HP Series Pure Sine Wave Inverter/Charger User`s Manual Version

HP Series Pure Sine Wave Inverter/Charger User`s Manual Version

HP Series

Pure Sine Wave Inverter/Charger

User’s Manual

Version 1.0

Franklin Chu Date: JULY, 2013

1

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 ........................................................................................................................................ 8

2.5.3 Transfer ............................................................................................................................................ 10

2.5.4 Solar Charger ................................................................................................................................... 10

2.5.5 Power Saver ..................................................................................................................................... 12

2.5.6 Protections........................................................................................................................................ 13

2.5.7 Remote control ................................................................................................................................. 13

2.5.8 LED Indicator & LCD ..................................................................................................................... 14

2.5.9 Audible Alarm ................................................................................................................................. 16

2.5.10 FAN Operation............................................................................................................................... 16

2.5.11 DIP Switches .................................................................................................................................. 17

2.5.12 Other features ................................................................................................................................. 19

3 Installation..................................................................................................................................................... 20

3.1 Location .............................................................................................................................................. 20

3.2 DC Wiring Recommendation ............................................................................................................. 20

3.3 AC Wiring Recommendation ............................................................................................................. 22

3.4 Grounding ........................................................................................................................................... 24

3.5 Install Flange ....................................................................................................................................... 25

4 Troubleshooting Guide ................................................................................................................................. 26

5 Warranty ....................................................................................................................................................... 28

6 Model Numbering ......................................................................................................................................... 28

Appendix 1 ....................................................................................................................................................... 29

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1. Important Safety Information

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 30CM(11.81 inches) of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit. A minimum air flow of 300CFM is required.

1-1-2. To avoid a risk of fire and electronic shock. Make sure that existing wiring is 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 userserviceable 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 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 APC SERIES 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 for at least 20 minutes 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 rechargeable batteries such as deep-cycle lead acid, lead antimony, lead calcium gel cell, absorbed mat, NiCad/NiFe or Lithium battery. Other types of batteries may burst, causing personal injury and damage.

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2. Introduction

2-1. General Information

Thank you for purchasing the HP Series Inverter/Charger.

HP Series Pure Sine Wave Inverter is a combination of an inverter, battery charger, auto generator starter and AC auto-transfer switch into one complete system with a peak conversion efficiency of 88%.

It is 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.

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.

The HP Series Inverter is equipped with a powerful charger of up to120Amps (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, the HP Series Pure Sine Wave Inverter is suitable for Renewable energy system, Utility, RV, Marin 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 trimmers, 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.

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2.3 Mechanical Drawing

5

6

2-4. Features

High overload ability up to 300% of rated power(20 sec)

Low quiescent current, low power „Power Saving Mode‟ to conserve energy

Automatic Generator Starting

Battery Temperature Sensing for increased charging precision

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 with optional LCD display

15s delay before transfer when AC resumes, extra protection for loads when used with generator

Allows start up and through power with depleted batteries

Multiple controlled cooling fan

Extensive protections against various harsh situations

Low battery recover function and Battery priority mode, dedicated for renewable energy systems

2.5 Electrical Performance

2.5.1 Invert

Topology

The HP inverter/charger is built according to the following topology.

Invert: Full Bridge Topology.

Charge: Isolated 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 8% (min 3%, max 10% under full linear load) depending of load connected and battery voltage.

The peak efficiency of HP series is 88%.

Overload Capacity

The HP series 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%≧Load>150%(±10%), beeps 0.5s every 1s and Fault(Turn off) after 20s.

Caution:

After the inverter is switched on, it takes a finite time for it to self diagnose and get ready to deliver full power. Hence, always switch on the load(s) after a few seconds of switching on the inverter. Avoid switching on the inverter with the load already switched on. This may prematurely trigger the overload protection. When a load is switched on, it may require initial higher power surge to start. Hence, if multiple loads are being powered, they should be switched on one by one so that the inverter is not overloaded by the higher starting surge if all the loads are switched on at once.

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2.5.2 AC Charger

HP Series 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, HP 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 model).

The HP series inverter has a very rapid charge current available, and the max charge current can be adjusted from 0%-100% via a liner switch to the right of the battery type selector. This will be helpful if you are using our powerful charger on a small capacity battery bank.

Choosing “0” in the battery type selector will disable charging function.

There are 3 main 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 T0×10 = T1.

Absorb Charging: This is the second charging stage and begins after the absorb voltage has been reached.

