Form: 121958E Oct 2012
Sensata Technologies
4467 White Bear Parkway
St. Paul, MN 55110-7626
(651) 653-7000
Fax (651) 653-7600
Form: 121958E
Oct 2012
DC to AC Power Inverters
Owners Manual for Models:
12X16
12X20
12X25
12X30
12X36
Including Options:
A: Emergency Vehicles
B3: 3-Step Battery Charger
R: Remote Status Panel
R2: Remote “On/Off” Switch - Ground Start
T: Transfer Switch Relay
U: Utility Vehicles
1
Form 121958E
Table of Contents:
Section
Description
Page
1
Safety Instructions ..…………………………………………………..…
1.1
Warning and Danger Symbols ……..……..…………….…….…..
1.2
Standby Power Systems Precautions ……………..……….………
1.3
Battery Precautions …………………….……..………………...……
Specifications ……..……………………..…...……………………..……
Technical description …..……………………………………………..…
3.1
Standby Power Systems …….……….…………………...……....…
3.1.1 Inverter Power Mode …………………………………….….
3.1.2 External Power Mode ….…………………………………….
3.2
Available Options …………………………………………………….….
3.2.1 Emergency Vehicles – “A” Option .…………………..….
3.2.2 Battery Charger – “B3” Option ……….………………….
3.2.3 Remote Status Display Panel – “R” Option
3.2.4 Remote “On/Off” Switch, Ground Start - “R2” Option
3.2.5 Transfer Switch – “T” Option ……………………..………
3.2.6 Utility Vehicles – “U” Option ………………………………
SPS Physical Description ..……….…………………………………….
4.1
SPS Module ………….…………………..……………….……………….
Installation ..………………………….……………………………………
5.1
Tools Needed for Installation ..…………………………….……….
5.2
System Components ..………………………………….……………...
5.3
Mounting the SPS ….……………………………………………………
5.3.1 Chassis Bonding Lug .……………………………………..…
5.3.2 Temperature Compensation Sense Probe ……………..
SPS Wiring …………..……….…………………………………………….
6.1
DC Wiring …………………………………………………………….…….
6.1.1 Inverter Cable .…………………….…………………………..
6.1.2 Charge Cable ..……………………….……..……………..….
6.1.3 Connecting the DC Cables ………..…………………..…….
6.1.4 Remote “On/Off” Switch ……………………………………
6.1.5 Remote “On/Off” Switch, Ground Start - “R2” Option
6.1.6 Deep Cycle Batteries .…………………………………..……
6.2
AC Wiring …………………………………………….…………….…..….
6.2.1 AC Output …..…………………………….…………………….
6.2.2 AC Input ……..…………………………….……..…………….
6.3
DC Wiring Diagram ..……………………………………………………
DC Wiring Diagram – “R2” Option ……………..……………………
6.4
AC Wiring Diagram ……………………..………..………………………
Operation and Troubleshooting ..………………………………....….
7.1
Operation …..………………………………………………………………
7.1.1 Setting the Battery Size and Type ..….…………….…..
7.1.2 Turning the SPS On ………….…………..……………..…..
7.2
Troubleshooting ……………..………………..………………..….…..
Warranty ………………………………………..…………………….……
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2
Form 121958E
Safety Instructions
Important: Read this manual before installation, it contains important safety,
installation, and operating instructions. Save this manual and keep it in a safe place.
1.1 Warning and Danger Symbols:
To reduce the risk of electrical shock and to ensure the safe operation of your
Dimensions power inverter, the following symbols are used throughout the manual.
ATTENTION:
DANGER:
Important operating instructions.
Follow them closely.
Risk of personal harm and/or
electrocution exists in this area.
Use extreme caution.
1.2 Standby Power System Precautions:
•
•
•
•
•
•
•
•
Standby Power Systems produce hazardous voltages. To avoid risk of harm or fire,
the unit must be properly installed.
There are no user serviceable parts inside, do not remove the cover.
The Standby Power Systems should not be mounted in a location that may be
exposed to rain or spray.
The Standby Power Systems should not be installed in a zero clearance enclosure.
Damage to the Standby Power Systems will occur if correct polarity is not observed
when installing the DC input cables.
Damage to the Standby Power Systems will occur if an external AC power source is
applied to the inverter’s AC hardwire output.
The Standby Power Systems contains a circuit breaker and capacitor that may
produce a spark. Do not mount in a confined battery or gas compartment.
