User Manual - Magnum Dimensions
Contents
1. 5 0 Specifications eeeeeseseeeeseseeen nnana 23 6 0 Limited Warranty eese esee nennen nnne inus ununu nun 24 6 1 How to Receive Warranty Service ccceseceseceeeeeeeeeeeeseeeereeeener 24 6 2015 Sensata Technologies iii List of Figures Figure 1 1 Front Panel Features CSW1012 and 050 2012 s 1 Figure 1 2 Back Panel Features CSW1012 ssessen 2 Figure 1 3 Back Panel Features CSW2012 iere eterne sete nen 2 Figure 1 4 Front Panel Features CSW412 ccceceeeeeee tees ee eee eee ee ee teenies 3 Figure 1 5 Back Panel Features CSW412 eter enne 4 Fig re 2 1 Basic Systemi 6 Figure 2 2 RV OEM System Dlagrarm x i tonos otia roro nsa eran uk m REM 7 Figure 2 3 Approved Mounting Positions eren nen nnns 9 Fig re 2 4 CSW412 9 Fig re 2 5 CSW1012 DIMENSIONS 24 10 65 2012 2 6 cr ph EAR DUREE UE 10 Figure 2 7 DC Cable to Battery Terminals 5 17 Figure 2 8 DC Cable to Inverter s DC Terminals een 17 Tables Table 2 1 DC Terminal Torque Requirements seeen 11 Table 2 2 DC Wire Overcurrent Device for 80660 esses 13 Table 2 3 Appliance Power Consumption and Run Time eese 15 Table 3 1 Examples of Digital Display Readings sese 20 Table 4 1 Troubleshooting Gulde rto rr nx tnter hn ne cannes 22 Table 4 2 CSW1012 and CSW2012 Inverter Error2. CSW Series Pure Sine Wave Inverter Owner s Manual Thank you from all of us at Sensata Technologies for purchasing this CSW Series inverter The CSW Series includes the CSW412 CSW1012 and CSW2012 inverters all under the Magnum Dimensions brand from Sensata Technologies We understand that you have many purchasing options in the marketplace and are pleased that you have decided on this product At Sensata we are committed to providing you with quality products and services and hope that your experience with us is pleasant and professional Disclaimer of Liability Since the use of this manual and the conditions or methods of installation operation use and maintenance of the CSW Series inverter is beyond the control of Sensata Technologies this company does not assume responsibility and expressly disclaims liability for loss damage or expense whether direct indirect consequential or incidental arising out of or in any way connected with such installation operation use or maintenance Note as well that while every precaution has been taken to ensure the accuracy of the contents of this manual the specifications and product functionality may change without notice Sensata assumes no responsibility for errors or omissions Restrictions on Use The CSW Series inverter may only be used in life support devices or systems with the express written approval of Sensata Technologies Failure of the CSW Series inverter can reasonably
3. CSW1012 and other information DC Chassis Ground Connection the connection that is used to tie the exposed chassis of the inverter to the DC grounding system The DC grounding system could be the vehicle s chassis the DC grounding bus or to the engine s negative bus Input 12 5 VDC 10 12 Volt Bgftery only Do not operate or install on or ia 11 combust surfaces Reverse polarity will damage unit 1 2 M L Model ntertel 4005017 ETL Listed Conforms to ANSI UL STD 458 coin 13 Certified to CSA STD 0222 No 107 1 01 Figure 1 2 Back Panel Features CSW1012 Figure 1 3 Back Panel Features CSW2012 2015 Sensata Technologies 1 0 Introduction 1 2 Features CSW412 The CSW412 inverter is equipped with the following front panel features see Figure 1 4 1 Power Indicator an at a glance LED that lights green when the inverter is on see Section 3 0 Operation 2 Fault Indicator an at a glance LED that comes on to indicate an inverter fault see Section 4 0 for troubleshooting 3 USB Port allows USB enabled devices to be powered and charged 4 ON OFF Power Switch a 2 position switch that turns the inverter on and off 5 Serial Number the unique identification number assigned to each unit with a model specific prefix Note Enter your inverter s serial number in the table at the bottom of page i It is to easier to record this information now instead
4. Status GFCI was Check the connected load and indicator is green tripped reset the GFCI No AC output Fault Unit has Determine and resolve the indicator is on detected a fault fault condition e g high or and has shut low voltage load too large or down over temperature For CSW1012 Check error code on the display and CSW2012 and use Table 4 2 to correct Table 4 2 CSW1012 and CSW2012 Inverter Error Codes Unit has sensed the input Immediately recharge the voltage is low 10 5 VDC and battery to at least 11 8 VDC will shut down in 30 seconds and then restart unit Unit has sensed the input Check the battery voltage or if voltage is high and has shut an external charger is connected down to the battery bank Unit output has sensed an Check the load connected to overload or short circuit and the output Reduce the load was shut down and restart the unit Unit has sensed the internal Turn the unit off and wait 15 temperature was high and has minutes before restarting shut down Check if the air flow is being blocked Unit has sensed the input Recharge the battery to at voltage is low and has initiated least 11 8 VDC as the unit will a warning alarm 811 2 VDC shut down shortly Unit has sensed that the Reduce the connected load connected load is close to the overload shutdown limit Unit has sensed the internal Reduce the load and check if temperature is high and is close any of the
5. Codes 22 Table 5 1 CSW Series Specifications eseeeeeeseeenenee nennen 23 iv O 2015 Sensata Technologies 1 0 Introduction 1 0 Introduction Congratulations on your purchase of the CSW Series pure sine wave inverter The CSW Series includes the CSW412 CSW1012 and CSW2012 inverters under the Magnum Dimensions brand from Sensata Technologies The CSW Series inverters are pure sine wave inverters designed to be powerful yet simple to operate and will provide you with reliable AC power for trouble free use Please read this chapter to familiarize yourself with the features and benefits of your CSW Series inverter 1 1 Features CSW1012 and CSW2012 The front panels of the CSW1012 and CSW2012 inverters are similar and are equipped with the following features see Figure 1 1 1 Serial Number the unique identification number assigned to each unit with a model specific prefix Note Enter your inverter s serial number in the table at the bottom of page i It is to easier to record this information now instead of trying to gather it after the unit has been installed 2 GFCI a Ground Fault Circuit Interrupter protected AC outlet The GFCI outlet quickly stops the flow of electricity in the event a ground fault occurs on the device that is plugged into the inverter 3 Status Indicator an at a glance LED that provides the inverter s status lights green red or amber see Section 3 0 Opera