Absorb 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 in Boost CV 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 Absorb Charging time. While Float charging, the charge voltage is reduced to the float 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 battery voltage drops below 12Vdc/24Vdc/48Vdc, 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.

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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 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 from taking a charge and thus allow the plates to clean up and accept a charge once again.

Battery type selector

Switch setting

0

1

2

3

4

5

6

7

8

9

Description

Charger Off

Gel USA

AGM 1

AGM 2

Gel EURO

Open lead acid

Calcium

De sulphation

Not used

Boost / Vdc Float / Vdc

14.0

14.1

14.6

Sealed lead acid 14.4

14.4

14.8

15.1

13.7

13.4

13.7

13.6

13.8

13.3

13.6

15.5 (4 Hours then Off)

12Vdc Mode (*2 for 24Vdc ; *4 for 48Vdc)

Charging depleted batteries

The HP series 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.

Before the battery voltage going below 9VDC, the charging can activated when the switch is turned to “Off”, then to “ON”.

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 lose memory during this process.

Start up without battery function can be customized upon request.

Charging current for each model

Model

Watt

1KW

Battery Voltage

12 Vdc

Charging

Current

Model

Watt

35± 5 Amp 2KW

Battery Voltage

12 Vdc

Charging

Current

60± 5 Amp

1KW

1KW

3KW

3KW

3KW

5KW

24 Vdc

48 Vdc

12 Vdc

24 Vdc

48 Vdc

24 Vdc

20± 5 Amp 2KW

10± 5 Amp 2KW

80± 5 Amp 4KW

45± 5 Amp 4KW

25± 5 Amp 4KW

65± 5 Amp 6KW

24 Vdc

48 Vdc

12 Vdc

24 Vdc

48 Vdc

24 Vdc

30± 5 Amp

15± 5 Amp

100± 5 Amp

55± 5 Amp

35± 5 Amp

80± 5 Amp

5KW

8KW

8KW

48 Vdc

24 Vdc

48 Vdc

40± 5 Amp

100± 5 Amp

65± 5 Amp

6KW

10KW

12KW

48 Vdc

48 Vdc

48 Vdc

50± 5 Amp

80± 5 Amp

120± 5 Amp

The charging capacity will go to peak in around 3 seconds, this may probably cause a generator to drop frequency, making inverter transfer to battery mode.

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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.

Caution:

Pls turn the charge current control switch gently to avoid breakage due to over-turning.

To guarantee the best performance of AC charger when the AC input is from a generator, the standby generator should be at least 150% of higher capacity than the inverter

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), 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 hold them 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 switch when input utility is unstable.

2.5.4 Solar Charger

For HP series, solar chargeing modul is optional, and up to two pcs can be built in.

Listed below is the spec for solar charger

Table 1 Electrical Specifications @ 25(77)

Rated Voltage 12Vdc 24Vdc

Rated Charge Current

(Includes Load Current)

MAX DC Load Current

Input Voltage Range

Max. PV Open Circuit Array Voltage

40/60Amp

Overload Protection (DC load)

Typical Idle Consumption

Bulk Charge

Floating Charge

Equalization Charge

Over Charge Disconnect

Over Charge Recovery

48Vdc

40Amp

15-30Vdc

35Vdc

15Amp

30-55Vdc

60Vdc

60-100Vdc

105Vdc

2.0 * I(Rated)>5s;1.5 * I(Rated) >20s

1.25 * I(Rated) Temperature Controlled

14.6Vdc

13.4Vdc

14.0Vdc

14.8Vdc

13.6Vdc

At idle < 10mA

29.2Vdc

26.8Vdc

28.0Vdc

29.6Vdc

27.2Vdc

58.4Vdc

53.6Vdc

58.0Vdc

59.2Vdc

54.4Vdc

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Over Discharge Disconnect

Over Discharge Reconnect

Temperature Compensation

Lead Acid Battery Settings

NiCad Battery Settings

Low Voltage Reconnect

Low Voltage Disconnect

Ambient Temperature

Altitude

Protection Class

Battery Temperature Sensor①

10.8Vdc

12.3Vdc

-13.2mV/℃

21.6Vdc

24.6Vdc

-26.4mV/℃

Adjustable

Adjustable

24.0-28.0Vdc

21.0-25.0Vdc

43.2Vdc

49.6Vdc

-52.8mV/℃

12.0-14.0Vdc

10.5-12.5Vdc

48.0-56.0Vdc

42.0-50.0Vdc

0-40℃ (Full load) 40-60℃ (De-rating)

Operating 5000m, Non-Operating 16000m

IP21

BTS (Optional )

Remote Battery Temperature Sensor for Increased Charging Precision

#8 AWG Terminal Size (Fine/Single Wire)

NOTE:

① 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

Photovoltaic (PV) modules in a manner that allows the modules to produce all the power they are capable of.