Be sure the Standby Power Systems is turned OFF during installation.
1.3 Battery Precautions:
•
•
•
•
•
•
Working in the vicinity of lead-acid batteries is dangerous. There is a risk of acid
exposure.
Batteries generate explosive gases during operation.
There is risk of high current discharge from shorting a battery that can cause fire
and explosion. Use insulated tools during installation.
Remove all rings, watches, jewelry or other conductive items before working near
the batteries.
Inspect the batteries once a year for cracks, leaks or swelling.
Dispose of the batteries according to local regulations. Do not incinerate batteries;
risk of explosion exists.
3
Form 121958E
Specifications
DSI Series Power Inverters
Output Voltage (VAC)
Output Frequency:
Output Waveform:
Input Voltage: (VDC)
Operating Temperature:
Efficiency:
12X16, 12X20, 12X25,
12X30, 12X36
120 RMS ±5%
60 Hz ± 0.05%
Quasi-sine wave, with
waveform stabilizer
11 to 14
-20° to 40° C (0° to 104° F)
Up to 93%
Environmentally Friendly,
Quiet, Reliable, AC Power
Other Design Features:
•
•
•
•
•
•
•
•
•
Unit Protection:
Thermally-controlled cooling fan
GFCI outlet protection
Enclosed AC and DC cable connections with strain
relief
Remote ON/OFF switch hookup
LED for Inverter Power, Low Input Voltage, High
Temperature, & Overload
Battery voltage indicator with push-to-test
Optional Battery Charger “B3” and Transfer Relay “T”
Optional one wire ground start “R2”
•
•
•
Automatic electronic short
circuit/overload protection
Automatic high temperature
shutdown
Output circuit breakers
Battery Protection:
Automatic low battery shutdown at 10.5
VDC (with in-rush delay)
MODEL NUMBER
12X16
12X20
12X25
12X30
12X36
Output Power (Watts Cont.)
Output Current (Amps AC)
1,600
Up to 13
2,000
Up to 17
2,500
Up to 21
3,000
Up to 25
3,600
Up to 30
Peak Output (Amps AC)
55
70
80
90
90
Output Rating: (hp)
1
½
¾
1
1½
Up to 200
44
Up to 250
49
Up to 300
53
Up to 360
58
Input Current (Amps DC)
Weight (lbs.)
/3
Up to 160
40
Dimensions LxWxH (Inches)
BATTERY CHARGER “B3”
(Optional)
Output Current (Amps DC)
Input Current (Amps AC)
TRANSFER RELAY “T”
(Optional)
Current Rating (Amps AC)
15¾ x 11½ x 7¾
3 step charger with automatic conditioning; Temperature compensated
output voltage; selectable between wet and sealed lead acid batteries;
selectable between small and large battery banks
75
100
130
140
140
Up to 16
Up to 21
Up to 26
Up to 28
Up to 28
Fail-safe shore power Transfer Relay
30
Transfer Time (milliseconds)
•
•
Less than 16 typical
Usage: Any 120 VAC, 60 Hz single-phase products within the standby power system’s rating that does
not require a pure sine waveform.
Warranty: Full year parts and factory labor (with Advance Replacement Program)
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Form 121958E
Technical Description
3.1 Standby Power System:
A Standby Power System is a DC to AC power inverter with an optional battery charger
(“B3” option) and an automatic fast transfer switch (“T” option).
Note: In this manual, we will use the acronym SPS when referring to a Standby Power
System.
The main “On/Off” switch controls the SPS and the LED lights built on the front of the
SPS provide system status. The SPS can also be controlled by a customer supplied
remote “On/Off” switch connected to the violet wire labeled “remote switch hook-up”
located in the field-wiring compartment.
The system has two operational modes when a transfer switch “T” option is included:
Inverter mode and external power mode.
3.1.1 Inverter Power Mode: The SPS converts DC power from batteries to usable
120 VAC, 60 Hz power. The direct current (DC) that enters the SPS is filtered by a large
input capacitor and switched “On” and “Off” by the Metal Oxide Silicon Field Effect
Transistors (MOSFET) at a rate of 60 cycles per second, and directed into the
transformer which steps the voltage up to 120 volts. The unit has a Digital System
Processor (DSP) to control the output voltage and frequency as the DC input voltage
and/or output load varies. The signal output waveform shape is not sinusoidal; it has a
total harmonic distortion of 31% and a maximum single harmonic distortion of 25%.
