allow you to use the wire size given for 5  
foot and 10 foot distances. Also, increasing the wire size will provide longer inverter performance.  
Recommended DC Cable Sizes For Proper Operation  
Cable Length  
in Feet (from  
invert/charger  
to battery)  
5 ft  
10 ft  
15 ft  
20 ft  
30 ft  
PS 2.5 12-volt  
24-volt  
2/0 AWG  
2 AWG  
250MCM  
2/0 AWG  
350MCM  
3/0 AWG  
350MCM  
4/0 AWG  
500MCM  
250MCM  
500MCM  
250MCM  
750MCM  
350MCM  
750MCM  
350MCM  
1000MCM  
500MCM  
PS 3.0 12-volt  
24-volt  
3/0 AWG  
1 AWG  
DC Disconnect  
If a DC circuit breaker is used to provide over-current protection for the battery circuit, it will also  
meet the requirement to provide a disconnect. If a DC fuse is used to provide over-current, however, a  
separate DC disconnect switch or a combined “fusible disconnect” will be required. As with the AC  
disconnects, the DC disconnect is not intended for disconnection under load.  
Battery Cable Routing  
When a distance separates positive and negative battery cables, they have much more inductance than  
if they are close together, and when the high current drawn by the inverter is flowing, strong magnetic  
fields are generated. These fields may interfere with sensitive equipment, so it is very important to  
route the positive and negative cables in parallel, as close together as possible.  
DC Cabling Connections  
Color-code your battery cables with colored tape or heat shrink tubing. The standard is red for  
positive (+) and black for negative (–).  
Use crimp-on ring terminals or set-screw type pressure connectors (i.e., “box lugs”).  
For marine installations, you must use a wire protector between the set-screw and stranded wire.  
If you are using crimp-on terminals, use the manufacturer’s recommended crimping tool to install  
them.  
Prosine Installation & Operation Guide  
47  
         
Recommended DC Cable Sizes For Proper Operation  
Do not place anything between  
battery cable lug and terminal  
surface. Assemble exactly as shown  
Copper Compression Lug  
Aluminum Box Lug  
DC Cabling Procedure  
CAUTION Reversing the positive and negative battery cables will damage the Prosine inverter/  
charger and void your warranty. This type of damage is easily detected. Before making the final  
DC connection, check cable polarity at both the battery and the inverter/charger. Follow the procedure  
outlined below to make your DC cable connections. Observe the polarities carefully while performing  
the installation, and route both cables before making any connections.  
1. Cut the cables to the correct length with enough insulation stripped off to properly  
install the lugs.  
2. If using compression lugs, attach the terminals to both cables using the crimp tool  
recommended by the manufacturer of the ring terminals. There must be no stray wire  
strands protruding from the terminal. If using box lugs, attach the lug to the Prosine  
first, then insert the wire and tighten the set screw to the torque recommended by the lug  
manufacturer.  
3. Connect the positive cable to the positive battery connector (stud) on the Prosine  
inverter/charger and tighten to a torque of 216–240 inch-pounds (24–27Nm) with a  
wrench. Test that the cable is secure.  
4. Install an inline fuse between the Prosine inverter/charger and the battery. Refer to the  
tables to determine the fuse sizes required. This protects your battery and wiring in case  
of accidental shorting. The fuse and fuse holder must be installed in the positive side of  
the DC circuit, as close as possible to the batteries.  
5. Connect the cable from the POSITIVE connector on the Prosine inverter/charger to the  
POSITIVE (POS +) terminal on the battery fuse.  
6. Connect the DC NEGATIVE cable to the NEGATIVE (NEG -) terminal on the battery.  
7. Connect the DC NEGATIVE cable to the negative terminal on the inverter/charger. This  
connection should be the last connection made. A spark when making this final  
connection is normal.  
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Section 4: Inverter/Charger Installation  
8. If you are using the remote temperature sensor, plug it into the temperature sensor jack  
(BATT TEMP) on the side of the Prosine inverter/charger chassis. Route the sensor wire  
safely to the battery location and mount the sensor's ring tongue connector directly on  
the NEGATIVE battery post. Do not mount the sensor between the DC negative power  
cable and the negative battery terminal.  
9. For residential installations, a DC wiring enclosure is required to cover DC connections  
and cables. Contact Xantrex or your distributor for this part. For other installation,  
install the red and black DC terminal covers over the positive and negative terminals,  
respectively.  
DC Grounding  
The Prosine inverter/charger has a lug on the rear panel labeled Chassis Ground. This lug is used to  
connect the chassis of the inverter/charger to your DC ground as is required by regulations for some  
installations. Depending on where the inverter/charger is being installed, follow the instructions below  
that correspond to your installation location.  
Recreational Vehicle Installations  
Use #8 AWG or larger copper wire (green if insulated) and secure it to the Chassis Ground Lug as  
well as the grounding point in your vehicle (usually the vehicle chassis).  
Residential Installations  
The chassis of the Prosine inverter/charger must be connected to the system’s DC grounding point.  
Typically wire is #2 AWG (12-volt models) or #6 AWG (24-volt models) copper wire. Consult your  
codes.  
Marine Installations  
The Chassis Ground Lug should be connected to the boat’s Engine Negative bus or DC Grounding  
bus. The ABYC recommends the following, based on 75 C wire:  
PS2.5/12: # 1/0 AWG  
PS3.0/12: # 2/0 AWG  
PS2.5/24: # 3 AWG  
PS3.0/24: # 1 AWG  
Connecting the Battery Temperature Sensor  
Mounting Options  
You can mount the battery temperature sensor (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.  
Prosine Installation & Operation Guide  
49  
     
Connecting the Battery Temperature Sensor  
Attaching the sensor to the side of the battery using the self-adhesive backing also provides  
good results in most situations.  
WARNING: Energy and Explosion Hazard  
Mounting to the Negative Battery Terminal  
To mount the sensor on the negative battery terminal:  
See Figure 5.  
Figure 5. BTS Attached to Negative Battery Terminal  
1. Decide which battery is to be monitored.  
When all battery banks are located in the same compartment, select the battery that  
requires the most frequent charging (in a boat or an RV, this is usually the “house”  
battery). Where a battery is located in a separate compartment from other batteries, and  
where temperatures are constantly high (as in an engine room), it is a good idea to  
monitor this battery to keep it from being overcharged as a result of its constant high  
temperature. In this situation, the cooler battery bank will be slightly undercharged  
since it will be at a lower temperature than the battery being monitored, but this  
procedure will prolong the warmer battery’s life.  
2. Switch off all devices operating from the battery, or open the battery switch, if present,  
to disconnect the battery.  
3. If the charger has been operating, wait ten minutes for any explosive battery gasses to  
dissipate.  
4. Remove the nut that secures the existing negative DC wire to the battery.  
5. Move or reorient the existing negative DC wire so there is a flat surface on which to  
seat the battery temperature sensor mounting plate. You may need to bend the ring  
terminal and/or wires downward to allow the sensor to seat on the top surface of the  
upper ring terminal.  
6. Mount the sensor directly on top of the negative DC wire terminal, as shown in  
Figure 5, and tighten the terminal nut firmly.  
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Section 4: Inverter/Charger Installation  
7. Check that the sensor and all wires are fastened securely.  
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 TEMP  
jack. Secure the cable along its length.  
NOTE  
In this procedure, you must install the DCcable on the battery terminal first. Then  
the sensor is installed on top of the DC cable. This sequence is required to provide  
the best connection to the battery and to thereby ensure correct performance of the  
sensor.  
Mounting to the Side of the Battery Case  
To mount the sensor on the battery case  
See Figure 6.  
Adhesive backing allows  
for easy mounting on side  
of battery.  
Figure 6. BTS Attached to Battery Case  
1. Select the battery to be monitored (see step 1 in the preceding procedure).  
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. As well, this surface must be in direct internal contact with  
battery electrolyte, so do not install the sensor on a side 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, and 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.  
6. Route the sensor cable to the inverter/charger and plug it into the BATTERY TEMP  
jack. Secure the cable along its length.  
Prosine Installation & Operation Guide  
51  
   
Typical System Diagrams  
Typical System Diagrams  
Every installation is a custom-designed system. It could be a residential, solar, marine, or RV  
installation with an almost unlimited number of variations. The following diagrams illustrate a few  
typical system designs for residential, solar, and marine installations.  
Residential Backup System  
This diagram illustrates a typical residential backup system. This system features:  
1. AC power supplied by a utility system  
2. DC power supplied by a battery bank and protected by a DC fuse in the positive cable  
3. A main AC distribution center that includes a maximum 30-amp circuit breaker that  
supplies the inverter/charger  
4. A sub-panel AC distribution center with branch circuit breakers that supply only loads  
that run off of the inverter/charger  
5. The earth ground  
d
DC Fuse or  
Circuit Breaker  
"
%
AC Sub-panel  
$
120Vac from  
Utility Grid  
!
#
AC Main Panel  
52  
Prosine Installation & Operation Guide  
   
Section 4: Inverter/Charger Installation  
Recreational Vehicle System  
The diagram below illustrates a typical RV system with the following components:  
1. AC power supplied from a shorepower connector  
2. AC power supplied from a generator  
3. AC Source Selector switch that isolates the two AC supply sources  
4. AC distribution panel that provides a 30-amp circuit breaker that feeds the inverter  
5. AC sub-panel with branch circuit breakers that supply only inverter loads  
6. Inverter/charger  
7. DC power supplied by a house battery bank that is isolated from the vehicle starting  
batteries  
8. Vehicle starting battery  
9. Battery isolator  
10. DC alternator  
11. Chassis grounds for both the inverter and the DC components  
)
Battery Isolator  
DC Fuse or  
Circuit Breaker  
&
12 Volt Deep  
Cycle Battery  
'
11  
Chassis Ground  
%
$
AC Sub Panel  
*
(
11  
Chassis Ground  
Vehicle Start  
Battery  
Main AC Panel  
Automatic or Manual  
Source Transfer Switch  
#
!
"
Shore Power  
Generator  
Prosine Installation & Operation Guide  
53  
 
Typical System Diagrams  
Residential Solar and Wind System  
This diagram illustrates a residential system that features the following components:  
1. AC power from utility lines  
2. Main AC distribution center with 30-amp circuit breaker feeding the inverter/charger  
3. Inverter/charger  
4. AC sub-panel distribution center with circuit breakers for all branch circuits  
5. DC supply from dedicated battery bank  
6. A wind generagtor providing DC charging current to the battery bank through a charge  
controller  
7. A solar panel providing DC charging current to the battery bank through a charge  
controller  
8. Inverter chassis ground to earth ground  
DC Fuse or  
Circuit Breaker  
#
%
$
(
AC Sub Panel  
!
'
&
Main AC Panel  
"
Charge Controller, Wind  
Generator, and other  
components  
Charge Controller, Solar Array,  
and other components  
54  
Prosine Installation & Operation Guide  
 