The PV-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).

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-30VDC.

For 24VDC inverter, the output voltage of solar charger will be accordingly 24VDC, and the qualified DC input volt range is 30V-55VDC.

For 48VDC inverter, the output voltage of solar charger will be accordingly 48VDC, and the qualified DC input volt range is 60v-110VDC.

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.

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2.5.5 Power Saver

There are 2 different working statuses for HP inverter: “Power On” and “Power Off”.

When power switch is in “Unit Off” position, the inverter is powered off.

When power switch is turned to either of “Power Saver Auto” or “Power Saver Off”, the inverter is powered on.

Power saver function is to dedicated to conserve battery power when AC power is not or little 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 consumption 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 in every 3 seconds. This power sensing can be customized to “Unit off charging” via the SW3 on DIP switch.

Power saver on Power saver off Power saver on(Load detected)

Note: The minimum power of a load to take inverter out of sleep mode (Power Saver On) is 25 Watts.

The whole HP Series inverter is designed with extraordinarily low idle power consumption which is

0.8-1.8% of its rated power.

HP Series Idle Power Consumption(in Watts)

Model

Power Saver Off

Idle(Max)

Power Saver Auto

3Secs(Max) Stand-By Mode

1KW

2KW

3KW

4KW

5KW

6KW

8KW

10KW

12KW

18W

30W

60W

70W

80W

90W

120W

150W

180W

7.5W

10.0W

15.0W

20.0W

25.0W

25.0W

30.0W

35.0W

40.0W

2.5W

For more detailed technical information, please contact the supplier.

When in the search sense mode, the green power LED will blink and the inverter will make a ticking sound.

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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 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.

2.5.6 Protections

The HP series 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

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 of 10VDC to 10.5VDC through the SW1 on the DIP switch. the inverter.

The HP series Inverter is with 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.

2.5.7 Remote control

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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

Only when both panels are turned to “Unit Off” position, the inverter will be powered off.

WARNING

Never cut the telephone cable when the cable is attached to inverter and battery is connected to the inverter.

Even the inverter is turned off, this will damage the remote PCB inside if the cable is short circuited during cutting.

2.5.8 LED Indicator & LCD

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SHORE POWER ON

INVERTER ON

FAST CHARGE

FLOAT CHARGE

OVER TEMP TRIP

OVER LOAD TRIP

POWER SAVER ON

GREEN LED lighting on “Line Mode”

GREEN LED lighting on “Inv Mode”

Yellow LED lighting on “Fast CHG”

GREEN LED lighting on “Float CHG”

RED LED lighting on “Over Temp”

RED LED lighting on “Over Load”

GREEN LED lighting on “Power Saver on”

Please refer to „Indicator and Buzzer‟ for the detailed information.

The LCD will display the following content:

Greeting message of “Welcome to ”

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AC Status & Input Voltage

“AC: abnormal” is displayed when AC input is not qualified.

Output Voltage/Frequency and Output Current( in percentage) in Inverter mode

Battery voltage

Note:

When the inverter is in Battery Priority mode, “AC:abnormal” will also be displayed when the inverter finishes a complete charging circle and switches to inverter mode.

In AC mode, the LCD will not display the status of AC load.

2.5.9 Audible Alarm

Battery Voltage Low

Battery Voltage High

Invert Mode Over-Load

Over Temperature

Inverter green LED Lighting, and the buzzer beep 0.5s every 5s.

Inverter green LED Lighting, and the buzzer beep 0.5s every 1s, and Fault after 60s.

(1)110%<load<125%(±10%), No audible alarm in 14 minutes,

Beeps 0.5s every 1s in 15 th

minute and Fault after 15 minutes;

(2)125% <load<150%(±10%), Beeps 0.5s every 1s and Fault after 60s;

(3)Load>150%(±10%), Beeps 0.5s every 1s and Fault after 20s;

Heat sink temp. ≥105ºC(221℉), Over temp red LED Lighting, beeps 0.5s every 1s;

2.5.10 FAN Operation

For 1-3KW, there is one multiple controlled DC fan, for 4-6KW, there is two multiple controlled DC fan which starts to work according to the following logic.

