Clayton Power G3 COMBI User manual
Clayton Power
G3 Combi and Inverter
User Manual
Models: 1012-50, 1312-80, 1512-80, 2012-100, 1024-30, 1524-40, 2324-50, 1012,
1312, 1512, 2012, 1024, 1524, 2324
Author: RUP
Date: 1/16/2015
Revision 2.01
Clayton Power
Pakhusgaarden 42 – 48
5000 Odense
Denmark
Phone: +45 4698 5760
2
Contents
Compliance ................................................................................................................................................................... 4
Warranty ....................................................................................................................................................................... 5
General precautions .................................................................................................................................................. 5
Device overview ......................................................................................................................................................... 6
Installation .................................................................................................................................................................... 7
DC Cables ....................................................................................................................................................................... 7
AC Mains Cables .......................................................................................................................................................... 7
Operation....................................................................................................................................................................... 9
Inverter mode ......................................................................................................................................................... 9
Inverter Load Search Mode ........................................................................................................................10
Charger mode........................................................................................................................................................11
Charge current adjustment .........................................................................................................................11
Automatic charge current reduction.......................................................................................................11
Charge LED ........................................................................................................................................................12
Recommended charge current setting ...................................................................................................12
Temperature compensation (NTC sensor) ...........................................................................................12
G3 Display ...................................................................................................................................................................13
LED code pattern description..............................................................................................................................14
Data connections .................................................................................................................................................15
Technical specification...........................................................................................................................................16
Inverter ...................................................................................................................................................................16
Charger ....................................................................................................................................................................17
Mechanical .............................................................................................................................................................17
3
Compliance
The G3 Inverter and Combi comply with the following standards:
2006/95/EC
EN62040-2/2006
EN55022/2006 Class B
EN60950-1/2006
E13 – 10R-03 9803
RoHS
(Low voltage directive)
(UPS standard)
(Emission and Immunity)
(Safety standard)
(Automotive)
4
Warranty
Installation, operation, technical support, warranty and service issues should initially be
directed towards the outlet at which you purchased your Clayton Power Product.
Caution and warning:
DO NOT USE OR ATTEMPT TO USE THIS PRODUCT UNTIL YOU HAVE READ THIS USER
MANUAL IN ITS INTIRETY!
IMPROPER INSTALATION OR USE OF THIS DEVICE MAY BE HAZERDOUS AND MAY CAUSE
DAMAGE TO OTHER ELECTRICAL EQUIPMENT AND WILL VOID THE WARRANTY!
Clayton Power warrants to the original purchaser only for a period of 24 months from the
date of purchase, that the Clayton Power product will be in good working order when
properly installed and operated as described in this manual.
If the inverter fails within this period under normal use, Clayton Power will, without charge,
at the place of Clayton Powers choosing, repair or replace the inverter – with new or
reconditioned parts or a new or reconditioned product of same model/type as Clayton Power
deems necessary.
This warranty is void and will not be applied if:
• The inverter has been used against the recommendations of this manual.
• The inverter has been used in an application outside of general automotive, solar,
industrial or marine applications without the agreement of Clayton Power.
• The inverter has been modified or repaired without written authorization of Clayton
Power.
• Reverse polarity, excessive overloading, general abuse, neglect, wear & tear, ingress of
liquids (water, oil, acid, or otherwise), foreign objects, lightening strikes, over or under
voltage, RFI/EMI, etc.
Obtaining Warranty Service
To obtain warranty service, please contact the outlet at which you purchased your product.
Do not contact Clayton Power directly. For warranty service you will require the following:
1. Proof of purchase
2. Model number
3. Serial number
4. Brief description of application and problem Telephone your Clayton Power dealer for
an authorization number prior to dispatch - do not send without authorization. Once
this number has been obtained, please carefully package your inverter and send
(freight paid) to the Clayton Power dealer.
General precautions
When working with batteries always ensure that no short circuits occurs.
Always refer to the local safety standards in your country regarding electrical installations.