6. Marine Crafts for use in the US and are also certified to CSA Standard C22 2 No 107 1 01 General Use Power Supplies for use in Canada These inverters have been tested and certified to product safety standards by Intertek Testing Services known as ETL which is a Nationally Recognized Testing Laboratory NRTL NRTLs are qualified organizations that meet Occupational Safety and Health Administration OSHA regulations to perform independent safety testing and product certification 4 O 2015 Sensata Technologies 2 0 Installation 2 0 Installation Review this section and all safety instructions before proceeding with the installation of your inverter WARNING Installations should be performed by qualified AN personnel such as a licensed or certified electrician The installer determines which safety codes apply and ensures all applicable installation requirements are followed Applicable installation codes vary depending on the specific location and application WARNING Before installing review the Important Product Safety AN Information on page ii and adhere to all cautionary markings located on the inverter and on the batteries 2 1 Pre Installation Before proceeding read the entire Installation section to determine how best to install your CSW Series inverter The more thorough you plan in the beginning the better your inverter needs will be met Depending on your application there are simplified system diagr
7. WARNING The power select button is not a power disconnect Disconnect all power to the inverter before working on the inverter Status Indicator The Status indicator on the front panel may light green amber or red to indicate the inverter s status When the status indicator lights e Green the inverter is operating normally e Amber a warning has been detected The inverter will shut down at any time Check the error code on the digital display e Red an error has been detected and the unit has shut down Check the error code on the digital display When the status indicator lights amber or red use the digital display and the troubleshooting tables in Section 4 0 to resolve the issue Digital Display The Digital Display has one line of three alphanumeric characters that alternately shows the inverter s measured battery voltage in volts and AC output power in kilowatts under normal operating conditions It also displays error warning codes that alert you to problems with the unit and are used in conjunction with the troubleshooting tables in Section 4 0 to resolve any issues with the inverter s operation See Table 3 1 below Table 3 1 Examples of Digital Display Readings Measured battery voltage Total AC output power in kW 800W as shown Error or warning code See Troubleshooting section for details Remote Port The Remote Port is used to connect an optional ON OFF remote switch sold separately that works
8. been damaged from abuse neglect accident high voltage or corrosion e the product was not installed operated according to instructions 6 1 How to Receive Warranty Service If your product requires warranty service contact Sensata Magnum Dimensions at e Telephone 425 353 8833 or e Email MagnumWarranty Sensata com If returning your product directly to Sensata in Everett WA you must 1 Return the unit in the original or equivalent shipping container 2 Receive a Return Materials Authorization RMA number from Sensata prior to the return of the product for service 3 Place RMA numbers clearly on the shipping container or the packing slip When sending your product for service please ensure it is properly packaged Damage due to inadequate packaging is not covered under warranty We recommend sending the product by traceable and insured service BEFORE RETURNING ANY UNIT A RETURN MATERIAL AUTHORIZATION RMA NUMBER IS REQUIRED 24 2015 Sensata Technologies Magnum Dimensions Products Manufactured by Sensata Technologies 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www Magnum Dimensions com PN 64 0063 Rev B
9. unit s ventilation is to the thermal shutdown limit blocked 22 O 2015 Sensata Technologies 5 0 Specifications 5 0 Specifications Table 5 1 CSW Series Specifications Model CSW412 CSW1012 CSW2012 Electrical Specifications Continuous Power Surge Power Peak AC Output Voltage 12 5V AC Output Current AC Output Voltage Range AC Output Frequency AC Output Waveform AC Output Receptacle Optimum Efficiency DC Input Voltage Nominal DC Operation Voltage Range DC Input Current Full Load DC Input Current No Load DC Output USB port 400 W 800W 1000 W 2000 W 2000 W 4000 W 120 VAC RMS 5 3 3 AAC 8 3 AAC 104 127 VAC 60 H2 EOFS HZ 16 6 AAC Pure sine wave lt 3 THD NEMA 5 15 Dual GFCI with LED indicator 10 5 15 75 38 DCA 0 8 ADC gt 90 12 5 VDE 10 5 15 5 VDC 94 DCA 187 DCA 1 2 ADC 1 2 ADC 5V 750 mA Protection Low Voltage Alarm Low Voltage Shutdown Low Voltage Recovery High Voltage Shutdown Output Power Warning Output Power Shutdown Output Power Shutdown Temperature Warning Temperature Shutdown 11 0 VDC 12 0 VDC 15 75 VDC NA Yes Yes NA Yes 11 2 VDC 10 5 VDC 11 8 VDC 15 5 VDE Yes with warning code Yes with shutdown code Yes with shutdown code Yes with warning code Yes with shutdown code Display Specifications LED Status Indicator Digital display NA es Power Fault volts in power out e
10. versa try to make the wires at the crossing point perpendicular 90 degrees to one another DC overcurrent protection must be provided as part of the installation Use only copper wires with a minimum temperature rating of 75 C 194 F 2 3 2 Torque Requirements All wiring to the DC terminals and DC ground connection should be checked periodically once a month for proper tightness For the torque requirements refer to Table 2 1 If you don t have a torque wrench ensure all connections are tight Table 2 1 DC Terminal Torque Requirements Inverter DC Torque Torque Wrench Model Terminals Requirements Size Needed Hex Cap 52 to 58 Ibf in M6 x 1 0 79 to 96 Ibf in CSW1012 Hex nuts g 9to10 9 N m 10 m wrench M8 x 1 25 16 to 21 Ibf ft CSW2012 Hex nuts 22 to 28 N m 13 mm wrench 2015 Sensata Technologies 11 2 0 Installation 2 4 DC Wiring This section describes the inverter s required DC wire sizes the recommended disconnect overcurrent protection and how to make the DC connections to the inverter and the battery bank voltage significant hazards may be present particularly from short circuits of the battery system WARNING Even though DC voltage can be regarded as low 0 CAUTION The inverter is NOT reverse polarity protected which means if the negative and positive battery voltage is connected to the inverter backwards the inverter will likely be damaged Use a voltmeter to verify th
