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User Manual - Energy Conscious

1. Page 21 INSTALLATION The success of a DC to AC power inverter installation depends mainly on the methods and materials used for installation Please read and comply with instructions given below GENERAL Installation and wiring compliance Installation and wiring must comply with the local and the national electrical codes and must be done by a certified electrician In building residential applications electrical codes do not allow permanent connection of AC distribution wiring to the inverter s AC output receptacles The receptacles are intended for temporary as needed connection of cord connected loads only Model PSE 12275A has a provision for hard wiring to an electrical breaker panel load center Read details under AC Power Distribution and Grounding on page 8 The inverter does not have integral over current protection for the AC output side Except in the case of model PSE 12275A where a 15 A breaker is provided if the AC output is to be fed directly from the front panel of the unit through the NEMA 5 15R receptacle Protection should be provided by the installer Over current protection of the cables from the battery to the inverter has to be provided by the installer The DC input positive and negative terminals are isolated from the chassis Similarly the neutral pole of the AC receptacles the neutral wire is not bonded to the chassis System grounding to suit the national local electrical codes is to
2. A samlexpower DC AC A Mek Inverters m PSE 12125A PSE 12175A PSE 12275A INDEX S fety Instructi ns susnsgsuinsensiaskiaisganieiebaisisnstelssteaindsetne 2 3 Inverters General Information rrrrrnrrrnnnnrrnrrnrrnnrnnrnrsnenvnnnensrenannnensnenannrensenn 4 5 6 Characteristics of Sinusoidal AC Power esnernnrnrnvvnrnrrennvnenrrenrnvennererrnenenerrensnrnsnnen 7 AC Power Distribution and Grounding eererenvnvenrnrnrrennenerrnsrnrnennnnerrvennesener 8 9 10 Principle of Operation iire acca ata 15546656051 665 610 s5 6 su 081116 E Route aes 11 Devices that may not Operate Correctly with Modified Sine Wave Inverterssarsssert julen ean Gores 12 Limiting Electromagnetic Interference ornnnrrnrvrnvnnvvrrenrvnrvrnrrnvvrvernvevensvevveevsee 13 TEAYOUL 6 n ealvsazensdas ues beSevate chet onsets de teundsuauy E E TER SHG 14 Features Controls and I ndiCatIOnS lt lt 555222 S2 lt 33 sese 15 16 Specifying Batteries Chargers and Alternators 17 18 19 20 21 Installation isi cte ais dese eben tated en 22 23 24 25 26 27 Operation guan aikido aut staat 0860568414250 het 11466155 8450208142 28 29 Protection Against Abnormal Conditions 55 5 lt lt ssee 29 30 Troubleshooting Guide sssr iisi niesie isens l6 v l x i l bay s3 t4 31 32 SPeCwiCatlOns wii iag 6600156 00s Gh Rha ease ihe ake ai ais he 33 MAIT
3. cable and fuse sizes The flow of electric current in a conductor is opposed by the resistance of the conductor The resistance of the conductor is directly proportional to the length of the conductor and inversely proportional to its cross section thickness The resistance in the conductor produces undesirable effects of voltage drop and heating Thus thicker and shorter conductors are desirable The size thickness cross section of the conductors is desig nated by AWG American Wire Gauge Please note that a smaller AWG denotes a thicker size of the conductor upto AWG 1 e g AWG 2 is thicker than AWG 4 The DC input circuit is required to handle very large DC currents and hence the size of the cables and connectors should be selected to ensure minimum voltage drop between the battery and the inverter Thinner cables and loose connections will result in poor inverter performance and will produce abnormal heating leading to risk of insulation melt down and fire Use oil resistant multi stranded copper wire cables rated at 90 C minimum Do not use aluminium cable as it has higher resistance per unit length Cables can be bought at a marine welding supply store The cables from the battery to the inverter should be protected by a suitable very fast acting DC fuse Use a DC fuse of the appropriate capacity in line with the positive cable The fuse should be within 18 from the battery Type ANN fuses with Fuse Block 4164 made by
4. Version PSE 12125 12175 12275 Sep 2005 T 604 525 3836 F 604 525 5221 e mail samlex samlexamerica com website www samlexamerica com YOUR S a 9 DISTRIBUTOR SOLIGENT 800 967 6917 www soligent net
5. and PSE 12175A The DC input terminals on PSE 12125A and PSE 12175A have a tubular hole with a set screw suitable pin type of copper terminal should therefore be used on the cable end A pair of pin type terminals has been provided Crimp these terminals on the inverter end of the cables Do not insert the stranded bare end of the cable directly into the tubular hole as the set screw will not pinch all the strands and will thus make only a partial and loose contact For thicker cables a suitable adapter with pin type of termination should be used There should be no stray wire strands protruding from the terminals as these may produce a short circuit due to the close vicinity of the plus and minus terminals DC input terminals on PSE 12275A The DC input terminals on PSE 12275A have nut and bolt connections that will accept 3 8 inch of ring terminal Use appropriate compression lugs or aluminium box lugs There should be no stray wire strands protruding from the terminals as these may produce a short circuit due to the close vicinity of the plus and minus terminals After the DC input cables have been connected cover the terminals with the plastic protective covers provided Reducing RF interference To reduce the effect of radiated interference twist the DC side cables To further reduce RF interference shield the cables with sheathing copper foil braiding Taping battery cables together to reduce inductance Do not keep the battery
6. cables far apart In case it is not convenient to twist the cables keep them taped together to reduce their inductance Reduced inductance of the battery cables helps to reduce induced voltages This reduces ripple in the battery cables and improves performance and efficiency AC SIDE CONNECTIONS Preventing paralleling of the AC output The AC output of the inverter cannot be synchronised with another AC source and hence it is not suitable for paralleling The AC output of the inverter should never be connected directly to an electrical breaker panel load center which is also fed from the utility power generator Such a connection may result in parallel operation of the different power sources and AC power from the utility generator will be fed back into the inverter which will instantly damage the output section of the inverter and may also pose a fire and safety hazard If an electrical breaker panel load center is fed from an inverter and this panel is also required to be powered from additional alternate AC sources the AC power from all the AC sources like the utility generator inverter should first be fed to a manual selector switch and the output of the selector switch should be connected to the electrical breaker panel load center To prevent possibility of paralleling and severe damage to the inverter never use a simple jumper cable with a male plug on both ends to connect the AC output of the inverter to a handy wall recept
7. deliver 5 Amperes for 20 hours Battery capacity is also expressed as Reserve Capacity RC in minutes Reserve capacity is the time in minutes for which the battery can deliver 25 Amperes at 80 F till the voltage drops to 10 5 Volts for 12 V battery and 21 V for 24 V battery Approximate relationship between the two units is as follows Capacity in AH Reserve Capacity in RC minutes x 0 6 Page 17 Typical battery sizes Below is a chart of some battery sizes applicable for powering inverters BCI Group Battery Voltage V Battery AH 27 31 12 105 4D 12 160 8D 12 225 GC2 6 220 Battery Council International Golf Cart Reduction in usable capacity at higher discharge rates As stated above the rated capacity of the battery in AH is applicable at a discharge rate of 20 Hours As the discharge rate is increased the usable capacity reduces due to Peukert Effect This relationship is not linear but is more or less according to the table below Table 1 Battery Capacity versus Rate of Discharge Hours of Discharge Usable Capacity 20 100 0 87 83 75 70 60 50 40 PNWND Ore Using the above table will show that a 100 AH capacity battery will deliver 100 i e full 100 AH capacity if it is slowly discharged over 20 hours at the rate of 5 Amperes However if it is discharged at a rate of 50 Amperes then theoretically it should provide 100 AH 50 2 hours However the Table above shows that for 2 hours
8. fan for cooling Overtemp shut down and automatic recovery Output instantaneous overload shut down amp auto recovery Output continuous overload shut down amp latch INDICATIONS Input voltage LED bar graph Input current LED bar graph Red LED for overload Red LED for over temperature INPUT SIDE DC FUSES Automotive Type ATC 32V ENVIRONMENTAL CONDITIONS Operating Temperature degree C Storage Temperature degree C Relative Humidity TPUT CONNECTORS Wires for connection to external distribution panel Receptacle NEMA 5 15R Dimensions W x D x H mm Weight Kg NOTE Specifications are subject to change without notice PSE 12125A 10 16 5 V 120 V 5 10 60Hz 5 1250 W 2500 W 320 mA Modified Sine Wave 85 to 90 PSE 12175A 10 16 5 V 120 V 5 10 60Hz 5 1750 W 3500 W 370 mA Modified Sine Wave 85 to 90 PSE 12275A 10 16 5 V 120 V 5 10 60Hz 5 2750 W 4500 W 600 mA Modified Sine Wave 85 to 90 This is the active power for resistive type of loads which have power factor 1 Reactive loads may have power factor of 0 8 to 0 6 The active power rating will reduce by this factor See page 7 for details 16 5 V 10 5 V 10 V Yes Yes Yes Yes Yes Yes Yes Yes 35 Ax 5 pcs 0 to 40 C 10 to 65 C Up to 85 No 238 x 342 x 86 4 1 Page 33 16 5 V 10 5 V 10V Yes Yes Yes Yes Yes Yes Yes Yes 35A x 8 pcs 0 to 40 C