5
Device overview
11
6
9
10
G3 Combi Layout
Pos. Description
1
ON/OFF Power switch
2
Charge current adjustment (Ampere)
3
Charger active LED – Green
4
Inverter active LED – Blue
5
Battery LED – Red
6
AC charger input
7
Positive DC voltage terminal
8
Negative DC voltage terminal
9
Data and temperature sensor connector
10
Data and Remote connector
11
Fuse for AC input (10AT, 32mm x Ø6,3mm)
12
AC output
3
12
4
5
G3 Combi LED functions
Pos. Color
Description
A
Green Data link “High”
B
Yellow Data link “low”
C
Orange Remote active
D
Green Not used
1
A
7
B
C
D
8
12
6
Installation
The Combi/Inverter is IP21 rated and should be mounted in a dry and dust free location.
Avoid mounting the device next to flammable materials.
The device can be mounted vertically or horizontal by using the 4x Ø5mm holes.
It is important that the airflow to and from the device is not obstructed to insure prober
cooling of the device.
Optimum cooling is achieved by mounting the device vertically with the DC terminals pointing
down.
DC Cables
The table below lists the recommended cable cross section and its recommended maximum
length for each device model.
Note: If using cables longer than 3 meters it is advisable to oversize the DC cables. It is necessary
to insure the cables are placed close together.
Note: The cable length is defined as the length between the battery and the Combi/Inverter.
mm2
15
25
35
50
70
AWG
5
3
2
1/0
2/0
1012(-50)
1312(-80)
1512(-80)
2012(-100)
1024(-30)
1524(-40)
2324(-50)
1,5 m
2m
3m
-
1,5 m
2,5 m
3m
1,5 m
2,5 m
3m
1,5 m
2m
1,5 m
2,5 m
3m
-
1,5 m
2,5 m
3m
-
1,5 m
2m
3m
Table 1 Recommended DC cable length and cross section
The following table shows the recommended torque the cables must be connected with to
ensure a good connection to the DC terminals
Screw Torque
M8
12Nm
Warning: Connecting the device with incorrect voltage or battery polarity will damage
the device and is not covered by the warranty.
Note: When connecting the last DC cable to the device a spark will occur. This is normal and is
caused from the internal DC filter capacitors being charged.
It is advisable to avoid sparks near the battery.
AC Mains Cables
Note: When installing AC cables, always refer to the local safety standards in your country!
7
The table below gives the recommended minimum wire cross sections for the AC mains
cables.
1012(-50)
mm2
AWG
mm2
1
17 AWG
1312(-80)
mm2
1
17 AWG
1512(-80)
mm2
1
17 AWG
2012(-100)
mm2
1,5
15 AWG
1024(-30)
mm2
1
17 AWG
1524(-40)
mm2
1
17 AWG
2324(-50)
1,5 mm2
15 AWG
Table 2 Recommended minimum AC cross section.
Warning: Do not connect the AC outputs in parallel or serial. It will damage the device
and is not covered by the warranty.
Warning: Do not connect a generator or AC mains to the output (gray neutrik). It will
damage the device and is not covered by the warranty.
Note: Using RCD devices is highly recommended in any installation. The schematic below
shows a recommended installation of an RCD.
8
Operation
This section describes the three different modes of operation.
-
Inverter mode.
Energy is taken from the battery and converted to 230 Vac and delivered at the output
(grey Neutrik).
-
Charger mode (Combi only).
Energy is taken from the AC input (blue Neutrik) and passed directly through to the
output. Part of the energy is converted to DC and used to recharge the battery.
-
Backup mode (Combi only).
If the device is charging from the AC input, and the inverter mode has been activated,
and the 230 Vac is removed, the Combi will switch to inverter mode.
Inverter mode
The bare minimum setup is shown in the schematic below illustrated with a G3 Combi.
9
The device can also be activated by placing a voltage on the remote pin of one of the three
connectors on the front of the device. This is illustrated in the schematic below.
If the device is connected to a Clayton Power Lithium battery with data the inverter will by
default start when the battery is activated. To change this behavior, please refer to the Clayton
Power Lithium Battery User Manual.
Note: if the battery is discharged the red LED will continue to light. Recharge the battery and try
again.
Inverter Load Search Mode
The inverter can be put into load search mode to lower the standby power consumption.
When the inverter is in load search mode, the inverter will automatically shut down when the
AC load is lower than 10 W. The inverter will turn on every 2 seconds and detect if a load is
present.