Section 5: Operation  
After all the AC and DC wiring has been installed, you can follow the instructions below to perform  
the initial startup. First, take a moment to go back over all connections and make sure they are secure  
and in the proper terminal. If the system utilizes flooded lead-acid type batteries instead of sealed gel-  
cell type, use the ACS or the DIP switch settings to change the set-up for battery type from gel-cell to  
flooded lead-acid. If you don’t know which battery type you have, use the gel-cell setting just to be  
safe, and then contact the battery manufacturer.  
1. Verify that the DIP switch settings are correct for  
your system. See “Section 3: Configuration” if  
you have the standard control panel, or the ACS  
Control Panel section if you have that.  
2. Check to see that the inverter BYPASS/ON slide  
switch is in the BYPASS position.  
3. Connect the battery cable (or close the battery disconnect switch) to complete the  
battery circuit. Turn the inverter BYPASS/ON slide switch to the ON position. The  
System Startup Default is set at the factory at INV OFF/ CHG ON. Press the Inverter  
ON/OFF switch on the control panel to enable the inverter. When the DC connection is  
completed, the inverter will begin inverting if there is an AC load and the AC  
shorepower has not been connected.  
4. Place a load on the inverter (plug in a light or other load to an outlet the inverter is  
powering), and make sure it works. The inverter should run a load without AC  
shorepower connected (battery only).  
5. If the inverter does not come on or go through the start-up, check all connections.  
Check the inverter’s DC voltage on the positive (+) and negative (–) terminals. If the  
DC voltage is low or if the battery bank needs to be charged, go directly to Step 6.  
6. To charge your batteries, connect shorepower to the inverter by plugging in the  
shorepower cord and turning on the shorepower breaker. After a few seconds delay, the  
utility/shorepower LED should light and the Charge LED on the front of the inverter  
should indicate it is charging. This indicates the charger is working properly. Any AC  
loads connected to the AC output should also work at this point.  
The delay before connecting to the utility AC supply is the inverter sampling the  
shorepower to see that it is within acceptable frequency and voltage limits. This delay  
also allows time for a generator to spin up to a stable operating condition before the  
inverter/charger places a load on it.  
7. Disconnect shorepower by turning the shorepower breaker off, or unplugging the  
shorepower. The inverter should transfer to inverter mode immediately. This will be  
indicated by a clicking sound as the internal transfer relays change position. The loads  
should continue to operate uninterrupted.  
The preceding steps will complete a functional test of the inverter. If all areas pass, the inverter is  
ready for use. If any area fails, determine why before proceeding. “Appendix C: Troubleshooting”  
will help you solve problems you encounter.  
Prosine 2.5/3.0 Installation & Operation Guide  
55  
           
Prosine Inverter Load Sense Mode  
Prosine Inverter Load Sense Mode  
When the inverter is ON, it can be set up so that it periodically searches for the presence of a load. The  
unit will “sleep” if the load it detects is less than the search mode setting. This “sleep” mode shuts off  
much of the power control circuitry of the Prosine inverter/charger, reducing the standby current draw  
considerably. The Prosine inverter/charger detects the presence of a load by sending out pulses  
depending on user settings. Full output power is available with the detection of a load. You can set the  
minimum load required to start the inverter, by either changing the configuration DIP switches on the  
side of the chassis, or using the ACS Panel (Advanced Control System Panel). The INVERT LED will  
blink approximately once per second when the Prosine inverter/charger is in this search mode. There  
are four choices for the setting of the minimum load start power when using the chassis DIP switches  
(the ACS Panel offers a much wider range of load start-power settings):  
Setting  
Description  
0 watts  
Inverter always on, search mode disabled  
10 watts  
25 watts  
50 watts  
Set to the load rating that you want the inverter  
to power. Example Set at 50-watts, a 75-watt  
light bulb will activate the inverter; a 25-watt  
bulb will not activate inverter.  
Operating Limits for Inverter Operation  
Power Output:. The invert mode output rating for your Prosine inverter/charger is:  
Prosine 2.5 = 2500 watts or 21 amps @ 120VAC; surge to 4kw  
Prosine 3.0 = 3000 watts or 25 amps @120VAC; surge to 4kw  
The units should be able to operate all AC loads rated at or below their respective power ratings. Some  
high horsepower induction motors used in pumps and other motor operated equipment require very  
high surge currents to start and the Prosine inverter/charger may have difficulty starting these loads. If  
you have problems with the Prosine inverter/charger starting certain loads, ensure that battery  
connections are solid, DC and AC wiring is of sufficient size, and that the battery is of sufficient  
capacity and fully charged.  
56  
Prosine 2.5/3.0 Installation & Operation Guide  
                     
Section 5: Operation  
Input Voltage: The Prosine inverter/charger operates from an input voltage ranging from 10 volts to  
16 volts, (20 to 32 volts on 24V models) and peak performance occurs when voltage is in the range of  
12 volts to 13 volts (24 to 26 volts on 24V models) as shown in the following table.  
Prosine Operating Voltage Limits  
Operating  
Condition  
Voltage Range  
12-Volt System  
Voltage Range  
24-Volt System  
Normal  
10V - 16V  
12V - 13V  
20V - 32V  
24V - 26V  
Peak Performance  
High Voltage Alarm  
LED On  
>15.5V  
>16V  
>31V  
>32V  
Unit Shuts Down  
Low Voltage Alarm  
LED Flashes  
10.5V  
10.0V  
12.3V  
21V  
≤20V  
Unit Shuts Down  
Unit Restarts  
24.6V  
Prosine 2.5/3.0 Installation & Operation Guide  
57  
 
Operating Limits for Inverter Operation  
58  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 6: Multistage Charging  
The Prosine inverter/charger has a fully functional multistage battery charger. Any time an acceptable  
(within frequency and voltage parameters) AC source is presented to the unit, it will charge the  
batteries connected to it. When AC is present and the charger is enabled, the charger will charge the  
battery bank regardless of the position of the inverter’s On/Off switch.  
Charging Profile  
The battery charger in the Prosine charges in three stages—BULK, ABSORPTION, and FLOAT—  
to provide rapid and complete charge cycles without undue battery gassing. The figure below shows  
how DC voltage and current change with time through the different charge stages.  
Absorption Charge  
Float Charge  
Bulk  
Charging  
Started  
Bulk Volts Setting  
Float Volts Setting  
DC Voltage  
Constant Current  
@ Maximum  
Charge Rate  
Reduced Voltage  
Load current on demand  
Constant Voltage  
DC Current  
Time  
Figure 7. Three-Stage Charging Profile  
Bulk Charge  
In the first step, known as the bulk charge, the Prosine inverter/charger delivers the maximum charge  
current allowable given the configuration settings, that is, battery type and temperature, maximum AC  
input setting and battery bank size. This current is delivered to the batteries until the battery voltage  
approaches its gassing voltage—typically around 14.4 volts for 12 volt batteries and 28.8 volts for 24  
volt batteries (again this voltage can vary depending on battery type and other settings). The bulk  
charge step restores about 75% of the battery's charge. The gassing voltage is the voltage at which the  
electrolyte in the battery begins to break down into hydrogen and oxygen gases. Under normal  
circumstances, a battery should not be charged at a voltage above its gassing voltage since this will  
cause the battery to lose electrolyte and dry out over time. Therefore the Prosine inverter/charger  
transfers to the next stage, known as the absorption charge.  
Absorption Charge  
During the absorption charge, the charging voltage is held constant near the gassing voltage and the  
charging current is steadily decreased. When the charging current has decreased to a predetermined  
Prosine 2.5/3.0 Installation & Operation Guide  
59  
                   
Charging Profile  
limit, based on battery size settings, charging moves on to the next stage. For flooded batteries, the  
absorption charge is maintained for approximately one more hour. The absorption charge stage  
restores the remaining 25% of the battery’s charge.  
Float Charge  
The float charge is a maintenance mode in which the output voltage of the Prosine inverter/charger is  
reduced to a lower level, typically about 13.5 volts, (27 volts for 24V models) to maintain the battery's  
charge without losing electrolyte through gassing. Unlike many stand-alone chargers, the Prosine  
inverter/charger can be left connected to your battery indefinitely without risk of overcharging. When  
DC loads are placed on the battery, the charger will deliver currents up to the Maximum Charge Rate  
setting while maintaining the float voltage.  
Equalization Charge  
The fourth charging step, known as the equalization charge, is manually initiated because it is not  
required every time the battery is recharged. Equalization is a deliberate overcharge of the battery.  
Equalizing your batteries will reduce sulfation and help reach and maintain the peak capacity of the  
battery.  
During normal charging, temperature and chemical imbalances prevent some cells from reaching full  
charge. These reduced capacity cells accelerate sulfation (the build up of lead sulfate on the battery  
plates) and decrease the ampere-hour capacity of the battery. During equalization, the battery is  
intentionally held above the gassing voltage. Fully charged cells dissipate the charging energy by  
gassing while incompletely charged cells continue to charge. The rapid gassing that occurs during  
equalization also helps to recondition the battery. The gassing creates a stirring action which reverses  
electrolyte stratification (the separation of the liquid electrolyte into layers of different acid  
concentrations). The stirring action also helps to break up any lead sulfate which may remain after  
normal charging.  
An equalization charge should only be performed on vented, flooded (non-sealed or "wet") batteries  
and only as often as recommended by the battery manufacturer. The battery section of this manual  
provides further information on battery types and their charging characteristics. Refer to “Operation in  
60  
Prosine 2.5/3.0 Installation & Operation Guide  
       
Section 6: Multistage Charging  
Operation in Charger Mode  
WARNING Explosion hazard: During charging, the battery may generate potentially explosive gases.  
Follow all the Important Safety Instructions that start on page i. Ventilate the area around the battery  
thoroughly and ensure that there are no sources of flame or sparks in the vicinity.  
Study all battery manufacturer’s specific precautions such as removing or not removing cell caps  
while charging and recommended rates of charge. When using a non-sealed battery, before charging  
add distilled water in each cell until electrolyte level reaches the level specified by battery  
manufacturer. This helps purge excessive gases from cells. Do not overfill. For a battery without cell  
caps, carefully follow manufacturer’s recharging instructions.  
If AC power is available, upon system power-up, the unit will begin charging. If AC power is not  
available the charger will automatically enter into STANDBY mode. If the inverter mode is not  
enabled then the charger STANDBY LED will turn off after a few seconds as the unit enters low  
power-draw sleep mode. If the inverter mode is enabled and the unit is inverting, when AC power  
becomes available the unit automatically switches from inverter mode to charger mode after an 8  
second delay. This delay gives the AC source time to stabilize. The Prosine inverter/charger senses the  
battery state and the appropriate charge is delivered to the batteries. During charging, the charging  
current will be indicated by the current bar graph on the Prosine inverter/charger control panel. As the  
battery charges and the end of the charge cycle nears, the charging current will decrease and  
eventually the READY LED will come on. This indicates that Prosine inverter/charger is now in Float  
mode and will maintain the battery’s charge as long as AC is supplied to the Prosine inverter/charger.  
Operation in Equalization Mode  
Follow your battery manufacturer’s recommendations for equalizing your batteries. “Section 7:  
Batteries” provides some background on different batteries. As a guide, a heavily used flooded battery  
may need to be equalized once per month and a battery in light duty service, every two to four months.  
CAUTION Sealed lead-acid and gel batteries must NEVER be equalized. Premature battery failure will  
result if these types of battery are equalized. Equalization should only be performed on flooded lead-  
acid batteries. As a general rule, do not equalize a battery unless there are provisions to add water to  
the battery. Equalize mode is disabled if the Battery Type is set to GEL.  
If performed too frequently, or done improperly, equalization can be hazardous to the health of your  
batteries. Never equalize a battery more than necessary. Always check battery fluid level before AND  
after equalization. Fill only with DISTILLED water. Monitor the electrolyte specific gravity (S.G.)  
with a hydrometer throughout the equalization.  
WARNING Explosion hazard Equalization generates explosive gas. Maintain adequate ventilation to  
the battery enclosure during equalization.  
The Prosine inverter/charger delivers a high quality charge so batteries will not need to be equalized as  
often as may be necessary when using a lower quality charger.  
Equalization Procedure  
1. Turn off or disconnect all DC loads on the battery during equalization. The voltage  
applied to the battery during equalization may be above safe levels for some loads and  
this high voltage can damage some electronic equipment. Equalization also won’t be as  
successful if additional loads are drawing current from the batteries. Be sure to check  
Prosine 2.5/3.0 Installation & Operation Guide  
61  
                     