11. ET button should pop out and the power should shut off light bulb goes out Note If the bulb remains lit or the RESET button does not pop out the GFCI may not be functioning properly 5 Press the RESET button The AC load should come back on bulb lights again 18 O 2015 Sensata Technologies 3 0 Operation 3 0 Operation When the inverter is properly connected to batteries and turned on the direct current DC from the batteries is transformed into a pure sine wave alternating current AC This AC is similar to the voltage provided by your utility and is used to power any electrical appliances i e AC loads connected to the inverter s output 3 1 CSW412 Operation The CSW412 inverter uses a front panel that contains a power on off switch two LED indicators a USB port and a GFCI AC output receptacle Turning the Inverter on and off The ON OFF Power switch is used to turn the inverter on and off To turn the unit on toggle the switch to the ON I position The Power indicator lights green to indicate that the AC output power is available Press the ON OFF switch to the OFF O position to turn the unit off WARNING The Power ON OFF Switch is not a power disconnect AN switch and will not remove the DC power from the inverter Disconnect all power to the inverter before working on the unit LED Indicators The LED indicators on the front panel are used to indicate the inverter s status e Power LED green the inverter
12. able directly to the inverter s negative terminal DO NOT connect the negative battery cable meant for the inverter to the vehicle s frame safety ground 2 4 4 DC Cable Connections Do not put anything between the battery cable ring lug and the battery post see Figure 2 7 or the flat metal part of the inverter s DC terminal see Figure 2 8 When connecting the battery cable it should be placed directly against the battery post or inverter terminal Incorrectly installed hardware causes a high resistance connection which could lead to poor inverter performance and may melt the cable and terminal connections See Table 2 1 for the torque requirements Info The DC terminal and Hex nuts on the CSW1012 and CSW2012 i are made of stainless steel which has a high likelihood of galling or thread seizing while being tightened causing the bolts to strip or to snap break off To reduce this risk use an anti seize lubricant tighten the fasteners slowly at low rpms without interruption and apply only light pressure 14 O 2015 Sensata Technologies 2 0 Installation 2 4 5 Wiring the Battery Bank negative cables attached to the battery bank touch each other During the installation and wiring process ensure the cable ends are insulated or covered to prevent touching shorting the cables Info DO NOT connect the DC wires from the battery bank to i the inverter until 1 all DC wiring is complete 2 the correct DC overcurrent protection
13. ams shown in Figure 2 1 and Figure 2 2 These should be reviewed to assist you in planning and designing your installation These drawings are not intended to override or to restrict any national or local electrical codes and should not be the determining factor as to whether the installation is compliant that is the responsibility of the electrician and the onsite inspector 2 1 1 Installation Guidelines e Before connecting any wires determine the cable routes throughout the vehicle or boat both to and from the inverter e Always check for existing electrical plumbing or other areas of potential damage BEFORE drilling or cutting into walls e Make sure all wires have a smooth bend radius and do not become kinked e If installing this inverter in a boat RV or truck ensure the conductors passing through walls bulkheads or other structural members are protected This minimizes insulation damage such as chafing which can be caused by vibration or constant rubbing 2 1 2 Unpacking and Inspection Carefully remove the inverter from its shipping container and inspect all contents Verify the following items are included CSW Series inverter CSW Series Owner s Manual If items appear to be missing or damaged contact your authorized Magnum Dimensions dealer or Magnum Dimensions directly Save your proof of purchase as a record of your ownership it is needed if the unit should require in warranty service 2 1 3 Tool
14. be expected to cause the failure of that life support device or system or to affect the safety or effectiveness of that device or system If the CSW Series inverter fails it is reasonable to assume that the health of the user or other persons may be endangered Copyright Notice Copyright 2015 by Sensata Technologies All rights reserved Permission to copy distribute and or modify this document is prohibited without express written permission from Sensata Document Information Description CSW Series Owner s Manual Part Number and Revision 64 0063 Rev B Date Published April 2015 This manual is printed without color for cost savings However this entire manual is available with many of the figures in color and can be downloaded at www magnum dimensions com Contact Information For Magnum Dimensions products Sensata Technologies Phone 425 353 8833 2211 West Casino Rd Fax 425 353 8390 Everett WA 98204 Web www magnum dimensions com Record the unit s model and serial number in case you need to provide this information in the future It is much easier to record this information now instead of trying to gather it after the unit has been installed Serial Number CSW412 CSW1012 CSW2012 BD S 6 2015 Sensata Technologies i IMPORTANT PRODUCT SAFETY INSTRUCTIONS This manual contains safety instructions that must be followed during the installation and operation of this product Read all instructions an
15. d safety information on the inverter and in this manual before installing or using Safety Symbols To reduce the risk of electrical shock fire or other safety hazard the following safety symbols have been placed throughout this manual to indicate dangerous situations and important safety instructions AN WARNING Indicates that failure to take a specified action could result in physical harm to the user 0 CAUTION Indicates that failure to take a specified action could result in damage to the equipment i Info Indicates information that emphasizes or supplements important points of the main text Product Safety Warnings WARNINGS Failure to follow the instructions below and in this manual can result in death or serious injury All electrical work must be performed in accordance with local state and federal electric codes This product is designed for indoor compartment installation Do not expose to rain snow moisture or liquids of any type Use insulated tools to reduce the chance of electrical shock or accidental short circuits Be sure to remove all jewelry such as rings watches bracelets etc when installing or performing maintenance on the inverter Always disconnect the batteries or energy source prior to installing or performing maintenance on the inverter Live power may be present at more than one point since an inverter utilizes both batteries and AC Do not cover or obstruct any air vent openings and o