Press duration
2 seconds
1 second
10 seconds
10 seconds
Precondition
Inverter mode is Off
Inverter mode is On
Inverter mode is Off and
not in load search mode
Inverter mode is Off and
not in load search mode
Function
Turn on inverter mode
Turn off inverter mode
Unit enters load search mode
All LEDs lights solid
Unit exits load search mode
All LEDs blink
Note: When using the device with a Clayton Power Lithium battery it is not advised to use
load search mode.
10
Charger mode
Activate the charger by applying 230 Vac to the AC input.
Normal voltage range
Extended voltage range*
Minimum voltage
185 Vac
110 Vac
Maximum voltage
265 Vac
265 Vac
* The extended range is available if the inverter mode is not active. In the extended range the
device will charge with reduced current (10A).
The charge is a fully automatic 3-stage charger with IUoUo characteristic.
Charge current adjustment
It is possible to reduce the charge current by adjusting the charge current potentiometer (2).
Note: the scale is in amperes out of the DC terminals, thus if adjusting e.g. a 1012-50 unit, the
adjustment will have no effect from 50 – 100.
Automatic charge current reduction
The device output is rated for 2300 W when AC is present on the input for all the Combi
devices. If the load power + maximum charging power exceed 2300 W, the charger will reduce
the charge current to maintain a maximum of 2300 W from the input.
11
Charge LED
When the charger is charging the green LED has the following meanings:
-
Green LED flashes fast: The charger delivers full charge current (with respect to charge
current adjustment) and is in constant current mode.
-
Green LED flashes slowly: The charger is reducing the current and maintaining a
constant voltage.
-
Green LED lights continuously: The battery is fully charged.
Recommended charge current setting
When using a Combi with a lead acid battery the following table shows the recommended
maximum charge current compared with the battery capacity.
Charge current
15 A
20 A
25 A
30 A
40 A
50 A
60 A
80 A
100 A
Battery capacity
50 – 150 Ah
60 – 200 Ah
80 – 250 Ah
100 – 300 Ah
135 – 400 Ah
165 – 500 Ah
200 – 600 Ah
260 – 800 Ah
330 – 1000 Ah
Table 3 Recommended charge current
compared to battery capacity
Attention:
- If a sealed lead-acid battery is overcharged it will result in gassing and drying
out. This may damage the battery.
- Wet batteries (open type) will lose water and need be refilled
- If you are in doubt how your battery should be charged please consult your
battery technical document or your battery distributor.
Temperature compensation (NTC sensor)
When using the external temperature sensor (NTC) the charger will reduce the charge voltage
with respect to the maximum allowed battery voltage at the actual battery temperature.
The temperature sensor shall be mounted at a point on the battery with good thermal contact.
Use the temperature sensor for optimal battery performance when using lead acid batteries.
When using Clayton Power Lithium batteries the temperature sensor is not needed.
12
G3 Display
It is possible to connect a Clayton Power G3 Display/Remote to visually get information about
the device.
The Display can also be used to control the operation of the device. The schematic below
shows a setup where the display is able to start and stop the device with the remote pin.
To get more information about the Display/Remote please refer the Clayton Power G3 Display
User Manual.
13
LED code pattern description
The following tables describe the meaning of the different LEDs
The blue LED is for the inverter section
The green LED is for the charger section
The red LED is indicating the status of the battery.
Two or all of the LEDs can flash at the same time
Blue LED
ON
1 short flash every 2 seconds
1 flash
2 flash
3 flash
4 flash
5 flash
Description
Inverter is activated
Load search mode (Inverter mode ready)
Inverter output is overloaded
Internal temperature is too high
(automatic cooling and restart)
Short circuit at inverter output
Short circuit in internal power supply
Overload in power supply during startup
Green LED
ON
Slow flashing (approximately 1Hz)
Fast flashing (approximately 2Hz)
1 flash
2 flash
Description
Battery fully charged – float charging
Charger is in top charging (boost voltage)
Charger is boost charging
AC input present but too low
AC input present but too high
Red LED
No light
ON
Flashing
Description
Battery OK
Battery voltage too low
Battery voltage too high
All LEDs simultaneously
4 flash
Description
External temperature sensor not detected
14
Data connections
Pin 1
RJ12
Pin1
Phoenex
The connectors in position 9 and 10 are a RJ12 of type 6P6 connector.
