Zamp Solar ZS 1000PSC, 2000PSC, 3000PSC, 1000-PS40-C, 2000-60PS-C, 3000-PS60-C, 4000-PS560-C, 5000-PS60-C, 6000-PS60-C Inverter/Charger User’s Manual
ZS 1000PSC, ZS 2000PSC, ZS 3000PSC, ZS 1000-PS40-C, ZS 2000-60PS-C, ZS 3000-PS60-C, ZS 4000-PS560-C, ZS 5000-PS60-C, ZS 6000-PS60-C are pure sine wave inverters/chargers that combine an inverter, battery charger, and AC auto-transfer switch. These devices feature a powerful charger, high overload ability, and low quiescent current to support demanding loads. They have a 10 ms typical transfer time between battery and AC, guaranteeing power continuity. You can easily customize the inverter to Battery priority via a DIP switch. These inverters also offer extensive protections against various harsh situations, including over-voltage protection, low battery alarm, over-temperature protection, and short circuit protection.
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Zamp Solar, USA www.zampsolar.com я ZAMP SOLAR DOWER INVERTERS Pure Sine Wave Inverter/Charger User’s Manual Version 1.0 Zamp Solar, USA WWW, zampsol ar.COMm Table of Contents 1. Important Safety Information 3 1-1. General Safety Precautions 3 1-2. Precautions When Working with Batteries 3 2. Introduction 4 2-1, General Information 4 2-2. Application 4 2.3 Mechanical Drawing 5 2-4. Features 7 2.5 Electrical Performance 7 2.5.1 Invert 7 2.5.2 AC Charger 7 2.5.3 Transfer 10 2.5.4 Auto frequency adjust 10 2.5.5 Solar Charger 11 2.5.6 Automatic Voltage Regulation 12 2.5.7 Power Saver 13 2.5.8 Protections.. 14 2.5.9 Remote control 15 2.5.10 LED Indicator & LCD 15 2.5.11 Audible Alarm 16 2.5.12 FAN Operation 17 2.5.13 DIP Switches 17 2.5.14 Output Socket 18 2.5.15 Other features 18 3 Installation 19 3.1 Location ........ 19 3.2 DC Wiring recommendation 19 3.3 AC Wiring 20 3.4 Install Flange 21 4 Troubleshooting Guide ‚24 5 Warranty 26 Appendix 1 27 Zamp Solar,USA 1. Important Safety Information <I. WARNING! Before using the Inverter, you need to read and save the safety instructions. 1-1. General Safety Precautions 1-1-1.Do not expose the Inverter to rain, snow, spray, bilge or dust. To reduce risk of hazard, do not cover or obstruct the ventilation openings. Do not install the Inverter in a zero-clearance compartment. Overheating may result. Allow at least 12” of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit. A minimum air flow of 145 CFM is required. 1-1-2. To avoid a risk of fire and electronic shock. Make sure that existing wiring 1s in good electrical condition; and that wire size is not undersized. Do not operate the Inverter with damaged or substandard wiring. 1-1-3. This equipment contains components which can produce arcs or sparks. To prevent fire or explosion do not install in compartments containing batteries or flammable materials or in locations which require ignition protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, or joints, fittings, or other connection between components of the fuel system. See Warranty for instructions on obtaining service. 1-1-4. Do not disassemble the Inverter/Charger. It contains no user-serviceable parts. Attempting to service the Inverter/Charger yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. 1-1-5. To reduce the risk of electrical shock, disconnect both AC and DC power from the RV Series Inverter/Charger before attempting any maintenance or cleaning. Turning off controls will not reduce this risk CAUTION: Equipment damage The output side of the inverter's AC wiring should at no time be connected to public power or a generator. This condition is far worse than a short circuit. If the unit survives this condition, it will shut down until corrections are made. Installation should ensure that the inverter’s AC output is, at no time, connected to its AC input, Warning: Limitations On Use SPECIFICALLY, PLEASE NOTE THAT THE ZAMP POWER INVERTER/CHARGER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. 1-2. Precautions When Working with Batteries 1-2-1. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water and get medical attention immediately. 1-2-2. Never smoke or allow a spark or flame in vicinity of battery or engine. 1-2-3. Do not drop a metal tool on the battery. The resulting spark or short-circuit on the battery of other electrical part may cause an explosion. 1-2-4. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery produces a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 1-2-5. To reduce the risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium gel cell, absorbed mat, or NiCad/NiFe type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage. www.zampsolar.com Zamp Solar,USA www.zampsolar.com 2. Introduction 2-1. General Information Zamp Solar Pure Sine Wave Inverter is a combination of an inverter, battery charger and AC auto-transfer switch into one complete system with a peak conversion efficiency of 88%. Itis packed with unique features and it is one of the most advanced inverter/chargers in the market today. It features power factor corrected, sophisticated multi-stage charging and pure sine wave output with unprecedentedly high surge capability to meet demanding power needs of inductive loads without endangering the equipment. For the regular model, when utility AC power cuts off{or falls out of acceptable range), the transfer relay is de-energized and the load is automatically transferred to the Inverter output. Once the qualified AC utility is restored, the relay is energized and the load is automatically reconnected to AC utility. Zamp Solar Inverter is equipped with a powerful charger of up to 90Amp(depending on model). The overload capacity is 300% of continuous output for up to 20 seconds to reliably support tools and equipment longer Another important feature is that the inverter can be easily customized to Battery priority via a DIP switch, this helps to extract maximum power from battery in renewable energy systems. Thus, Zamp Solar Pure Sine Wave Inverter is suitable for Renewable energy system, Utility, RV, Marine and Emergency appliances. To get the most out of the power inverter, it must be installed, used and maintained properly. Please read the instructions in this manual before installing and operating. 