9. is connected in reverse polarity DC fuse s inside the inverter will blow and may also cause permanent damage to the inverter Page 3 INVERTERS GENERAL INFORMATION Why an inverter is needed The utility grid supplies you with alternating current AC electricity AC is the standard form of electricity for anything that plugs in to the utility power Direct current DC electricity flows in a single direction Batteries provide DC electricity AC alternates its direction many times per second AC is used for grid service because it is more practical for long distance transmission For more details read Characteristics of Sinusoidal AC Power on page 7 An inverter converts DC to AC and also changes the voltage In other words it is a power adapter It allows a battery based system to run conventional AC appliances directly or through conventional home wiring There are ways to use DC directly but for a modern lifestyle you will need an inverter for the vast majority if not all of your loads in electrical terms loads are devices that use electrical energy Incidentally there is another type of inverter called grid interactive It is used to feed solar or other renewable energy into a grid connected home and to feed excess energy back into the utility grid This inverter is NOT grid interactive Inverter should meet the application To choose an inverter you should first define your needs Where is the inverter to be
10. is recommended that for powering the inverter one or more auxiliary deep cycle batteries should be used that are separate from the SLI batteries The inverter should be powered from the deep cycle batteries For charging the SLI and the auxiliary deep cycle batteries the output from the alternator should be fed to these two sets of batteries through a battery isolator of appropriate capacity The battery isolator is a device that will allow the alternator to charge the two sets of batteries when the engine is running The isolator will allow the inverter to be operated from the auxiliary batteries and also prevent the SLI batteries from charging the auxiliary deep cycle batteries when the engine is not running Battery isolators are available from auto RV marine parts suppliers A majority of smaller vehicles have 40 to 105 Ampere alternator and RVs have 100 to 130 Ampere alternator When in use the alternators heat up and their output current capacity can drop by up to 25 When heated up their charging voltage may also not reach the desired absorption voltage and will result in return of only about 80 of the battery capacity In case the current output of the standard alternator is not adequate to charge the two sets of batteries rapidly and fully to 100 of their capacity use heavy duty alternator that can produce higher current and voltage required to charge multiple battery systems These alternators are available with auto RV parts suppliers
11. isolated or auto transformer of suitable wattage rating 25 more than the wattage rating of the inverter with primary of 120 VAC and secondary of 120 240 VAC Two 120 VAC split phases 180 degrees apart should be used The hot and neutral of the 120 VAC output of the inverter should be fed to the primary of this trans former and the 2 hot outputs 120 VAC split phases and the neutral from the secondary of this transformer should be connected to the electrical breaker panel load centre Preventing input over voltage It is to be ensured that the input voltage of the inverter does not exceed 16 5 VDC to prevent permanent damage to the inverter Please observe the following precautions Ensure that the maximum charging voltage of the battery charger alternator solar charge controller is below 16 5 VDC Do not use unregulated solar panels to charge a battery Under cold ambient tempera tures the output of the solar panel may exceed 18 VDC Always use a charge controller between the solar panel and the battery Do not connect a 12 VDC input inverter to a battery system with a voltage higher than 12 VDC nominal Preventing reverse polarity on the input side When making battery connection on the input side make sure that the polarity of battery connection is correct Connect the positive of the battery to the positive terminal of the inverter and the negative of the battery to the negative terminal of the inverter If the input
12. of 3rd 180 Hz 5 300 Hz 7th 420 Hz and so on The high frequency harmonic content produces enhanced radio interference higher heating effect in motors microwaves and produces overloading due to lowering of the impedance of low frequency filter capacitors power factor improvement capacitors NOTE Electric motors and microwaves will run hotter when operated with modified sine wave Please ensure proper ventilation for adequate cooling Some examples of devices that may not work properly with modified sine wave and may also get damaged are given below e The built in clocks in devices such as clock radios alarm clocks coffee makers bread makers VCR microwave ovens etc may not keep time correctly e Output voltage control devices like dimmers ceiling fan motor speed control may not work properly dimming speed control may not function e __ Transformer less capacitive input powered devices like i Razors flashlights night lights smoke detectors etc ii Re chargers for battery packs used in hand power tools These may get damaged Please check with the manufacturer of these types of devices for suitability e Devices that use radio frequency signals carried by the AC distribution wiring Oil burner primary controls some new furnaces with microprocessor controls High intensity discharge HID lamps like Metal Halide lamps These may get damaged Please check with the manufacturer of these types of devices for suitabil
13. one cycle it slowly rises in the positive direction from 0 V to a peak positive value Vpeak 170 V slowly drops to 0 V changes the polarity to negative direction and slowly increases in the negative direction to a peak negative value Vpeak 170 V and then slowly drops back to 0 V There are 60 such cycles in I sec Cycles per second is called the frequency and is also termed Hertz Hz If a linear load is connected to this type of voltage the load will draw current which will also have the same sine wave form However the peak value of the current will depend upon the impedance of the load Also the phase of the sine wave form of the current drawn by the linear load may be the same or lead lag the phase of sine wave form of the voltage This phase difference determines the Power Factor mathematically the cosine of the phase difference of the load In a resistive type of load like incandescent lamps heaters etc the sine wave form of the current drawn by the load has 0 phase difference with the sine wave form of the voltage of the AC power source The Power Factor of a resistive load is unity 1 The rated output power in Watts of the inverters is normally specified for resistive type of loads that have unity 1 Power Factor In a reactive type of load like electric motor driven loads fluorescent lights computers audio video equipment etc the phase of the sine wave form of the current drawn by the load may lead or la
14. set again If the red overload LED C still remains lighted without any load the inverter has developed an internal defect Please call Technical Support Page 30 TROUBLESHOOTING GUIDE SYMPTOM On switching on the input voltage bar graph indicator does not light There is no AC voltage AC output voltage reads low 96 to 104 VAC when measured with an ordinary voltmeter Low AC output voltage and the battery current bar graph indicator shows very high current No buzzer alarm Buzzer alarm is sounded when load is switched on DC input voltage bar graph indicator reads between 10 and 10 5 V AC output voltage is available Buzzer alarm is sounded when load is switched on DC input voltage bar graph indicator reads below 10 V There is no AC output There is no AC output The voltage bar graph indicator shows normal DC input voltage POSSIBLE CAUSE There is no voltage at the DC input terminals Polarity of the input voltage has been reversed that has blown the internal DC side fuses The voltmeter being used is not designed to read the true RMS value of modified sine wave form Low input voltage at the inverter terminals and the load is close to the maximum allowable power DC input voltage is less than 10 5 V Shut down due to low input DC voltage Less than 10 V Note The unit will be latched in this shut down condition To reset switch the power on off switch to off and then on again Before swit
15. the use of a grounded electrical distribution system As per this system one of the two current carrying conductors is required to be grounded This grounded conductor is called the Neutral Cold Return As this conductor is bonded to earth ground it will be at near zero voltage or potential There is no risk of electrical shock if this conductor is touched The other current carrying conductor is called the Line Live Hot The connection between the Neutral and the grounding electrode conductor is made only at one point in the system This is known as the system ground This single point connection bond is usually made in the service entrance or the load center If this connection is inadvertently made in more than one place then unwanted currents will flow in the equipment grounding conductors These unwanted currents may cause inverters and charge controllers to be unreliable and may interfere with the operation of ground fault detectors and over current devices NOTE A current carrying conductor that is not bonded to the earth ground cannot be called a neutral This conductor will be at an elevated voltage with respect to the earth ground and may produce electrical shock when touched Polarity and color codes for power cords and plugs for AC devices and appliances Single phase 120 VAC 60 Hz AC devices and appliances use 2 pole 3 wire grounding configuration for connection to the AC power source The plug of
16. used Inverters are available for use in buildings including homes for recreational vehicles boats and portable applications Will it be connected to the utility grid in some way Electrical conventions and safety standards differ for various applications so don t improvise Electrical Standards The DC input voltage must conform to that of the electrical system and battery bank 12 volts is recommended for small simple systems 24 and 48 volts are the common standards for higher capacities A higher voltage system carries less current which makes the system wiring cheaper and easier The inverter s AC output must conform to the conventional power in the region in order to run locally available appliances The standard for AC utility service in North America is 120 and 240 Volts at a frequency of 60 Hertz cycles per second In Europe South America and most other places it is 230 volts at 50 Hertz Power capacity Continuous and Surge How much load can an inverter handle Its power output is rated in Watts Read details under Characteristics of Sinusoidal AC Power on page 7 There are two levels of power rating a continuous rating and a surge rating Continuous means the amount of power the inverter can handle for an indefinite period of hours When an inverter is rated at a certain number of Watts that number generally refers to its continuous rating The surge power indicates the power to handle instant