3.1.2 External Power Mode – “T” option only: 120 VAC, 60 Hz external power
can be applied directly to the SPS by hardwire connections to the AC input wire leads
provided in the field-wiring compartment (available with the “T” option only). When
external power is present, the internal transfer switch cannot be defeated; it
automatically turns the DC to AC inverter OFF and activates the three-step battery
charger if the “B3” option is included. At this time the loads attached to the SPS output
will operate directly from the external power line even if the SPS has been turned OFF
manually. The internal transfer relay automatically switches the SPS back to “inverter
power” mode in the absence of external power whenever the SPS was previously set to
ON.
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Form 121958E
3.2 Available Options
3.2.1 Emergency Vehicles – “A” Option: Available only on 12X16, 12X20 and
12X25 models. The “A” option provides SPS internal GFCI protection to the AC hardwire
output.
3.2.2 Battery Charger – “B3” Option: External power 120 VAC, 60 Hz is applied
as explained in section 3.1.2 The internal transfer switch automatically turns the DC to
AC inverter OFF and turns the three
three-step built-in
in battery charger ON. The battery
charger cannott be defeated at this time and will engage even if the inverter has been
set OFF manually. SPSs with the three
three-step
step battery charger feature require the transfer
switch “T” option to operate.
The 3-steps
steps of the charging process are as follows:
Bulk mode: Charging current is passed through the batteries until a factory set
acceptance voltage limit is reached. The charger’s maximum output and/or the state of
charge of the batteries determine the amount of current.
Acceptance mode: Charging continues with the voltage held at the accept voltage
until current flow decreases to the factory set end value or the factory set acceptance
mode time limit is reached.
Float mode: Battery voltage is held at a factory set value, which will neither charge nor
discharge the batteries.
Condition mode occurs every 10th charge cycle between Acceptance mode and Float
mode to ensure full restoration of active materials in all the plates of the battery cells.
The SPS has an automatic power sharing feature that automatically decreases
dec
the
battery charger output so that the total AC input current draw by the SPS for both the
AC loads and the battery charger does not exceed 30 amps AC. If the loads exceed 30
amps the charger will be at zero amp draw and the AC input circuit breaker will trip. The
battery charger draw will automatically increase when the external loads are reduced if
the batteries will accept more current.
3.2.3 Remote Display Status Panel - “R” Option: If the “R” option is included,
a Remote Status Display Panel is supplied as shown in Figure 1.
Figure 1 – Remote Display Status Panel, “R” Option
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Form 121958E
121958
3.2.4 Remote “On/Off Switch, Ground Start – “R2” Option: If the “R2”
option is included, the SPS can be controlled by a customer supplied remote “On/Off”
switch connected to the 18-gauge black wire labeled “remote switch hook-up” which is
located in the field-wiring compartment, the line side of the switch must be connected to
ground.
3.2.5 Transfer Switch – “T” Option: The transfer switch automatically switches
between “Inverter mode” and “External power mode” depending on the external power
line availability. 120 VAC, 60 Hz external power is applied directly to the SPS AC input.
Refer to section 3.1.2.
3.2.6 Utility Vehicles – “U” Option: SPS having the “U” option are designed for
use on utility vehicle applications. The “U” option provides two AC output
circuits; one circuit is GFCI protected and has one 20A branch breaker. The
second circuit (hardwire output) is not GFCI protected and has a 30A output
breaker. All SPS having the “U” option come with a set of two heat sinks located
at the back of the chassis for heat dissipation purposes. A push to test LED
battery voltage meter is also included with the “U” option.
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Form 121958E
SPS Physical Description
4.1 SPS Module
2
1
10
3
4
9
8
5
7
6
FIGURE 2:
Item #
1
2
3
4
5
6
7
8
9
10
Chassis physical description
Description
“On/Off” Switch.
Branch Breaker – 20A
Function
Turns the inverter ON/OFF
Trips to protect the inverter from GFCI outlet short
circuit or overload. Not available with “A” option.
Output Breaker – 15A, 20A or 30A
Trips to protect the inverter from hardwire AC output
short circuit or overload.
GFCI Outlets
Two receptacles, 120 VAC 60 HZ output power.
Field Wiring Compartment Cover
Removable to access the AC Input/Output hardwire
leads and the DC input lugs.
Temperature Compensation Probe Connects to the remote temperature sense probe.
probe
Connector
Available with the “B3” option only.