2-2. Application Power tools—circular saws, drills, grinders, sanders, buffers, weed and hedge trimimers, air compressors. Office equipment — computers, printers, monitors, facsimile machines, scanners. Household items — vacuum cleaners, fans, fluorescent and incandescent lights, shavers, sewing machines. Kitchen appliances — coffee makers, blenders, ice markers, toasters. Industrial equipment — metal halide lamp, high — pressure sodium lamp. Home entertainment electronics — television, VCRs, video games, stereos, musical instruments, satellite equipment. www.zampsolar.com Zamp Solar, USA 2.3 Mechanical Drawing Model No: ZS-1000PSC, ZS-2000PSC, ZS-3000PSC, ZS-1000-PS40-C, ZS-2000-60PS-C ZS-3000-PS60-C (below) O DE Terminal о SE a 3 =>. CANTOS: ELK LER AL HEN. É FT PCT | TE FACHO ESA E DIP Switch (— RT a _ Tp < 5 pr te © DC Terminal © DIP Switch (Battery/AC Priority) _ Generator Starting Terminal : CAUTHIN su. DE Terminal(Solar) q e Grounding Terminal + - + — Le INPUT | CEA] © Inverter Output Cuit Breaker 4 Charger Input Circurt Breaker GFCI 4 AC Terminal | | Zamp Solar,USA www.zampsolar.com Model No: ZS-4000-PS560-C, ZS-5000-PS60-C, ZS-6000-PS60-C (below) / | | | | | | | | | REGATIVE PORITIVE BATIENY Ре, И РОТ ВД Ball THERE T SA AMC mia EAT o —|Bi_—l.]—]]€“—— OOOO OOO BATTERY TERMINAL CONNECTORS N © DC Terminal Le! @ = J Battery Negative | @ й HIE DC Terminal(Solar) [| — TTON: CAU , RISK OF ELECTRICAL SHOCK. MSCONNECT BOTH AC 4 DC so DC Terminal — | fi == | | © N A | A —— Battary Positive [DE OUTPUT] OUTPUT * | 1 DE Fan ©) 1 DC Terminæl{Battery} £3) HOT BLOCK THE FAN. ICM CLEARANCE IS Y RECOMMENDED 9 — AC Terminal Charger Input Circuit Breaker CHARGER INPUT PROTECT P AC Fan DIP Switch © Inverter Output Circuit Breaker @ Generator Starting Terminal (5) DIP Switch (Battery/AC Priority] Grounding Terminal Zamp Solar, USA 2-4, Features High overload ability up to 300% rated power (20 sec) Low quiescent current, low power “Power Saving Mode” to conserve energy 4-step intelligent battery charging, PFC (Power Factor Correction) for charger 8 pre set battery type selector plus de-sulphation for totally flat batteries Powerful charge rate up to 120Amp, selectable from 0%-100% 10 ms typical transfer time between battery and AC, guarantees power continuity Smart remote control 15s delay before transfer when AC resumes, extra protection for loads when used with generator Allows start up and through power with depleted batteries | 30A/40A through current ability Multiple controlled cooling fan Extensive protections against various harsh situations 13VDC battery recover point, dedicated for renewable energy systems 2.5 Electrical Performance 2.5.1 Invert Topology Zamp Solar inverter/charger is built according to the following topology. Invert: Full Bridge Topology. Charge: Isolate Boost Topology Because of high efficiency Mosfets and 16bit, 4 9MHZ microprocessor and heavy transformers, it outputs PURE SINE WAVE AC with an average THD of 15% (min 5%, max 25%) depending of load connected and battery voltage. The peak efficiency of ZS series is 88%. Overload Capacity Zamp Solar inverters have different overload capacities, making it ideal to handle demanding loads. 1 For 110%<Load<125%(+10%), no audible alarm in 14 minutes, beeps 0.5s every 1s in the 15th minute, and Fault{Turn off) after the 15th minute. 2 For 125%<Load<150%(+10%), beeps 0.5s every 1s and Fault(Turn off) after the 1 minute. 3 For 300% E Load>150%(+10%), beeps 0.5s every 1s and Fault(Turn off) after 20s. 2.5.2 AC Charger Zamp Solar inverter is equipped with an active PFC (Power Factor Corrected) multistage battery charger. The PFC feature is used to control the amount of power used to charge the batteries in order to obtain a power factor as close as possible to 1. Unlike other inverters whose max charging current decreases according to the input AC voltage, Zamp Solar series charger is able to output max current as long as input AC voltage is in the range of 164-243VAC(95-127VAC for 120V model), and AC freq is in the range of 48-54Hz(58-64Hz for 60Hz 7 www.zampsolar.com Zamp Solar, USA www. zampsolar.com model). Zamp Solar inverter has a strong charging current of 90Amp (for 3KW,12V), and the max charge current can be adjusted from 0%-100% via a liner switch at the right of the battery type selector. This will be helpful if you are using our powerful charger on a small capacity battery bank. Fortunately, the liner switch can effectively reduce the max charging current to 20% of its peak. Choosing “0 in the battery type selector will disable charging function. Ue 4000 mes SRG Ji rie