Operation in Equalization Mode  
battery electrolyte level. Fill only with distilled water if the electrolyte level is low. Use  
a battery hydrometer to measure specific gravity of each cell. For lead-acid batteries that  
are fully charged, the reading should be approximately 1.265 (consult your battery man-  
ufacturer). Equalization is needed if one or more cells have substantially lower S.G.  
than the others.  
2. To start the equalization charging cycle, the charger must already be in operation. With  
the Standard Control Panel, press and hold the CHARGER ON/OFF push-button switch  
on the control panel for five seconds until the EQUALIZE LED comes on. With the  
ACS control panel, the equalize mode must be initiated through the menu system. When  
the charger is waiting to enter equalization mode, the EQUALIZE LED stays lit  
constantly. Equalization will start when the bulk and absorption charge have finished,  
that is, when the battery current is less than 1% of the amp-hour setting. When the  
system is in equalization, the CHARGE and EQUALIZE LEDs will blink.  
Even if the batteries are fully charged, it will take several minutes after the charger is  
first turned on for it to enter equalization mode. It takes a minimum of three minutes for  
the charger to move through bulk and another three minutes to go through absorption  
before equalization begins.  
3. Monitor the battery specific gravity during equalization with a battery hydrometer.  
When all cells have a specific gravity of approximately 1.265, manually terminate  
equalization. Terminate the equalization charge by momentarily depressing the  
CHARGE ON/OFF push-button. As a safety feature, the Prosine will time-out and exit  
Equalize Mode after eight hours. If the battery specific gravity is still rising and has not  
yet reached the target value when the charger exits equalization, restart equalization by  
holding the push-button for five seconds. To cancel equalization at any time, turn  
charger off.  
4. When equalization is finished, be sure to check battery electrolyte level. Refill with  
distilled water only.  
Adjustable Charger Mode Settings  
These settings can be changed by adjusting the DIP switches on the chassis, or by using the optional  
Advanced Control System which gives a finer degree of control over the setpoint adjustability. For  
further details on these settings and instructions for changing them, refer to “Section 3:  
Configuration” starting on page 25.  
CAUTION Incorrect settings can damage your batteries. Refer to “Section 3: Configuration”.  
Temperature Compensation: Configuration DIP switches found on the side of the chassis can be set  
up on the Prosine inverter/charger to modify the charging characteristics depending on battery  
temperature. By setting the switches correctly before charging your battery, you can ensure that your  
batteries receive the best possible charge. The Prosine inverter/charger also has a jack for a remote  
battery temperature sensor which automatically adjusts the charge according to the temperature of the  
battery. This allows the Prosine inverter/charger to provide a more accurate temperature compensated  
charge.  
Battery Type Selection: The DIP switch for “Battery Type” allows you to set the charge output of the  
Prosine inverter/charger for the charging characteristics of sealed lead acid “gel” batteries, or for the  
charging characteristics of conventional flooded “wet” batteries. If you can add water to your  
batteries, this switch should be set to the FLOODED position. If your batteries are sealed, then set this  
62  
Prosine 2.5/3.0 Installation & Operation Guide  
                   
Section 6: Multistage Charging  
switch to the GEL position even if they use starved-electrolyte technology rather than gelled  
electrolyte technology.  
Battery Size Selection: Given the wide variety of potential installations, the size of the battery bank  
used with the Prosine inverter/charger will vary greatly. Four DIP switches on the Prosine inverter/  
charger chassis can be set to indicate your battery capacity and allow the Prosine inverter/charger to  
deliver the charging requirements to match your battery capacity.  
Maximum AC Current (AC service setting): The Prosine inverter/charger has been designed so it  
does not overload the AC breaker to which it is connected. The Prosine inverter/charger measures the  
current it draws from the breaker and reduces charge current to prevent breaker overloading. Two DIP  
switches need to be configured on the Prosine inverter/charger to match your AC breaker.  
Battery Charging Times  
Charging time will depend on the capacity of your battery bank and on how deeply it is discharged.  
The following equation gives an approximate charging time:  
Charging time = CAP x DOD  
CC x 80  
where:  
Charging Time = Battery recharge time in hours  
CAP = Battery capacity in ampere-hours  
DOD = Battery depth of discharge in % (A fully discharged battery has 100% DOD)  
CC = Charge current, the current output of the charger in amps. (charge current  
depends on battery size and breaker size settings)  
Example for 12V model:  
The battery bank is made up of two 8D Group size batteries with a rated capacity of 200 amp/hours  
each. The bank is 80% discharged (i.e. DOD = 80). The approximate charging time with the Prosine  
inverter/charger will be:  
400 x 80 =4 hours  
100 x 80  
Operating Limits for Charger Operation  
Output Current: The maximum output current for the Prosine 2.5/12 is 100 amps and the Prosine  
3.0/12 can deliver 120 amps. The maximum output current for the 24V Prosine 2.5/24 is 50 amps and  
the Prosine 3.0/24 can deliver 60 amps. The total output can be reduced by changing the battery size  
or maximum AC input current (breaker) selection switches.  
Input Voltage: The wide input voltage range specification allows the Prosine inverter/charger to  
deliver a precise charge to your batteries even when incoming AC voltage is less than ideal. The  
Prosine inverter/charger maintains the correct charging voltage for your battery when the AC line  
voltage drops as low as 90VAC, or rises as high as 135VAC. A built in surge protector in the Prosine  
inverter/charger protects it, and your DC circuits, from surges and spikes on the AC power line.  
Prosine 2.5/3.0 Installation & Operation Guide  
63  
                         
Operating Limits for Charger Operation  
Battery Charging and Equalization Guide  
The following table lists several popular batteries by brand and type, and provides charging and  
equalization guidelines:  
Manufacturer  
Model  
Flooded/  
Gel  
Comments  
Trojan  
All deep  
cycle  
flooded  
Set to  
FLOODED  
Equalize on each charge cycle to reach and maintain  
maximum capacity. If 100% of capacity is not required,  
equalize less often to reduce maintenance and increase  
battery life.  
West Marine  
Delco  
All deep  
cycle  
flooded  
Set to  
FLOODED  
Equalize on each charge cycle to reach and maintain  
maximum capacity. If 100% of capacity is not required,  
equalize less often to reduce maintenance and increase  
battery life.  
Voyager  
Set to  
FLOODED  
This is a calcium/lead type battery and requires a higher  
charging voltage than normal. Though performance should  
be good, this battery will not reach full charge without  
equalization. Set temperature to “Cold” and/or equalize on  
every charge cycle to improve performance. Stop  
equalization/charging when green dot appears in battery  
hydrometer. Shake occasionally during equalizing (if  
possible to do so safely) to ensure adequate mixing of  
electrolyte at hydrometer.  
GNB  
EVolyte  
For Charge:  
GEL  
Set battery type to “Flooded” after battery reaches  
“Ready”. Since charging cycle of the Prosine inverter/  
charger does not match GNB’s recommended charge cycle  
the following routine can be followed every few charge  
cycles to maximize performance. Charge to “Ready” with  
battery type set to “Gel”. Set battery type to “Flooded” and  
equalize the battery for 45 minutes to 1 hour. Reset battery  
type to Gel and turn charger OFF and ON again to reset to  
Bulk charge mode. Battery will be ready in approximately  
10 minutes.  
Industrial  
For Float:  
FLOODED  
GNB  
SUNlyte For Charge:  
GEL  
Can be equalized on every charge cycle to reach and  
maintain maximum capacity. With battery type at Flooded,  
equalize for a maximum of 4 hours. Manually turn off  
equalize if charger does not terminate equalize after 4  
hours. This is the recommended charge routine for this  
battery as specified by GNB, but for convenience sake,  
this battery can be left on FLOODED for both charging  
and float operation with no apparent consequence.  
For Float:  
FLOODED  
GNB  
Action  
Pac  
Set to  
FLOODED  
Equalize every 1 to 2 months for heavy use, 4 to 6 months  
for light use. Battery is fully charged at a specific gravity  
of 1.265. If battery is not reaching full charge, equalize  
more often or set to “Cold” temperature setting when  
charging. “Warm” temperature setting (or optional remote  
sensor) must be selected when battery is at float.  
64  
Prosine 2.5/3.0 Installation & Operation Guide  
 