17. water pipe or to another connection that is solidly bonded to the earth ground The connections must be tight against bare metal Use star washers to penetrate paint and corrosion When using the inverter in a mobile RV connect a 8 AWG insulated stranded copper wire from the above equipment grounding bolt to the appropriate ground bus of the RV usually the vehicle chassis or a dedicated DC ground bus The connections must be tight against bare metal Use star washers to penetrate paint and corrosion Grounding of PSE 12275A to earth or to other designated ground Please see details regarding grounding under AC Power Distribution and Grounding on page 8 In case of hard wiring of the PSE 12275A to a building s service entrance electrical breaker panel load center proper grounding and bonding have to be undertaken as per the applicable national local electrical codes In such cases the electrical installation should be undertaken by a qualified electrician When using the inverter independently by connecting the provided plate with NEMA 5 15R receptacle and breaker to their front panel it should be grounded as in the case of PSE 12125A and PSE 12175A i e connect a f 8 AWG insulated stranded copper wire from the equipment grounding bolt to the earth ground connection a connection that connects to the ground rod or to the water pipe or to another connection that is solidly bonded to the earth ground The connections must be t
18. will be approximately 2 times the cooking power The surge power of the inverter should be 2 times the electrical power 1 e 4 times the cooking power Please note that the surge power of the microwave is not as long as the motor load and hence the surge power of the inverter can be considered to determine adequacy of meeting the starting surge power Powering a water supply pump A water well or pressure pump often places the greatest demand on the inverter It warrants special consideration Most pumps draw a very high surge of current during start up The inverter must have sufficient surge capacity to handle it while running any other loads that may be on It is important to size an inverter sufficiently especially to handle the starting surge If the exact starting rating is not available the starting surge can be taken as 3 times the normal running rating of the pump Oversize it still further if you want it to start the pump without causing lights to dim or blink In North America most pumps especially submersibles run on 240 VAC while smaller appliances and lights use 120 VAC To obtain 240 VAC from a 120 VAC inverter use a 120 VAC to 240 VAC transformer If you do not already have a pump installed you can get a 120 volt pump if you don t need more than 1 2 HP Idle power Idle power is the consumption of the inverter when it is on but no loads are running It is wasted power so if you expect the inverter to be on
19. 10 to 65 C Up to 85 No 238 x 462 x 86 5 7 16 5 V 10 5 V 10V Yes Yes Yes Yes Yes Yes Yes Yes 30 A x 12 pcs 0 to 40 C 10 to 65 C Up to 85 Yes 216 x 495 x 160 10 1 2 YEAR Limited Warranty PSE 12125A PSE 12175A amp PSE 12275A s manufactured by Samlex America Inc the Warran tor are warranted to be free from defects in workmanship and materials under normal use and service This warranty is in effect for 2 years from the date of purchase by the user the Purchaser For a warranty claim the Purchaser should contact the place of purchase to obtain a Return Authoriza tion Number The defective part or unit should be returned at the Purchaser s expense to the authorized location A written statement describing the nature of the defect the date of purchase the place of purchase and the Purchaser s name address and telephone number should also be included If upon the Warrantor s examination the defect proves to be the result of defective material or work manship the equipment will be repaired or replaced at the Warrantor s option without charge and returned to the Purchaser at the Warrantor s expense No refund of the purchase price will be granted to the Purchaser unless the Warrantor is unable to remedy the defect after having a reasonable number of opportunities to do so Warranty service shall be performed only by the Warrantor Any attempt to remedy the defect
20. AHDWSS 6100436120 e cag cheades E E ove shave EE E E l o G049 2186 0x4 15E144944145515615 160G 34 Page 1 SAFETY INSTRUCTIONS Please read these instructions before installing or operating the inverter to prevent personal injury or damage to the inverter GENERAL Installation and wiring compliance Installation and wiring must comply with the local and national electrical codes and must be done by a certified electrician Preventing electrical shock Always connect the grounding connection on the inverter to the appropriate grounding system Disassembly repair should be carried out by qualified personnel only Disconnect all AC and DC side connections before working on any circuits associated with the inverter Turning the on off switch on the inverter to off position may not entirely remove dangerous voltages Be careful when touching bare terminals of capacitors The capacitors may retain high lethal voltages even after the power has been removed Discharge the capacitors before working on the circuits Installation environment The inverter should be installed indoor only in a well ventilated cool dry environment Do not expose to moisture rain snow or liquids of any type To reduce the risk of overheating and fire do not obstruct the suction and discharge openings of the cooling fans To ensure proper ventilation do not install in a low clearance compartment Preventing fire and explosion hazards Workin
21. Bussmann are recommended The following size of cables and fuses are recommended The distance shown is the distance between the battery and the inverter The recommended size of the cables will limit the voltage drop to approximately 2 The length of the cable for calculating the voltage drop has been taken as 2 times the distance between the inverter and the battery assuming that two one positive and one negative cables are used for the connection Distance up to 4 Distance up to 6 Ampere rating of fuse PSE 12125A 1AWG 2 0 AWG 250 A ANN 250 PSE 12175A 1 0 AWG 3 0 AWG 350 A ANN 350 PSE 12275A 2 0 AWG 4 0 AWG 450 A ANN 500 CAUTION The input section of the inverter has large value capacitors connected across the input terminals As soon as the DC input connection loop Battery gt fuse gt inverter gt inverter gt battery negative is completed these capacitors will start charging and will momentarily draw very heavy current that will produce sparking on the last contact in the input loop even when the on off switch on the inverter is in the off position Ensure that the fuse is inserted only after all the connections in the loop have been completed so that the sparking is limited to the fuse area Page 24 Using proper DC cable termination The battery end and the inverter end of the cables should have proper terminals that will ensure a firm and tight connection DC input terminals on PSE 12125A
22. Make sure that all the accessories are off so that you do not cause a spark DC SIDE CONNECTIONS The DC input power to the inverter is derived from deep cycle batteries of the required capacity Read under Specifying Batteries Chargers and Alternators on page 17 for details on sizing and charging of batteries Preventing input over voltage It is to be ensured that the input voltage of the inverter does not exceed 16 5 VDC to prevent permanent damage to the inverter Please observe the following precautions Ensure that the maximum charging voltage of the battery charger alternator solar charge controller is below 16 5 VDC Do not use unregulated solar panels to charge a battery Under cold ambient tempera tures the output of the solar panel may exceed 18 VDC Always use a charge controller between the solar panel and the battery Do not connect to a battery system with a voltage higher than 12 VDC nominal Page 23 Preventing reverse polarity on the input side When making battery connection on the input side make sure that the polarity of battery connection is correct Connect the positive of the battery to the positive terminal of the inverter and the negative of the battery to the negative terminal of the inverter If the input is connected in reverse polarity DC fuse s inside the inverter will blow and may also cause permanent damage to the inverter Connection from the batteries to the DC input side of the inverter
23. a constant discharge rate to have the capability to be deeply discharged up to 80 capacity and to repeatedly accept recharging They are marketed for use in recreation vehicles RV boats and electric golf carts so they may be referred to as RV batteries marine batteries or golf cart batteries There are two categories of deep cycle lead acid batteries wet and sealed A wet cell battery has a high tolerance to overcharg ing However it will release hydrogen gas when charging that must be properly vented and the water level must be checked frequently Sealed batteries can either be Gel Cell or AGM Absorbed Glass Mat Both the Gel Cell and AGM are maintenance free have no liquid to spill and gassing is minimal The Gel Cell is the least affected by temperature extremes storage at low state of charge and has a low rate of self discharge An AGM battery will handle overcharging slightly better than the Gel Cell Units of Battery capacity The battery capacity is the measure of the energy the battery can store and deliver to a load It is determined by how much current any given battery can deliver over a stipulated period of time The energy rating is expressed in Ampere Hours AH As a bench mark the battery industry rates batteries at 20 hour rate i e how many Amperes of current the battery can deliver for 20 hours at 80 F till the voltage drops to 10 5 Volts for 12 V battery and 21 V for 24 V battery For example a 100 AH battery will