alba LHARGEH leh ATER NI 1... _ нина Ен o i Ed A = ну ны Well Ha "il emma Aa dere Ge a july dll rei There are mainly 3 stages: Bulk Charging: This is the initial stage of charging, While Bulk Charging, the charger supplies the battery with controlled constant current. The charger will remain in Bulk charge until the Absorption charge voltage (determined by the Battery Type selection) is achieved. Software timer will measure the time from A/C start until the battery charger reaches 0.3V below the boost voltage, then take this time asT0 and TOx2 =T1. Absorption Charging: This is the second charging stage and begins after the absorb voltage has been reached, Absorption Charging provides the batteries with a constant voltage and reduces the DC charging current in order to maintain the absorb voltage setting. In this period, the inverter will start a T1 timer; the charger will keep the boost voltage m Boost CY mode until the T1 timer has run out. Then drop the voltage down to the float voltage. The timer has a minimum time of 1 hour and a maximum time of 12 hours. Float Charging: The third charging stage occurs at the end of the Absorption Charging time, While Float charging, the charge voltage is reduced to the fl oat charge voltage (determined by the Battery Type selection*). In this stage, the batteries are kept fully charged and ready if needed by the inverter. If the A/C is reconnected or the battéry voltage drops below 12Vde/24Vdc, the charger will reset the cycle above. If the charge maintains the float state for 10 days, the charger will deliberately reset the cycle to protect the battery. Zamp Solar, USA www.zampsolar.com Battery Charging Processes Lex tQ haa ter Max $2 die | : 14.5 + asia hata toas 24 0 и! A ME 2 : Te, I E чести | _2 hae me he un] RR “ / | CA à» [Му фр ' Voitage Current— — — a a e 5 tas Ma AMUSTARIS FT: VY'F DEPCNDING ON há TRAY RANK CEFACITF Table 2.1 Battery type selector Switch Setting Description | Boost / Vde | Float / Vdc 0 Charger Off 1 Gel USA 14.0 13.7 2 AGM 1 14.1 13.4 3 AGM 2 14.6 13.7 4 Sealed lead acid 14.4 13.6 5 Gel EURO 14.4 13.8 6 Open lead acid 14.8 13.3 7 Calcium 15.1 13.6 8 De-sulphation 15.5 (4 Hours then Off) 9 Not used - | - 12Vdc Mode (*2 for 24Vde ; *4 for 48Vdc) De-sulphation The de-sulphation cycle on switch position 8 is marked in red because this is a very dangerous setting if you do not know what you are doing. Before ever attempting to use this cycle you must clearly understand what it does and when and how you would use it. What causes sulphation? This can occur with infrequent use of the batteries(nor), or if the batteries have been left discharged so low that they will not accept a charge. This cycle is a very high voltage charge cycle designed to try to break down the sulphated crust that is preventing the plates taking a charge and thus allow the plates to clean up and so accept charge once again. Charging depleted batteries Zamp Solar inverter allows start up and through power with depleted batteries. For 12VDC model, after the battery voltage goes below 10V, if the switch is still (and always) kept in "ON" position, the inverter is always connected with battery, and the battery voltage doesn't drop below 2V, the inverter will be able to charge the battery once qualified AC inputs are present. Before the battery voltage goes below 9VDC, the charging can be activated when the switch is turned to “Off”, then to “ON” Zamp Solar,USA www.zampsolar.com When the voltage goes below 9VDC, and you accidently turn the switch to OFF or disconnect the inverter from battery, the inverter will not be able to charge the battery once again, because the CPU loses memory during this process. Table 2.2 Charging Current for each model Model Battery Voltage AC Charger Current Model Battery AC Charger Current Watt Max Watt Voltage Max 1000 12 Vdc 45 + 5 Amp 12 Vdc 70 + 5 Amp = 24 Vdc 25 + 5 Amp 2000 24 Vdc 35 + 5 Amp 1500 48 Vdc 15 £ 5 Amp 48 Vdc 20 + 5 Amp 12 Vdc 90 + 5 Amp 12 Vdc 120 + 5 Amp 3000 24 Vdc 50 + 5 Amp 4000 24 Мас 65 + 5 Amp 48 Vdc 30 + 5 Amp 48 Vdc 40 Е 5 Amp 5000 24 Vdc 80 — 5 Amp 6000 24 Voc 90 + 5 Amp 48 Vdc 50 + 5 Amp 48 Vdc 60 £ 5 Amp The charging capacity will go to peak in around 3 seconds. This may cause a generator to drop frequency, making inverter transfer to battery mode. It is suggested to gradually put charging load on the generator by switching the charging switch from min to max, together with the 15s switch delay, our inverter gives the generator enough time to spin up. This will depend on the size of the generator and rate of charge. 2.5.3 Transfer While in the Standby Mode, the AC input is continually monitored. Whenever AC power falls below the VAC Trip voltage (154 VAC, default setting for 230VAC,90VAC for 120VAC), the inverter automatically transfers back to the Invert Mode with minimum interruption to your appliances - as long as the inverter is turned on. The transfer from Standby mode to Inverter mode occurs in approximately 10 milliseconds. And it is the same time from Inverter mode to Standby mode. Though it is not designed as a computer UPS system, this transfer time is usually fast enough to keep your equipment powered up. There is a 15-second delay from the time the inverter senses that continuously qualified AC is present at the input terminals to when the transfer is made. This delay is built in to provide time for a generator to spin-up to a stable voltage and avoid relay chattering. The inverter will not transfer to generator until it has locked onto the generator’s output. This delay is also designed to avoid frequent switching when input utility is unstable. 