Bonding Lug
Connects to the ground system.
DC input entry strain reliefs
Allows the DC cables to reach the DC input lugs.
Battery Capacity Selector Switch
Sets the correct battery type and the capacity of the
battery bank for proper charging. Available with “B3”
option only.
LED Status Panel
Provides inverter status – See next page
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Form 121958E
121958
p
a
o
b
n
c
m
d
l
e
f
g
k
h
i
j
FIGURE 3:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
LED Status Panel – “U” Option
External power – “T” option: Green LED that indicates there is external 120
VAC, 60 Hz connected to the unit.
Inverter power: Green LED that indicates the SPS is operating from batteries
in “inverter mode”.
Low battery: Red LED that indicates the SPS is in a low battery voltage
condition.
Overload: Red LED that indicates the SPS is in an overload condition.
High temp: Red LED that indicates the SPS has a high internal temperature.
temperatur
Bulk mode – “B3” option: Green LED that indicates the battery charger is in
the bulk mode.
Accept mode – “B3” option: Green LED that indicates the battery charger is
in the acceptance mode.
Float mode - “B3” option: Green LED that indicates the battery
y charger is in
the float mode.
Condition mode - “B3” option: Green LED that indicates the battery charger
is in the condition mode.
Check battery - “B3” option: Yellow LED that indicates a possible fault in the
battery bank or DC cables.
Push to test – “U” option: Pressing and holding this button enables the
display of the DC input voltage as shown below.
10 – 11 VDC (Battery voltage): Yellow LED.
11 – 12 VDC (Battery voltage): Yellow LED.
12 – 13 VDC (Battery voltage): Green LED.
13 – 14 VDC (Battery v
voltage): Green LED.
14 – 15 VDC (Battery voltage): Green LED.
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Form 121958E
121958
Installation
5.1 Tools for Installation:
Tools required for installation: 3/8” Allen Wrench and socket wrench, connectors (butt
type and insulated), drill, Crimpers (for insulated and non
non-insulated
nsulated connectors), volt
meter with probes, electrical tape, #2 Phillips screwdriver, wire cutters, wire strippers,
cable ties, tape measure.
5.2 System Components:
Picture
Model and Description
Qty.
1
12X16, 12X20, 12X25, 12X30, 12X36 with options A, B3, T & U
Temp. Comp. Cable 611440
611440-XX (“B3” option only)
XX: Length of the cable in feet
1
5.3 Mounting the SPS:
The SPS mounting location should provide adequate ventilation and clearance
to maintain room temperature during operation. At least 1/2 inch of clearance
is required on all sides.
Heatsinks
•
•
All dimensions are in inches
Heatsinks available with the “U”
option only.
Figure 3: Inverter footprints
•
Locate a suitable, secure vertical or
horizontal mounting surface as close to the
batteries as possible without being in the same
airtight compartment.
•
If mounting the SPS on a vertical
surface, it is recommended that the front
control panel be pointing down whenever
possible.
•
Locate the mounting holes on the
chassis flanges and fasten them using ¼ inch
diameter screws to secure the inverter. See
figure 3.
5.3.1 Chassis Bonding Lug: Connect the
bonding lug located at the right side of the SPS
chassis to the earth grounding system using an
8-gauge copper wire.
5.3.2 Temperature Compensation Sense Probe: If the SPS has the battery
charger “B3” option, connect the two-conductor
conductor wire lug to a negative post of the
10
Form 121958E
121958
battery bank. Failure to connect the remote temperature sense probe correctly will result
in improperly charged batteries.
SPS Wiring:
6.1 DC Wiring:
1
2
3
4
5
It is recommended in all cases to use stranded copper wires.
Use SGX cross-linked polyurethane insulation type that complies with the high
temperature insulation requirements (125°C.) of SAE J-1127 and vehicle
manufacturer requirements.
Wire gauge recommendations are minimum. For higher temperature applications (in
engine compartments) or for large motor loads and other applications with high
surge currents use wire gauge 1 to 2 sizes larger than shown on table I.
Keep the wire runs between battery and SPS as short as possible.
Use Bussmann fuse type ANN-XXX and fuseblock # 3576 where XXX is the size of
the fuse.
6.1.1 Inverter Cable: This is the cable that runs from the SPS module to the
batteries. Estimate the “inverter cable” length and locate your SPS model on table I,
cross-reference the wire gauge and fuse size.