24. acle in the home RV Page 25 Connecting to multi wire branch circuits Do not directly connect the hot side of the 120 VAC of the inverter to the two hot legs of the 120 240 VAC electrical breaker panel load centre where multi wire common neutral branch circuit wiring method is used for distribution of AC power This may lead to overloading overheating of the neutral conductor and is a risk of fire A split phase transformer isolated or autotransformer of suitable wattage rating 25 more than the wattage rating of the inverter with primary of 120 VAC and secondary of 120 240 VAC Two 120 VAC split phases 180 degrees apart should be used The hot and neutral of the 120 VAC output of the inverter should be fed to the primary of this transformer and the 2 hot outputs 120 VAC split phases and the neutral from the secondary of this transformer should be connected to the electrical breaker panel load centre AC output connections PSE 12125 A PSE 12175A These inverters use NEMA 5 15R receptacles for connecting the AC output to devices and appliances fitted with a NEMA 5 15P plug In these NEMA 5 15 R receptacles two rectangular slots are connected to the current carrying conductors of the AC power source inside the inverter The round slot is the equipment grounding connection and is internally connected to the metal chassis of the inverter CAUTION In these NEMA 5 15R receptacles the current carrying conduc
25. afe operation The cooling fan will automatically turn off when the temperature drops to a safe operating level This fan does not run continuously h Power Input Terminals WHITE or BLACK Negative RED Positive i Chassis Ground Terminal Lug j Circuit Breaker This is provided for PSE 12275A k Punched Holes These holes are provided for entry of cables going to the external Breaker Panel when hard wired Page 16 SPECIFYING BATTERIES CHARGERS amp ALTERNATORS The inverter will require Deep Cycle Lead Acid Batteries of appropriate capacity Lead acid batteries can be categorized by the type of application automotive service Starting Lighting Ignition SLI a k a cranking and deep cycle service SLI Batteries Everybody is familiar with the SLI batteries that are used for automotive starting and powering vehicular accessories SLI batteries are designed to produce high power in short bursts but must be constantly recharged normally with an alternator while driving Vehicle starting typically discharges 1 3 of a healthy SLI battery s capacity The automotive SLI battery is not designed for repeated deep discharge where up to 80 of the battery capacity is discharged and then recharged If an SLI battery is used for this type of application its useful service life will be drastically reduced Deep Cycle Batteries Deep cycle batteries are designed with thick plate electrodes to serve as primary power sources to have
26. aneous overload of a few seconds to provide the higher power required to start certain type of devices and appliances Page 4 Loads that require surge power to start Resistive types of loads like incandescent lamps toaster coffee maker electric range iron etc do not require extra power to start Their starting power is the same as their running power Some loads like induction motors and high inertia motor driven devices will initially require a very large starting or surge power to start from rest Once they have started moving and have attained their rated speed their power requirement reduces to their normal running power The surge may last up to 5 seconds TVs and microwave ovens also require surge power for starting The manufacturers specification of the appliances and devices indicates only the running power required The surge power required has to be guessed at best See below under Sizing of inverter for loads that require starting surge If an inverter cannot efficiently feed the surge power it may simply shut down instead of starting the device If the inverter s surge capacity is marginal its output voltage will dip during the surge This can cause a dimming of the lights in the house and will sometimes crash a computer Any weakness in the battery and cabling to the inverter will further limit its ability to start a motor A battery bank that is undersized in poor condition or has corroded conn
27. be undertaken by the installer Read details under AC Power Distribution and Grounding on page 8 Preventing electrical shock Always connect the grounding connection on the inverter to the appropriate grounding system Read details under AC Power Distribution and Grounding on page 8 Installation environment The inverter should be installed indoor only in a well ventilated cool dry environment Do not expose to moisture rain snow or liquids of any type To reduce the risk of overheating and fire do not obstruct the suction and discharge openings of the cooling fan To ensure proper ventilation do not install in a low clearance compartment Working with the inverter may produce arcs or sparks Thus the inverter should not be used in areas where there are inflammable materials or gases requiring ignition protected equipment These areas may include spaces containing gasoline powered machinery fuel tanks battery compartments Mounting position of the inverter The inverter may be mounted horizontally on the top of a horizontal surface or under a horizontal surface The inverter may be mounted on a vertical surface only horizontally the fan axis should always be horizontal i e the fan should not be pointing up or down Page 22 Cooling by forced air fan ventilation The inverters produce heat when operating The amount of heat produced is proportional to the amount of power supplied by the inverter DC fan is
28. by anyone other than the Warrantor shall render this warranty void There shall be no warranty for defects or damages caused by faulty installation or hook up abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spray or water immersion No other express warranty is hereby given and there are no warranties which extend beyond those described herein This warranty is expressly in lieu of any other expressed or implied warranties including any implied warranty of merchantability fitness for the ordinary purposes for which such goods are used or fitness for a particular purpose or any other obligations on the part of the Warrantor or its employees and representatives There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and representatives for injury to any persons or damage to person or persons or damage to property or loss of income or profit or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment including any possible failure of mal function of the equipment or part thereof The Warrantor assumes no liability for incidental or consequential damages of any kind Samlex America Inc the Warrantor 110 17 Fawcett Road Coquitlam BC V3K6V2 Canada 604 525 3836 Page 34 A samlexpower 110 17 Fawcett Rd Coquitlam B C Canada V3K 6V2 Soligent
29. ching on again remove the cause of the shut down Shut down due to high input DC voltage gt 16 5 V Note The unit will be latched in this shut down condition To reset switch the power on off switch to off and then on again Before switching on again remove the cause of the shut down Page 31 REMEDY 1 Check the continuity of the battery input circuit 2 Check that the battery fuse is intact Replace if blown 3 Check that all connections in the battery input circuit are tight Correct the polarity of the input connections and replace the internal fuses Note Reverse polarity may cause permanent damage If the unit does not work after replacing the fuses the unit has been permanently damaged Call Technical Support Use a true RMS reading voltmeter like Fluke 87 1 Check that the battery is fully charged Recharge if low 2 Check that the battery cables are thick enough to carry the required current over the required length Use thicker cables if required 3 Tighten connections of the battery input circuit 4 Reduce the load 1 Check that the battery is fully charged Recharge if low 2 Check that the battery cables are thick enough to carry the required current over the required length Use thicker cables if required 3 Tighten connections of the battery input circuit 1 Check that the battery is fully charged Recharge if low 2 Check that the battery cables are thick enough to ca
30. d in this position To reset the unit switch the on off switch a to the off position and on again Shut down due to high DC input voltage If the voltage at the DC input terminals exceeds 16 5 V the inverter will be shut down completely The unit will be latched in this condition To reset switch the on off switch a to the off position and on again Page 29 Shut down due to reversal of polarity at the DC input terminals The positive of the battery should be connected to the positive DC input terminal of the inverter and the negative of the battery should be connected to the negative DC input terminal of the inverter A reversal of polarity the positive of the battery wrongly connected to the negative DC input terminal of the inverter and the negative of the battery wrongly connected to the positive DC input terminal of the inverter will blow the DC side fuses inside the inverter If the DC side fuses are blown the inverter will be dead There will be no indication of any voltage on the bar graph voltage indicator and also there will be no AC output The internal fuses should be replaced with the correct size of fuses shown under specifications If the unit does not work after replacing the fuses it has been permanently damaged Please call Technical Support for assistance Shut down due to over temperature In case of failure of the cooling fan or in the case of inadequate heat removal due to higher ambient temperatures insuffici