2.5.4 Auto frequency adjust The inverter, has Auto Frequency adjust function. The factory default configuration for 220/230/240VAC inverter is 50Hz, and 60Hz for 110/110/120VAC inverter. The output frequency is automatically adjusted once a qualified frequency is applied to the inverter. If you want to get 60Hz from a 30Hz inverter, just input 60Hz power, and the inverter will automatically adjust the output freq to 60Hz and vice versa. 10 Zamp Solar, USA. 2.5.5 Solar Charger Listed are the specifications for solar charger. Table 2.3 Electrical Specification @ 25°C www.zampsolar.com Rated Voltage 12Vdc | 24Vdc 48Yde Rated charge current (includes CE od curren 40/60 Amp 40Amp Load current 15Amp Input voltage range 15-30Vdc 30-55Vde 60-100Vdc Max, PV open cırcult array 30Vde 55Vde 100Vde voitage 2.0 * I(Rated)}>5s Overload protection (DC load) 1.5 * I(Rated) >20s 1.25 * I(Rated) temperature controlled Typical idle consumption At idle < 10mA Bulk charge 14.6Vdc 29.2Yde 58.4Vdc Floating charge 13.4Vde 26.8Vdc 53.6Vdc Equalization charge 14.0Vdc 28.0Vdc 58.0Vdc Over charge disconnect 14.8Vde 29.6Vdc 59.2Vdc Over charge recovery 13.6Vde 27.2 Vdc 54.4Vdc Over discharge disconnect 10.8Vdc 21.6Vde 43.2Vdc Over discharge reconnect 12.3Vde 24 .6Vde 49.6Vde Temperature compensation -13.2mV/C -26.4mY/C -32.8mV/C Lead acid battery settings Adjustable NiCad battery settings Adjustable | Low voltage reconnect 12.0-14.0Vdc 24.0-28.0Vdc 48.0-56.0Vdc Low voltage disconnect 10.5-12.5Vde 21.0-25.0Vdc 42.0-50.0Vdc Ambient temperature 0-40°C (Full load) 40-60°C (De-rating) Altitude Operating 5000m, Non-Operating 16000m Protection class [P21 BTS Battery temperature sensor(D Optional remote battery temperature sensor for increased charging precision Terminal size (fine/single wire) #8 AWG NOTE: (D The optional battery temperature sensor automatically adjusts the charging process of the controller according to the type of battery that is selected by user through battery type selector. With the battery temperature sensor installed, the controller will increase or decrease the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and maintain optional performance of the battery. Maximum Power Point Tracking (MPPT) Function Maximum Power Point Tracking, frequently referred to as MPPT, is an electronic system that operates the 11 Zamp Solar, USA www.zampsolar.com Photovoltaic (PV) modules in a manner that allows the modules to produce all the power they are capable of. The PY-seeker Charge controller is a microprocessor-based system designed to implement the MPPT. And it can increase charge current up to 30% or more compared to traditional charge controllers (see figure 1). < Module Termperature : 25UT3) i20 | + J =! gl В | I OOOW Arf } 3 51 ATP someras | | # e 5 1 ergeben RS HT = 4 | : E 1 atras coser 0 i oy | ea Sa TEE | BOOW io _ 1000W я NT нА 5 0 15 20 35 Figure 1 Current, Power vs. Voltage Characteristics The Charge controller built in is with 12/24V battery voltage auto detecting function. For 12VDC inverter, the output voltage of solar charger will be accordingly 12VDC, and the qualified DC input volt range is 15v-30YDC. For 24VDC inverter, the output voltage of solar charger will be accordingly 24VDC, and the qualified DC input volt range is 30v-55VDC. If the voltage falls out of this range, the charger will not work properly. Special attention should be paid to this when configuring the solar array. 2.5.6 Automatic Voltage Regulation (Optional) Instead of simply bypassing the input AC to power the loads, the inverter stabilizes the input AC voltage to a range of 230V/120Y 10%. Connected with batteries, the Zamp Solar inverter will function as a UPS with max transfer time of 10 ms. With all the unique features our inverter provides, it will bring you long-term trouble free operation beyond your expectation. Function Introduction 12 Zamp Solar, USA ; www.zampsolar.com When power switch is turned to either of “Power Saver Auto” or “Power Saver Off”, the inverter is powered on. Power saver function is designed to conserve battery power when AC power is not or rarely required by the loads. In this mode, the inverter pulses the AC output looking for an AC load (i.e., electrical appliance). Whenever an AC load (greater than 25 watts) is turned on, the inverter recognizes the need for power and automatically starts inverting and output goes to full voltage. When there is no load (or less than 25 watts) detected, the inverter automatically goes back into search mode to minimize energy ftnsumption from the battery bank. In “Power saver on” mode, the inverter will draw power mainly in sensing moments, thus the idle consumption is significantly reduced. The inverter is factory defaulted to detect load for 250ms every 30 seconds. This cycle can be customized to 3 seconds thru SW3 on the DIP switch. Power saver off Power saver on Power saver on{Load detected) Zamp Solar,USA www.zampsolar.com MOCE Irp.t Voltage Transfer Molris Scttery 1 Всс* = Norme + Line Bocs:+ Obl Boog!" mm Jotlery + AB C DB E F G # 1 35 Nomre Volage ____ ** Qaly *spolzebis. Table 2.4 Input Voltage Transfer Points Function LV (NA/JPN) HV (INTL) Acceptable Input Voltage Range (Vac) 