16. e correct polarity BEFORE connecting the DC wires A CAUTION DO NOT connect the battery cables to the inverter until all wiring is complete and the correct DC voltage and polarity have been verified Refer to Figure 2 7 when connecting the DC wires to the battery and to Figure 2 8 when connecting to the inverter Also consider the following requirements to ensure maximum performance The DC positive and negative cables connected to the inverter from the battery bank should be tied together with wire ties straps or electrical tape approximately every 6 inches 15 3 cm This helps improve the surge capability and reduces the effects of inductance which improves the inverter waveform and reduces the wear of the inverter s filter capacitors Keeping the battery cables close together also reduces the chance of radio frequency interference Be aware that over tightening or misthreading the nuts on the DC terminals can cause the bolts to strip and snap break off Make sure cables have a smooth bend radius and do not become kinked Follow existing wire runs where possible Crimped and sealed copper ring terminal lugs with at least a 6 mm 1 4 bolt hole to connect the DC wires to the inverter s DC terminals The battery bank voltage MUST be between 10 5 15 5 10 5 15 75 for the CSW412 for the inverter to operate If the voltage exceeds 16 0V the inverter may be damaged To ensure the maximum performance from the inverter all connections
17. e sense tnn opu renes 1 1 2 Features CSW4 12 isse ete ieiki e pp RALARRRE IRI RP IRR AR ERR Pix 3 1 3 Regulatory COMPNANCE rss aur esser a her ex tiere sa nsa a 4 2 0 Installation eeeeeeeeeeeee nennen nenne nunununu sunu nuu a auus unu 5 2 4 Pre Installadbloh 3 23 22 race toin e eoe aa oDSE RAP Dex ddUnS 5 2 1 1 Installation Guidelines 5 2 1 2 Unpacking and 1526600 aen d t tenin is 5 2 13 TOONS 5 2 2 Locating and Mounting the Inverter ceceeeeeee eset ee eee eee ee ee ee eeeee 8 2 3 Wiring the Inverter General Requirements 11 2 31 Wiring 11 23 2 Torque Esiin ses vitat hapas Esca ER MEE RETOUR dU 11 pese 12 2 4 1 DC Wire 13 2 4 2 DC Overcurrent 14 2 4 3 DC Grounding iiti rem DR tenete RERin mM Re Ra Ra m RI RAE ERREUR 14 2 4 4 DC Cable 14 2 4 5 Wiring the Battery Bank uiii teeth rrr nn 15 2 4 6 Appliances and RUN TIME 15 2 4 7 Wiring the Inverter to the Battery 16 2 5 TESEING ChE Inwerter sicci teo pneu ce dim rona du gmsises e kk est Accu dE re DE RI 18 2 5 1 Inverter Functional Test isacuc isto ec encsouciten iie PRG Ue RRNEESNE 18 2 5 2 03 61 F nctlon Test 2 18 19 CSW412 Operation ire eene er dinaa n Ra rea RS eeii 19 3 1 and 65 2012 Operation ener rennen dese 20 6500 1012 3 2 Understanding Load Sinira tee SERE UcR c EEE EEeG 21 3 3 21 System 3 4 22
18. eries have been completed plug a small AC load e g 40W light bulb or small appliance into the GFCI s outlet and follow these steps to test the installation and the inverter s operation e CSW412 inverters 1 Toggle the ON OFF Power Switch to the ON I position to turn the unit on 2 The Power Indicator will turn on to indicate that the AC output power is available 3 Check that the AC load is on i e the bulb lights Note If the bulb does not light the GFCI may have tripped Reset the GFCI by pressing the RESET button e CSW1012 and CSW2012 Inverters 1 Press and hold the Power Select button until a beep sound is heard about 1 second The Status light turns on 2 Check that the digital display alternately shows the inverter s measured battery voltage and output power 3 Check that the AC load is on i e the bulb lights Note If the bulb does not light the GFCI may have tripped Reset the GFCI by pressing the RESET button If the inverter passes all steps it is functioning properly and ready for use If the inverter fails any of the steps refer to the troubleshooting information in Section 4 0 2 5 2 6 61 Function Test Use the steps below to periodically test the GFCI to ensure it is functioning properly 1 Turn the inverter on 2 Plug a small AC load e g 40W light bulb into the GFCT s outlet 3 Check that the AC load is on i e the bulb lights 4 Press the GFCI s TEST button The GFCI s RES
19. from the battery bank to the inverter should be minimized The exceptions are the DC fuse and disconnect or the DC circuit breaker required at the battery to protect the DC wiring in the positive line Any other additional connection will contribute to additional voltage drops and these extra connection points may loosen during use A brief spark or arc may occur when connecting the battery cables to the inverter DC terminals this is normal and due to the inverter s internal capacitors being charged Before routing the wiring color code the DC cables wires with colored tape or heat shrink tubing RED for positive WHITE for negative and GREEN or bare copper for DC ground to avoid polarity problems A cable should be connected directly from the inverter negative terminal to the battery negative connection this ensures the inverter has a reliable return path directly to the battery Do not use the chassis in place of the battery negative connection to the inverter 12 O 2015 Sensata Technologies 2 0 Installation 2 4 1 DC Wire Sizing It is important to use the correct sized DC wire to achieve maximum efficiency from the system and to reduce fire hazards associated with overheating Always keep your wire runs as short as practical to prevent low voltage shutdowns and to keep the DC breaker from nuisance tripping or open fuses because of increased current draw See Table 2 2 to select the minimum DC wire size and correspondi
20. has been installed and 3 the correct DC voltage and polarity have been verified WARNING Lethal currents will be present if the positive and Depending upon the voltage of the batteries 6 or 12 VDC the batteries must be wired in series parallel or series parallel to provide the correct voltage The interconnecting DC wires must be sized and rated exactly the same as those used between the battery bank and the inverter Place the batteries as close as practical to the inverter preferably in an insulated and ventilated enclosure Allow adequate space above the batteries to access the terminals and vent caps as applicable Also allow at least 1 2 5 cm of space between the batteries to provide good air flow DO NOT mount the batteries directly under the inverter CAUTION Install batteries in a well ventilated area Batteries can produce explosive gasses For compartment or enclosure installations always vent batteries to the outside Info To ensure the best performance from your inverter system i batteries should be of the same size type rating and age Do not use old or untested batteries 2 4 6 Appliances and Run Time The CSW Series inverters can power a wide range of household appliances including small motors hair dryers clocks and other electrical devices As with any appliance using batteries for power there is a certain length of time that it can run this is called run time Table 2 3 below provides es
