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2015 Sensata Technologies

4.0 Troubleshooting

Problem

Possible Cause/

Condition

Solution

Heavy

spark when

connecting the

battery power.

This is a normal

condition. It occurs

when the internal

DC input capacitors

(

lter) are discharged

after the battery was

disconnected for at

least 30-40 seconds.

Due to a sudden high DC

surge (inrush) current

that charges the internal

big capacitors and quickly

disappears (milliseconds) once

capacitors get charged. Does

not represent any drawing

current from the battery.

The unit’s 20A

thermal breaker

trips even when

the unit is not

in an overload

condition.

This happens mainly

in By-Pass mode when

the maximum rating

of the unit’s breaker is

exceeded.

For maximum capacity, use

AC 1 (L1/N1) Output terminals

which are out of the tripping

uence of the GFCI outlet

and the unit’s 20A thermal

breaker. Otherwise, do not

exceed the current ratings on

the GFCI outlet and AC 2 (L2/

N2) Output.

The unit cannot

be turned off

when using the

Power button in

By-Pass mode.

This is normal.

The unit has a PS1

(factory default)

setting. Use the

procedure on the right

to turn off the unit.

Note:

The Power

button’s on/off action

takes place at its

release moment and

after a “beep” is

heard.

To turn unit off when in By-

Pass mode: 1) disconnect the

AC input that feeds the unit—

forcing the unit into Inverter

mode. 2) push and hold the

Power button for 1 sec. (after

hearing beep) to turn unit off.
Set unit to PS4 mode. The

Power button can now be

used to turn the unit on and

off when in either By-Pass or

Inverter modes.

The display

doesn’t work as

expected (no

display or 888

shows) and the

operability of

the unit may be

affected.

A loose contact or

pin-out problems in

the RJ12 detachable

display panel cable

may have occurred.

A short (7”) RJ12 cable is used

when the detachable display

panel is unit-mounted (factory

default). Alternatively, a 25ft.

RJ12 cable is provided for

installing the display further

away. Swap cables to see if it

makes a difference.
Check the pin-to-pin

conductivity of the cable and

the corresponding pin-out as

shown in Figure 2-8.

Excessive EMI/

RFI interference

(electromagnetic

induction or

electromagnetic

radiation) emitted

from an external

source.

Avoid running the cable close

to motors, power contractors/

relays, ballasts, transformers,

or high voltage devices. In

high noisy environments,

consider using metal conduits

or a shielded cable grounded

at one end, and/or reduce

cable length.

Содержание CSW2012-X

Страница 1: ...Owner s Manual CSW2012 X Pure Sine Wave Inverter ...

Страница 2: ... on Use The CSW2012 X inverter may only be used in life support devices or systems with the express written approval of Sensata Technologies Failure of the CSW2012 X inverter can reasonably be expected to cause the failure of that life support device or system or to affect the safety or effectiveness of that device or system If the CSW2012 X inverter fails it is reasonable to assume that the healt...

Страница 3: ...n the inverter Always disconnect the batteries or energy source prior to installing or performing maintenance on the inverter Live power may be present at more than one point since an inverter utilizes both batteries and AC Do not cover or obstruct any air vent openings and or install in a zero clearance compartment always operate unit in an open area When working with electrical equipment or lead...

Страница 4: ... 14 2 5 AC Wiring 16 2 5 1 Pre AC Wiring Requirements 16 2 5 2 AC Wire Size and Overcurrent Protection 16 2 5 3 AC Neutral to Safety Ground Bonding 17 2 5 4 AC Terminal Block Connections 18 2 5 5 AC Conductor Wiring Steps 18 2 5 6 Removing the Display Panel 22 2 6 Testing the Inverter 23 2 6 1 Inverter Functional Test 23 3 0 Operation 24 3 1 Inverter Mode 24 3 2 By Pass Mode 24 3 3 Display Panel O...

Страница 5: ...ring 20A By Pass and GFCI output 20 Figure 2 7 AC Wiring 30A By Pass 21 Figure 2 8 Remote Cable 22 Figure 3 1 Display Panel 25 Figure 3 2 Inverter Setting Flow Chart 26 Figure A 1 Series Battery Wiring 36 Figure A 2 Parallel Battery Wiring 37 Figure A 3 Series Parallel Battery Wiring 37 Tables Table 2 1 Torque Requirements 9 Table 2 2 DC Wire Overcurrent Device for Rated Use 11 Table 2 3 Appliance...

Страница 6: ... Interrupter GFCI protected AC outlet This GFCI outlet quickly stops the flow of electricity in the event a ground fault occurs on the device that is plugged into the inverter 3 USB Port allows USB enabled devices to be powered and charged provides 5 VDC 750 mA 4 Serial Number the unique identification number assigned to each unit with a model specific prefix Note Enter your inverter s serial numb...