For 8-12KW, 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.

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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 DC fan at the DC terminal side is controlled in the following logic:

Condition

HEAT SINK

TEMPERATURE

Enter Condition

T ≤ 60℃(140℉)

Leave condition

T > 65℃(149℉)

Speed

OFF

65℃(149℉)≤ T < 85 ℃(185℉) T ≤ 60℃(140℉) or T ≥ 85℃(185℉) 50%

CHARGER

CURRENT

LOAD Percentage

(INV MODE)

T > 85℃(185℉)

I ≤ 15%

20%< I ≤ 50%Max

I > 50%Max

Load < 30%

30% ≤ Load < 50%

Load ≥ 50%

T ≤ 80℃(176℉)

I ≥ 20%

I≤ 15% or I > 50%Max

I ≤ 40%Max

Load ≥ 30%

Load ≤ 20% or Load ≥ 50%

Load ≤ 40%

100%

OFF

50%

100%

OFF

50%

100%

Allow at least 30CM of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit.

Fan noise level <60db at a distance of 1m

2.5.11 DIP Switches

On the DC end of inverter, there are 5 DIP switches which enable users to customize the performance of the device.

Switch NO Switch Function

SW1 Low Battery Trip Volt

SW2(230V)

SW2(120V)

AC Input Range

AC Input Range

Position: 0

10.0VDC

Position: 1

10.5VDC

*2 for 24VDC, *4 for 48VDC

184-253VAC 154-264VAC(40Hz+)

100-135VAC 90-135VAC(40Hz+)

SW3

SW4

SW5

Power Saver & Unit Off

Charging

Output Frequency

Battery/AC Priority

Unit Off charging Power Saver

50Hz

Utility Priority

60Hz

Battery Priority

Low Battery Trip Volt:

Deep discharge of the lead acid battery leads to high losses in capacity and early aging. In different applications, different low voltage disconnection level is preferred. For example, for solar application, user intended to have less DOD to prolong the battery cycle life. While for mobile application, users intend to have more DOD to reduce battery capacity and on board weight.

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:

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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.

In order to make the inverter accept dirty power from a generator, when the SW2 is switched to position “1”, the inverter will bypass an AC input with a higher voltage(164-264Vac for 230Vac model) and wider frequency (40Hz plus for 50Hz/60Hz). Accordingly, the AC charger will also work in a higher voltage(174-254Vac for 230Vac model) wider freq range (43Hz plus for 50Hz/60Hz).

This will avoid frequent switches between battery and generator. But some sensitive loads will suffer from the low quality power.

The pros and cons should be clearly realized.

Power Saver & Unit Off Charging:

Under the Battery Priority Mode (SW5 in position “1”), the inverter can be switched between two modes:

Power Saver Mode (SW3 in position “1”) and Unit Off Charging Mode (SW3 in position “0”). The power

Switch should be in “Power saver on” position all the time for using these functions.

In Power Saver Mode, the inverter is initially in standby mode and sends a pulse to detect the presence of a load every 3 seconds. Each pulse lasts for 250ms. The inverter will remain in standby mode until a load has been detected. Then it will wake up from standby mode and start to invert electricity from the battery bank to supply the load. As this function is under Battery Priority, the inverter will always prefer to invert electricity from battery first even there is a qualified AC input present.Only when the battery voltage is lower than the low voltage alarm point, will the inverter switch to AC input power to charge the battery and supply the load at the same time.

This Power Saver Mode can be changed to Unit Off Charging mode via SW3 by switching it to “0” position.

(SW5 still in “1”)

In Unit Off Charging mode, the inverter will stay in standby mode without sensing loads. It won‟t output any power even if a load is turned on or a qualified AC input is present. The inverter will not perform any function and only stay idle in this mode, unless the battery voltage is low. Then it will start charging the battery. This feature is ideally suitable for applications where energy conservation is required. Charging will only be activated when required.

Output Frequency:

The output frequency of the inverter can be set at either 50Hz or 60Hz by SW4.

AC/Battery Priority:

Our inverter is designed 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 will the inverter start a battery inverting cycle to protect the battery. After

1 normal charging cycle ac through put will be restored. For more info, pls refer to our manual at AC

Charging Section.

The AC Priority and Battery Priority switch is SW5. When set in battery priority, the inverter will invert from battery despite the AC input. Only when the battery voltage reaches the low voltage alarm point(10.5Vdc for 12Vdc, 21Vdc for 24Vdc, 42Vdc for 48Vdc) will the inverter transfer to AC Input, charge battery, and switch back to battery when the battery is fully charged. This function is mainly for wind/solar systems using utility power as back up.