Section 6: Multistage Charging  
GNB  
Stow-  
away  
Set to  
Battery is fully charged at a specific gravity of 1.285. This  
FLOODED. is a calcium/lead type battery and requires a higher  
Set to Cold  
for all  
ambient  
temps  
charging voltage than normal. If performance is poor, this  
battery will likely need to be equalized on every charge  
cycle. It is very important to check electrolyte level  
regularly when equalizing on every charge cycle. Set  
battery size 20% lower than actual battery capacity.  
Motomaster  
Nautilus  
Set to  
Fully charged at a specific gravity of 1.265 - 1.280.  
FLOODED. Equalize on every charge cycle to maximize capacity and  
Temperature performance.  
switch  
should be  
set one  
setting  
higher.  
Hawker  
Energy/  
Gates  
Genesis  
Set to  
FLOODED  
Do not Equalize.  
Do not Equalize.  
Optima  
Yellow  
Top  
Set to GEL  
Johnson  
Controls  
Dynasty: Set to GEL  
Do not Equalize. The “Gel” setting should give you the  
best performance with your batteries. However, if you  
suspect your batteries need equalizing, charge them once  
using the “Flooded” setting. Set back to Gel when batteries  
return to “Ready”.  
Gel, GC  
Series,  
AGM,  
U131  
Sonnenshein  
West Marine  
Exide  
Prevailer Set to GEL  
Do not Equalize.  
SeaGel  
Set to GEL  
Set to  
Do not equalize.  
Marine/  
Deep  
Cycle/  
Golf  
Fully charged at a specific gravity of 1.265 - 1.280.  
FLOODED. Equalize on every charge cycle to maximize capacity and  
Temperature performance.  
switch  
Cart  
should be  
set one  
setting  
higher.  
Exide  
Gel  
Set to GEL  
Do not equalize.  
Ramcar  
Flooded  
Type  
Set to  
FLOODED  
This battery performs poorly with Xantrex charging  
products. Try setting to “Cold” for all ambient  
temperatures if battery does not charge. Try equalizing on  
every charge cycle. Full charge may take 2 or more  
equalization charge cycles.  
Prosine 2.5/3.0 Installation & Operation Guide  
65  
Operating Limits for Charger Operation  
66  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 7: Batteries  
This section of the manual is included to help you better understand the factors involved with battery  
charging, care, and maintenance, by discussing the physical make-up and characteristics of chemical  
storage batteries. This is not intended to be an exhaustive discussion of battery types, but simply a  
guideline. The manufacturer of each specific battery is the best authority as to its use and care.  
Batteries come in different sizes, types, amp-hours, voltages and chemistries. It is not possible here to  
discuss all aspects in detail. However, there are basic guidelines you can follow that will help in  
battery selection and ensure that your batteries are better maintained than the majority.  
Terminology  
A description of battery charger operation requires the use of terms with which you may not be  
familiar. The following terms appear in the description of batteries and battery charger operation.  
Electrolyte Typically a mixture of water and sulfuric acid, it is commonly referred to as battery acid.  
Plates Originally made of lead, now fabricated from lead oxide. Plates connect to the battery  
terminals and provide a structure for the chemicals that create current. There are several plates in each  
cell, each insulated from the other by separators.  
Sulfating As a battery discharges, its plates become covered with lead sulfate. During recharging,  
the lead sulfate leaves the plates and recombines with the electrolyte. If the lead sulfate remains on  
the plates for an extended period of time (over two months), it hardens, and recharging will not  
remove it. This reduces the effective plate area and the battery’s capacity. Equalization helps reduce  
sulfation on flooded batteries.  
Stratification Over time, a battery’s electrolyte (liquid) tends to separate. The electrolyte at the top  
of the battery becomes watery while at the bottom it becomes more acidic. This effect is corrosive to  
the plates. Equalization helps reduce stratification.  
Deep Cycle A deep cycle occurs when a battery is discharged to less than 50% of its capacity (50%  
depth-of-discharge). A deep cycle battery is one that is intended to be repeatedly, deeply discharged  
and charged.  
Temperature Compensation Optimal battery charging voltage is temperature dependent. As  
ambient temperatures fall, the proper voltage for each charge stage needs to be increased. A battery  
temperature sensor automatically re-scales charge-voltage settings to compensate for ambient  
temperatures. The compensation slope based on cell voltage is -2.17mv per degree Fahrenheit per cell  
(30mv per degree Celsius) for lead-acid batteries.  
Types  
There are two principal types of batteries: starting and deep-cycle. There are several different types of  
battery chemistries including flooded lead-acid, nickel-iron (NiFe), nickel-cadmium (NiCad),  
alkaline, and gel-cell just to name a few. Batteries are either sealed or vented. However, there are even  
different kinds of these batteries. This section explains some of the differences between the different  
lead acid batteries to help you choose a battery which best suits your needs.  
Prosine 2.5/3.0 Installation & Operation Guide  
67  
             
Types  
Your Prosine inverter/charger is designed to be used with deep-cycle, lead-acid batteries. These  
batteries are designed for deep discharge service where they will be repeatedly charged and  
discharged. This type of battery is often labeled as a marine, recreational vehicle, or golf cart battery.  
Xantrex recommends you use one or more of these batteries separated from the starting battery of  
your vehicle or boat with a battery isolator.  
Starting Batteries  
Starting batteries are designed for high cranking power, not deep discharge cycling. Do not use them  
with your inverter. They do not hurt the inverter but they simply will not last long in a deep-cycle  
application. The way they are rated should give a good indication of their intended use: “Cold  
Cranking Amps” is a measure of the amperage output of a starting battery.  
Starting batteries use lots of thin plates to maximize the surface area of the battery. This allows very  
high starting current but allows the plates to warp when the battery is cycled. The most familiar lead-  
acid battery is probably the starting battery in your automobile. An automotive starting battery is  
designed to deliver a large amount of current for a short period of time (so it can start your engine).  
Only a small portion of the battery’s capacity is used when starting the engine and it is quickly  
recharged by the running engine. It is not designed for repeated charge-discharge cycles where the  
battery is almost completely discharged and then recharged. Starting batteries used in this kind of deep  
discharge service will wear out rapidly.  
Deep-Cycle Batteries  
Deep-cycle batteries are best suited for use with inverters. They are designed to have the majority of  
their capacity used before being recharged. Available in many sizes and types, the most common type  
is the non-sealed, liquid electrolyte “flooded” battery used in boats and motor homes. Non-sealed  
types have removable battery caps. The caps should be removed at least monthly to check the level of  
electrolyte. When a cell is low, only distilled water should be added. The electrolyte level should be  
checked monthly and topped up if needed after recharging.  
The many different types of deep cycle lead acid batteries can be grouped into four categories: flooded  
(or wet), sealed flooded (“maintenance free”), recombinant flooded (often “starved electrolyte”), and  
gel batteries.  
Another popular and inexpensive battery of this type is the “golf car” (T-105 or CG220) battery. Rated  
at about 220 amp-hours, these six-volt batteries can be connected in series to produce 12- or 24-volt  
battery banks, and discharged repeatedly to 80% of their capacity without being damaged. This is the  
minimum quality of battery that should be used with the Prosine inverter in normal applications.  
Some systems use the L16 type of battery. These are 6-volt batteries rated at 350 amp-hours and are  
available from a number of manufacturers. They are 17 inches (430mm) in height and weigh up to 130  
pounds (60kg) each—which may be troublesome in some installations.  
Type 8D batteries are available in either cranking or deep-cycle construction. The deep-cycle versions  
are 12-volt batteries rated at 200 amp-hours or so. Since they are most commonly used to start truck  
engines, you should make sure you purchase the deep cycle version, not the cranking version. Type  
4D batteries are very similar in construction, but somewhat smaller (about 170Ah).  
68  
Prosine 2.5/3.0 Installation & Operation Guide  
         
Section 7: Batteries  
Sealed Gel Cell  
Another type of deep-cycle battery construction is the sealed gel-cell. They don’t use removable  
battery caps. The electrolyte is in the form of a gel rather than a liquid. The sealed construction allows  
the batteries to be mounted in any position without spilling. The advantages are no maintenance (to  
the battery itself—the system will still require routine maintenance), long life (800 cycles claimed)  
and low self-discharge. The disadvantages are high initial cost and the possibility of damage from  
overcharging.  
While there are many manufacturers of quality flooded batteries, there are only a few manufacturers  
of suitable gel-cells. Don’t confuse gel batteries with maintenance free batteries. The latter is typically  
a standard liquid electrolyte type battery without caps for adding water, and if the electrolyte gets low,  
you replace the battery.  
AGM (absorbed glass mat) batteries are similar to gel-cells and deep-cycle types may be used in  
inverter applications.  
Environment  
For long life and good performance, batteries need to be located in protected, ventilated enclosure  
insulated from extremes in temperature.  
Location  
Batteries should be located in an accessible location with access to the battery caps and terminals. At  
least six inches of clearance above is recommended. They must be located as close as possible to the  
inverter, but can not limit the access to the inverter and the inverter’s over-current protection device.  
Do not locate the inverter in the same space as the batteries, unless the batteries are of the sealed gel-  
cell type.  
Enclosures  
Batteries must be protected inside a ventilated enclosure. The enclosure should be ventilated to the  
outdoors from the highest point to prevent accumulation of hydrogen gasses released in the charging  
process. An air intake should also be provided at a low point in the enclosure to allow air to enter the  
enclosure to promote good ventilation.  
Temperature  
The effective capacity of a battery is reduced when cold. This phenomenon is more significant with  
lead-acid type batteries compared to alkaline types. When the internal temperature of a lead-acid  
battery is 32°F (0°C) the capacity can be reduced by as much as 50%. This effectively reduces the size  
of the system’s “gas tank”, requiring more frequent “refueling” by the charger. This should be  
considered when designing the system. If extremely cold temperatures are expected at the location of  
a system, a heated equipment room should be considered.  
If the system is located in an unheated space, an insulated enclosure is highly recommended for the  
batteries. During the charging process, the batteries release heat due to the internal resistance of the  
battery. If the batteries are insulated, the heat can be kept in the batteries to keep them warmer. This  
will substantially increase the performance of the system.  
Prosine 2.5/3.0 Installation & Operation Guide  
69  
                                         
Battery Bank Sizing  
Insulated battery enclosures also ensure that the temperatures of the individual battery cells are more  
consistent, preventing unequal charging which can cause battery failure (some cells will be  
overcharged while others are undercharged).  
The batteries should also be protected from high temperatures >20°C (70°F). High temperatures can  
be caused by high ambient temperatures, solar heating of the battery enclosure, or heat released by a  
closely located engine or generator. High battery temperatures result in short battery life and should  
be avoided by ventilating the enclosure and reducing the external heat sources by shading and  
insulation.  
Battery Bank Sizing  
Just as important as the type of battery selected for use with your Prosine inverter/charger is the  
battery size or capacity. The batteries are the most important part of your system, so we recommend  
you purchase as much battery capacity as possible. A large battery will extend running time and  
ensure your inverter/charger delivers full rated surge. Your inverter/charger can be configured to work  
with batteries from 50Ah (120 reserve minutes) to 2000Ah (4800 reserve minutes).  
There are a number of different standards for rating 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, either “amp-  
hours” (“Ah”) or “reserve capacity” in minutes. Battery reserve capacity is a measure of how long a  
battery can deliver a certain amount of current—usually 25 amps. For example, a battery with a  
reserve capacity of 180 minutes can deliver 25 amps for 180 minutes before it is completely  
discharged. Amp-hour capacity is a measure of how many amps a battery can deliver for a specified  
length of time—usually 20 hours. For example, a typical marine or RV battery rated for 100 amp-  
hours can deliver 5 amps for 20 hours (5 amps x 20 hours = 100 amp-hours). This same battery can  
deliver a higher or lower current for less or more time, limited approximately by the 100Ah figure  
(e.g., 50A for 2 hours, or 200A for 1/2 hour), but usually the capacity figure given is only accurate at  
the specified rate (20 hrs.)  
The minimum battery size you can use with the Prosine inverter/charger is 50Ah. However, you can  
expect performance to suffer with such a small battery. Even if your battery is in excellent shape and is  
fully charged, you will likely experience poor surge power performance and unsatisfactory operating  
time with anything but a small AC load. Xantrex recommends a minimum battery size of 200Ah for  
moderate loads (<1000W) and greater than 400 Ah for heavy loads.  
Estimating Battery Requirements  
To determine the proper battery bank size, it is necessary to compute the number of amp-hours that  
will be used between charging cycles. When the required amp-hours are known, size the batteries at  
approximately twice this amount. Doubling the expected amp-hour usage ensures that the batteries  
will not be overly discharged and extends battery life. To compute total amp-hours usage, the amp-  
hour requirements of each appliance that is to be used can be determined and then added together, or  
the watt-hours can be totaled and converted to amp-hours.  
Start with the nameplate ratings of your appliances. If the wattage is marked on the appliance, you can  
use that number directly; otherwise, multiply the marked voltage and amperage: WATTS = VOLTS X  
AMPS. Once the AC wattage drawn from the inverter is known, multiply that by the length of time the  
appliance will be used to determine the energy the load will require: WATT-HOURS = WATTS X  
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Prosine 2.5/3.0 Installation & Operation Guide  
                       
