KUSSMAUL 091-263-12-1500 Instruction Manual Download Page 24

Page: 24 / 31

170 Cherry Avenue

West Sayville, NY 11796

www.kussmaul.com

Ph: 800-346-0857

Fax: 631-567-5826

[email protected]

This troubleshooting guide contains information about how to troubleshoot possible error

conditions while using the Inverter/Charger. The following chart is designed to help you quickly

pinpoint the most common inverter failures.

MAINTENANCE AND TROUBLESHOOTING

√

√, blink

Float

√

Standby

√

Inverter On

√

Power Saver

Battery Low

√

Battery High

√

Overload On

Invert Mode

√

Over-Temp On

Invert Mode

√

Over-Temp On

Line Mode

√

Over Charge

√

Fan Lock

Battery High

√

Inverter Mode

Overload

√

Output Short

√

Over-Temp

√

Over Charge

√

Back Feed Short

Line Mode

Inverter Mode

Indicator on top cover

Status

Item

SHORE POWER

INVERTER ON

FAST CHG

FLOAT CHG

OVER TEMP

TRIP

OVER LOAD

TRIP

Inverter Mode

Fault Mode

Replacement GFCI Recommendation:

Use the following GFCIs for the output circuits from AC terminal blocks:

Manufacturer

Model No.

ZHEJIANG SHOUXIN ELECTRICAL APPARATUS CO LTD

TS20

II. Trouble Shooting Chart

Summary of Contents for 091-263-12-1500

Page 1: ...ON MANUAL INPUT 12 VDC OUTPUT 1500W 120 VAC MODEL 091 263 12 1500 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com Compatible with Super Auto Eject with Deluxe Covers Remote Displays Available 5 Year Warranty Power Inverter Charger E 503855 ...

Page 2: ...mperature Sensing 19 XIV Other Features 20 Installation 21 I Location 21 II DC Wiring Recommendation 21 III AC Wiring Recommendation 23 IV Grounding 23 Maintenance Troubleshooting 24 I GFCI Replacement Recommendations 24 II Trouble Shooting Guide 1 24 Please record the unit s model and serial number in case you need to provide this information in the future It is much easier to record this informa...

Page 3: ... air flow of 145CFM is required 3 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 4 This equipment contains components which can produce arcs or sparks To prevent fire or explosion do not install in compartments containing batteries or flam...

Page 4: ...oper earth safety ground All wiring shall comply with UL recommendations NEC or NFPA standards and local ordinances Never alter the AC cord or plug if provided Any modification of the cord must only be done by a qualified electrician Improper cord outlet connection may result in a risk of electrical shock 3 Observe color coding of the AC wiring as follows Black AC Hot or LINE fused White AC Neutra...

Page 5: ...manding inductive loads The AC Battery priority and auto generator start functionality make it ideally suitable to work in either backup power or renewable energy applications When customized to Battery priority mode via a DIP switch the inverter will extract maximum power from external power sources in renewable energy systems and a minimal cycle of battery will be required With the availability ...

Page 6: ...MECHANICAL DRAWING 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com 6 ...

Page 7: ... I INVERTER A Topology The Auto Power Inverter Charger is built according to the following topology Invert Full Bridge Topology Charge Isolated Boost Topology When operating in invert mode the direct current DC that enters the inverter from the batteries 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 50 Hz or 6...

Page 8: ... able to output max charge current as long as input AC voltage is in the range of 95 127VAC for 120V model and AC freq is in the range of 48 54Hz 58 64Hz for 60Hz model The Auto Power Inverter Charger has a very rapid charge current available and the max charge current can be adjusted from 0 100 via a liner switch on the DC side of the inverter This will be helpful if this powerful charger apply c...

Page 9: ...u 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 As the saying goes desperate diseases must have desperate remedies This cycle is a very...

Page 10: ... can activated when the switch is turned to Off then to ON When the voltage goes below 9VDC and the power switch is turned to OFF or disconnect the inverter from battery the inverter will not be able to charge the battery once again be cause the CPU lose memory during this process Charging current for each model Model Wattage Battery Voltage Charging Current 1 5KW 12Vdc 55 Amp The charging capacit...

Page 11: ...he 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 IV Power Saver There are two different working statuses for Auto Power inverter Power On an...

Page 12: ...reen power LED will blink and the inverter will make a tick ing 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 function should be defeated Exceptions Some devices when scanned by the load sensor cannot be detected Small fluorescent lights are th...

Page 13: ...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 V Protections 13 The Inverter can also be switch on off through the RMT SW pin in the right of AC terminal They inverter will be powered on once a 12Vdc acceptable range 10 16Vdc source is con nected to the PIN and powe...

Page 14: ...ld be single pole single throw with at least a 1Amp rating The wire used should be at least 18ga 12Vdc Remote Control Wiring Diagram 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com VII ...

Page 15: ...port together with the panel on the inverter case the two panels will be connected and operated in parallel Whichever first switches from Unit Off to Power saver off or Power saver on it will pow er 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 turn...