The AC/Battery Priority function can be activated by sliding the switch even when the inverter is in operation.

18

Note: In battery priority mode, when qualified AC inputs for the first time and the battery voltage is below 12.5Vdc(12.5Vdc for 12Vdc, 25Vdc for 24Vdc, 51Vdc for 48Vdc), the inverter will go into battery priority mode only after a cycle of bulk charging and absorb charging is finished. The inverter will not go into float charging mode.

2.5.12 Other features

Battery Temperature Sensing

Applying the proper charge voltage is critical for achieving optimum battery performance and longevity. The ideal charge voltage required by batteries changes with battery temperature.

The battery temperature sensor allows the charge controller to continuously adjust charge voltage based on actual battery temperature.

Temperature compensation of charge voltage assures that the battery receives the proper charge voltage as battery temperature varies.

The entire line are equipped with Battery Temperature Sensing for increased charging precision.

It sends precise information to the charger, which automatically adjusts voltage to help ensure full battery charge depending on the ambient temperature of your battery installation.

When the battery voltage is over 40℃(104℉), it will reduce the charging voltage by 0.1Vdc with every degree of temperature rise.

We recommend that you install Battery Temperature Sensors on all banks to protect your batteries and to provide optimal charging of each bank.

The battery temperature sensor mounts on the side of a battery or any other location where the precise temperature of battery can be detected such as battery mounting racks.

The following table describes approximately how much the voltage may vary depending on the temperature of the batteries.

Inverter Condition

Charger Mode

Temp on BTS

BTS ≥ 50℃(122℉)

BTS ≤ 40℃(104℉)

Operation

Automatically turns off charger

Inverter Mode

Automatically turns on charger

Increases the low voltage shut down

40℃(104℉) ≤ BTS ≤ 50℃(122℉)

BTS ≥ 50℃(122℉) point by 0.5Vdc

Over Temp Fault

Important: If the battery temperature is allowed to fall to extremely cold temperatures, the inverter with a

BTS may not be able to properly recharge cold batteries due to maximum voltage limits of the inverter.

Ensure the batteries are protected from extreme temperatures.

Battery voltage recovery start

After low battery voltage shut off(10V for 12V model or 20V for 24V model or 40V for 48V model), the inverter is able to restore to work after the battery voltage recovers to 13V/26V/52V(with power switch still in “On” position). This function helps to save the users extra labor to reactivate the inverter when the low battery voltage returns to acceptable range in renewable energy systems.

WARNING

Never leave the loads unattended, some loads (like a Heater) may cause accidents in such cases.

It is better to shut everything off after low voltage trip than to leave your load in the risk of fire. Nobody

19

wants to return home, finding house surrounded by fire trucks and naughty neighborhood kids toasting hot dogs against his house.

Auto Gen Start

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 turn 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/close relay that will short circuit the positive and negative cable from a generator. The input DC voltage can vary, but the Max current the relay can carry is 16Amp.

Conformal Coating

The entire line of inverters have been processed with a conformal coating on the PCB, making it water, rust, and dust resistant.

While these units are designed to withstand corrosion from the salty air, they are not splash proof.

3 Installation

3.1 Location

Follow all the local regulations to install the inverter.

Please install the equipment in a location of Dry, Clean, Cool with good ventilation.

Working temperature: ‐10℃ to 40℃(-14℉to 104℉)

Storage temperature: ‐40℃ to 70℃(-40℉to 158℉)

Relative Humidity: 0% to 95%,non-condensing

Cooling: Forced air

3.2 DC Wiring Recommendation

It is suggested the battery bank be kept as close as possible to the inverter. The following table is a suggested wiring option for DC cable with length from 1 meter to 5ms.

Model

Watt

Battery

Voltage

Minimun Wire Gage Model

0~1.0m 1.0~5.0m Watt

Battery

Voltage

Minimun Wire Gage

0~1.0m 1.0~5.0m

1KW

1KW

1KW

3KW

3KW

3KW

12 Vdc

24 Vdc

48 Vdc

12 Vdc

24 Vdc

48 Vdc

30mm²

15mm²

10mm²

90mm²

45mm²

25mm²

40mm²

20mm²

15mm²

120mm²

60mm²

30mm²

2KW

2KW

2KW

4KW

4KW

4KW

12 Vdc

24 Vdc

48 Vdc

12 Vdc

24 Vdc

48 Vdc

60mm²

30mm²

15mm²

120mm²

60mm²

30mm²

75mm²

45mm²

25mm²

150mm²

75mm²

40mm²

5KW

5KW

8KW

8KW

24 Vdc

48 Vdc

24 Vdc

48 Vdc

75mm²

40mm²

120mm²

60mm²

95mm²

50mm²

150mm²

75mm²

Please follow the above minimum wire size requirement.