21. has power and is turned on e Fault LED red an inverter fault has been detected which caused the inverter to shut down If the fault indicator comes on 1 Determine and resolve the fault condition e g high or low voltage load too large or over temperature 2 Reset the inverter by toggling the ON OFF Power Switch off then back on USB Port The USB Port enables you to power and charge a USB enabled device provides 5 VDC 750 mA CAUTION Some USB powered products may be damaged when connected to this USB port If in doubt check with the product s manufacturer GFCI Outlet The two GFCI protected AC outlets are used to plug in and power an AC load It protects the user against hazardous electrical shocks 2015 Sensata Technologies 19 3 0 Operation 3 2 CSW1012 and CSW2012 Operation The CSW1012 and CSW2012 inverters use a front panel that contains a power select button a status indicator a digital display for viewing system status a remote port a USB port and a GFCI AC output receptacle Turning the Inverter on and off The Power Select button is used to turn the inverter on and off To turn the unit on press and hold the button for 1 second until you hear a beep The digital display alternately shows the unit s measured battery voltage and AC output power and the status indicator lights green Press the power select button to turn the unit off switch and will not remove the DC power from the inverter
22. in parallel with the power select button USB Port The USB Port enables you to power and charge a USB enabled device provides 5 VDC 750 mA CAUTION Some USB powered products may be damaged when connected to this USB port If in doubt check with the product s manufacturer GFCI Outlet The two GFCI protected AC outlets are used to plug in and power an AC load It protects the user against hazardous electrical shocks 20 O 2015 Sensata Technologies 3 0 Operation 3 3 Understanding Loads The inverter can power most loads within its power rating however there are special conditions that can cause a load to behave differently than expected Following are some common problems encountered when using this inverter USB loads When using the USB connector be sure that the device you will be connecting will accept 5 volts 750mA and can be charged or powered using another power source The USB port can safely power and charge alot of devices such as MP3 players mobile phones and portable video game players However some devices such as GPS receivers and some cameras may not work and may even be damaged Refer to the owner s guide for each device to determine its compatibility Motor loads not starting Some appliances particularly those with induction motors require a much higher start up surge than they do when running Pumps freezers and refrigerators compressors are the most common The inverter may not be able to star
23. ng overcurrent device required based on your inverter model The cable sizes listed in this table are required in order to reduce stress on the inverter minimize voltage drops increase system efficiency and ensure the inverter s ability to surge heavy loads If the distance from the inverter to the battery is lt 5 feet 1 5 m the DC wire will need to be increased Longer cable distances affect the performance of the inverter See the lower part of Table 2 2 to determine the minimum DC wire size needed for various distances greater than 5 feet based on your inverter model DC Wire Size Exception In an OEM RV application smaller DC wire with appropriate overcurrent protection may be used if the inverter will only be connected to a dedicated load as shown in Figure 2 2 and the inverter and dedicated load have been thoroughly tested and sold together by the OEM as a complete system Table 2 2 DC Wire Overcurrent Device for Rated Use DC Gro 8 AWG 8 AWG 8 AWG V Ni e Size 8 36 mm 8 36 mm 8 36 mm 10 AWG 2 AWG 3 0 AWG 5 26 mm 33 6 mm 85 mm2 50 amps 170 amps 310 amps EM Enea Giza 50 amps with 150 amps with 300 amps with rp cR time a time DU time IU 10 t 8 AWG 1 AWG a AWG 1 5 3 8 36 mm 42 4 mm 107 mm 6 AWG 1 0 AWG 13 3 mm 53 5 mm To Note 1 Maximum Continuous Current is based on the inverter s continuous power rating at the lowest input voltage with an inefficienc
24. o the batteries and leave open i e no power to inverter WARNING DO NOT close the DC circuit breaker or connect the fuse to connect battery power to the inverter at this time This will occur after the installation is complete 0 CAUTION If connecting live battery cables to the inverter DC terminals a brief spark or arc may occur this is normal and due to the inverter s internal capacitors being charged Route and connect an appropriately sized DC positive wire marked red from the inverter s positive DC terminal Item 11 Figures 1 2 and 1 3 Item 13 Figure 1 5 to one end of the fuse disconnect assembly or circuit breaker Connect a short wire same rating as the DC wires to the other side of the DC circuit breaker or one end of the fuse disconnect assembly and the other end of that short wire to the positive terminal of the battery bank see Figure 2 1 or Figure 2 2 for reference This is essential to ensure even discharging across the entire battery bank Ensure the DC wire connections on the batteries inverter and DC circuit breaker fuse are flush on the surface of the DC terminals and all hardware used to hold these connections are stacked correctly see Figures 2 7 and 2 8 Verify all DC connections on the inverter are torqued correctly see Table 2 1 and the total cable distance from the inverter to the battery is within the requirement of Section 2 4 1 DC Wire Sizing Once the DC connections are comple
25. oduces extreme heat The ambient temperature should be between 32 F 0 C and 104 F 40 C note that the inverter s output specifications are rated at 775 F 25 C so the cooler the better Ventilated In order for the inverter to provide full output power and avoid over temperature fault conditions do not cover or block the inverter s ventilation openings or install this inverter in an area with limited airflow Allow a minimum airspace clearance of 3 7 6 cm around the unit to provide optimum ventilation Safe Keep any flammable combustible material e g paper cloth plastic etc that may be ignited by heat sparks or flames at a minimum distance of 2 feet 60 cm away from the inverter Do not install in any area that contains extremely flammable liquids like gasoline or propane or in locations that require ignition protected devices Close to the battery bank As with any inverter it should be located as close to the batteries as possible Long DC wires tend to lose efficiency and reduce the overall performance of an inverter However the unit should not be installed in the same compartment as the batteries or mounted where it will be exposed to gases produced by the batteries These gases are corrosive and will damage the inverter also if these gases are not ventilated and if allowed to collect they could ignite and cause an explosion Accessible Do not block access to the front or back of the inverter Allow room to