Section 7: Batteries  
HOURS. This can then be easily converted to an estimate of the battery amp-hours that the appliance  
requires:  
BATTERY AMP-HOURS USED = AC WATT-HOURS / 10 (for a 12-volt battery), or  
BATTERY AMP-HOURS USED = AC WATT-HOURS / 20 (for a 24-volt battery)  
For example, a 100W light bulb that is used for 4 hours will use 400 watt-hours (Wh) and the inverter  
will consume approximately 40Ah from a 12V battery, or 20Ah from a 24V battery.  
Another useful rule of thumb is that the current drawn from the battery can be estimated from the AC  
output watts by using these same factors (10 for 12V systems, 20 for 24V systems). For example,  
when running an 800W microwave oven, the inverter will draw approximately 800 divided by 10 =  
80A from a 12V battery.  
Motors are normally marked with their running current rather than their starting current. Starting  
current may be three to six times running current. The manufacturer’s literature may provide more  
accurate information than the motor nameplate. If large motors will be started, you may need increase  
the battery size to allow for the high start-up demand.  
Battery Bank Sizing Example & Worksheet  
The following battery sizing example illustrates a typical calculation, assuming an opportunity to  
charge the batteries every three days:  
Table 3: Battery Sizing Example  
Appliance  
(A)  
(B)  
Daily watt-  
hours needed  
for this  
Power  
Consumption  
Operating Time per  
day  
appliance  
( = A x B )  
400 Wh  
200 Wh  
720 Wh  
150 Wh  
150 Wh  
1620 Wh  
3
TV & VCR  
Small microwave oven  
3 lamps, 60W each  
Coffee maker  
200 W  
800 W  
180 W  
600 W  
1500W  
2 hours  
15 mins = 1/4 hour  
4 hours  
15 mins = 1/4 hour  
6 mins = 1/10 hour  
Hair dryer  
Total Daily Watt hours of AC load:  
x Number of Days between charges:  
= Total Watt hours of AC load between charges:  
Battery Ah used between charges  
4860 Wh  
486 Ah  
(divide by 10 for 12V system, divide by 20 for 24V 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 re-  
charge more frequently.  
Prosine 2.5/3.0 Installation & Operation Guide  
71  
       
Estimating Battery Requirements  
When sizing your battery, be conservative, and resist the temptation to skip the last (multiply by 2)  
step of this calculation. 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.  
As your power requirements increase, you may need to use more than one battery to obtain sufficient  
capacity. Batteries can be connected in parallel or series to create higher capacity systems. It is not  
recommended to connect batteries from different manufacturers, different types, or that have different  
amp-hour ratings in parallel. Improper charging and decreased battery life will result. See “Cabling &  
Hook-up Configurations‚” on page 75 for more information on battery inter-connection schemes.  
The following worksheet is provided as a guide for determining your battery needs. Be generous in  
estimating the time for which you will run each of the loads to ensure sufficient battery capacity.  
Table 4: Battery Sizing Worksheet  
Appliance  
(A)  
(B)  
Daily watt-  
hours needed  
for this  
Power  
Operating  
appliance  
Consumption  
Time per day  
( = A x B )  
Wh  
W
W
W
W
W
W
W
W
W
W
W
W
hours  
hours  
hours  
hours  
hours  
hours  
hours  
hours  
hours  
hours  
hours  
hours  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Wh  
Total Daily Watt hours of AC load:  
x Number of Days between charges:  
Wh  
= Total Watt hours of AC load between charges:  
Battery Ah used between charges  
Wh  
Ah  
(divide by 10 for 12V system, divide by 20 for 24V system)  
Recommended Battery Bank Size in Ah (multiply by 2)  
Ah  
72  
Prosine 2.5/3.0 Installation & Operation Guide  
Section 7: Batteries  
Monthly Battery Maintenance  
WARNING Wear appropriate attire and eye protection. Use caution when working with metal tools  
around batteries. Do not allow any metal object to come into contact with both battery terminals at the  
same time. Battery explosion or failure can occur.  
At a minimum, check the level of the electrolyte in each battery cell once a month (for non-sealed  
batteries). It should be above the top of the plates, but not completely full. Most batteries have a  
plastic cup that, when full, just touches the electrolyte. Don’t overfill the batteries or the electrolyte  
will spill out of the batteries when they are being charged. Refill the batteries with distilled water  
only— “spring” water and regular tap water may have high levels of minerals that can poison the  
battery chemistry and reduce battery life.  
It is also good to periodically check the battery connections for tightness and corrosion. If any  
corrosion is found, disconnect power from the Prosine, disconnect the cables, and carefully clean with  
a mild solution of baking soda and water. Do not allow the solution to enter the battery. Rinse the top  
of the battery with clean water when finished.  
To reduce the amount of corrosion on the battery terminals, after reassembly, coat them with anti-  
corrosion grease or liquid neoprene (liquid electrical tape) available from automotive parts stores or  
battery suppliers. Do not apply anything between the terminal and the cable lugs. The connection  
should be metal to metal. Apply the protective material only after the bolts have been tightened.  
Cleaning Batteries  
Dirty batteries may leak current, and tend to run warmer. Cleaning the batteries, when necessary, is  
easy and safe when the instructions presented here are followed.  
Preparation  
You will need appropriate attire, a few tools, and some equipment and supplies on hand. Read over the  
list and gather what you need before you begin.  
WARNING Wear appropriate attire and eye protection.  
Attire  
Appropriate attire might include old clothes, rubber boots or old shoes. Battery acid is very corrosive  
and will dissolve most textiles within a few days after exposure, so wear something you can live  
without just in case you splash some on yourself. Be sure to wear rubber gloves and eye protection.  
Tools  
½-inch and/or 9/16 wrench as required, or an equivalent socket and ratchet  
adjustable and/or locking pliers  
torque wrench (suggested, not required)  
soft-bristled brush (discarded toothbrushes work just fine)  
6-inch scrub brush  
inexpensive ½ inch chip brush or soldering brush  
Prosine 2.5/3.0 Installation & Operation Guide  
73  
                     
Monthly Battery Maintenance  
Equipment  
Water hose with spray nozzle or 5-gallon watering bucket  
Empty spray bottle  
Old clothing  
Eye protection  
Rubber gloves  
Supplies  
Baking soda (always keep a supply on hand in the event of a spill)  
Water  
Hand cleaner or soap  
Towel  
After re-attaching cables only: liquid neoprene or white lithium grease (available at auto,  
RV, and marine stores)  
Procedure  
Battery Enclosure and Batteries Mix four ounces of baking soda with a gallon of fresh water  
and fill a spray bottle. Spray solution on all exposed surfaces of the battery compartment and wash  
down the exposed surfaces of the batteries and their enclosure. Scrub stubborn areas. Baking soda will  
neutralize any acid that may have collected on these surfaces. Finish by rinsing with water.  
Terminals & Lugs Loose battery terminals and lugs exposed to open air corrode rapidly. The  
corrosion appears as a white powder or granular foam on the terminals and any nearby exposed metal  
parts. This is actually crystallized sulfuric acid, which is extremely corrosive. If it contacts your skin,  
it will burn unless you rinse it off immediately. Most textiles that are exposed to this corrosive  
eventually dissolve.  
The most common cause of battery system failure is loose or corroded battery terminals and cable  
lugs. If any white residue forms between the battery cable lug and the battery terminal, remove the  
cable for cleaning. When you need to detach a battery cable, disconnect all loads and charging  
sources. Using the appropriate tool, remove the Negative battery cable first and install it last.  
Use a toothbrush (or other soft bristle brush) and baking soda to remove any stubborn residue.  
Sprinkle the baking soda directly on the area and scrub with a wet toothbrush, adding water as  
required, then rinse.  
Reconnect the battery cable terminals to the battery lugs and tighten to the torque specified by the  
battery or terminal lug manufacturer. If you do not have a torque wrench, use the appropriate tool to  
tighten the bolts reasonably snug. Do not over-tighten.  
After tightening the cables, evenly coat all the exposed metal surfaces of the battery terminals and  
lugs with liquid neoprene, which will cure to form an airtight protective layer. If liquid neoprene is not  
available, use a light coating of white lithium grease or other sealant. Don’t let anything come  
between the mating surfaces of the lugs and terminals.  
74  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Section 7: Batteries  
Cables  
Inspect all battery cables for missing or damaged insulation or loose connections. Inspect any  
openings through which the cables pass. Ensure that all such openings are equipped with a rubber  
grommet or conduit to prevent chafing the cable. If necessary, replace worn grommets. If the cable  
insulation is worn, replace the cable.  
Cabling & Hook-up Configurations  
It is possible to connect individual batteries together to make a larger battery “bank” with heavy  
cables. The actual size of the cable depends upon whether the batteries are connected in parallel or  
series. Generally, the cables 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 both in series and parallel—a configuration often  
called “cross-tying”. This requires additional cables but reduces imbalances in the battery and can  
improve the overall performance. Consult your battery supplier for more information regarding the  
hook-up configuration required for your system.  
Connect several smaller batteries together when creating a battery bank of substantial size. There are  
three ways to do this. Batteries can be connected in parallel series or series—parallel and cross-tied.  
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 amp/hour rating equal to the sum of the  
individual batteries.  
12V  
50 Ah  
12V  
50 Ah  
12V  
50 Ah  
12V  
50 Ah  
FUSED  
DISCONNECT  
12V  
(Total Battery Capacity  
= 200 Amp Hours)  
Prosine 2.5/3.0 Installation & Operation Guide  
75  
         
Cabling & Hook-up Configurations  
Series Connection  
When batteries are connected with the positive terminal of one to the negative terminal of the next,  
they are connected in series. In a series configuration, the battery bank has the same amp/hour rating  
of a single battery, but an overall voltage equal to the sum of the individual batteries.  
6V  
100 Ah  
6V  
100 Ah  
FUSED  
DISCONNECT  
12V  
(Total Battery Capacity  
= 100 Amp Hours)  
6V  
100 Ah  
6V  
6V  
6V  
100 Ah  
100 Ah  
100 Ah  
FUSED  
DISCONNECT  
24V  
(Total Battery Capacity  
= 100 Amp Hours)  
76  
Prosine 2.5/3.0 Installation & Operation Guide  
   