31. discharge rate the capacity is reduced to 50 i e 50 AH Therefore at 50 Ampere discharge rate the battery will actually last for 50 AH 50 Amperes 1 Hour Page 18 Depth of discharge and battery life The more deeply a battery is discharged on each cycle the shorter the battery life Using more batteries than the minimum required will result in longer life for the battery bank A typical cycle life chart is given at Table 2 below TABLE 2 TYPICAL CYCLE LIFE CHART Depth of Discharge Cycle Life Cycle Life Cycle Life of AH Capacity Group 27 31 Group 8D Group GC2 10 1000 1500 3800 50 320 480 1100 80 200 300 675 100 150 225 550 It is recommended that the depth of discharge should be limited to 50 Loss of battery capacity at low temperatures Batteries lose capacity in low temperatures At 32 F a battery will deliver about 70 to 80 of its rated capacity at 80 F If the air temperature near the battery bank is lower than 80 F additional batteries will be needed to provide the same usable capacity For very cold climates an insulated heated battery compartment is recommended Series and parallel connection of batteries When two or more batteries are connected in series their voltages add up but their AH capacity remains the same For example when two 12 V 105 AH batteries are connected in series it becomes a 24 V 105 AH battery Positive of the first battery is the positive terminal of the series connectio
32. ec tions can be a weak link in the power chain The inverter cables and the battery intercon nect cables must be sized properly The spike of DC current through these cables is many hundreds of amps at the instant of motor starting Please follow the instructions under Installation DC side connections on pages 23 amp 24 Sizing of inverter for loads that require starting surge Observe the following guideline to determine the continuous wattage of the inverter for powering loads that require starting surge Multiply the running watts of the device appliance by the surge factor NOTE The surge power rating specified for the inverter is valid for duration of less than 1 second This very short duration may not be sufficient to start motor based loads which may require up to 5 seconds to complete the starting process Hence for purposes of sizing the inverter use only the continuous power rating of the inverter Type of Device or Appliance Surge Factor for Determining the Continuous Wattage of the Inverter No of times the running power rating of the device appliance Refrigerator Freezer Air Compressors Dishwasher Automatic Washer Sump pump Furnace fans Industrial motors Portable kerosene diesel fuel heater Circular saw Bench Grinder WWNWWWWW WN Page 5 Power rating of Microwaves The power rating of the microwave generally refers to the cooking power The electrical power consumed by the microwave
33. ent air exchange the temperature inside the unit will increase The temperature of a critical hot spot inside the inverter is monitored and at a particular upper limit the AC output of the inverter is shut down temporarily The red Over Temp LED b is lighted and a buzzer is sounded The unit will automatically reset after the unit has cooled down Shut down due to instantaneous overload The inverter can provide a higher than normal instantaneous lt 1 second power limited to the surge power rating of the inverter If the instantaneous power required by the load exceeds the surge power rating of the inverter the AC output of the inverter is shut down temporarily for the duration of the instantaneous overload It resets automatically when the load reduces below the level of the surge rating Shut down due to continuous overload beyond the continuous power rating The inverter is designed to deliver continuous power limited to its continuous power rating If there is a continuous overload beyond the continuous power rating of the inverter the inverter will shut down completely The red Overload LED c will be lighted The unit will be latched in this condition To reset switch the on off switch a to the off position and on again Before switching on again please ensure that the cause of continuous overload has been removed NOTE If the overload LED C remains lighted after re setting the unit remove all the loads from the inverter and re
34. erload prior to resuming operation of the equipment or appliance Turning the inverter ON will re set it Page 15 Battery Current amp Voltage Bar Graph Meters GREEN YELLOW RED d Current Indicator This illuminated Bar Graph monitors the current being drawn from the battery by the inverter Depending on the amount of current being drawn the Bar Graph reading generally will be in the GREEN or YELLOW zone When the reading rises to the RED zone the inverter may automatically shut down e Two Standard North American NEMA 5 15R Receptacles are provided on models PSE 12125A and PSE 12175A On PSE 12275A the output is available from unconnected Line BLACK Neutral WHITE and chassis equipment ground GREEN wires for connection to an external breaker panel A plate with standard North American NEMA 5 15 receptacle e wired in series with a 15 A circuit breaker j is provided as an accessory Use this receptacle if you require power to be drawn from the front panel This will require connection As this receptacle e is fed through a 15A breaker j the power drawn from here should be limited to 1500 watts f Remote Operation Socket The inverter is designed to be operated from a remote location via the remote control switch which plugs into this socket This optional accessory is available from Samlex g High Speed Cooling Fan This fan will turn on automatically when the internal temperature exceeds the designed parameters for s
35. for many hours during which there is very little load as in most residential situations you want this to be as low as possible Phantom and idling loads Most of the modern gadgets draw some power whenever they are plugged in Some of them use power to do nothing at all An example is a TV with a remote control Its electric eye system is on day and night watching for your signal to turn the screen on Every appliance with an external wall plug transformer uses power even when the appliance is turned off These little loads are called phantom loads because their power draw is unexpected unseen and easily forgotten A similar concern is idling loads These are devices that must be on all the time in order to function when needed These include smoke detectors alarm systems motion detector lights fax machines and answering machines Central heating systems have a trans former in their thermostat circuit that stays on all the time Cordless rechargeable appliances draw power even after their batteries reach a full charge If in doubt feel the device If it s warm that indicates wasted energy Page 6 CHARACTERISTICS OF SINUSOIDAL AC POWER Voltage current power factor types of loads The voltage waveform of 120 VAC 60 Hz mains utility power is like a sine wave In a voltage with a sine wave form the instantaneous value and polarity of the voltage varies with respect to time and the wave form is like a sine wave In
36. from the 12 V batteries is the AC power delivered by the inverter to the load in Watts W divided by 10 Formula 3 Energy required from the battery DC current to be delivered A x time in Hours H The first step is to estimate the total AC watts W of load s and for how long the load s will operate in hours H The AC watts are normally indicated in the electrical nameplate for each appliance or equipment In case AC watts W are not indicated formula 1 given above may be used to calculate the AC watts by multiplying 120 VAC by the AC current in Amperes The next step is to derive the DC current in Amperes A from the AC watts as per formulae 2 above An example of this calculation is Let us say that the total AC Watts delivered by the inverter 1000 W Then using formula 2 above the DC current to be delivered by the 12 V batteries 1000 W 10 100 Amperes Next the energy required by the load in Ampere Hours AH is determined For example if the load is to operate for 3 hours then as per Formula 3 above Energy to be delivered by the 12 V batteries 100 Amperes x 3 Hours 300 Ampere Hours AH Now the capacity of the batteries is determined based on the run time and the usable capacity From Table 1 above the usable capacity at 3 Hour discharge rate is 60 Hence the actual capacity of the 12 V batteries to deliver 300 AH will be equal to 300 AH 0 6 500 AH And finally the actual desired rated capacity of the batte
37. g the sine wave form of the AC voltage source In this case the power factor of reactive loads is lower than unity 1 generally between 0 8 and 0 6 reactive load reduces the effective wattage that can be delivered by an AC power source RMS and peak values As explained above in a sine wave the instantaneous values of AC voltage Volt V and current Ampere A vary with time Two values are commonly used Root Mean Square RMS value and peak value For simplicity RMS value can be considered as an average value Mathematically Peak Value 1 414 x RMS value For example the 120 VAC 60 Hz mains utility power is the RMS value The peak value corresponding to this is 1 414 x 120 170V The values of the rated output voltage and current of an AC power source are their RMS values AC power Watts VA The power rating of an AC power source is designated in Volt Amperes VA or in Watts W Power in Volt Amperes VA RMS Volts V x RMS Amps A Power in Watts RMS Volts V x RMS Amps A x Power Factor NOTE The rated power of the inverter in Watts W is normally designated for a linear resistive type of load that draws linear current at unity 1 power factor If the load is linear and reactive type the rated power of the inverter in watts will be limited to its normal rated power in watts W x Power Factor For example an inverter rated for 1000 W at unity power factor will be able to deliver only 600 wat
38. g with the inverter may produce arcs or sparks Thus the inverter should not be used in areas where there are inflammable materials or gases requiring ignition protected equipment These areas may include spaces containing gasoline powered machinery fuel tanks battery compartments Precautions when working with batteries Batteries contain very corrosive diluted sulphuric acid as electrolyte Precautions should be taken to prevent contact with skin eyes or clothing Batteries generate hydrogen and oxygen during charging resulting in evolution of explosive gas mixture Care should be taken to ventilate the battery area and follow the battery manufacturer s recommendations Never smoke or allow a spark or flame near the batteries Use caution to reduce the risk of dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Remove metal items like rings bracelets and watches when working with batteries The batteries can produce a short circuit current high enough to weld a ring or the like to metal and thus cause a severe burn If you need to remove a battery always remove the ground terminal from the battery first Make sure that all the accessories are off so that you do not cause a spark Page 2 INVERTER RELATED Preventing paralleling of the AC output The AC output of this inverter cannot be synchronised with another AC source and hence it i