0-160 0-300 Nominal Input Voltages (Vac) 100 110 120 220 230 240 (A) Line low loss N/W (On battery) 75/65 | 84/72 | 92/78 | 168/143 | 176/150 | 183/156 (B) Line Low comeback N/W (On Boost) | 80/70 | 89/77 | 97/83 | 178/153 | 186/160 | 193/166 (C) Line 2nd boost threshold (On Boost) «+ E cos du A (D) Line 2nd boost comeback (On normal) ad + ** + ++ ** (E) Line 1st boost threshold (On Boost) 90 99 108 198 207 216 (F) Line 1st boost comeback (On normal) 93 103 112 205 215 225 (GQ) Line buck comeback (On Normal) 106 118 128 235 246 256 (H) Line buck threshold (On Buck) 110 121 132 242 253 264 (I) Line high comeback (On Buck) 115 127 139 253 266 278 | (7) Line high loss (On Battery) 120 | 132 | 144 | 263 276 288 2.5.7 Power Saver There are 2 different working statuses for Zamp Solar inverter: “Power On” and “Power Off” When power switch is in “Unit Off” position, the inverter is powered off. 13 Note:fThe minimum power of load to take inverter out of sleep mode (Power Saver On) is 25 Watts. Idle Power Consumption Model Power Saver Off Power Saver Auto Idle 3Secs (Max) 30Secs (Max) 1000W 16W 7.5W 5.3W 1500W 18W 7.5W 5.3W 2000W 32W 11.5W 5.8W 3000W 45W 20.0W 6.6 4000W 50W 20.0W 6.6W 5000W 55W 25.0W 6.8W -— 6000W TTIW 30.0W 7.2W When in the search sense mode, the green power LED will blink and the inverter will make a ticking sound. At full output voltage, the green power LED will light steadily and the inverter will make a steady humming sound. When the inverter is used as an “uninterruptible” power supply the search sense mode or “Power Saver On” function should be defeated. Exceptions: Some devices when scanned by the load sensor cannot be detected. Small fluorescent lights are the most common example. (Try altering the plug polarity by turning the plug over.) Some computers and sophisticated electronics have power supplies that do not present a load until line voltage is available. When this occurs, each unit waits for the other to begin. To drive these loads either a small companion load must be used to bring the inverter out of its search mode, or the inverter may be programmed to remain at full output voltage. 2.5.8 Protections 14 Zamp Solar,USA www. zampsolar.com Zamp Solar inverter is equipped with extensive protections against various harsh situations/faults. These protections include: AC Input over voltage protection/AC Input low voltage protection. Low battery alarm/High battery alarm, Over temperature protection/Over load protection. Short Circuit protection (1s after fault). Back feeding protection. E © @ When Over temperature /Over load occur, after the fault is cleared, the master switch has to be reset to restart the inverter. The Low battery voltage trip point can be customized from defaulted value 10VDC to 10.5VDC thru the SW1 on DIP switch. The inverter will go to over temp protection when the heat sink temp. >105"%C, and go to Fault (shutdown Output) after 30 seconds. The switch has to be reset to activate the inverter. Zamp Solar Inverter has back feeding protection which avoids presenting an AC voltage on the AC input terminal in Invert mode. After the reason for fault is cleared, the inverter has to be reset to start working. 2.5.9 Remote control (Optional) Apart from the switch panel on the front of the inverter, an extra switch panel connected to the RJ11 port at the DC side of the inverter thru a standard telephone cable can also control the operation of the inverter. If an extra switch panel is connected to the inverter via “remote control port”, together with the panel on the inverter case, the two panels will be connected and operated in parallel. Whichever first switches from “Off” to “Power saver off” or “Power saver on”, it will power the inverter on. If the commands from the two panels conflict, the inverter will accept command according to the following priority: » Power saver on> Power saver off> Power off. e Only when both panels are turned to “Unit Off” position will the inverter be powered off. * The Max length of the cable is 30 Ft. WARNING Never cut the telephone cable when the cable is attached to inverter and battery is connected to the inverter. Even if the inverter is turned off. It will damage the remote PCB inside if the cable is short circuited during cutting. 2.5.10 LED Indicator & LCD 15 Zamp Solar,USA www.zampsolar.com | ОВ À Г 4 Ris ist ji Asta SHORE POWER ON GREEN LED lit in AC Mode INVERTER ON GREEN LED lit in Inverter Mode FAST CHARGE Yellow LED lit in Fast Charging Mode FLOAT CHARGE GREEN LED lit in Float Charging Mode OVER TEMP TRIP RED LED lit in Over Temperature OVER LOAD TRIP RED LED lit in Over Load POWER SAVER ON GREEN LED lit in Powet Saver Mode (Power Saver Load =25W) The LCD will display the following content: 1 Greeting message “Welcome to ZAMP SOLAR” WELCOME TO 2 AC Status & Input Voltage AL: normal L'PV:230V “AC: abnormal” will be displayed when AC input 18 not qualified. 