SPS
Model
12X16U
12X20U
12X25U
12X30U
12X36U
Full Load
(Amps DC)
160
200
250
300
360
SPS to battery estimated cable length in feet
1’ – 10’
11’ – 15’
16’ – 20’
2-gauge, 250A fuse
1-gauge, 300A fuse
1/0-gauge, 350A fuse
1-gauge, 300A fuse
1/0-gauge, 350A fuse 2/0-gauge, 400A fuse
1/0-gauge, 350A fuse 2/0-gauge, 400A fuse 3/0-gauge, 500A fuse
2/0-gauge, 400A fuse 3/0-gauge, 500A fuse 4/0-gauge, 600A fuse
4/0-gauge, 600A fuse 4/0-gauge, 600A fuse
Not Recommended
Table I: Wire and Fusing Guide for 12VDC systems at 5% Voltage Drop at Full Output
A terminal:
3/8” Ring
A
To
Battery(s)
B terminal: 5/16” Ring
Fuse
B
18” max.
B
Red wire (+)
Fuse-holder
A
Black wire (-)
To inverter
DC input
20 feet maximum
Figure 4: Inverter cable assembly
11
Form 121958E
6.1.2 Charge Cable: This is the cable that runs from the batteries to vehicle
alternator or OEM engine battery. Use 2-gauge cables and 250A fuse for small OEM
alternators and 1/0-gauge and 350A fuse for heavy-duty alternators.
6.1.3
Connecting the DC cables:
Damage to the SPS not covered under warranty will occur if correct polarity is
not observed when installing the DC input cables.
•
•
•
•
•
•
•
•
•
•
Refer to Figure 5A: DC wiring diagram.
Open the SPS field-wiring compartment to access the DC input lugs.
Unscrew the DC input lug POS (+) and NEG (-) 3/8” Allen screws.
Remove the fuse from the fuseholder for cable installation.
Remove 1 inch of insulation from the un-terminated ends of the red and black
cables.
Insert the stripped end of the red wire into the DC input lug labeled POS (+) and the
stripped end of the black wire into the DC input lug labeled NEG (-). Tighten the
3/8” Allen screws to 23 Ft. Lbs.
Tighten the cover DC cable strain relief screws to 1 Ft. Lb.
Connect the end of the short red cable to a POS (+) battery post.
Connect the terminated end of the black cable (neg. return cable) directly to a
battery NEG (-) post (DO NOT connect to the chassis).
Install the in-line fuse in the fuseholder that is within 18” of the positive post of the
battery bank (a one-time spark will occur when this final DC connection is made). To
determine the fuse size, refer to section 6.1.1.
6.1.4
Remote “On/Off” Switch: An optional customer supplied “On/Off” switch
may be connected to the SPS. The remote switch will operate only if the main “On/Off”
switch on the face of the SPS is turned ON.
•
•
•
•
•
•
Open the SPS field-wiring compartment to access the DC input connector area.
Locate the violet wire labeled “Remote Switch Hook-up” and remove it from the
positive battery connector.
Using 18-gauge wire, connect the violet wire to the load side of the “On/Off” remote
switch.
Using 18-gauge wire, connect fused (5 amp recommended) +12VDC battery voltage
to the line side of the switch.
The fuse should be mounted within 18 inches of the battery’s positive post.
All material used for the remote switch should be UL listed and installed per code.
6.1.5
Remote “On/Off” Switch, Ground Start – “R2” Option: An optional
customer supplied “On/Off” switch may be connected to the SPS. The remote switch will
operate only if the main “On/Off” switch on the face of the SPS is turned ON.
•
•
•
Open the SPS field-wiring compartment to access the DC input connector area.
Locate the black wire labeled “Remote Switch Hook-up” and remove it from the
negative battery connector.
Using 18-gauge wire, connect the black wire to the load side of the “On/Off” remote
switch.
12
Form 121958E
•
•
Using 18-gauge wire, connect the line side of the switch to ground.
All material used for the remote switch should be UL listed and installed per code.
6.1.6
Deep Cycle Batteries:
Do not use vehicle-starting batteries; deep discharge cycles typical with SPS
applications can shorten the life of this type of batteries.
•
•
•
•
•
•
Install at least one auxiliary deep cycle battery to feed the SPS directly. Depending
on the application running time, more batteries could be added if necessary. The
vehicle alternator will recharge the batteries.
It is recommended to mount the battery bank close to the SPS. The maximum
recommended distance between the SPS and the battery bank is 20 feet.