39. ger rectangular slot is not grounded to the earth ground The longer rectangular slot is therefore not a neutral Do not touch this slot as it will be at an elevated voltage with respect to the metal chassis earth ground and may produce an electrical shock when touched AC output connections PSE 12275A The AC output connections of inverter model PSE 12275A have three insulated conduc tors one black and one white for carrying current and one green for equipment grounding The green color equipment grounding conductor is connected to the metal chassis of the inverter These three conductors exit through a pocket in the front side of the inverter These three conductors are used for hard wiring the inverter to a breaker panel For drawing the full rated power of the inverter the output conductors should be hard wired to a suitable breaker panel Page 9 PSE 12275A is also provided with a separate plate which has a NEMA 5 15R receptacle wired through a 15 A beaker This plate with the receptacle and breaker fits in the pocket through which the output conductors exit the inverter The NEMA 5 15R receptacle can be connected to the three output conductors if the AC power output is required to be drawn from the front panel of the inverter Please note that the NEMA 5 15R receptacle is wired through a 15 breaker and hence the power delivered from this receptacle will be limited to 1500 watts only CAUTION The white curren
40. his will partially cancel out the radiated noise from the cables Shield the DC side cables with metal sheathing copper foil braiding Use co axial shielded cable for all antenna inputs instead of 300 ohm twin leads Use high quality shielded cables to attach audio and video devices to one another Do not operate other high power loads when operating audio video equipment Page 13 LAYOUT PSE 12125A PSE 12175A Bottom View Rear View PSE 12275A aon E Rear View Page 14 FEATURES CONTROLS amp INDICATIONS Important Each of the following operating procedures and safety features must be carefully reviewed and thoroughly understood prior to using the inverter Failure to do so may result in damage to the inverter or equipment or serious personal injury a ON OFF Switch This switch operates a low power control circuitry which in turn controls the high power circuitry b High Temperature LED Indicator Light This light will turn RED and the inverter will automatically shut down when the internal temperature exceeds the designed parameters for safe operation When this occurs turn the equipment or appliance off c Over Load LED Indicator Light This light will turn RED and the inverter will automatically shut down when the continuous power draw from the inverter exceeds the maximum continuous power rating for the inverter Turn the inverter OFF determine and resolve the cause of the ov
41. ight against bare metal Use star washers to penetrate paint and corrosion When using these inverters in a mobile RV connect a 8 AWG insulated stranded copper wire from the equipment grounding bolt to the appropriate ground bus of the RV usually the vehicle chassis or a dedicated DC ground bus The connections must be tight against bare metal Use star washers to penetrate paint and corrosion Page 27 OPERATION Powering on the loads After the inverter is switched on it takes a finite time for it to become ready to deliver full power Hence always switch on the load s after a few seconds of switching on the inverter Avoid switching on the inverter with the load already switched on This may prematurely trigger the overload protection When a load is switched on it may require initial higher power surge to start Hence if multiple loads are being powered they should be switched on one by one so that the inverter is not overloaded by the higher starting surge if all the loads are switched on at once Switching the inverter on off Before switching on the inverter check that all the AC loads have been switched off The on off switch a on the front panel of the inverter is used to switch on and switch off the AC power output of the inverter This switch operates a low power control circuitry which in turn controls all the high power circuitry CAUTION Please note that this switch is not switching the high power battery inp
42. inverter Use the insulated wire nuts butt splices provided to splice the wires Please note that the NEMA 5 15R receptacle is wired through a 15 A breaker and hence the power delivered from this receptacle will be limited to 1500 watts only CAUTION The white current carrying conductor is not bonded to the metal chassis of the inverter Hence when the metal chassis of the inverter is connected to the earth ground this white current carrying conductor will not be grounded to earth ground The white conductor is therefore not a neutral Do not touch this conductor as it will be at an elevated voltage with respect to the metal chassis earth ground and may produce electrical shock Page 26 Grounding of PSE 12125A PSE 12175A to earth or to other designated ground Please see details regarding grounding under AC Power Distribution and Grounding on page 8 For safety the metal chassis of the inverter is required to be grounded to the earth ground or to the other designated ground For example in a mobile RV the metal frame of the RV is normally designated as the negative DC ground An equipment grounding bolt with a wing nut has been provided for grounding the metal chassis of the inverter to the appropriate ground When using the inverter in a building connect a 8 AWG insulated stranded copper wire from the above equipment grounding bolt to the earth ground connection connection that connects to the ground rod or to the
43. is or a dedicated DC ground bus The connections must be tight against bare metal Use star washers to penetrate paint and corrosion Grounding of PSE 12275A to earth or to other designated ground In case of hard wiring of the PSE 12275A inverter to a building s service entrance electrical breaker panel load center proper grounding and bonding have to be undertaken as per the applicable national local electrical codes In such cases the electrical installation should be undertaken by a qualified electrician When using these inverters independently by connecting the provided plate with NEMA 5 15R receptacle and breaker to their front panel these should be grounded as in the case of PSE 12125A and PSE 12175A i e connect a 8 AWG insulated stranded copper wire from the equipment grounding bolt to the earth ground connection a connection that connects to the ground rod or to the water pipe or to another connection that is solidly bonded to the earth ground The connections must be tight against bare metal Use star washers to penetrate paint and corrosion When using these inverters in a mobile RV connect a 8 AWG insulated stranded copper wire from the equipment grounding bolt to the appropriate ground bus of the RV usually the vehicle chassis or a dedicated DC ground bus The connections must be tight against bare metal Use star washers to penetrate paint and corrosion Page 10 PRINCIPLE OF OPERATION The inverter conver
44. ity e Some fluorescent lamps light fixtures that have power factor correction capacitors The inverter may shut down indicating overload e Sewing machines with speed microprocessor control Page 12 LIMITING ELECTRO MAGNETIC INTERFERENCE EMI The inverter contains internal switching devices which generate conducted and radiated electromagnetic interference EMI The EMI is more pronounced in inverters whose output voltage has modified sine wave form as modified sine wave form is composed of odd harmonics of the fundamental frequency These harmonics may produce buzzing sound in inexpensive stereo systems because the power supply of these systems does not provide adequate filtration In such cases use stereo systems with better quality power supply The magnitude of EMI is limited to acceptable levels by circuit design but can not be entirely eliminated The effects of EMI will also depend upon a number of factors external to the power supply like proximity of the inverter to the EMI receptors types and quality of connecting wires and cables etc EMI due to factors external to the inverter can be reduced as follows Ensure that the inverter is firmly grounded to the ground system of the building or the vehicle Locate the inverter as far away from the EMI receptors like radio audio and video devices as possible Keep the DC side cables between the battery and the inverter as short as possible Twist the DC side cables T
45. n The negative of the first battery is connected to the positive of the second battery The negative of the second battery is the negative of the series connection When two or more batteries are connected in parallel their voltages remain the same but their capacities add up For example if two 12 V 105 AH batteries are connected in parallel their voltage remains 12 V but their capacity becomes 105 x 2 210 AH Connect the positive terminal of the first battery to the positive terminal of the second battery These paralleled common positive terminals become the positive terminal of the parallel combination Connect the negative terminal of the first battery to the negative terminal of the second battery These paralleled common negative terminals becomes the negative terminal of the parallel combination Page 19 Sizing the Inverter Battery Bank One of the most frequently asked question is how long will the batteries last This question cannot be answered without knowing the size of the battery system and the load on the inverter Usually this question is turned around to ask How long do you want your load to run and then specific calculation can be done to determine the proper battery bank size There are a few basic formulae and estimation rules that are used Formula I Power in Watts W Voltage in Volts V x Current in Amperes A Formula 2 For an inverter running from a 12 V battery system the DC current required