Section 7: Batteries  
Series – Parallel Connection  
As the name implies, both the series and parallel techniques are used in combination. The result is an  
increase in both the voltage and the capacity of the total battery bank. This is done very often to make  
a larger, higher voltage battery bank out of several smaller, lower voltage batteries. This is common  
with all battery-inverter system voltages. The smaller, lower voltage batteries are first connected in  
series to obtain the needed voltage, and then these “batteries, connected in series” sets are connected  
in parallel to increase the battery bank capacity.  
The best arrangement when using a series-parallel configuration is to connect all the smaller, lower  
voltage batteries in parallel, then connect all these “batteries in parallel” into series sets to obtain the  
needed voltage. This configuration is often called “cross-tying.” This is less convenient and requires  
additional cables but reduces imbalances in the battery, can improve the overall performance.  
Cross-tying (shown as dashed -------- lines in the illustration below) helps equalize the voltage in the  
batteries. If cross-tying is not desired, the dash lines can be ignored.  
6V  
100 Ah  
6V  
100 Ah  
6V  
100 Ah  
6V  
100 Ah  
FUSED  
DISCONNECT  
12V  
(Total Battery Capacity  
= 200 Amp Hours)  
6V  
100 Ah  
6V  
100 Ah  
6V  
6V  
100 Ah  
100 Ah  
6V  
6V  
6V  
100 Ah  
6V  
100 Ah  
100 Ah  
100 Ah  
FUSED  
DISCONNECT  
24V  
(Total Battery Capacity  
= 200 Amp Hours)  
Prosine 2.5/3.0 Installation & Operation Guide  
77  
   
Cabling & Hook-up Configurations  
78  
Prosine 2.5/3.0 Installation & Operation Guide  
Appendix A: Specifications  
Prosine 2.5 12-volt;  
Prosine 3.0 12-volt;  
INVERTER  
(24-volt in parenthesis)  
(24-volt in parenthesis)  
Continuous output power /  
current  
2500W / 21A RMS  
3000W / 25A RMS  
Surge rating (5 seconds)  
Peak output current  
4000W  
50A  
4000W  
50A  
Peak inverter efficiency  
88%  
88%  
No load current draw, in load  
sense mode  
<3W  
<3W  
Idle circuit adj. load sensing  
OFF, 10W, 25W, 50W [dip  
switches]  
OFF, 10W, 25W, 50W [dip  
switches]  
No load current draw, inverter 60W  
idle  
60W  
Output frequency  
60Hz ± 0.05% (crystal con-  
trolled)  
60Hz ± 0.05% (crystal con-  
trolled)  
Output waveform  
Sine wave <5%THD  
10-16Vdc (20-32Vdc)  
120Vac RMS ± 3%  
120Vac RMS -10% / +4%  
Sine wave <5%THD  
10-16Vdc (20-32Vdc)  
120Vac RMS ± 3%  
Input voltage range  
Output voltage (at no load)  
Output voltage (over full load  
& battery voltage range)  
120Vac RMS -10% / +4%  
Low Battery Cut-out  
10Vdc, 10.5Vdc warning  
(20Vdc, 21Vdc warning)  
10Vdc, 10.5Vdc warning  
(20Vdc, 21Vdc warning)  
High Battery Cut out  
Protection  
16Vdc (32Vdc)  
16Vdc (32Vdc)  
Automatic overload, short cir-  
cuit, overtemperature  
Automatic overload, short cir-  
cuit, overtemperature  
Reverse polarity (fuse)  
Reverse polarity (fuse)  
CHARGER  
Battery capacity selections  
50, 75, 100, 150, 200, 300,  
50, 75, 100, 150, 200, 300,  
400, 500, 600, 700, 800, 1000, 400, 500, 600, 700, 800, 1000,  
1200, 1400, 1700, >2000  
1200, 1400, 1700, >2000  
Charge Rate 12V (24V)  
Charger Power Factor Rating  
Charger Efficiency  
100A (50A)  
120A (60A)  
.99  
.99  
> 80%  
> 80%  
Charge banks  
1 high current  
1 high current  
Charge control  
3-stage with manual equalize  
3 settings or optional sensor  
flooded/gel  
3-stage with manual equalize  
3 settings or optional sensor  
flooded/gel  
Temperature compensation  
Electrolyte compensation  
Input voltage range  
90-135 Vac  
90-135 Vac  
AC service setting [max. cur-  
rent draw]  
10 [8], 15 [12], 20 [16] , 30 [24] 10 [8], 15 [12], 20 [16] , 30 [24]  
amps  
amps  
Transfer Relay rating  
30A  
30A  
Prosine 2.5/3.0 Installation & Operation Guide  
79  
   
Prosine 2.5 12-volt;  
(24-volt in parenthesis)  
Prosine 3.0 12-volt;  
(24-volt in parenthesis)  
GENERAL  
Transfer Time Inverter to AC  
zero seconds, [8 second  
delay]  
zero seconds, [8 second  
delay]  
Transfer Time AC to Inverter  
(including detect time)  
20 milliseconds  
20 milliseconds  
Regulatory Approvals  
CSA/NRTL approved to CSA  
107.1, UL 458 and UL 1741,  
FCC Class A  
CSA/NRTL approved to CSA  
107.1, UL 458 and UL 1741,  
FCC Class A  
Dimensions (L x W x H)  
20” x 15” x 5.5”, 508mm x  
381mm x 140mm  
20” x 15” x 7.0”, 508mm x  
381mm x 178mm  
Weight  
32 lbs, 14.5 kg  
32 lbs, 14.5 kg  
Operating Temperature  
Range (power derating above 0-50°C Charger mode  
25°C)  
0-60°C Inverter mode,  
0-60°C Inverter mode,  
0-50°C Charger mode  
Storage Temperature Range  
-30°C to 70°C  
-30°C to 70°C  
Charger Output Voltages  
Absorption / Float Voltage  
(Volts)  
Cold  
Warm  
Hot  
Flooded  
Gel  
14.8 / 13.9  
14.6 / 14.2  
14.4 / 13.5  
14.4 / 13.8  
14.0 / 13.1  
13.8 / 13.4  
80  
Prosine 2.5/3.0 Installation & Operation Guide  
   
Appendix A: Specifications  
Prosine 2.5/3.0 Chassis Dimensions  
Prosine 2.5/3.0 Installation & Operation Guide  
81  
     
Prosine 2.5/3.0 Chassis Dimensions with Brackets  
82  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Appendix A: Specifications  
Prosine 2.5 Efficiency Curve  
Prosine 2.5 Efficiency  
120Vac, 12Vdc model  
90.0  
89.0  
88.0  
87.0  
86.0  
85.0  
84.0  
83.0  
82.0  
81.0  
80.0  
Eff. @ 13.0V  
Eff. @ 12.5V  
Eff. @ 12.0V  
Eff. @ 11.5V  
Eff. @ 10.5V  
500  
1000  
1500  
2000  
2500  
3000  
Output Power (Watts)  
Prosine Over-Current Shutdown Response  
Prosine Output Protection  
PS2.5  
PS3.0  
10000.0  
1000.0  
100.0  
10.0  
1.0  
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50  
Output current (Amps)  
Prosine 2.5/3.0 Installation & Operation Guide  
83  
84  
Prosine 2.5/3.0 Installation & Operation Guide  
Appendix B: Inverter Applications  
AC loads on the inverter differ in the way they perform. There are different types of loads: resistive  
loads, inductive loads, and problem loads.  
Resistive Loads  
These are the loads that the inverter finds the simplest and most efficient to drive. Voltage and current  
are in phase, or, in this case, in step with one another. Resistive loads usually generate heat in order to  
accomplish their tasks. Toasters, coffee pots and incandescent lights are typical resistive loads. Larger  
resistive loads—such as electric stoves and water heaters—are usually impractical to run off an  
inverter due to their high current requirements. Even though the inverter can most likely  
accommodate the load, the size of battery bank required would be impractical.  
Inductive Loads  
Any device that has a coil of wire in it probably has an inductive load characteristic. Most electronics  
have transformers (TVs, stereos, etc.) and are therefore inductive. Typically, the most inductive loads  
are motors. The most difficult load for the inverter to drive will be the largest motor it manages to  
start. With inductive loads, the rise in voltage applied to the load is not accompanied by a  
simultaneous rise in current. The current is delayed. The length of the delay is a measure of  
inductance. The current makes up for its slow start by continuing to flow after the inverter stops  
delivering a voltage signal. How the inverter handles current that is delivered to it while it is  
essentially “turned off”, affects its efficiency and “friendliness” with inductive loads. The best place  
for this out-of-phase current is in the load. Inductive loads, by their nature, require more current to  
operate than a resistive load of the same wattage rating, regardless of whether power is being supplied  
by an inverter, a generator, or utility power (the grid).  
Induction motors (motors without brushes) require two to six times their running current on start-up.  
The most demanding are those that start under load, e.g., compressors and pumps. Of the capacitor  
start motors (typical in drill presses, band saws, etc.), the largest you may expect to run is ½ to 1 hp  
(depending on inverter size and surge power capability). Universal motors are generally easier to start.  
Since motor characteristics vary, only testing will determine if a specific load can be started and how  
long it can be run.  
If a motor fails to start within a few seconds, or it begins to lose 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, it will  
turn itself off after about 10 seconds.  
Problem Loads in Load Sense  
Very small loads - If the power consumed by a device is less than the threshold of the load sense  
circuitry, it will not run. See “Load Sense” information in “Section 3: Configuration” (page 25 and  
following) for ways to solve this problem. Most likely the solution will be to defeat the load sense  
feature.  
Fluorescent lights & power supplies - Some devices when scanned by load sense circuitry cannot be  
detected. Small fluorescent lights are the most common example. (Try altering the plug polarity by  
turning the plug over). Some computers and sophisticated electronics have power supplies that do not  
Prosine 2.5/3.0 Installation & Operation Guide  
85  
                                                                 
Problem Loads in Load Sense  
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 must be used to bring the inverter out of its search  
mode, or the inverter may be programmed to remain at full output voltage by defeating the search  
mode feature. See “Section 3: Configuration” (page 25 and following).  
Clocks- The inverter’s crystal controlled oscillator keeps the frequency accurate to within a few  
seconds a day. Most clocks do not draw enough power to trigger the load sensing circuit. In order to  
operate without other loads present, the load sensing will have to be defeated. See “Load Sense”  
information in “Section 3: Configuration” (page 25 and following). Clock accuracy is also affected by  
the accuracy of the generator. The best solution is to buy a battery-operated clock, or a clock that is not  
dependent on line frequency or voltage. Any clock with a crystal controlled oscillator will probably  
work just fine.  
Searching- If the amount of power a load draws decreases after it turns on, and if this “on” load is less  
than the load sensing threshold, it will be turned alternately on and off by the inverter. Incandescent  
light bulbs may present this problem when the search threshold is set near the wattage rating of the  
bulb.  
Other Problem Loads  
Electronics- AM radios may pick up noise, especially on the lower portion of their band. Inexpensive  
tape recorders are likely to pick up a buzz.  
Computers - Computers may crash if large loads are started while the inverter is operating. The  
inverter output voltage may fall briefly, allowing computers to fall. Large motors may generate  
voltage spikes that are not completely suppressed by the inverter's internal voltage transient  
suppression circuit.  
86  
Prosine 2.5/3.0 Installation & Operation Guide  
                   