The battery compartment must be vapor-tight to the interior of the vehicle and
vented directly to the exterior.
Install several vent-plugs within one inch of the top of the battery compartment to
allow for ventilation. Install a ventilation assembly as needed.
Allow space around the battery and especially above the battery for inspection, and
maintenance purposes.
The battery should not be able to move more than 1 inch in any direction.
6.2 AC Wiring:
6.2.1 AC Output: The 120 VAC, 60 Hz current produced by the SPS is provided at
the GFCI receptacle outlets located on front of the SPS (“A” or “U” options only). The
output is also presented behind the wiring compartment panel for direct hardwire leads.
Remove the SPS field-wiring compartment cover plate to access the 120VAC, 60Hz input
and output hardwire leads and follow the color code connections: Hot - Black wire,
Neutral - White wire, Ground - Green wire. The cable clamp strain reliefs should be used
to secure the field wires (screws tightened to 1 Ft. Lb.).
•
•
•
Refer to Figure 6: AC wiring diagram.
If the option “A” is included, the output hardwire leads are GFCI protected;
therefore there is no need to install remote GFCI outlets.
If the option “A” is not included, the output hardwire leads are not GFCI protected
and the installation of remote GFCI outlets is required. The GFCI outlet model
recommended is Hubbell # GFR 5352XX (20A) or GFR 5252XX (15A).
Do not connect another source of AC power directly to the output of the SPS.
This will result in damage to the SPS that is not covered under warranty.
6.2.2 AC Input: If the transfer switch “T” option is included, the AC input hardwire
leads can be connected to an 120VAC, 60Hz external power source. The cable clamp
strain reliefs should be used to secure the field wires (screws tightened to 1 Ft. Lb.).
The external power circuit should have 30-amp circuit protection in the distribution
panel.
13
Form 121958E
6.3 DC Wiring Diagram
Remote
On/Off Switch
Fuse
Violet wire
Fuse
Red (+)
Black (-)
-
AC Output AC Input
“T” Option
+
Aux.
12 Volt
Battery
2-pin
Connector
“B3” Option
Fuse
Remote Temp. Sense
“B3” Option
Charge Cable
Red (+)
Service Body
Engine Compartment
•
•
•
•
•
Charge Cable
Black (-)
Vehicle Alternator
OEM
Fuse
Connect the charging cables directly to the
vehicle alternator whenever possible or to
the OEM starting engine battery.
AC input cable set is available with options
“T” only.
Remote Temperature Sense available with
option “B3” only.
Remote “On/Off” switch and fuse is
customer supplied.
If the remote “On/Off” is not used no
connection is necessary.
OEM
12 Volt
Battery
Figure 5A: DC wiring diagram
14
Form 121958E
Remote
On/Off Switch
(“R2” Option)
Ground start
Black wire
Fuse
Red (+)
Black (-)
-
AC Output AC Input
“T” Option
+
Aux.
12 Volt
Battery
Fuse
2-pin
Connector
“B3” Option
Remote Temp. Sense
“B3” Option
Charge Cable
Red (+)
Service Body
Engine Compartment
•
•
•
•
•
Charge Cable
Black (-)
Vehicle Alternator
OEM
Fuse
Connect the charging cables directly to the
vehicle alternator whenever possible or to
the OEM starting engine battery.
AC input cable set is available with options
T” only.
Remote Temperature Sense available with
option “B3” only.
Remote “On/Off” switch and fuse is
customer supplied.
If the remote “On/Off” is not used no
connection is necessary.
OEM
12 Volt
Battery
Figure 5B: DC wiring diagram – “R2” Option
15
Form 121958E
6.4 AC Wiring Diagram
“A” option: 20A
Not available with the “A” option
Output
Breaker
30
Branch
Breaker
20
GFCI Outlets
Available with the
“U” or “A” options only
AC Output
AC Input
Circuit Protection
30A
Circuit
Protection
20A
or
15A
Black wire – Hot
White wire – Neutral
AC Input
Green wire - Ground
Black
White
Green
Wire
Wire
Wire
Hot Neutral Ground
•
•
No “A” option: Install GFCI outlets
Hubbell # GFR5352XX (20A) or
Hubbell # GFR5252XX (15A)
“A” option: GFCI outlets not needed.