46. ne wave AC produced by the inverter has an RMS Root Mean Square value of 120 V A general purpose AC voltmeter is designed to accurately measure the RMS value of a normal sine wave and not a modified sine wave If this voltmeter is used to read the AC voltage of a modified sine wave it will indicate a lower value 96 V to 104 V For accurately measuring the voltage of a modified sine wave use a voltmeter which is designed to measure true RMS values like Fluke 87 Fluke 8060A etc Page 11 DEVICES THAT MAY NOT OPERATE ON MODIFIED SINE WAVE The output wave form of these inverters is a modified sine wave See the diagram under Principle of Operation on page 11 In a sine wave the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses 0 Volts In a modified sine wave the voltage rises and falls abruptly the phase angle also changes abruptly and it sits at 0 Volts for some time before changing its polarity Thus any device that uses a control circuitry that senses the phase for voltage speed control or instantaneous zero voltage crossing for timing control does not work properly Also as the modified sine wave is a form of square wave it is comprised of multiple sine waves of odd harmonics multiples of the fundamental frequency of the modified sine wave For example a 60 Hz modified sine wave will consist of sine waves with odd harmonic frequencies
47. ounded system is a system in which one of the current carrying conductors is grounded An equipment grounding conductor is a conductor that does not normally carry current except under fault conditions and is also connected to earth It is used to connect the exposed metal surfaces of electrical equipment together and then to ground Examples are the bare copper conductor in non metallic sheathed cable Romex and the green insulated conductor in power cords in portable equipment These equipment grounding conductors help to prevent electric shock and allow over current devices to operate properly when ground faults occur The size of this conductor should be coordinated with the size of the over current devices involved A grounding electrode is the metallic device that is used to make actual contact with the earth Other types of grounding electrodes include metal water pipes and metal building frames A grounding electrode conductor is the conductor between a common single grounding point in the system and the grounding electrode Bond refers to the connection between the grounded conductor the equipment grounding conductors and the grounding electrode conductor Bonding is also used to describe connecting all of the exposed metal surfaces together to complete the equipment grounding conductors Page 8 Grounded Electrical Power Distribution System The National Electrical Code NEC requires
48. ries is determined based on the fact that normally only 80 of the capacity will be available with respect to the rated capacity due to non availability of ideal and optimum operating and charging conditions So the final requirements will be equal to 500 AH 0 8 625 AH note that the actual energy required by the load was 300 AH It will be seen from the above that the final rated capacity of the batteries is almost 2 times the energy required by the load in AH Thus as a thumb rule the AH capacity of the batteries should be twice the energy required by the load in AH For the above example the 12 V batteries may be selected as follows Use 6 Group 27 31 12 V 105 AH batteries in parallel to make up 630 AH or Use 3 Group 8D 12 V 225 AH batteries in parallel to make up 675 AH Page 20 Charging Batteries The batteries can be charged by using good quality AC powered battery charger or from alternative energy sources like solar panels wind or hydro systems Make sure an appropriate battery charge controller is used It is recommended that the batteries may be charged at 10 to 13 of the Ampere Hour capacity 20 hour discharge rate Also for complete charging return of 100 capacity it is recommended that a 3 stage charger may be used Constant current bulk charging followed by constant voltage boost absorption charging followed by constant voltage float charging Batteries alternators and isolators on vehicles RVs It
49. rry the required current over the required length Use thicker cables if required 3 Tighten connections of the battery input circuit 1 Check that the voltage at the DC input terminals is less than 16 5 V 2 Ensure that the maximum charging voltage of the battery charger alternator solar charge controller is below 16 5 V 3 Ensure that an un regulated solar panel is not used to charge a battery Under cold ambient temperatures the output of the solar panel may exceed 18 V Ensure that a charge controller is used between the solar panel and the battery SYMPTOM The AC output shuts down sometimes and resumes automatically Overload LED is not lighted might happen during starting of certain loads The AC output shuts down completely The red overload LED is lighted Buzzer alarm is sounded Red Over Temp LED is on There is no AC output POSSIBLE CAUSE Temporary shut down of the AC output due to instantaneous overload beyond the surge power rating of the inverter Permanent shut down of the AC output due to continuous overload beyond the continuous power rating of the inverter Note The unit will be latched in this shut down condition To reset switch the power on off switch to off and then on again Before switching on again remove the cause of the shut down Shut down due to over temperature because of fan failure or inadequate cooling as a result of high ambient temperature or insufficient air e
50. s not suitable for paralleling The AC output of the inverter should never be connected directly to an electrical breaker panel load center which is also fed from the utility power generator Such a connection may result in parallel operation of the different power sources and AC power from the utility generator will be fed back into the inverter which will instantly damage the output section of the inverter and may also pose a fire and safety hazard If an electrical breaker panel load center is fed from an inverter and this panel is also required to be powered from additional alternate AC sources the AC power from all the AC sources like the utility generator inverter should first be fed to a manual selector switch and the output of the selector switch should be connected to the electrical breaker panel load center To prevent possibility of paralleling and severe damage to the inverter never use a simple jumper cable with a male plug on both ends to connect the AC output of the inverter to a handy wall receptacle in the home RV Connecting to multi wire branch circuits Do not directly connect the hot side of the 120 VAC of the inverter to the two hot legs of the 120 240 VAC electrical breaker panel load centre where multi wire common neutral branch circuit wiring method is used for distribution of AC power This may lead to overloading overheating of the neutral conductor and is a risk of fire A split phase transformer
51. t carrying conductor is not bonded to the metal chassis of the inverter Hence when the metal chassis of the inverter is connected to the earth ground this white current carrying conductor will not be grounded to the earth ground The white conductor is therefore not a neutral Do not touch this conductor as it will be at an elevated voltage with respect to the metal chassis earth ground and may produce electrical shock Grounding of PSE 12125A PSE 12175A to earth or to other designated ground For safety the metal chassis of the inverter is required to be grounded to the earth ground or to the other designated ground For example in a mobile RV the metal frame of the RV is normally designated as the negative DC ground An equipment grounding bolt with a wing nut has been provided for grounding the metal chassis of the inverter to the appropriate ground When using the inverter in a building connect a 8 AWG insulated stranded copper wire from the above equipment grounding bolt to the earth ground connection a connection that connects to the ground rod or to the water pipe or to another connection that is solidly bonded to the earth ground The connections must be tight against bare metal Use star washers to penetrate paint and corrosion When using the inverter in a mobile RV connect a 8 AWG insulated stranded copper wire from the above equipment grounding bolt to the appropriate ground bus of the RV usually the vehicle chass
52. the power cord has three pins two flat pins also called poles that are connected to the two current carrying conductors and a round pin which is connected to a non current carrying conductor this will carry current only during ground fault conditions One flat pin is connected to a black current carrying conductor which is also called Line Live Hot pole The other flat pin is connected to the white current carrying conductor also called the Neutral Return Cold pole The third round pin is connected to the non current carrying green equipment grounding conductor This green equipment grounding conductor is bonded to the metal chassis of the device or appliance AC output connections PSE 12125 A PSE 12175A The 120 VAC 60 Hz version of these inverters use NEMA 5 15R receptacles for connect ing the AC output of the inverter to devices and appliances fitted with a NEMA 5 15P plug The two rectangular slots are connected to the current carrying conductors of the AC power source inside the inverter The round slot is the equipment grounding connection and is internally connected to the metal chassis of the inverter CAUTION For the 120 VAC 60 Hz NEMA 5 15R receptacles in PSE 12125A and PSE 12175A the current carrying conductor connected to the longer rectangular slot is isolated from the metal chassis of the inverter Hence when the metal chassis of the inverter is connected to the earth ground the lon
53. the value of the voltage display will decrease due to drop in the battery voltage on load and also due to the voltage drop in the DC side cables Indications for normal operation When the inverter is operating normally and supplying AC load s only the voltage and current displays will be on In case of abnormal operation other displays and alarms will be activated Please see under Protections Against Abnormal Conditions on page 29 Page 28 Switching on off using the optional remote on off Remote Control An optional corded Remote Control Model No RC 15 is available to enable switching on and off from a distance of 18 ft The remote on off control comes with 18 ft of wire One end of the remote control is plugged into the 6 position modular jack f provided on the inverter To use the remote control the inverter is first required to be switched on from the on off switch on the front panel Now the inverter can be toggled between off on conditions by pressing the push button on the remote control The LED on the remote control will light when the inverter is in the on condition No load draw idle current When the on off switch is turned on all the circuitry inside the inverter becomes alive and the AC output is made available In this condition even when no load is being supplied or if a load is connected but has been switched off the inverter draws a small amount of current from the batteries to keep the circui