26. of trying to gather it after the unit has been installed 6 GFCI a Ground Fault Circuit Interrupter protected AC outlet The GFCI outlet quickly stops the flow of electricity in the event a ground fault occurs on the device that is plugged into the inverter Figure 1 4 Front Panel Features CSW412 6 2015 Sensata Technologies 3 1 0 Introduction The back panel of the CSW412 inverter is equipped with the following features see Figure 1 5 8 Cooling Fan an intake cooling fan that automatically turns on when the inverter s internal temperature rises above 122 F 50 C The fan turns off when the inverter s internal temperature falls below 122 F 50 C 9 DC Negative Terminal black the inverter s connection to the negative terminal on the 12 VDC battery bank 10 Mounting Flanges front and rear used to mount and secure the inverter to a shelf wall 11 Model Number the model number of the inverter i e CSW412 and regulatory compliance information 12 DC Positive Terminal red the inverter s connection to the positive terminal on the 12 VDC battery bank Input 12 5VDC 38A continuous Figure 1 5 Back Panel Features CSW412 1 3 Regulatory Compliance The CSW Series inverters are intended to be used for land vehicles RVs or trucks or marine craft They are listed to UL Standard 458 5th Edition Power Converters Inverters and Power Converter Inverter Systems for Land Vehicles and
27. protection system In these instances a higher power inverter may be required Running several loads at once Sometimes the total surge requirement of all the loads is higher than the CSW Series inverter can deliver You may want to turn them on individually to ensure that the inverter does not have to deliver the starting current for all the loads at once 3 4 System Maintenance Battery Charging When possible recharge your batteries when they are about 50 discharged or earlier This gives them a much longer life cycle than recharging when they are almost completely discharged Inverter Maintenance Routine maintenance is required to keep the CSW Series inverter operating properly Periodically you should Clean the exterior of the unit with a damp cloth to prevent the accumulation of dust and dirt e Tighten the screws on the DC input terminals 6 2015 Sensata Technologies 21 4 0 Troubleshooting 4 0 Troubleshooting Use Table 4 1 to troubleshoot your inverter For CSW1012 or CSW2012 inverters also use Table 4 2 to view the unit s digital display to determine what condition triggered the error warning code and what corrective action is needed Table 4 1 Troubleshooting Guide am mi luti No AC output Status The unit is off Turn on the unit See Operation indicator is off instructions No power to Check if fuse or disconnect inverter switch if installed is either blown or turned off No AC output
28. r install in a zero clearance compartment always operate unit in an open area When working with electrical equipment or lead acid batteries have someone nearby in case of an emergency Study and follow all the battery manufacturer s specific precautions when installing using and servicing the battery connected to the inverter While working with batteries wear eye protection and gloves and avoid touching your eyes Keep fresh water and soap on hand in the event battery acid comes in contact with eyes If this occurs cleanse right away with soap and water for a minimum of 15 minutes and seek medical attention Batteries produce explosive gases DO NOT smoke or have an open spark or fire near the system Avoid dropping any metal tool or object on the battery Doing so could create a spark or short circuit which goes through the battery or another electrical tool and may cause an explosion Shock Hazard Keep away from children These inverters provide household AC treat the AC output sockets the same as regular wall AC sockets at home Explosion hazard DO NOT use this inverter in the vicinity of flammable fumes or gases such as propane tanks or large engines These inverters contain no user serviceable parts See the Warranty section for how to handle service issues O 2015 Sensata Technologies Table of Contents 1 0 Introduction eeeeeeeeeeeee sensn nu nune nanus enun 1 1 1 Features CSW1012 and C5W2012 iss
29. rror codes General Specifications Operating Temperature Inverter Weight CSW412 CSW1012 CSW2012 Inverter Size Lx Warranty 32 F to 3 8 Ib 1 7 kg 104 F 0 C to 40 C 6 6 Ib 3 0 kg 11 5 Ib 5 2 kg 7 9 x 6 9 x 3 4 20 x 17 5 x 8 7 cm 12 6 x 6 9 x 3 4 32 1 x 17 5 x 8 7 cm 16 5 x 9 1 x 3 5 41 9 x 23 0 x 8 9 cm One Year Regulatory Approval Conforms to UL STD 458 Certified to CSA STD C22 2 No 107 1 1 Specifications met when DC voltage at nominal 12 5V and temp at 25 2 Surge ratings are based on resistive load output voltage may drop 3 Damage can occur if input voltage exceeds 16 VDC 6 2015 Sensata Technologies 23 6 0 Service and Warranty Info 6 0 Limited Warranty Sensata Technologies warrants the CSW Series inverter to be free from defects in material and workmanship that result in product failure during normal usage according to the following terms and conditions 1 Thelimited warranty for this product extends for a maximum of 12 months from the product s original date of purchase 2 The limited warranty extends to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser 3 During the limited warranty period Sensata will repair or replace at our option any defective parts or any parts that will not properly operate for their intended use with factory new or remanufactured replacement items if
30. s Required Installing the inverter is simple and requires the following e Adjustable wrench 10 13 mm gt Level e Drill 10 Mounting screws x4 e Pencil e Drill bits e Phillips screwdriver 2015 Sensata Technologies 5 2 0 Installation AC Source 120VAC 60 Hz Sinewave AC Main Panel Branch Circuit Breaker to Transfer Switch 15A max CSW TS15 Transfer Switch CSW Series Inverter AC Sub Panel AC M NE IT Outlet l Vehicle chassis DC p cg AC Loads negative bus 5A max Pos E NN IDA N qu 0 i Tools l l l Figure 2 1 Basic System Diagram 6 2015 Sensata Technologies AC Source 120VAC 60 Hz Sinewave CSW TS15 Transfer Switch CSW Series Inverter Ground Vehicle chassis DC ground bus or engine negative bus Nae 2 0 Installation AC Main Panel Branch Circuit Breaker to Transfer Switch 15A max Dedicated Notes The NEC requires overcurrent protection for wiring and equipment in both AC and DC circuits As shown in this diagram the RVIA allows the following application where an inverter is installed in a RV Pass thru mode When the AC source generator or shore power powers loads thru a transfer switch i e pass thru mode the conductor from the transfer switch to the dedicated load will be protected as long a