3 Output Voltage/Frequency and Battery voltage O/P-V-230V F-50H7 + Та ЧЕ) EN 4 Output Current( in percentage) O/P Current: 100%, 2.5.11 Audible Alarm 16 Zamp Solar,USA www.zampsolar.com Battery Voltage Low Inverter green LED lit, and the buzzer beeps 0.5s every 5s. Battery Voltage High A green LED lit, and the buzzer beeps 0.5s every 1s and Fault after (1)110%<load<125%(+10%), No audible alarm in 14 minutes, Knvert Mode Over-Load | 125% tonte S0V4( 1049 Boop 05 vay 1 ad Fu fer бо: (3)Load>150%(+10%), Beeps 0.5s every 1s and Fault after 20s; Over Temperature но sink temp. =105°C, Over temp red LED Lighting, beeps 0.5s every 2.5.12 FAN Operation For 1-3KW, there is one multiple controlled DC fan which starts to work according to the following logic. For 4-6KW, there is one multiple controlled DC fan and one AC fan. The DC fan will work in the same way as the one on 1-3KW, while the AC fan will work once there is AC output from the inverter. So when the inverter is in power saver mode, the AC fan will work from time to time in response to the pulse sent by the inverter in power saver mode. The Operation of the DC fan at the DC terminal side is controlled by the following logic: Condition Enter condition Leave condition | Speed T < 60€ T > 65'C OFF . HEAT SINK T < 60% or 65C< T<85 © 50% TEMPERATURE T > 85€ ° T > 85°C T < 80€ 100% | < 15% | > 20% OFF CHARGER A | = 15%or < 50% CURRENT | 0%<1550%Max | > 50%Max N | > 50%Max | < 40% Мах 100% Load < 30% Load = 30% OFF LOAD% | Load < 20% or < < 50° 505 (INVMODE) | 30% 0ad<S0% | Load = 50% N Load > 50% Load < 40% 100% Allow at least 12” of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit. The fan noise level <60db at a distance of 3Ft. 2.5.13 DIP Switches On the DC end of inverter, there are 4 DIP switches which enable users to customize the performance of the device: 17 Zamp Solar, USA www.zampsolar.com Switch NO Switch Function Position: 0 Position: 1 : | 10.0YDC | 1O.SYDC SW1 Low Battery Trip Volt 10 *2 for 24VDC, *4 for 48VDC SW2(230V) | AC Input Range 184-253 VAC 154-253VAC SW2(120V) | AC Input Range 100-135VAC —. | 90-135VAC SW3 Load Sensing Cycle 30 seconds 3 secorfs SW4 Battery/AC Priority Utility Priority Battery Priority Low Battery Trip Volt: For 12VDC model, the Low Battery Trip Volt is set at 10.0VDC by default. It can be customized to 10.5VDC using SW1, this is to prevent batteries from over-discharging while there is only a small load applied on the inverter. *2 for 24VDC, *4 for 48VDC. AC Input Range: There are different acceptable AC input ranges for different kinds of loads. For some relatively sensitive electronic devices, a narrow input range of 184-253VAC (100-135V for 120VAC model) is required to protect them. While for some resistive loads which work in a wide voltage range, the input AC range can be customized to 154-253VAC (90-135V for 120VAC model), this helps to power loads with the most AC input power without frequent switches to the battery bank. Load Sensing Cycle: The inverter is factory defaulted to detect load for 250ms in every 30 seconds. This cycle can be customized to 3 seconds thru the SW3 on the DIP switch. AC/Battery Priority: Our inverter is designed with AC priority by default. This means, when AC input is present, the battery will be charged first, and the inverter will transfer the input AC to power the load. Only when the AC input is stable for a continuous period of 15 days, the inverter will start a battery inverting cycle to protect the battery. After 1 cycle normal charging and ac through put will be restored. The AC Priority and Battery Priority switch is SW4. When you choose battery priority, the inverter will inverting from battery despite the AC input. Only when the battery voltage is reaches low voltage alarm point(10.5V for 12V), the inverter transfers to AC Input, charges battery, and switches back to battery when battery is charged full. This function is mainly for wind/solar systems taking utility power as back up. 2.5.14 Output Socket The inverter is either equipped with a dual GFCT socket (rated at 30Amps) or an universal socket (rated at 10Amps) for more convenient wiring. 2.5.15 Other features Battery voltage recover start After low battery voltage shut off (10V for 12V model/20V for 24V model/40V for 48V model), the inverter is able to restore operation after the battery voltage recovers to 13Vdc/26Vde/52Vde (with power switch still in the “On” position). This function helps to save the users extra labor to reactivate the inverter when the low battery voltage returns to an acceptable range in the renewable energy systems. The built in battery charger will automatically reactivate as soon as city/generator ac has been stable for 15 seconds. 18 Zamp Solar,USA www.zampsolar.com Zamp Solar,USA www.zampsolar.com 1000 12 Vdc 30mm? | 40mm: 12 Vdc 60mm? 75mm? À a 24 Vdc 1mm? | 20mm? 2000 24 Vdc 30mm2 | 45mm? AN 1500 48 Vdc 10mm? | 15mm? 48 Vdc 15mm? | 25mm: as WARNING 12 Vdc 90mm? { 120mm? 12 Vdc 120mm? | 150mm? Never leave the loads unattended, some loads (like a Heater) may cause accident in such cases. 3000 24 Vdc 45mm? | 60mm? | 4000 24 Vdc 60mm® | 75mm? It is better to shut everything down after low voltage trip than to leave your load on, due to the risk of fire. 48 Vdc . 25mm? | 30mm? 48 Vdc nm? 40mm? 5000 24 Vdc fomm? | 95mm? 6000 24 Vdc 90m uE 120mm? Auto Gen Start 48 Vdc 40mm? | 50mm? 48 Vdc 45mm2 | 60mm? The inverter can be customized to start up a generator when battery voltage goes low. When the inverter - goes to low battery alarm, it can send a signal to start a generator, and tum the generator off after battery charging is finished. The auto gen start feature will only work with generators designed to work with this feature. There is an open/closed relay that will short circuit the positive and negative cable from a generator. a The input DC voltage can vary, but the Max current the relay can carry is 16Amp. Please note that if there is a problem obtaining for example 90mm? cable, use 2*50mm? or 3*35mm?. One cable is always best , but cable is simply copper and all you require is the copper, so it does not matter if it is one cable or 10 cables as long as the square area adds up. Performance of any product can be improved by thicker cable and shorter runs, so if in doubt round up and keep the length as short as possible, Conformal Coating Zamp Solar entire line of inverters has been processed with a conformal coating on the PCB making it water, rust, and dust resistant. 