54. tor connected to the longer rectangular slot is isolated from the metal chassis of the inverter Hence when the metal chassis of the inverter is connected to the earth ground the longer rectangular slot is not grounded to earth ground The longer rectangular slot is therefore not a neutral Do not touch this slot as it will be at an elevated voltage with respect to the metal chassis earth ground and may produce an electrical shock when touched AC output connections PSE 12275A The AC output connections have three insulated conductors one black and one white for carrying current and one green for equipment grounding The green color equip ment grounding conductor is connected to the metal chassis of the inverter These three conductors exit through a pocket in the front side of the inverter These three conductors are used for hard wiring the inverter to a breaker panel Use the insulated wire nuts butt splices provided to splice the wires For drawing the full rated power of the inverter the output conductors should be hard wired to a suitable breaker panel A separate plate which has a NEMA 5 15R receptacle wired through a 15 A beaker has also been provided This plate with the receptacle and breaker fits in the pocket through which the output conductors exit the inverter The NEMA 5 15R receptacle can be connected to the three output conductors if the AC power output is required to be drawn from the front panel of the
55. try alive and ready to deliver the required power on demand This is called the idle current or the no load draw Hence when the load is not required to be operated turn off the on off switch on the inverter to prevent unnecessary current drain from the battery PROTECTIONS AGAINST ABNORMAL CONDITIONS Low DC input voltage warning alarm The voltage at the DC input terminals will be lower than the voltage at the battery terminals due to the voltage drop in the battery cables and connectors The drop in the voltage at the DC input terminals of the inverter could be due to lower battery voltage or due to abnormally high drop in the cables if the cables are not thick enough Please read under Installation Connection from the batteries to the DC input side of the inverter cable and fuse sizes on page 24 If the voltage at the DC input terminals falls below 10 5 V a buzzer alarm will be sounded The AC output voltage will continue to be available This warning alarm indicates that the battery is running low and that the inverter will be shut down after sometime if the voltage at the inverter terminals further drops to 10 V Shut down due to low DC input voltage If the inverter continues to power the load after the low DC input voltage buzzer alarm is sounded it will shut down completely when the DC input voltage further drops below 10 V There will be no AC output voltage and the alarm will continue to sound The unit will be latche
56. ts the 12 V nominal DC voltage of the battery to 120 V 60 Hz AC voltage The voltage conversion takes place in two stages In the first stage the 12 V nominal DC voltage of the battery is converted to high voltage DC 155 V to 170 V using high frequency switching and Pulse Width Modulation PWM technique In the second stage the high voltage DC is converted to 120 V 60 Hz modified sine wave AC Note 120 V is the RMS value of the AC voltage The peak value of the AC voltage will be equal to the value of the above high voltage See the diagram below The output wave form of the inverter is a modified sine wave see the diagram given below In a sine wave the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses 0 Volts In a modified sine wave the voltage rises and falls abruptly the phase angle also changes abruptly and it sits at 0 Volts for some time before changing its polarity 170V Peak Sinewave Smoothly increases to 155 to 170V Peak its peak and smoothly decreases F It crosses 0 V immediately Has RMS value of 120V OV td eeedmekhe eee Modified Sinewave Shoots straight up levels off at peak amp drops straight down Also it sits at 0 V for some time Has RMS value of 120V 155 to 170V Peak p 170V Peak not to scale Measuring modified sine wave voltage with a voltmeter The modified si
57. ts to a reactive type of load with a power factor of 0 6 Page 7 AC POWER DISTRIBUTION AND GROUNDING CAUTION PLEASE NOTE THAT THE AC OUTPUT CONNECTIONS AND THE DC INPUT CONNECTIONS ON THESE INVERTERS ARE NOT CONNECTED BONDED TO THE METAL CHASSIS OF THE INVERTER BOTH THE INPUT AND OUTPUT CONNECTIONS ARE ISOLATED FROM THE METAL CHASSIS AND FROM EACH OTHER SYSTEM GROUNDING AS RE QUIRED BY NATIONAL LOCAL ELECTRICAL CODES STANDARDS IS THE RESPONSIBILITY OF THE USER SYSTEM INSTALLER Conductors for electrical power distribution For single phase transmission of AC power or DC power two conductors are required that will be carrying the current These are called the current carrying conductors A third conductor is used for grounding to prevent the build up of voltages that may result in undue hazards to the connected equipment or persons This is called the non current carrying conductor will carry current only under ground fault conditions Grounding terminology The term grounded indicates that one or more parts of the electrical system are connected to earth which is considered to have zero voltage or potential In some areas the term earthing is used instead of grounding A grounded conductor is a current carrying conductor that normally carries current and is also connected to earth Examples are the neutral conductor in AC wiring and the negative conductor in many DC systems A gr
58. used to provide forced air cooling of this inverter The fan is thermostatically controlled and will be switched on only if the temperature of certain hot spot inside the inverter rises above a certain temperature At lower loads and or at lower ambient temperatures the fan may not switch on at all This is normal The units are protected against over temperature due to failure of the fan inadequate heat transfer The AC output will be shut down if the hot spot inside the inverter reaches a certain higher temperature Precautions when working with batteries Batteries contain very corrosive diluted sulphuric acid as electrolyte Precautions should be taken to prevent contact with skin eyes or clothing Batteries generate hydrogen and oxygen during charging resulting in evolution of explosive gas mixture Care should be taken to ventilate the battery area and follow the battery manufacturer s recommendations Never smoke or allow a spark or flame near the batteries Use caution to reduce the risk of dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Remove metal items like rings bracelets and watches when working with batteries The batteries can produce a short circuit current high enough to weld a ring or the like to metal and thus cause a severe burn If you need to remove a battery always remove the ground terminal from the battery first
59. ut circuit Parts of the DC side circuit will still be alive even when the switch is in the off position Hence disconnect the DC and AC sides before working on any circuits connected to the inverter When the inverter is switched on the green LED bar graph voltage indicator d will be lighted and the voltage at the input terminals will be indicated It should read between 12 to 13 volts if the batteries are fully charged Switch on the AC load s The green LED bar graph current indicator d will show the current drawn by the inverter from the batteries The value of the current drawn will be proportional to the AC power drawn by the load The voltage shown will decrease slightly and this decrease will be proportional to the power drawn by the load DC side input voltage and current display Two LED bar graph indicators d indicate the voltage at the DC input terminals of the inverter and the current drawn from the batteries The voltage at the DC input terminals will always be less than the voltage at the battery terminals due to the drop in voltage in the battery side cables and connectors When no load is connected to the inverter the voltage at the inverter terminals will be almost same as the voltage at the battery terminals If the batteries are fully charged the voltage display should read between 12 to 13 Volts As the AC power delivered by the inverter increases the value of the DC side current display will increase At the same time
60. xchange Page 32 REMEDY 1 Reduce the load 2 The load is not suitable as it requires higher power to operate Use an inverter with higher power rating 1 Reduce the load 2 The load is not suitable as it requires higher power to operate Use an inverter with higher power rating 4 If the unit goes into permanent overload again after resetting and removing the load completely the unit has become defective Call Technical support 1 Check that the fan is working If not the fan fan control circuit may be defective Call Technical Support 2 If the fan is working check that the ventilation slots on the suction side and the openings on the discharge side of the fan are not obstructed 3 If the fan is working and the openings are not obstructed check that enough cool replacement air is available Also check that the ambient air temperature is less than 40 C 4 Reduce the load to reduce the heating effect 5 After the cause of over heating is removed and the unit cools down it will reset automatically SPECIFICATIONS Input Voltage Volts DC Output voltage Volts RMS Output frequency Hz Continuous output power Watts Instantaneous overload surge lt 1 second No load current draw Output Waveform Peak efficiency PROTECTIONS High input voltage shut down amp latch Volts DC Low input voltage warning alarm volts DC Low input voltage shutdown amp latch Volts DC Temperature controlled

User Manual - Energy Conscious

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