120VAC 60Hz Output
Remote GFCI outlet
Figure 6:
AC wiring diagram
16
Form 121958E
Operation and Troubleshooting
7.1 Operation
The battery voltage must be higher than 9 volts for the SPS to operate.
7.1.1 Setting the Battery Size and Type (“B3 Option): The battery selector
switch located at the right side of the chassis must be set according to the type and size
of the battery bank the SPS is connected to as shown in table II below.
TABLE II: BATTERY SELECTOR SWITCH POSITION
BATTERY BANK SIZE
DEEP CYCLE BATTERY TYPE
(Amp-Hour)
SEALED LEAD ACID
WET LEAD ACID
More than 400
A
C
Less than 400
B
D
TABLE III: BATTERY CHARGER VOLTAGES
BATTERY
WET CELL BATTERIES
SEALED BATERIES
TEMPERATURE ACCEPT FLOAT CONDITIONING ACCEPT FLOAT CONDITIONING
(Volts) (Volts)
(Volts)
(Volts) (Volts)
(Volts)
°F
°C
78
25
14.6
13.2 14.9 to 15 max.
14.2
13.2 14.4 to 15 max.
BATTERY BANK SIZE
(Amp-Hour)
Less than 400
Greater than 400
TABLE IV: BATTERY CHARGER TIME PERIODS
WET CELL TYPE BATTERIES
SEALED TYPE BATTERIES
BULK ACCEPT CONDITIONING BULK ACCEPT CONDITIONING
(max.) (max.)
(max.)
(max.) (max.)
(max.)
6 hrs.
2 hrs.
3 hrs.
6 hrs.
2 hrs.
3 hrs.
8 hrs.
3 hrs.
6 hrs.
8 hrs.
3 hrs.
4 hrs.
If the bulk mode times-out the charging process will go to the float mode
immediately bypassing the acceptance mode.
7.1.2 Turning the SPS “ON”: To turn the SPS ON, set the On/Off switch to the
“On” position. The green “Inverter Power” LED will light. If the “T” option is included,
the green “Inverter Power” LED will not light if external power 120VAC 60 Hz is applied
to SPS AC input (the green “External Power” LED will light). If the remote switch is
installed, the inverter is turned on or off by the remote switch (SPS On/Off switch must
be on).
Turn the SPS OFF when not in use. There is an approximated 1 to 2 amp DC
draw from the batteries at idle or no load.
17
Form 121958E
7.2 Troubleshooting
Call or e-mail Customer Service Department for free consultation during business hours
(central time zone) at: 1-800-553-6418 or 1-651-653-7000; fax: 1-651-653-7600;
e-mail: inverterinfo@Airpax.net
•
•
A TRUE RMS voltmeter is required for accurate AC output voltage measurements on
a quasi-sine SPS. A voltmeter that uses averaging circuitry will give incorrect
measurements.
Unplug all loads and connect a 100-watt light bulb to the inverter output. Observe
the LED Status Panel then check troubleshooting Table V.
Troubleshooting Table V
PROBLEM
No LEDs: No power output. The SPS is not connected
to the Battery Disconnect Switch; the battery voltage
is below 9 volts DC, the SPS is not connected to the
Module Disconnect Switch or a fault in the remote
On/Off circuit.
POSSIBLE CAUSES OR SOLUTIONS
Check the in-line fuses for continuity. Make sure the DC wires
are clean and tight. Check the DC voltage at the SPS DC input.
Check or bypass the remote On/Off circuit.
Low battery: Red LED indicator light on steady.
Indicates that the SPS has shut off due to a low
battery voltage condition.
Fault in the battery wiring, battery capacity and voltage or an inline fuse. This message will automatically clear or the SPS will
shut off.
Overload: Red LED indicator light on steady.
Indicates that the SPS has shut off due to an overload
condition.
The SPS output wiring is shorting or loads exceed the inverter
rating. This message will automatically clear or the SPS will shut
off. Remove the short circuit or excessive load from the output,
and then switch the SPS off then on.
High Temp: Red LED indicator light on steady.
Indicates that the SPS has shut off due to high internal
temperature. The unit will automatically turn back on
when it has cooled down to 40°C (104°F).
Verify that the SPS is in a vented compartment and that the fan
is not blocked. High ambient temperatures combined with poor
ventilation may also contribute to the shut down.
Red LED indicator light blinking. Indicates that the SPS
has shut off due to high battery temperature 47°C –
50°C (117°F-122°F).