6KW

6KW

8KW

12KW

24 Vdc 90mm² 120mm²

48 Vdc 45mm² 60mm²

48 Vdc 75mm² 95mm²

48 Vdc 90mm² 120mm²

20

thicker cable and shorter runs, so if in doubt round up and keep the length as short as possible.

Battery cables must have crimped (or preferably, soldered and crimped) copper compression lugs unless aluminum mechanical lugs are used. Soldered connections alone are not acceptable. High quality, UL-listed battery cables are available .These cables are color-coded with pressure crimped, sealed ring terminals.

Battery terminal must be clean to reduce the resistance between the DC terminal and cable connection. A buildup of dirt or oxidation may eventually lead to the cable terminal overheating during periods of high current draw. Use a stiff wire brush and remove all dirt and corrosion from the battery terminals and cables.

Reducing RF interference

To reduce the effect of radiated interference, twist the DC cables. To further reduce RF interference, shield the cables with sheathing /copper foil / braiding.

Taping battery cables together to reduce inductance

Do not keep the battery cables far apart. In case it is not convenient to twist the cables, keep them taped together to reduce their inductance. Reduced inductance of the battery cables helps to reduce induced voltages. This reduces ripple in the battery cables and improves performance and efficiency.

WARNING

The torque rating range for DC terminal is 12.5NM-20.5NM(9.25-15.19 pound-foot), and the suggested torque rating is 17NM(12.6 pound-foot). Over torquing may cause the bolt to break.

Equipment Damage

The inverter is not reverse polarity protected. Reversing the battery polarity on the DC input connections will cause permanent damage to the inverter which is not covered under warranty. Always check polarity before making connections to the inverter.

The inverter contains capacitors that may produce a spark when first connected to battery.

Do not mount in a confined a battery or gas compartment.

Ensure the inverter is off before disconnecting the battery cables, and that AC power is disconnected from the inverter input.

21

3.3 AC Wiring Recommendation

We recommend using 10 to 5Awg wire to connect to the ac terminal block.

When in AC mode the AC input power will supply both the loads and AC charger, a thicker wire gauge for

AC Input is required. Pls consult a qualified electrician about the specific wire gauge required in terms of wire material and inverter power.

There are 3 different ways of connecting to the terminal block depending on the model. All the wirings are

CE compliant, Call our tech support if you are not sure about how to wire any part of your inverter.

Wiring Option 1

230V single phase/120V single phase

Input: Hot line+Neutral+Ground

Output: Hot line+Neutral+Ground

Wiring Option 2

230V split phase

Input: Hot line+ Hot line

+Ground

Output: Hot line+ Hot line +Neutral

22

Wiring Option 3

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.

Caution:

Wiring Option 2 and Wiring Option 3 are only allowed for split phase models.

Pls wire all the other models according to Wiring Option 1.

23

WARNING

For split phase models, AC input neutral is not required in wiring. Never Connect Input Neutral to

Output Neutral. Damage will result which is not covered under warranty.

WARNING

The output voltage of this unit must never be connected in its input AC terminal, overload or damage may result.

Always switch on the inverter before plugging in any appliance.

3.4 Grounding

Connect an AWG 8 gauge or greater copper wire between the grounding terminal on the inverter and the earth grounding system or the vehicle chassis.

24

3.5 Install Flange

25

4 Troubleshooting Guide

Troubleshooting contains information about how to troubleshoot possible error conditions while using the

HP Inverter & Charger.

The following chart is designed to help you quickly pinpoint the most common inverter failures.