Страница 7: ...inal block allows a service distribution panel main panel to be wired to the inverter s input 10 AC Output Terminal this four pole terminal block is used to connect the inverter s AC output wiring This terminal block allows a dedicated panel sub panel to be connected between the inverter s output wiring and the AC loads The AC 1 output terminals L1 N1 allow a pass thru By Pass mode current of 30 a...

Страница 8: ...and rear used to mount and secure the inverter to a shelf wall 14 DC Positive Terminal red the inverter s connection to the positive terminal on the 12 VDC battery bank 15 DC Negative Terminal black the inverter s connection to the negative terminal on the 12 VDC battery bank 16 DC Ground Connection the connection that is used to tie the exposed chassis of the inverter to the DC grounding system T...

Страница 9: ...ces 1 3 Advantages of a Pure Sine Wave Inverter Today s inverters come in three basic output waveforms square wave modified sine wave which is actually a modified square wave and pure sine wave see Figure 1 4 Modified sine wave inverters approximate a pure sine wave form and will run most appliances and electronics without any problems These inverters are less expensive and therefore offer a viabl...

Страница 10: ...etermining factor as to whether the installation is compliant that is the responsibility of the electrician and the onsite inspector 2 1 1 Installation Guidelines Before connecting any wires determine the cable routes throughout the vehicle or boat both to and from the inverter Always check for existing electrical plumbing or other areas of potential damage BEFORE drilling or cutting into walls Ma...

Страница 11: ...ads L1 N1 30A max L2 N2 20A max AC Sub Panel AC Outlet DC Ground Vehicle chassis DC ground bus or engine negative bus CSW2012 X Inverter AC Source 120VAC 60 Hz Sinewave DC Disconnect Fuse Battery Bank Tools TV DVD Maximum pass thru current from AC output terminals L1 N1 output terminals 30 amps L2 N2 output terminals 20 amps in series with GFCI outlet ...

Страница 12: ...t 60 cm away from the inverter Do not install in any area that contains extremely flammable liquids like gasoline or propane or in locations that require ignition protected devices Close to the battery bank As with any inverter it should be located as close to the batteries as possible Long DC wires tend to lose efficiency and reduce the overall performance of an inverter However the unit should n...

Страница 13: ...on a horizontal surface right side up or upside down DC terminals to the right left or top Note CSW2012 X cannot be mounted with DC terminals facing down Figure 2 3 CSW2012 X Dimensions 8 1 2 21 6 cm Top 12 5 31 8 cm 8 6 21 8 cm 9 1 23 cm 17 1 43 5 cm Front AC Side Back DC Side 4 5 11 5 cm ...

Страница 14: ...rs that are at risk for physical damage must be protected by tape or placed in a raceway Always check for existing electrical plumbing or other areas of potential damage prior to making cuts in structural surfaces or walls Use only copper wires with a minimum temperature rating of 75 C 194 F Do not mix AC and DC wiring in the same conduit or panel unless specifically approved designed for both AC ...

Страница 15: ... or misthreading the nuts on the DC terminals can cause the bolts to strip and snap break off Make sure cables have a smooth bend radius and do not become kinked Follow existing wire runs where possible Crimped and sealed copper ring terminal lugs with at least a 6 mm 1 4 bolt hole to connect the DC wires to the inverter s DC terminals The battery bank voltage MUST be between 10 5 15 5 for the inv...

Страница 16: ...er than 5 feet based on your inverter model DC Wire Size Exception In an OEM RV application smaller DC wire with appropriate overcurrent protection may be used if the inverter will only be connected to a dedicated load and the inverter and dedicated load have been thoroughly tested and sold together by the OEM as a complete system Table 2 2 DC Wire Overcurrent Device for Rated Use CSW2012 X 190 am...

Страница 17: ...allic chassis of the various enclosures together to have them at the same voltage potential to reduce the possibility for electric shock For most installations the inverter chassis and the negative battery conductor are connected to the system s ground bond via a safety grounding conductor bare wire or green insulated wire at only one point in the system The grounding conductor for the DC system s...

Страница 18: ...icable Also allow at least 1 2 5 cm of space between the batteries to provide good air flow DO NOT mount the batteries directly under the inverter CAUTION Install batteries in a well ventilated area Batteries can produce explosive gasses For compartment or enclosure installations always vent batteries to the outside Info To ensure the best performance from your inverter system batteries should be ...

Страница 19: ...attery cables to the inverter DC terminals a brief spark or arc may occur this is normal and due to the inverter s internal capacitors being charged 3 Route and connect an appropriately sized DC positive wire marked red from the inverter s positive DC terminal Figure 1 3 Item 14 to one end of the fuse disconnect assembly or circuit breaker 4 Connect a short wire same rating as the DC wires to the ...