Page 16: ...LED Lighting beeps 0 5s every 1s X FAN Operation For 1 3KW models there is one multiple controlled DC 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 The DC fans are designed to operate according to the following logic Condition Enter Condition Leave condition Speed HEAT SINK TEMPERATURE T 60 ºC 140ºF T 65 C 149 F OF...

Page 17: ...li cations users may intend to have more DOD to reduce battery capacity and on board weight 2 for 24VDC 4 for 48VDC AC Input Range SW2 There are different acceptable AC input ranges for different kinds of loads For some relatively sensitive electronic devices a narrow input range of 100 135Vis required to protect them While for some resistive loads which work in a wide voltage range the input AC r...

Page 18: ...disabled The inverter only consumes as little as 3 watts in Unit Off Charging mode Output Frequency SW4 The output frequency of the inverter can be set at either 50Hz or 60Hz by SW4 which make the inverter charger an international models for most electricity systems AC Battery Priority SW5 The Auto Power Inverter Charger is designed with AC Battery priority switch DIP switch 5 Switch the battery p...

Page 19: ...harge on the batteries Battery Temperature Sensing Applying the proper charge voltage is critical for achieving optimum battery performance and lon gevity The ideal charge voltage required by batteries changes with battery temperature The battery temperature sensor allows the charge controller to continuously adjust charge volt age based on actual battery temperature Temperature compensation of ch...

Page 20: ...operly recharge cold batteries due to maximum voltage limits of the inverter Ensure the batteries are protected from extreme temperatures For more detailed technical information please contact us XIV Other Features 20A DC output When there is ignition signal on Pin 1 or when the inverter transfers to qualified AC input the Pin 3 will output 12Vdc 20A DC power 4 Pins for KECO Deluxe Auto Eject Remo...

Page 21: ...g Cooling Forced air Warning Operation in a condensing environment will invalid warranty II DC Wiring Recommendations 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 to 15 ft Battery cables must have crimped or preferably soldered and crimped copper compression lugs unless aluminum mechan...

Page 22: ...rference twist the DC cables To further reduce RF interfer ence 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 r...

Page 23: ...Recommendation We recommend using 12 Awg 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 The wirings are UL458 compliant please consult a qualified elec trician or call our tech support if you are not sure about how to wire any part of your inverter III Wiring Option 1 120V single ph...

Page 24: ...dby Inverter On Power Saver Battery Low Battery High Overload On Invert Mode Over Temp On Invert Mode Over Temp On Line Mode Over Charge Fan Lock Battery High Inverter Mode Overload Output Short Over Temp Over Charge Back Feed Short Line Mode Inverter Mode Indicator on top cover Status Item SHORE POWER ON INVERTER ON FAST CHG FLOAT CHG OVER TEMP TRIP OVER LOAD TRIP Inverter Mode Fault Mode Replace...

Page 25: ...djusting the Charger Rate Low AC input voltage Source qualified AC power Loose battery or AC input Check all DC AC connections connections Charger turns OFF while charging High AC input voltages from the Load the generator down with a from a generator generator heavy load Turn the generator output voltage down Sensitive loads turn off temporarily when transferring between grid and inverting Invert...

Page 26: ...ting or releasing the steel case at a specific frequency this may also cause noise This noise may also be generated the mo ment 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 will not do any harm to the inverter or the loads Figure 1 Half Cycle Waveform OUTLINE DRAWING 26 ...

Page 27: ...n Lead Acid Calcium De sulphation Remote Control Input Voltage Waveform Nominal Voltage Input Voltage Range Input Frequency Range 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 ...

Page 28: ... 60Hz Wide 40 0 3Hz for 50Hz 60Hz 135V 4 150VAC 80V 90V 4 90V 100V 4 140V 4 BYPASS AND PROTECTION Status LEDs LCD 5 Years 15A 20A OTHER FEATURES 389 295 200mm 19KG 389 295 200mm 21KG Available Available Floor horizontal mount MECHANICAL SPECIFICATIONS Wide No up limit for 50Hz 60Hz Circuit breaker 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 ...

Page 29: ...s digital voltage and ampere display 5 segment bar graph display indicates output current 4 LED s to show the condition of the batteries Indicator is housed in a watertight bezel Bezel is available in 6 different colors Red White Blue Yellow Gray and Black Specify color choice when ordering 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul co...

Page 30: ...r graph provides Auto Charger status Includes rear mounted premolded rubber gasket for extra protect from the elements Available in YEL RED BLU WHT GRY and BLK VI SUPER AUTO EJECT DELUXE COVER DIGITAL DISPLAY COVER MODEL 091 55 194E XXX Incorporates Auto Eject cover and Digital Display volts and amperes into one product Lid on cover opens 180 degrees to prevent beakage 10 LED bar graph provides Au...

Page 31: ...charges paid Kussmaul Electronics Company Inc shall have no liability for damages of any kind to associated equipment arising from the installation and or use of the Kuss maul Electronics Company Inc products The purchaser by the acceptance of the equipment assumes all liability for any damages which may result from its installation use or misuse by the purchaser his or its employees or others WAR...

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