Indicator and Buzzer

SHORE

Status Item

POWER

ON

INVERT

ER ON

FAST

CHG

Indicator on top cover

OVER

FLOAT

TEMP

CHG

TRIP

OVER

LOAD

TRIP

POWER

SAVER

ON

LED on Remote Switch

BATT

CHG

INVERTE

R

Alarm Buzzer

CC

×

× × × ×

× × ×

Line

Mode

Inverter

CV

Float

Standby

Inverter On

×

×

×

×

√, blink

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Power

×

Mode

× × × × × ×

× × × ×

Saver

Inverter

Mode

Battery

Low

Battery

High

Overload

On Invert

Mode

Over-Temp

On Invert

Mode

Over-Temp

On Line

Mode

Over

Charge

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Beep 0.5s every 5s

Beep 0.5s every 1s

Refer to

“Audible alarm”

Beep 0.5s every 1s

Beep 0.5s every 1s

Fan Lock ×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Beep 0.5s every 1s

Beep continuous

Beep continuous

Fault

Mode

Battery

High

Inverter

Mode

Overload

Output

Short

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Beep continuous

Over-Temp

Over

Charge

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Beep continuous

Beep continuous

Beep continuous

26

Back Feed

Short

× × × × × × × × × ×

Beep continuous

Symptom

Inverter will not turn on during initial power up.

No AC output voltage and no indicator lights ON.

AC output voltage is low and the inverter turns loads OFF in a short time.

Charger is inoperative and unit will not accept AC.

Charger is supplying a lower charge rate.

Charger turns OFF while charging from a generator.

Possible Cause

Batteries are not connected, loose battery-side connections.

Low battery voltage.

Inverter has been manually transitioned to OFF mode.

Low battery.

AC voltage has dropped out-of-tolerance

Charger controls are improperly set.

Low AC input voltage.

Loose battery or AC input connections.

High AC input voltages from the generator.

Recommended Solution

Check the batteries and cable connections. Check DC fuse and breaker.

Charge the battery.

Press the switch to Power saver on or Power saver off position.

Check the condition of the batteries and recharge if possible.

Check the AC voltage for proper voltage and frequency.

Refer to the section on adjusting the “Charger Rate”.

Source qualified AC power..

Check all DC /AC connections.

Load the generator down with a heavy load.

Turn the generator output voltage down.

Sensitive loads turn off temporarily when transferring between grid and inverting.

Noise from Transformer/case*

Inverter's Low voltage trip voltage may be too low to sustain certain loads.

Applying specific loads such as hair drier

Choose narrow AC voltage in the

DIP switch, or Install a UPS if possible.

Remove the loads

*The reason for the noise from transformer and/or case

When in inverter mode and the transformer and/or case of the inverter sometimes may vibrate and make noise.

The noise may come from transformer.

According to the characteristics of our inverter, there is one type of load which will most likely to cause rattles of transformer, that is a half-wave load, load that uses only a half cycle of the power(see figure 1). This trends to cause imbalance of magnetic field of transformer, reducing its rated working

Figure 1

Half Cycle Load Waveform freq from 20KHz to, say, maybe 15KHz (it varies according to different loads). This way, the freq of noise falls exactly into the range (200Hz-20KHz) that human ear can sense.

The most common load of such kind is hair drier.

If the noise comes from case.

27

Normally when loaded with inductive loads, the magnetic field generated by transformer keeps attracting or releasing the steel case at a specific freq, this may also cause noise.

This noise may also be generated the moment a load is detected in the power saver mode.

Reducing the load power or using an inverter with bigger capacity will normally solve this problem.

The noise willn‟t do any harm to the inverter or the loads.

5 Warranty

We offer 1 year limited warranty.

But 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 Operation in a condensing environment.

4 Operation with an undersized generator or generator with unqualified wave form.

To guarantee the best performance of inverter, the standby generator should be at least of

150%higher capacity than the inverter.

6 Model Numbering

The HP Inverter is identified by the model/serial number labels. Model Number label is located on the side of the cover. All the necessary information is provided on the label such as battery voltage, AC output voltage, power and frequency.

For example

Model Number Power

HP1012120 1000W

HP2012230 2000W

HP12048120230 12000W

Battery voltage AC voltage

12Vdc

12Vdc

48Vdc

120Vac

230Vac

120/230Vac

Phase

Single phase

Single phase

Split phase

28

Appendix 1

HP Series Inverter & Charger Spec Sheet

Electrical Specifications

Model

Input Voltage Range

Input Frequency Range

HP

1KW

HP

1.5KW

HP

2KW

HP

3KW

HP

4KW

HP

5KW

HP

6KW

HP

8KW

HP

10KW

HP

12KW

Continuous Output

Power

Surge Rating(20s)