Appendix C: Troubleshooting  
What to do if a problem occurs  
This section may help you narrow down the source of any problem you may encounter. Before  
contacting Xantrex, please work through the steps listed below.  
WARNING: Shock and energy hazards. Some of the troubleshooting solutions below require  
knowledge of electrical principles, servicing, and the hazards involved. Refer service to a qualified  
electrician or technician.  
1. Check for an Error Code display (see “Error Code Displays and What They Mean‚” on page 88). If  
a code is displayed, record its number before doing anything further.  
2. As soon as possible, record the conditions at the time the problem occurred, in the event you need  
to contact Xantrex. These details should include:  
Serial number of the unit  
Make or model of batteries  
Wiring diagram with all devices  
Grounding information  
Equipment or loads the Prosine was running or attempting to run  
Battery condition at the time (voltage, state of charge), if known  
Recent sequence of events (for example, charging had just finished, we disconnected shore-  
power as we were preparing to leave the dock, but the inverter didn’t come on, and so on.)  
Any known unusual AC shorepower factors—low voltage, unstable generator output, etc.  
Any extreme ambient conditions existing at the time (temperature, vibrations, moisture, etc.)  
3. Attempt the solution indicated in the “Error Code Table‚” on page 89 for the indicated error code  
(if any).  
4. If you see an error code of 000 it means that no errors were detected. Check the following  
conditions to make sure the present state of the installation allows proper operation of the unit (refer to  
details elsewhere in this manual):  
Is the inverter located in a clean, dry, adequately ventilated location?  
Are the battery cables the right size and length for your installation? (See “Recommended DC  
Is the battery in good condition?  
Are the AC input and output connections and wiring in good shape?  
Are the DIP switch and/or ACS settings correctly configured for your particular installation?  
Is the Display Panel and/or ACS cable properly connected and undamaged?  
Is the Bypass/On switch on?  
If any of these conditions are not met, look through the “Possible Cause” column of the Error Code  
table below for similar conditions, and consider attempting the indicated solution.  
5. Contact Xantrex for further assistance. Please be prepared to describe details of your system  
installation and to provide the model and serial number of the unit.  
Prosine 2.5/3.0 Installation & Operation Guide  
87  
     
Error Code Displays and What They Mean  
Error Code Displays and What They Mean  
Many types of faults are recognized by the Prosine inverter/charger. Should a recognized fault occur,  
the fault LED will illuminate and an error code will be displayed. These error codes will override any  
other menu items being displayed. The way in which this is done is different for the Standard Control  
Panel and the Advanced Control System (ACS).  
Control Panel  
When the WARNING, FAULT, or TEMP LED is on, try to find what is causing the fault condition by  
following these steps:  
1. Press and hold the RESET button to display the error. It takes about five seconds before the code  
displays.  
2. Note the LEDs that illuminate to determine the 3-digit fault code, as in the example below.  
3. Look up the error code in the Error Code Table to assist in troubleshooting the fault condition.  
While the RESET button is pressed, the 3-digit number is displayed as follows:  
1. The first digit is shown in the FAULT section, TEMP = 0, FAULT = 1, WARNING = 2.  
2. The second digit is shown on the DC VOLTS bar graph, the bottom LED = 0, the second lowest  
LED = 1, and so on to the top LED = 9.  
3. The third digit is shown on the DC AMPS bar graph, the bottom LED= 0, the second lowest LED=  
1, and so on to the top LED = 9.  
When none of the FAULTS lights are on, pressing and holding the RESET switch will display the last  
recorded fault.  
Advanced Control System (ACS)  
Should a fault occur, the Fault LED will illuminate and an error code will be displayed in the LCD.  
The error code display will override any other menu items being displayed.  
88  
Prosine 2.5/3.0 Installation & Operation Guide  
     
Appendix C: Troubleshooting  
Error Code Table  
The following table lists the error codes, likely causes, and suggested solutions.  
Error  
Code  
Description of Fault  
Possible Cause  
Solution  
No faults detected since the  
Prosine was turned on.  
000, 255 No Fault recorded  
001  
A. Battery Temperature is  
1. Room temperature around  
the batteries is too high or  
too low.  
1. Keep the temperature  
around batteries moder-  
ate. In cold weather, try a  
battery heating blanket.  
In warm weather, try  
too high or too low. (This  
code only applies if the  
external battery tempera-  
ture sensor is connected)  
improving the ventilation.  
2. For flooded batteries,  
check the electrolyte level  
and top up with distilled  
water if necessary. Check  
the tightness of all con-  
nections. If the condition  
persists, the battery may  
be faulty and need  
2. Battery heating (battery or  
battery terminals are  
warmer than room tempera-  
ture  
replacement.  
3. Faulty connection of battery  
temperature probe.  
3. Check connections and  
make sure probe is in  
good thermal contact with  
battery. Probe may  
require replacement.  
B. If there is no external  
battery temperature sen-  
sor, there may be a wiring  
fault inside the unit.  
B. Damage has likely  
occurred during shipping or  
there has been extreme  
shock or vibration.  
B. Record the error code  
and contact Xantrex.  
Prosine 2.5/3.0 Installation & Operation Guide  
89  
 