Pin # Signal
Description
1
-TempX
Negative connection for NTC temperature sensor
2
User GND User ground (fused)
3
+TempX
Positive connection for NTC temperature sensor
4
Not Used Do not connect
5
DATA
Clayon Power Single Wire communication
6
Remote
If connected to positive battery voltage, it will switch on the G3 Combi
If left open, it will have no influence
The connector in position 11 is a Phoenix Combicon MSTB 2.5 / 3-ST-5.08
Pin # Signal
Description
1
DATA
Clayon Power Single Wire communication
2
Remote
If connected to positive battery voltage, it will switch on the G3 Combi
If left open, it will have no influence
3
Not Used Do not connect
The two signals DATA and Remote are internally connected.
15
Technical specification
Inverter
Model
1012
1312
1512
2012
1024
1524
2324
2336
1000W
1300W
1500W
2000W
1000W
1500W
2300W
2300W
2000W
3000W
3000W
4000W
2000W
3000W
4000W
4000W
1500W
1800W
2000W
2800W
1500W
1800W
3000W
3000W
1200W
1500W
1700W
2200W
1200W
1700W
2500W
2500W
90%
92%
90%
90%
93%
93%
92%
92%
10W
10W
15W
15W
10W
10W
15W
17W
Power rating
Continues output power
Output power surge
(1 sec)
Output power surge
(10 sec)
Output power surge
(15 min)
Max efficiency
Self Power Consumption
No load
<3W
<8mA
Load search mode
Sleep mode
Thermal Management
Max operating
temperature
Min operating
temperature
Max internal temperature
50°C
-20°C
80°C
Voltage out
230 VAC
Nominal output voltage
50 Hz
Sine
3%
Frequency
Waveform
THD Max.
DC Voltage
Battery input voltage
(nominal)
Max battery input voltage
Low battery cutoff
(slow reaction 3 sec)
Low battery cutoff
(fast reaction <10 ms)
Voltage before inverter
can switch on again after
low battery cutoff
-18% ,
+5%
-10% , +5%
Output voltage tolerance
12 VDC
24 VDC
36 VDC
15 VDC
30 VDC
45 VDC
10,5 VDC
21 VDC
25 VDC
9 VDC
18 VDC
23 VDC
12,75 VDC
25,5 VDC
38,25
VDC
16
Charger
Model
1012-50
1312-80
1512-80
2012-100
1024-30
1524-40
2324-50
Battery
Open, Sealed Lead Acid and Clayton Power Lithium Ion
IUoUo
Battery Types
Charge characteristics
Battery Temperature
sensor
Yes (Optional)
Charge Current
Max Charge current
(adjustable)
Charge Current reduction
@ 50°C (% of max current)
Charge Current reduction
@ 60°C (% of max current)
Charge Current reduction
@ 80°C (% of max current)
0 – 50 A
0 – 80 A
0 – 80 A
0 – 100 A
0 – 30 A
0 – 40 A
0 – 50 A
0%
15 %
50 %
Charge Voltage
14,4 VDC
13,5 VDC
Boost charge voltage
Float charge voltage
28,8 VDC
27 VDC
Input Mains
265 VAC
AC Input voltage Max
AC input voltage min
(full charge current
AC input voltage min
(reduced charge current)
AC inrush current (max)
Power consumption (max)
185 VAC
110 VAC
1000
1500
1500
Frequency
Power factor
Max efficiency
50 A
1900
45 Hz – 65 Hz
0,9
90 %
1200
1500
1900
Bypass Current
AC input to AC output
(max)
Fuse Rating
10 A
10AT
Fuse type
Mechanical
Model
1012-50
1312-80
1512-80
2012-100
1024-30
1524-40
2324-50
Weight
7,5 kg
198
x 336
x 118
275
X 460
X 260
8,6 kg
7,5 kg
198
x 336
x 118
275
X 460
X 260
8,6 kg
9,5 kg
198
x 414
x 118
275
X 535
X 260
10,5 kg
9,5 kg
198
x 414
x 118
275
X 535
X 260
10,5 kg
7,5 kg
198
x 336
x 118
275
X 460
X 260
8,6 kg
7,5 kg
198
x 336
x 118
275
X 460
X 260
8,6 kg
9,5 kg
198
x 414
x 118
275
X 535
X 260
10,5 kg
Dimensions
(W x L x H)
Package dimensions
(W x L x H)
Package weight
17
18
19
20
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