Capable of Starting

Electric Motor

Output Waveform

Nominal Efficiency

Line Mode Efficiency

Power Factor

Nominal Output

Voltage RMS

Output Voltage

Regulation

Output Frequency

Short Circuit Protection

Typical transfer Time

THD

Nominal Input Voltage

Minimum Start Voltage

Low Battery Alarm

Low Battery Trip

High Voltage Alarm &

Fault

High DC Input

Recovery

Low Battery Voltage

Recover

Idle

Consumption-Search

Mode

1000W 1500W 2000W 3000W 4000W 5000W 6000W 8000W 10000W 12000W

3000W 4500W 6000W 9000W 12000W 15000W 18000W 24000W 30000W 36000W

1HP 1.5HP 2HP 3HP 4HP 5HP

Pure Sine wave/Same as input(Bypass mode)

>88%(Peak)

>95%

0.9-1.0

100-110-120Vac / 220-230-240Vac

±10% RMS

50/60Hz ± 0.3Hz

Yes, Current Limit Function (Fault after 1sec)

10ms(Max)

Typically <7%, Max 10% under full linear load

12.0Vdc( *2 for 24Vdc, *4 for 48Vdc)

10.0Vdc

10.5Vdc / 11.0Vdc

10.0Vdc / 10.5Vdc

16.0Vdc

15.5Vdc

13.0Vdc

6HP

< 25 W when Power Saver On

8HP 10HP 12HP

Narrow: 100~135VAC / 194~243VAC;

Wide: 90~135VAC / 164~243VAC;

Narrow: 47-55±0.3Hz for 50Hz, 57-65±0.3Hz for 60Hz

Wide:43±0.3Hz plus for 50Hz/60Hz

Depends on battery type Output Voltage

Charger Breaker

Rating(230Vac)

Charger Breaker

Rating(120Vac)

Max Charge Rate

10A

10A

10A

20A

10A

20A

20A

30A

20A

40A

30A

63A

30A

63A

15A to 120A +/-5A , depending on models

40A 40A 40A

29

Over Charge Protection

Shutdown

Battery type

Gel U.S.A

A.G.M 1

A.G.M 2

Sealed Lead Acid

Gel Euro

Open Lead Acid

Calcium

De-sulphation

Remote Control

Input Voltage

Waveform

Nominal Voltage

Low Voltage Trip

Low Voltage re engage

High Voltage Trip

High Voltage re engage

Max Input AC Voltage

Nominal Input

Frequency

15.7V for 12Vdc ( *2 for 24Vdc, *4 for 48Vdc)

Fast Vdc

14.0

14.1

14.6

14.4

14.4

14.8

15.1

120Vac

80V/90V±4%

90V/100V±4%

140V±4%

135V±4%

150VAC

15.5 for 4hrs

Yes. Optional

Sine wave (Grid or Generator)

50Hz or 60Hz (Auto detect)

Float Vdc

13.7

13.4

13.7

13.6

13.8

13.3

13.6

230Vac

184V/154V±4%

194V/164V±4%

253V±4%

243V±4%

270VAC

Low Freq Trip

Low Freq re engage

High Freq Trip

High Freq re engage

Narrow: 47±0.3Hz for 50Hz, 57±0.3Hz for 60Hz

Wide:40±0.3Hz for 50Hz/60Hz

Narrow: 48±0.3Hz for 50Hz, 58±0.3Hz for 60Hz

Wide:45±0.3Hz for 50Hz/60Hz

Narrow: 55±0.3Hz for 50Hz, 65±0.3Hz for 60Hz

Wide: No up limit for 50Hz/60Hz

Narrow: 54±0.3Hz for 50Hz, 64±0.3Hz for 60Hz

Wide: No up limit for 50Hz/60Hz

Output Short circuit protection

Bypass breaker rating(230Vac)

Bypass breaker rating(120Vac)

Mounting

10A

20A

15A

20A

20A

30A

30A

40A

Circuit breaker

30A

50A

40A

80A

Wall mount

40A

80A

50A 63A 63A

Inverter

Dimensions(L*W*H)

Inverter Weight

Shipping

Dimensions(L*W*H)

Shipping Weight

Display

388*415*200mm 488*415*200mm

16KG 17KG 20KG 24KG 35KG

550*520*310mm

45KG 45KG

650*520*310mm

588*415*200mm

60KG 66KG 70KG

760*540*410mm

18KG 19KG 22KG 26KG 37KG 47KG

Status LEDs+LCD

47KG 58KG 79KG 82KG

Standard Warranty 1 Year

Errors and omissions reserved. Specifications in this manual are subject to change without prior

notice.

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