Error Code Table  
Error  
Code  
Description of Fault  
Possible Cause  
Solution  
002  
Battery Voltage is too low  
1. Discharged battery.  
2. Old or faulty battery.  
1. Charge battery.  
2. Battery may not be hold-  
ing charge properly. If  
flooded, check electro-  
lyte level and fill with dis-  
tilled water if necessary.  
Equalization may help if  
recommended by the bat-  
tery manufacturer. Battery  
may be faulty and require  
replacement.  
3. Check cable size and  
length against recom-  
mendations in this man-  
ual. Check and tighten all  
connections. Large loads  
may draw the voltage  
down very quickly on a  
small battery or in an  
installation with cables  
that are too small or too  
long.  
3. Battery cables to the Pros-  
ine inverter/charger are too  
small, too long, or there is a  
loose connection.  
003  
Battery Voltage is too high.  
1. External charger or alterna- 1. Correct or disconnect the  
tor has output voltage  
greater than 16 V.  
external charging source.  
2. Make sure the battery  
bank is nominal 12V for a  
12v Prosine.  
2. A 12V Prosine inverter/  
charger could be connected  
to a 24V battery (two batter-  
ies in series).  
006,065  
Microprocessor communi-  
cation error.  
Remote display cable is  
pinched or has loose connec-  
tion.  
Check display cable con-  
nections and attempt  
restart. If the problem per-  
sists, try a replacement  
cable.  
If the problem persists, call  
Xantrex.  
90  
Prosine 2.5/3.0 Installation & Operation Guide  
Appendix C: Troubleshooting  
Error  
Code  
Description of Fault  
Possible Cause  
Solution  
008-015  
Ambient temperatures or  
internal component temper- is too high.  
atures are too high or too  
low.  
1. Power required by AC load  
1. Reduce AC load to spec-  
ified limits. Reduce AC load  
below rated maximum if  
room temperature is above  
25ºC / 77ºF. See tempera-  
ture de-rating curve in  
Owner’s Manual.  
2. Allow more room for air  
circulation around unit.  
3. Allow more ventilation in  
compartment.  
4. In extremely cold cli-  
mates (below freezing), a  
heated room may be  
required  
2. Blocked ventilation.  
3. Room temperature too high  
4. Room temperature too low.  
064  
066  
AC Output Overcurrent  
Communication Fault  
Temporary AC output over-  
load. The higher the output  
current, the faster the unit will  
shut down (minimum 2 sec-  
onds).  
Reduce AC load so that  
even for short times, the  
AC output current does not  
exceed 26 A. See Overcur-  
rent Protection curve in this  
manual.  
1. Faulty cable between Pros- 1. Check display cable con-  
ine and remote panel.  
nections and attempt  
restart. If problem persists,  
try a replacement cable. If  
problem still persists, call  
Xantrex.  
2. Internal Fault  
2. Record the error code  
and contact Xantrex.  
129-134  
135  
Internal fault  
Various. There could be a  
fault inside the unit or the  
microprocessor is fooled by  
some external condition.  
Record the error code and  
contact Xantrex.  
Battery voltage stays low in  
charge mode  
24 VDC model connected to a Correct the battery wiring or  
12 V battery or a 12 VDC  
model is connected to a 6 V  
battery  
replace Prosine with differ-  
ent battery nominal Dc volt-  
age.  
136,192- Internal fault  
194  
Various. There could be a  
fault inside the unit or the  
microprocessor is fooled by  
some external condition.  
Record the error code and  
contact Xantrex.  
Prosine 2.5/3.0 Installation & Operation Guide  
91  
Error Code Table  
Error  
Code  
Description of Fault  
Possible Cause  
Solution  
195  
Internal DC bus voltage is  
low in Charge mode  
1 There may be a hot to  
ground wiring error. A mis-  
take made in AC wiring  
caused internal traces to  
open. Shoring the AC line to  
the chassis ground occasion-  
ally causes damage espe-  
cially if supplied from a 50 A  
service with a short cord.  
2 Internal fault  
1. Contact Xantrex and  
return unit for repair.  
2. Record the error code  
and contact Xantrex.  
196  
197  
Internal fault  
Various. There could be a  
fault inside the unit or the  
microprocessor is fooled by  
some external condition.  
Record the error code and  
contact Xantrex.  
Unexpected AC output volt- AC Input Line and Neutral are  
age  
Check AC Input wiring.  
There should be less than  
5V RMS between AC Input  
Neutral and Earth Ground.  
If you measure higher volt-  
age from neutral to ground,  
then the AC shorepower  
source likely has reversed  
polarity and requires cor-  
rection.  
reversed.  
Long and/or loose connec-  
tions to the utility/shore-  
power can result in a high  
neutral voltage as well.  
Check connections and  
repair as necessary.  
198-201  
Internal fault  
Various. There could be a  
fault inside the unit or the  
microprocessor is fooled by  
some external condition.  
Record the error code and  
contact Xantrex.  
202,203  
204  
Relay Contact Fault  
One of the relay contacts is  
stuck in the closed position.  
Record the error code and  
contact Xantrex.  
AC Input Neutral Warning  
AC Input Neutral voltage is  
greater than 10 V with respect  
to Earth Ground.  
See Fault Code 197.  
205  
Internal fault  
Various. There could be a  
fault inside the unit or the  
microprocessor is fooled by  
some external condition.  
Record the error code and  
contact Xantrex.  
92  
Prosine 2.5/3.0 Installation & Operation Guide  
Appendix C: Troubleshooting  
Error  
Code  
Description of Fault  
Possible Cause  
Solution  
206  
AC Output voltage too high  
1. Some loads, like motors,  
can feed power back into  
the output of the Prosine.  
This may result in a tempo-  
rary over-voltage which  
may trigger a fault condi-  
tion.  
1. Try resetting the unit and  
running the load again.  
Contact Xantrex if you  
find consistent incompati-  
bility with a certain type of  
load.  
2. Record the error code  
and contact Xantrex.  
2. There is an internal hard-  
ware or software fault.  
207  
Internal DC Bus voltage is  
low in invert mode.  
1. Temporary condition  
caused by low battery volt-  
age in conjunction with an  
overload condition.  
1. Check if battery is OK  
(see error code 002). Dis-  
connect AC and DC  
power to the Prosine.  
Reconnect DC and AC  
power after 15 minutes. If  
the problem persists, con-  
tact Xantrex.  
2. Record the error code  
and contact Xantrex.  
2. Internal Fault.  
Prosine 2.5/3.0 Installation & Operation Guide  
93  
Error Code Table  
94  
Prosine 2.5/3.0 Installation & Operation Guide  
Index  
ACS menus, 14  
A
AC Information menu, 15, 29  
Battery Information menu, 16, 30  
Charger Information menu, 17, 33  
Inverter Information menu, 16, 32  
Version Information menu, 19  
System Information menu, 18, 35  
adjustable charger mode settings, 62  
AGM batteries, 69  
absorption charge  
defined, 59  
AC (shorepower) configuration, 29  
AC bonding, 45  
AC cabling, 40, 45  
AC circuit breakers, 45  
AC disconnect and overload device, 40  
AC disconnect and overload protection, 45  
AC distribution center, 40  
AC fuse, 40  
alkaline batteries, 69  
Amp-hour capacity, 70  
amp-hour capacity, 30  
AC grounding, 45  
audible alarm, 3  
AC information, 15  
AC Information menu, 15, 29  
Breaker Size, 15  
configuring, 18, 25, 27  
disabling, 35  
enabling, 35  
AC Input  
automatic transfer switch, 2  
automatic waveform regulation, 2  
AWG, 75  
circuit breaker, 45  
AC input current  
maximum, 2  
AC Output  
circuit breaker, 45  
B
AC service rating, 25  
setting, 27  
backlight for LCD display, 12  
band saw, 85  
AC service setting, 63  
AC terminal block, 6  
illustrated, 5, 38  
BATT TEMP jack, 5  
batteries  
AGM (absorbed glass mat), 69  
alkaline, 69  
AC terminals  
location, 6  
cleaning, 73  
AC wire size, 45  
deep-cycle, 68  
depth of discharge, 63  
gel-cell, 30, 69  
lead-acid, 30, 69  
parallel connection, 75  
precautions when working with, ii  
sealed, 61  
accessory jacks, 5  
ACS control panel, 12  
battery status display, 14  
Charger status indicator, 21  
dimensions, 22  
illustrated, 12  
installation procedure, 22  
liquid crystal display, 13  
menu navigation procedure, 14  
menu structure, 14  
Power indicator, 21  
used to configure inverter/charger, 28  
series connection, 76  
series—parallel connection, 77  
battery  
enclosures, 69  
selecting type, 26, 30, 55  
suitable location, 69  
95  
Index  
battery Amp-hour capacity, 70  
battery bank sizing, 70  
battery capacity, 30, 70  
battery configuration, 30  
battery current indicator, 8  
Battery Information menu, 16, 30  
battery requirements, estimating, 70  
battery reserve capacity, 70  
battery size  
charging profile, 59  
calculating, 63  
chassis ground, 49  
described, 6  
illustrated, 6  
circuit breakers  
AC, 40, 45  
DC, 41  
minimum, 70  
setting, 25, 27, 30, 63  
Battery status display (ACS control panel), 14  
Battery Temp jack, 51  
battery temperature, 69  
setting, 25, 26, 30  
battery temperature sensor, 49  
attaching to battery terminal, 50  
attaching to side of battery, 51  
cable, 51  
cleaning batteries, 73  
accuracy, 86  
battery-operated, 86  
compressors, 85  
conduit, 45  
configuration. See DIP switch settings or ACS  
menus.  
battery temperature sensor jack, 5  
battery temperature shut down, 2  
battery type  
control buttons (ACS control panel), 13  
control panel. See LED control panel or ACS  
control panel.  
control panels, using LED and ACS in series, 11, 22  
Customer Service, contacting, iv  
selecting, 25, 26, 55, 62  
battery voltage indicator, 8  
breaker size  
setting, 15, 29  
D
BTS. See battery temperature sensor.  
bulk charge  
DC cables, recommended sizes, 47  
DC cabling, 40, 46  
defined, 59  
DC connectors, illustrated, 5  
DC disconnect devices, 45  
DC fuses, 39  
DC grounding, 49  
marine, 49  
described, 6  
illustrated, 5  
C
recreational vehicles, 49  
residential, 49  
DC over-current protection, 46  
DC terminal covers, 39  
DC terminal covers, illustrated, 6  
dead batteries, charging, 1  
deep cycle, 67  
deep-cycle battery, 68  
default settings, described, 25  
depth of discharge, 63  
dimensions  
ACS control panel, 22  
inverter/charger chassis, 81, 82  
inverter/charger with brackets, 82  
LED control panel, 11  
DIP switch panel, 5  
cable, battery temperature sensor, 23, 51  
capacitor start motors, 85  
Charge LED, 10, 21  
charger configuration, 33  
Charger Configuration menu, 33  
Charger Information menu, 17  
charger mode settings  
AC service setting, 63  
adjusting, 62  
battery size selection, 63  
battery type selection, 62  
maximum AC current, 63  
temperature compensation, 62  
charger output voltage, 80  
Charger override, 33  
Charger status indicator (ACS control panel), 10, 21  
charging  
dead batteries, 1  
multi-stage, 59  
DIP switch settings, 25  
AC service rating, 25, 27  
audible alarm, 25, 27  
battery size, 25, 27  
96  
Prosine 2.5/3.0 Installation & Operation Guide  
Index  
battery temperature, 25, 26  
battery type, 25, 26  
load sense, 25, 26  
distilled water, 61, 62, 73  
down arrow key, 13  
drill press, 85  
H
high battery shut down, 2  
high temperature shut down, 3  
high voltage  
alarm, 32  
cutoff, 32  
hydrogen, 69  
E
I
efficiency, 85  
IC version, 19  
induction motors, 56, 85  
inductive loads, 85  
electrolyte, 67, 69, 73  
electrolyte level, 61, 62  
electronics, 86  
EMI bulb, 11, 39  
Enter key, 13  
equalization charge  
defined, 60  
described, 1  
equalization procedure, 61  
equalization request, 33  
status, 17  
Equalize LED, 10, 21  
error code display  
described, 8  
Escape key, 13  
estimating battery requirements, 70  
input voltage range, 57  
installation  
battery temperature sensor, 49  
installer configuration, 28  
Invert LED, 9, 20  
inverter configuration, 32  
Inverter Information menu, 16, 32  
Inverter status indicators, 9, 20  
inverter/charger chassis dimensions, 81, 82  
inverter/charger dimensions with brackets, 82  
inverter/charger installation  
AC cabling, 45  
DC cabling, 46  
designing an installation, 40  
environment, 42  
mounting the inverter/charger, 44  
overview, 37  
F
fault code display, 3  
Fault LED, 9, 20  
Faults display, 20  
Faults Indicator, 9  
FCC regulations, iii  
float charge  
tools and materials, 42  
inverter/charger operating limits, 56  
J
jacks  
Battery Temp/Remote, 51  
defined, 60  
fluorescent lights, 85  
functional test, 55  
fuses  
AC, 40  
DC, 39, 41  
L
lead-acid batteries, 69  
LED control panel, 7  
battery status indicator, 8  
dimensions, 11  
illustrated, 7  
required sizes for DC circuits, 46  
mounting procedure, 11  
LEDs  
G
gases, battery  
venting, 50  
gel-cell, 30  
generator, 41, 69, 70, 85  
spin up, 55  
GFCI outlet, 6  
GND, 38  
Battery Status, 8  
Charge, 10, 21  
Current, 8  
Equalize, 10, 21  
Fault, 9, 20  
Invert, 9, 20  
Ready, 10, 21  
Standby, 9, 10, 20, 21  
Temp, 9, 20  
ground  
AC line, 38  
Prosine 2.5/3.0 Installation & Operation Guide  
97  
Index  
Voltage, 8  
Warning, 9  
lights  
fluorescent, 85  
incandescent, 86  
line (hot), 38  
liquid crystal display, 13  
load sense  
described, 2  
problem loads, 85  
clocks, 86  
electronics, 86  
flourescent lights, 85  
power supplies, 85  
radios, 86  
small loads, 85  
pumps, 56, 85  
parameters, 32  
setting parameters, 25, 26, 32, 56  
threshold, 85  
R
radios, 86  
Ready LED, 10, 21  
recreational vehicle system  
diagram, 53  
loads  
inductive, 85  
problem, 85  
remote output jacks, 5  
reserve capacity, 70  
Reset button (ACS control panel), 20  
Reset button (LED control panel), 9  
residential backup system  
diagram, 52  
resistive loads, 85  
returning products  
policy, vii  
resistive, 85  
low batttery shut down, 2  
M
maintenance  
batteries, 73  
maintenance free batteries, 69  
materials list, iv  
maximum AC input current, 2, 63  
motor operated equipment, 56  
motors  
procedure, viii  
running current, 71, 85  
capacitor start, 85  
induction, 56, 85  
starting current, 71  
universal, 85  
S
safety instructions, i  
sealed batteries, 61  
sealed gel-cell batteries, 69  
self test procedure, 55  
serial number, recording, iv, v  
shorepower  
multi-stage charging, 59  
N
neoprene, liquid, 73  
neutral, 38  
configuring, 29  
defined, 40  
shut down  
O
battery temperature, 2  
high battery, 2  
high temperature, 3  
low battery, 2  
software version, 19  
solar and wind system  
diagram, 54  
On/Off button (Charger), 10, 21  
On/Off button (Inverter), 9, 20  
operating limits for charger, 63  
operating limits for inverter/charger, 56  
operation  
in charger mode, 61  
in equalization mode, 61  
output power derating, 43  
over-current protection, 3  
Override charger operating mode, 33  
specific gravity, measuring, 61, 62  
specifications, 79  
Standby LED, 9, 10, 20, 21  
starting batteries, 68  
starting current, 71  
stereo, 85  
P
surge capacity, 2  
surge power, 85  
power factor correction, 1  
Power indicator (ACS control panel), 21  
Power indicator (LED control panel), 10  
power output, 56  
switches  
bypass/on, 6  
bypass/on, illustrated, 5  
power supplies, 85  
98  
Prosine 2.5/3.0 Installation & Operation Guide  
Index  
system configuration, 35  
system diagrams  
recreational vehicle, 53  
residential backup system, 40, 52  
residential solar and wind, 54  
System Information menu, 18, 35  
system startup default, 35  
T
tape recorders, 86  
Temp LED, 9, 20  
temperature  
effect on batteries, 69  
temperature compensation, 1, 62, 67  
temperature sensor, 49  
three-stage charge  
described, 1  
TV, 85  
U
universal motors, 85  
up arrow key, 13  
V
Version Information Menu, 19  
W
Warning LED, 9  
warranty  
explained, vii  
obtaining service, vii  
wire size  
AC, 45  
DC, 46  
wiring separation, 45  
X
Xantrex web site, iv  
Prosine 2.5/3.0 Installation & Operation Guide  
99  
Xantrex Technology Inc.  
Toll free 1 800 670 0707  
Direct 1 604 422 2777  
Fax 1 800 420 2145  
www.xantrex.com  
445-0096-01-01 Rev. 3  
Printed in China  

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