3.3 AC Wiring We recommend using 10-5AWG wire to connect to the ac terminal block, 3 Installation There are 3 different ways of connecting to the terminal block depending on the model. All the wirings are ETL, CE and Conform ULA458 compliant, Call our tech support if you are not sure about how to wire any part of your inverter, 3.1 Location Wiring Option 1 De Follow all the local regulations to install the inverter. Please install the equipment in a location that is Dry, Clean, Cool and that has good ventilation. e Working temperature: - 10°C - 40°C * Storage temperature: - 40 - 70°C e Relative Humidity: 0% - 95%, non-condensing e Cooling: Forced air 230V single phase/120V single phase Input: Hot line+Neutral+Ground Output: Hot line+Neutral+Ground AC INPUT 3.2 DC Wiring recommendation i ; ; в . Wiring Option 2 It is suggested the battery bank be kept as close as possible to the inverter. The following able is a suggested o © = wiring option for 1 meter DC cable. 230Y split phase . Input: Hot line+ Hot line +Ground Output: Hot line+ Hot line +Neutral ) Please find the following minimum wire size. In case of DC cable longer than 1m, please increase the cross section of cable to reduce the loss. AC INPUT Wire Gage /Min Wire Gage /Min Model M | © Battery Voltage 1.0-5.0 ode Battery Watt 0~1.0m Watt Voltage 0~1.0m a m m 19 20 Zamp Solar, USA www. zampsolar.com Wiring Option 3 L LIL L N @ do 230V split phase | | Input: Hot line+ Hot line +Ground Output: Hot line +Neutral Remark: In such cases, each output hotline can only carry a max of half the rated capacity. AS INPUT ACINPUT AC CUTPUT » 3.4 Install Flange 21 Zamp Solar, USA www.zampsolar.com 1-3KW Model 412 /mm(16.48 Inch) 7mm(D.28 Inch) | i AY о o о № 3.Smm(0.37 Inch) 307.9mm(12.12 Inch) Frame 2 358.6mm(14.12 Inch) 257mm( 10.12 Inch} ___ 221.6mm(8.72 Inch) hy == о в = ds 7 с A = = Г —_ == RE ===, ® i = ==) | | == ‚ [em fer aa 1 ! | + === | 8 pu Tal | le! E de) od оО O NE Ro, № a x => a тат За Æ E Re Pa A Ë = a | Pe A | fi e. À Ÿ gr e minha Eyal E | i AEN SS A POE 1, = 7 a E Ma E = € e ras = А, 74 5 CO a: ire a fi) E ELU = CN co ti DEE И | | ul 14 иен 22 Omm(8.66 псп) --=—-- ZZ 22 Lump Sole LIRA т- 340 mim (13.38 Lach) _ EOE SEEN GE RE ce mm em ed wi ie cw ci a a Zr a m == ¡— 180 mm (7.48 lachi rat i WA SR im 23 46h Medel Zomp Sale LISA Www snmp con 4 Troubleshooting Guide Troubleshooting guide contains information about how to troubleshoot possible error conditions while using the Zamp Solar Inverter & Charger. The following chart is designed to help you quickly pinpoint the most common invéwer failures: Indicator and Buzzer et Fran Fanei Frau Na Ta Saad [river Chñ Ligurie Eolo irme Silver LAN [piers Per 0% every Ey [Eatery Mor 0 46 every a Tutor in “halide alicia" Chip Nips ime Мм Civ fren Lin heat ling Inverter | Mode Mery Uh %p ver is —— | Crer Tora E aL Нему П 51 ERE Ju Ffir en Dv Веер + % Ci TEE | 1 fire! CINTA. Faux Tauik Вайт ид fe САР | MEE His 1) чей И Но д НД Мас! АНЯ |НА Oberried Caipai Wide Estat Finili bez i ew le ! CIHTENEHINA mir He Change cinéastes | Mach [Teil Dee Rh diminue | 24 Zamp Solar, USA www.zampselar.com Symptom Possible Cause Recommended Solution Inverter will not turn on during initial power up. Batteries are not connected, loose battery-side comections. Low battery voltage. Check the batteries and cable comections. Check DC fuse and breaker. Charge the battery. No AC output voltage and no Inverter has been manually Press the switch to Power saver on indicator lights ON, transitioned to OFF mode. or Power saver off position. AC output voltage is low and the Check the condition of the inverter turns loads OFF in a short | Low battery. batteries and recharge if possible. time, Charger is inoperative and unit | AC voltage has dropped Check the AC voltage for proper Will not accept AC. out-of-tolerance voltage and frequency. Charger is supplying a lower charge rate. Charger controls are improperly set. Low AC input voltage. Loose battery or AC input connections. Refer to the section on adjusting the “Charger Rate”. Source qualified AC power.. Check all DC /AC connections. Charger turns OFF while charging from a generator. High AC input voltages from the generator, Load the generator down with a heavy load. Tum the generator output voltage down. Sensitive loads turn off . temporarily when transferring between grid and inverting. Inverter's Low voltage trip voltage may be too low to sustain certain loads. Choose narrow AC voltage in the DIP switch, or Install a UPS if possible. Noise from Transformer/case* Applying specific loads such as hair drier Remove the loads *The reason for the noise from transformer and/or case When in inverter mode sometimes the transformer and/or case of the inverter may vibrate and make noise. If the noise comes from transformer: According to the characteristics of our inverter, mainly