31. s the branch rated circuit breaker at the AC source does not exceed the ampacity of the conductor feeding the dedicated load Inverter Mode When the inverter is powering loads using power from the battery i e Inverter mode the conductor from the inverter output to the dedicated load will be protected as long as the ampacity of the conductor is sized based on the inverter s AC output rating In Inverter mode the inverter has overcurrent protection to limit the output current and to protect the conductor Figure 2 2 RV OEM System Diagram 2015 Sensata Technologies 2 0 Installation 2 2 Locating and Mounting the Inverter WARNINGS AN e Do not mount the inverter near any flammable or combustible fluid or components e Provide adequate clearance ventilation to the inverter Do not cover or obstruct any air vent openings and or install in a zero clearance compartment The inverter should only be installed and mounted in a location that meets the following requirements Clean and dry The inverter should not be installed in an area that allows dust fumes insects or rodents to enter or block the inverter s ventilation openings This area also must be free from any risk of condensation water or any other liquid that can enter or fall on the inverter Inverter failure under these conditions is not covered under warranty Cool The inverter should be protected from direct exposure to the sun or to any equipment that pr
32. side down DC terminals to the right left or to the top Pure Sine Wave Inverter For RV Installation Mount flat on a IET E horizontal surface only LL Figure 2 3 Approved Mounting Positions Top 6 3 16 1 cm Figure 2 4 CSW412 Dimensions 6 2015 Sensata Technologies 9 2 0 Installation cm 26 2 Top 6 9 17 5 cm 6 3 16 1 cm Figure 2 5 CSW1012 Dimensions 13 4 34 cm RE Top E o o v LI io co 16 5 41 9 cm Back DC Side Figure 2 6 CSW2012 Dimensions 10 2015 Sensata Technologies 2 0 Installation 2 3 Wiring the Inverter General Requirements This section describes the requirements and recommendations for wiring the CSW Series inverter Before wiring the inverter carefully read all instructions WARNING Wiring should meet all local codes standards and be performed by qualified personnel i e licensed electrician 2 3 1 Wiring Requirements All conductors that are at risk for physical damage must be protected by tape or placed in a raceway Always check for existing electrical plumbing or other areas of potential damage prior to making cuts in structural surfaces or walls Where DC wiring must cross AC or vice
33. such repair or replacement is needed because of product malfunction or failure during normal usage The limited warranty does not cover defects in appearance or cosmetic decorative structural or non operative parts Sensata s limit of liability under this warranty shall be the actual cash value of the product at the time the original purchaser returns the product for repair determined by the price paid by the original purchaser Sensata shall not be liable for any other losses or damages 4 Upon request from Sensata the original purchaser must prove the product s original date of purchase by a dated bill of sale itemized receipt 5 The original purchaser shall return the product prepaid to Sensata in Everett WA After the completion of service under this limited warranty Sensata will return the product prepaid to the original purchaser via a Sensata selected non expedited surface freight within the contiguous United States and Canada this excludes Alaska and Hawaii 6 1f Sensata repairs or replaces a product its warranty continues for the remaining portion of the original warranty period or 90 days from the date of the return shipment to the original purchaser whichever is greater All replaced products and parts removed from repaired products become the property of Sensata 7 This limited warranty is voided if e the product has been modified without authorization e the serial number has been altered or removed e the product has
34. t currents up to 100 000 amps and has a time delay that allows for momentary current surges from the inverter without opening the fuse In some installations if the combined short circuit current of all the batteries in the bank is determined to be 2 700 amps or less then an ANL type of fuse may be used if in doubt use a Class T fuse See Table 2 2 for the fuse size coordinated with the DC wire size recommended for your CSW inverter 2 4 3 DC Grounding The inverter should always be connected to a permanent grounded wiring system The idea is to connect the metallic chassis of the various enclosures together to have them at the same voltage potential to reduce the possibility for electric shock For most installations the inverter chassis and the negative battery conductor are connected to the system s ground bond via a safety grounding conductor bare wire or green insulated wire at only one point in the system The grounding conductor for the DC system shall meet the sizing requirements specified in the NEC for the application but must be no smaller than 8 AWG copper For instance An inverter used in a marine application under ABYC guidelines requires the size of the DC grounding conductor to be of an ampacity equal to or one size less than that of the DC positive conductor See Table 2 2 for the minimum ground wire size recommended for your inverter Info If the inverter is installed in a vehicle connect the battery i negative c
35. t some of these appliances even though their rated current draw is within the inverter s limits If you have the CSW1012 or CSW2012 and a motor operated appliance refuses to start observe the VOLTS indicator on the digital display while you are trying to start the appliance If the display shows a battery drop below 11 volts while the inverter is trying to start the motor this may explain why the appliance won t run Make sure the length and diameter of the battery cables are appropriate Check that the battery connections are good and that the battery is fully charged If the cables are sized correctly the connections are good and the battery is charged you may need a larger battery bank see Loads turning on and off Loads turning off and on If a load starts but quickly turns off then the battery may not be able to deliver the necessary amperage to drive the load If the battery bank cannot deliver the necessary amperage to drive a heavy load the inverter will shut OFF due to low voltage 10 5 VDC The battery voltage can then slowly rise back above the low voltage reconnect voltage 11 8 VDC causing the inverter to resume operation As soon as the heavy load draws the batteries down this cycle will continue unless the load is reduced or more batteries are added Loads too large Although the CSW Series inverter can provide high surge power up to two times the rated output power some appliances may still trigger the inverter shutdown