Страница 20: ...ut CAUTION Ensure nothing is placed between the DC terminal and the ring lug CSW2012 X Inverter Lock washer DC cable with ring lug BATTERY DC cable with ring lug bolt flat washer nut lock washer battery post battery terminal Verify that the DC cable lugs are flush with the battery terminals Figure 2 4 DC Cable to Battery Terminals ...

Страница 21: ...ility to safely handle the inverter s maximum load current The AC wiring must be protected from short circuits and overloads by an overcurrent protection device and have a means to disconnect the AC circuits AC overcurrent protection is not included in the inverter and must be provided as part of the inverter installation The AC overcurrent protection device must be a circuit breaker or a fuse dis...

Страница 22: ...is can be prevented if your inverter is equipped with automatic neutral to ground switching WARNING In most electrical systems the neutral to ground bond is located in the main utility service entrance panel Remove any bond downstream from the inverter to prevent multiple bonds If there is an inverter sub panel separate from a main electrical panel it should have a removable wire that allows the n...

Страница 23: ...cks have a stainless steel wire protector to prevent wire damage from the set screw The AC ground uses a Phillips head screw If wiring multiple grounds i e input and output ground connections use a pressure or mechanical connector to attach the wires to the AC ground screw 2 5 5 AC Conductor Wiring Steps The following sections are basic guidelines for installing and connecting the AC wiring to and...

Страница 24: ...the transfer relay contacts If hard wiring the AC output wires 1 Route the AC output wires hot neutral and ground from the AC electrical sub panel through the other strain relief clamp on the inverter 2 Connect the hot BLACK wire from the inverter s hot line L1 or L2 output terminal to the sub panel s main breaker 3 Connect the neutral WHITE from the inverter s neutral N1 or N2 output terminal to ...

Страница 25: ...connected to ground in main panel CSW2012 X Series Inverter Sub Panel and Outlet Inverter Loads ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 20 See NOTE below ON OFF ON OFF 120 VAC Maximum 20 amp breaker single pole required to inverter AC input Figure 2 6 AC Wiring 20A By Pass and GFCI output ...

Страница 26: ... connected to ground in main panel CSW2012 X Series Inverter Sub Panel and Outlets Inverter Loads ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 30 See NOTE below Maximum 30 amp breaker single pole required to inverter AC input ON OFF 120 VAC ON OFF 120 VAC ON OFF Figure 2 7 AC Wiring 30A By Pass ...

Страница 27: ...remote cable to the inverter and the other end of the cable to the display panel Please note polarity Remote cable To locate the display panel in a remote location the longer cable needs to be a 6 conductor telephony type with 6P6C 6 position 6 conductor connectors on each end With this cable when the 6P6C connectors are held side by side with both of the connector tabs facing the same way the col...

Страница 28: ...5 Check the output voltage of the inverter by connecting a multimeter to the outlets powered by the inverter Verify the voltage is from 104 to 127 VAC 6 Plug a small AC load e g 40W light bulb into the GFCI s outlet Turn it on and verify it comes on Continue to keep the load connected and turned on Note If the bulb does not light the GFCI may have tripped and needs to be reset 7 Press and hold the...

Страница 29: ...load greater than 10 watts is turned on the inverter recognizes the need for power and automatically starts inverting When there is no load or less than 3 watts detected the inverter automatically goes back into Search mode to minimize energy consumption from the battery bank Inverting When the inverter is on and not searching the CSW2012 X uses the DC power from the battery to supply 120 VAC powe...

Страница 30: ...y Pass mode within 20 seconds Red solid OFF E01 E12 Unit has shut down Display shows an error code see error code reference chart below 3 3 2 Understanding the Power and Select Buttons A beep sound occurs every time the Power or Select button is activated i e pressed for 1 second Power button Turns the inverter On Off during Inverter mode Press and hold it for 1 second to turn the inverter either ...

Страница 31: ...ess x1 sec to change setting Sd SdL SdH Press x1 sec to change setting Press x1 sec to move to next menu Press x5 sec to set selection and to exit to the next menu Function Set Menus Function Menus Fd Press x1 sec to move to next menu Press x1 sec Fd Factory Default Press x5 sec to set selection and to exit to the next menu POWER pushbutton SELECT pushbutton Figure 3 2 Inverter Setting Flow Chart ...

Страница 32: ...ps to 3W Note During Search mode the inverter turns on every few seconds for a few AC cycles to check on the 10W power consumption PS3 Not used PS4 Performs same function as PS1 The Power button can be used to turn AC output on and off even with AC input power being present in By Pass mode When the unit is turned off in By Pass mode using the Power button the display will continue to show battery ...