there is one type of load which most likely may cause rattles of transformer. That is half wave load: A load that uses only half cycle of the power (see figure 1). This tends to cause an imbalance of the magnetic field of the transformer, reducing its rated working freq from 20KHz to, say, maybe 15KHz (it varies according to different loads). In such a case the frequency of noise falls exactly into the range (200Hz-20KHz) that human ears can hear. The most common load of such kind is a hair drier. If the noise comes from the case: Normally when loaded with inductive loads, the magnetic field generated by the transformer keeps attracting or releasing the steel case at a specific freq, this may also cause noise. Reducing the load power or using an inverter with bigger capacity will normally solve this problem. The noise will not do any harm to the inverter or the loads. 25 Zamp Solar, USA wyww.zampsolar.com U “TEA a = Figure 1 5 Warranty We offer a 1 year limited warranty. The following cases are not covered under warranty. 1 DC polarity reverse. The inverter is designed without DC polarity reverse protection. A polarity reverse may severely damage the inverter. 2 Wrong AC wiring 3 Operating in a wet environment. 4 Operating with an undersized generator or generator with unqualified wave form. ZAMP SOLAR, USA Warranty Instructions: This product is designed using the most modern digital technology and under very strict quality control and testing guide lines. If however you feel this product is not performing as it should, please contact us: support(@zampsolar.com We will do our best to resolve your concerns. You have a full 1 year from date of purchase warranty. This warranty only applies to ZAMP SOLAR branded products. All other name brand products are warranted by and according to their respective manufacturer. All warranty claims must include an original receipt and are valid for original puschasur only. Please do not attempt to return non-Zamp Solar branded products to ZAMP SOLAR. To find out where to buy any of our products, you may visit us at www.zampsolar.com or e-mail us at: [email protected] or call 541-728-0924 Note: Specifications subject to change without notice. 26 Zamp Solar, USA www.zampsolar.com Bypass over load current 35amp: Alarm 45amp: Alarm AVR Function | Input AC Voltage Range 78-144V+4% 150-276V+4% (Optional) Stabilized Output Voltage rms 120VAC +10% RMS: 230VAC +10% RMS Rated Voltage 12V/24V/48V Solar Input Voltage Range 15-30Vde / 30-55Vdc / 55-100Vdc Rated Charge Current 40A/60A * Rated Output Current ISA Self Consumption < 10mA Bulk Charge 14.5 V(default) Solar Charger F loating Charge 13.5V (default) Equalization Charge 14.0V(default) Over Charge Disconnection 14.8 V(default) *2 for 24 Vdc; Over Charge Recovery 13.6 V(default) *4 for 48Vdc; Over Discharge Disconnection 10.8V (default) Over Discharge Reconnection 12.3V(default) Temperature Compensation - 13.2mYFC Ambient Temperature 0-40°C(Full load) 40-60'C (Derating) Mounting Wall mount Tower Inverter Dimensions(L* W*H) 598*215*179mm 470*190*340mm Inverter Weight 21KG | 22KG | 23KG | 27KG | 38KG | 48KG | 49KG Mechanical Shippin Specifications Eo ena *W*H) = a. Shipping Weight 23KG | 24kg | 25KG | 29KG | 40KG | 50KG | SIKG Display Status LEDs / Status LEDs+LCD Standard Warranty 1 Year Zamp Solar,USA www.zampsolar.com Appendix 1 Electrical Specifications Model 1000W | 1500W | 2000W | 3000W | 4000W | 5000W | 6000W Continuous Output Power 1000W | 1500W | 2000W | 3000W | 4000W | 5000W | 6000W Surge Rating(20s) 3000W | 4500W | 6000W | 9000W | 12000W | 15000W | 18000W Output Waveform Pure Sine wave/Same as input(Bypass mode) Nominal Efficiency >88%(Peak) Line Mode Efficiency >95% Power Factor 0.9-1.0 Inverter Output - Nominal Output Voltage rms 100-110-120Vac / 220-230-240Vac Output Voltage Regulation +10% RMS Output Frequency 50Hz + 0.3Hz/60Hz + 0.3Hz Short Circuit Protection Yes( ls after fault ) Typical transfer Time 10ms{Max) THD < 10% Nominal Input Voltage PS { *2 for 24Vdc, *4 for 48Vdc) Minimum Start Voltage 10.0Vde Low Battery Alarm 10.5Vde / 11.0Vdc DC Input Low Battery Trip 10.0Vde / 10.5Vdc High Voltage Alarm 16.0Vdc Low Battery voltage recover 15.5Vdc Idle Consumption-Search < 25 W When Power Saver On Mode Output Voltage Depends on battery type Charger Breaker Rating 104 | 15A | 204 | 20A | 20a | 30A | 30a Max Charge Rate Refer to Table2.2 (Pagel0) Charger | Battery Initial Voltage for 10-15.7V for 12V( *2 for 24V, *4 for 48V) Start Up a 3 15.7V for 12V (*2 for 24V, *4 for 48V) Shutdown Remote Control Yes, Optional Bypass & Input Voltage Waveform Sine wave (Grid or Generator) Protection — | Nominal Voltage 110Vac 120Vac 220Vac | 230Vac | 240Vac Max Input AC Voltage 150VAC 270VAC Nominal Input Frequency 50Hz or 60Hz (Auto detect) Low Freq Trip 4740.3Hz for 50Hz, 57+0.3Hz for 60Hz High Freq Trip 55+0.3Hz for 50Hz, 65+0.3Hz for 60Hz Overload protection(SMPS Circuit breaker load) Output Short circuit protection Circuit breaker Bypass breaker rating 10A | 15a | 20a | 30a 30A 40A 40A Transfer switch rating 30amp for UL & TUV 40amp for UL Bypass without batte ne 7 Max bypass current 30amp 40amp 27 28 ">

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Key features
- Pure sine wave output
- Multi-stage battery charging
- High overload capacity
- Low quiescent current
- Fast transfer time
- Battery/AC priority selection
- Extensive protections