Battery compartment is too hot and needs to cool down. The
charger will automatically turn back on when it has cooled down
to 40°C (104°F)
Overload & High Temp: Both of these red LED
indicator lights are on steady. Indicates that the
charger has shut off due to short or open temperature
compensating sensor cable.
Temperature compensation sensor cable needs to be replaced.
Check battery - “B3” Option: Green LED indicator
light. Indicates that the charger is operating in a low
DC output voltage condition. The battery voltage must
be higher than 9 volts for the charger to operate.
Shorted or defective battery. Make sure that the DC cable
connections are tight and clean and not shorted, and that the
proper wire gauge is used.
Indicates that the charger is operating in a high DC
output voltage condition.
There is another source of battery charging or there is a
defective battery charger. Disconnect and reconnect the external
AC power to restart the battery charger.
Check battery wiring or remove other source of battery charging,
such as the vehicle alternator. Disconnect and reconnect the
external AC power to restart the battery charger.
Indicates that the SPS has shut off due to high battery
voltage.
18
Form 121958E
Warranty
SHIPPING TERMS: F.O.B. St. Paul Minnesota. Freight prepaid and billed, subject to prior credit approval.
MINIMUM ORDER: $50.00 Net Price
LOSS OR DAMAGE: Loss or damage in transit are the responsibility of the carrier. Any claim should be filed with the
delivering transport company. Invoice, Bill of Lading and Delivery receipt with damage noted therein must accompany any
claims for freight damage. Claims for shortage and lost shipments must be made in writing to Sensata Technologies,
Power Controls White Bear, St. Paul, MN within 10 days of date of shipment. Claims not reported within this time frame
will not be honored.
PRICES: Prices are subject to change without notice. All orders are subject to acceptance at the factory. We reserve the
right to invoice prices in effect at time of shipment.
TERMS: Net 30 days with approved credit, credit card or C.O.D.
RETURN GOODS POLICY:
• No returned materials will be accepted without an accompanying Returned Materials Authorization Number (RMA) from
the factory.
• Credit will be issued for returned goods to the original purchaser within 60 days of purchase, provided the inverter is
returned to Sensata unused and not mounted. The amount of credit will be issued at Sensata’s discretion based on the
condition of the product.
• Customer must be in good standing with Sensata Technologies.
• Inverters that are discontinued, high-voltage (over 24vdc), special-order or used are excluded and will not be eligible for
credit. Non-inverter items such as cable assemblies, fuses and fuse holders, will not be eligible for credit
• Support components supplied by Sensata vendors will be covered under that manufacturer’s credit return policy.
• Customer pays return freight.
PLEASE SHIP AUTHORIZED RETURNS TO:
Sensata Technologies | Power Controls White Bear | 4467 White Bear Parkway | St. Paul, MN 55110
Return Freight Prepaid
LIMITED WARRANTY:
Sensata Technologies extends the following warranty to the original purchaser of those goods subject to the qualifications
indicated. Sensata warrants to the original purchaser for use that the goods or any component thereof manufactured by
Sensata will be free from defects in workmanship from the date of purchase for the period listed on the product label,
provided such goods are installed, maintained and used in accordance with Sensata and the original manufacturer’s
written instructions. Damages caused by the misuse, undue care or obvious wear through use will not be covered by this
warranty.
Components not manufactured by Sensata, but used within the assembly provided by Sensata, are subject to the
warranty period as specified by the individual manufacturer of said component, provided such goods are installed,
maintained and used in accordance with Sensata and the manufacturer’s written instructions.
Sensata’s sole liability and the Purchaser’s sole remedy for a failure of goods under this limited warranty and for any and
all claims arising out of the purchase and use of the goods, shall be limited to the repair or replacement of the goods that
do not conform to this warranty.
To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return
Material Authorization (RMA). Once obtained, send the Return Material Authorization Number along with the defective
part or goods to:
Sensata Technologies, Power Controls White Bear, 4467 White Bear Parkway, St. Paul, MN 55110. Return Freight Prepaid.
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE
YEAR FROM DATE OF PURCHASE.
SENSATA TECHNOLOGIES ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THE
PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY. SENSATA TECHNOLOGIES WILL IN NO EVENT BE LIABLE
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
WARNING: LIMITATIONS ON USE: DIMENSIONS® brand products are not intended for use in connection with Life
Support Systems and for Avionic use. Sensata Technologies makes no warranty or representation in connection with their
products for such uses.
19
Form 121958E
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