36. tely wired and tested coat the terminals with an approved anti oxidizing spray Ifthe batteries are in an enclosure perform a final check of the connections to the battery terminals then close and secure the battery enclosure Route an appropriately sized DC ground wire see Table 2 2 from the inverter s DC chassis ground connection to a dedicated system ground Once the entire installation is complete and all connections verified close the fuse disconnect or circuit breaker to provide power to the inverter 16 O 2015 Sensata Technologies 2 0 Installation DC cable nut with ring lug BATTERY Verify that the DC cable lugs are flush with the battery terminals Figure 2 7 DC Cable to Battery Terminals e P M6 1 0 hex nut lock washer 12 flat washer 2 DC cable with ring lug Inverter s DC terminal CSW1012 Inverter CAUTION Ensure nothing is placed between the DC terminal and the ring lug 9 Figure 2 8 DC Cable to Inverter s DC Terminals 2015 Sensata Technologies 17 2 0 Installation 2 5 Testing the Inverter Before proceeding you must first test whether the inverter was successfully installed Use the functional test below to test the inverter and then perform the GFCI test that follows to ensure the protection device is functioning properly 2 5 1 Inverter Functional Test After all electrical connections to the inverter and batt
37. timates of power consumption and run time for various appliances using a 12V 120AH battery bank Table 2 3 Appliance Power and Run Time a DS e ed ado Wi 6 2015 Sensata Technologies 15 2 0 Installation 2 4 7 Wiring the Inverter to the Battery Bank 0 CAUTION The inverter is NOT reverse polarity protected if the positive terminal of the battery is connected to the negative terminal of the inverter and vice versa severe damage to the inverter will occur and this will void the warranty Before connecting the DC wires from the batteries to the inverter verify the correct battery voltage and polarity using a voltmeter If necessary color code the cables with colored tape red for positive and white for negative to avoid polarity confusion i Info The DC overcurrent device i e circuit breaker or fuse must be placed in the positive red DC cable line between the inverter s positive DC terminal and the battery s positive terminal red as close to the battery as possible For maximum protection install it within 18 inches 45 cm of the battery Follow the steps below to wire the inverter to the battery bank d Route an appropriately sized DC negative wire marked white from the negative terminal of the battery bank to the inverter s negative terminal Item 10 Figures 1 2 and 1 3 Item 9 Figure 1 5 Mount the fuse disconnect assembly or circuit breaker as near as practical t
38. tion 4 Digital Display a three character alphanumeric display that shows the inverter s measured battery voltage total AC output power and any error or warning codes 5 Power Select Button a momentary button switch that allows the inverter to be quickly turned on or off 6 Remote Port a RJ11 connector that allows an optional remote switch to be connected via a remote cable Note Remote switch is sold separately PN CSW RS 7 USB Port allows USB enabled devices to be powered and charged Serial Number 2 Ss 120VAC 60Hz 1000W 8 3A continuous 4 Figure 1 1 Front Panel Features CSW1012 and CSW2012 2015 Sensata Technologies 1 1 0 Introduction The back panels of the CSW1012 and CSW2012 inverters are equipped with the following features See Figure 1 2 and Figure 1 3 8 10 11 12 13 Cooling Fan s an intake cooling fan that automatically turns on when the inverter s internal temperature rises above 1229F 509C The fan turns off when the inverter s internal temperature falls below 122 F 50 C Mounting Flanges front and rear used to mount and secure the inverter to a shelf wall DC Negative Terminal black the inverter s connection to the negative terminal on the 12 VDC battery bank DC Positive Terminal red the inverter s connection to the positive terminal on the 12 VDC battery bank Model Number the model number of the inverter i e
39. view any indictors or digital display and to access the AC and DC wiring connections they will need to be checked and tightened periodically Orientating the inverter When mounted indoors the CSW Series inverter can be mounted on underneath a horizontal surface shelf or table or on a vertical surface wall or bulkhead with the DC terminals facing left or right Additionally the CSW1012 and CSW2012 can be mounted with the DC terminals facing up CSW412 cannot be mounted with terminal s facing up or down do not mount with the DC terminals facing downward see Figure 2 3 When mounted in an RV mount flat on a horizontal surface only After determining your mounting position use the base of the inverter s chassis as a template to mark your mounting screw locations or refer to the dimensions in Figures 2 4 thru 2 6 Remove the inverter and drill pilot holes into the mounting surface Secure the inverter to the surface using the appropriate corrosion resistant hardware If this unit is used in a mobile application you may want to place flexible washers or bushings between the mounting surface and the inverter s mounting flanges to reduce vibration 8 O 2015 Sensata Technologies 2 0 Installation For Indoor Use CSW1012 and CSW2012 only CSW412 cannot be mounted with DC terminals facing up Pure Sine Wave Inverter Flat on a horizontal surface right side up or up
40. y factor Note 2 The grounding conductor for the DC system shall meet the sizing requirements specified in the NEC for the application but must be no smaller than 8 AWG copper In some applications the DC grounding conductor is required to be no less than the wire size of the DC positive negative cables O 2015 Sensata Technologies 13 2 0 Installation 2 4 2 DC Overcurrent Protection For safety reasons and to comply with electrical code regulations DC overcurrent protection must be provided as part of the installation The DC overcurrent protection device must be installed in the positive DC cable line it can be a fuse with a disconnect switch or a circuit breaker and must be DC rated It must be correctly sized according to the size of DC cables being used which means it is required to open before the cable reaches its maximum current carrying capability thereby preventing a fire The NEC requires both overcurrent protection and a disconnect switch Because batteries can deliver thousands of amps in an instant during a short you are required to install a DC rated fuse or circuit breaker that has a interrupt current rating known as Amps Interrupting Current or AIC that can withstand the short circuit current without explosion or damage If a fuse is used as an overcurrent device a Class T type or equivalent is highly recommended when used with inverters A Class T fuse is rated for DC operation can handle very high short circui
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