Страница 33: ...11 volts while the inverter is trying to start the motor this may explain why the appliance won t run Make sure the length and diameter of the battery cables are appropriate Check that the battery connections are good and that the battery is fully charged If the cables are sized correctly the connections are good and the battery is charged you may need a larger battery bank see Loads turning on an...

Страница 34: ...ted to the battery bank E03 AC output has sensed an overload or short circuit and was shut down Check the load connected to the output Reduce the load and then restart the unit E04 Internal temperature is too high the unit has shut down Turn unit off and then wait 15 minutes before restarting Ensure the unit s air flow and fans are not blocked and ensure the unit s fans are running E05 Input batte...

Страница 35: ...takes place at its release moment and after a beep is heard Turn the unit on by pressing the Power button when the unit is in Inverter mode or in By Pass mode if the PS4 parameter is set Otherwise the unit should always automatically turn on at the moment AC input power is connected No power coming into the unit Check the battery DC fuse the disconnect switch if installed and the AC input source T...

Страница 36: ...er either the E01 or the E05 alarm However the unit continues supplying AC output power Charge connect the battery bank or disable all the audible alarms with the AL0 setting Note The main purpose of the battery charger is to keep the unit s control electronics working even without a battery connected Its power is not necessarily enough to work as a real trickle charger for your battery bank There...

Страница 37: ...Note The Power button s on off action takes place at its release moment and after a beep is heard To turn unit off when in By Pass mode 1 disconnect the AC input that feeds the unit forcing the unit into Inverter mode 2 push and hold the Power button for 1 sec after hearing beep to turn unit off Set unit to PS4 mode The Power button can now be used to turn the unit on and off when in either By Pas...

Страница 38: ...the possible voltage drop between the battery posts and the unit s input terminals Excessive voltage drop between the battery bank and the inverter may be due to high resistance of the DC wires the battery disconnect switch is turned off or a faulty fuse DC breaker Make sure to use the recommended wire gauge and length Try to use fuses or DC breakers with very low voltage drop e g ANL type fuses e...

Страница 39: ... the battery voltage rapidly increases since the battery is not under a load condition after the inverter shutdown This is normal in all the battery banks and can confuse the user thinking the under voltage shutdown that triggers the E02 alarm occurs in advance at higher voltage thresholds than the ones specified The E05 warning and E01 shutdown alarm occurs well in advance due to the SdH setting ...

Страница 40: ...0 VDC 11 3 VDC Low Voltage Shutdown Recovery 10 5 VDC 12 0 VDC High Voltage Shutdown3 15 5 VDC AC Transfer Switch Transfer Time 30 ms Transfer Relay Rating 30A resistive load AC Output L1 N1 Hardwire 30A Max AC Output L2 N2 Hardwire 20A Max AC Output GFCI Outlet 20A Max Display Panel LED Status Indicators Status and Display Digital display DC Volts in power out error codes General Specifications O...

Страница 41: ...or the inverter installation and cost Use only the same battery type for all batteries in the bank For best performance all batteries should be from the same lot and date This information is usually printed on a label located on the battery Battery Configuration The battery bank must be wired to match the inverter s DC input voltage specifications 12 VDC In addition the batteries can be wired to p...

Страница 42: ...reases both voltage to match the inverter s DC requirements and capacity to increase run time for operating the loads using smaller lower voltage batteries In the example below Figure A 3 four 6 VDC 200 AHr batteries are combined into two strings resulting in a 12 VDC 400 AHr battery bank Figure A 2 Parallel Battery Wiring Figure A 3 Series Parallel Battery Wiring 12 volt battery bank total capaci...

Страница 43: ... battery voltages replace those that vary more than 0 3 VDC of each other Check all cable runs for signs of chafing replace if necessary Check the inverter s cooling vents clean as necessary to prevent the accumulation of dust and dirt RV Marine Off Season Storage When placing your coach or boat into seasonal storage it is recommended that you perform the following to ensure the system is properly...

Страница 44: ...ce pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will...

Страница 45: ...ata in Everett WA After the completion of service under this limited warranty Sensata will return the product prepaid to the original purchaser via a Sensata selected non expedited surface freight within the contiguous United States and Canada this excludes Alaska and Hawaii 6 If Sensata repairs or replaces a product its warranty continues for the remaining portion of the original warranty period ...

Страница 46: ...PN 64 0074 Rev B Magnum Dimensions Products Manufactured by Sensata Technologies 2211 West Casino Rd Everett WA 98204 Phone 425 353 8833 Fax 425 353 8390 Web www Magnum Dimensions com ...

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