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34 | SAMLEX AMERICA INC.

SECTION 8 |

Installation

nect the diversion load if the current rating of the controller is exceeded. Disconnec-
tion of the diversion load may damage the battery as well as the inverter or other DC
loads connected to the battery due to high voltages generated during conditions of
high winds (for wind generators), high water flow rates (for hydro generators). It is,
therefore, to be ensured that the diversion load is sized correctly to prevent the above
over voltage conditions.

- These units are designed to operate from Lead Acid Battery System with nominal volt-

age of 48 VDC. Do not operate these units from battery system voltage higher/lower
than 48 VDC.

8.4.2 Preventing Reverse Polarity on the DC Input Side

!

CAUTION!

Damage caused by reverse polarity is not covered by warranty! When making
battery connections on the input side, make sure that the polarity of battery
connections is correct (Connect the Positive of the battery to the Positive termi-
nal of the unit and the Negative of the battery to the Negative terminal of the
unit). If the input is connected in reverse polarity, DC fuse(s) inside the inverter
will blow and may also cause permanent damage to the inverter.

8.4.3 Connection from Batteries to the DC Input Side – Sizing of Cables

and Fuses

!

CAUTION!

The input section of the inverter has large value capacitors connected across the
input terminals. As soon as the DC input connection loop (Battery (+) terminal

Ò

External Fuse

Ò

Positive input terminal of the Inverter

Ò

Negative input terminal

of the Inverter

Ò

Battery (–) terminal) is completed, these capacitors will start

charging and the unit will momentarily draw very heavy current to charge these
capacitors that will produce sparking on the last contact in the input loop even
when the unit is in OFF condition. Ensure that the fuse is inserted only after all
the connections in the loop have been completed so that sparking is limited to
the fuse area.

Flow of electric current in a conductor is opposed by the resistance of the conductor.
The resistance of the conductor is directly proportional to the length of the conductor
and inversely proportional to its cross-section (thickness). The resistance in the conductor
produces undesirable effects of voltage drop and heating. The size (thickness / cross-
section) of the conductors is designated by AWG (American Wire Gauge). Conductors
thicker than AWG #4/0 are sized in MCM/kcmil. Table 8.1 gives Resistance in Ohm (Ω)
per Foot at 25°C / 77°F for the wire sizing recommended for use with this inverter.

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Содержание PST-1500-48

Страница 1: ...DC AC Power Inverter Pure Sine Wave PST 600 48 PST 1500 48 Please read this manual BEFORE installing your inverter Owner s Manual ...

Страница 2: ...MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION 2 ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER...

Страница 3: ...t personal injury or damage to the unit 1 2 SAFETY INSTRUCTIONS GENERAL Installation and wiring compliance Installation and wiring must comply with the Local and National Electrical Codes and must be done by a certified electrician Preventing electrical shock Always connect the grounding connection on the unit to the appropriate grounding system Disassembly repair should be carried out by qualifie...

Страница 4: ...could spark or short circuit the battery or other electrical parts and could cause an explosion Remove metal items like rings bracelets and watches when working with batteries The batteries can produce a short circuit current high enough to weld a ring or the like to metal and thus cause a severe burn If you need to remove a battery always remove the ground Negative terminal from the battery first...

Страница 5: ...e diversion load if the current rating of the controller is exceeded Disconnec tion of the diversion load may damage the battery as well as the inverter or other DC loads connected to the battery due to high voltages generated during conditions of high winds for wind generators high water flow rates for hydro generators It is therefore to be ensured that the diversion load is sized correctly to pr...

Страница 6: ... the current vector leads or lags the voltage vector in a sinusoidal voltage In a purely induc tive load the current vector lags the voltage vector by Phase Angle φ 90 In a purely capacitive load the current vector leads the voltage vector by Phase Angle φ 90 In a purely resistive load the current vector is in phase with the voltage vector and hence the Phase Angle φ 0 In a load consisting of a co...

Страница 7: ... Hence the inverter AC wiring and over cur rent protection devices have to be sized based on the combined effect of the Active and Reactive Powers that is called the Apparent Power Apparent S Power VA This power denoted by S is the vectorial sum of the Active Power in Watts and the Reactive Power in VAR In magnitude it is equal to the RMS value of voltage V X the RMS value of current A The Unit is...

Страница 8: ...rge of power with a value of up to 8 times the Maximum Continuous Running AC Power AC to DC Switched Mode Power Supplies SMPS This type of power supply is used as stand alone power supply or as front end in all electronic devices powered from Util ity Grid e g in audio video computing devices and battery chargers Please see Sec tion 4 for more details on SMPS When this power supply is switched ON ...

Страница 9: ... devices require Apparent Power VA from the AC power source The Apparent Power is a vectorial sum of Active Power Watts and Reactive Power VAR The AC power source has to be sized based on the higher Apparent Power VA and also based on the Starting Surge Power 2 2 OUTPUT VOLTAGE WAVEFORMS TIME 180 160 140 120 100 80 60 40 20 0 20 40 60 80 100 120 140 160 180 Modified Sine Wave sits at ZERO for some...

Страница 10: ...when powering these devices 2 3 ADVANTAGES OF PURE SINE WAVE INVERTERS The output waveform is a Sine Wave with very low harmonic distortion and cleaner power like Utility Grid supplied electricity Inductive loads like microwaves motors transformers etc run faster quieter and cooler More suitable for powering fluorescent lighting fixtures containing Power Factor Improvement Capacitors and single ph...

Страница 11: ... read details of the above two types of power ratings in Section 2 1 under DEFINITIONS i INFO The manufacturers specification for power rating of AC appliances and devices indicates only the Maximum Continuous Running Power Rating The high short duration surge of power required during start up of some specific types of devices has to be determined by actual testing or by checking with the manufact...

Страница 12: ...candescent Halogen Quartz Lamps 3 Laser Printer Other Devices using Infrared Quartz Halogen Heaters 4 Switch Mode Power Supplies SMPS no Power Factor correction 2 Photographic Strobe Flash Lights 4 See Note 2 NOTES FOR TABLE 2 1 1 Multiply the Maximum Continuous Running Power Rating Active Power Rating in Watts of the appliance device by the recommended Sizing Factor to arrive at the Maximum Conti...

Страница 13: ...r of factors external to the inverter like proximity of the inverter to the EMI receptors types and quality of connecting wires and cables etc EMI due to factors external to the inverter may be reduced as follows Ensure that the inverter is firmly grounded to the ground system of the building or the vehicle Locate the inverter as far away from the EMI receptors like radio audio and video devices a...

Страница 14: ...state input current of SMPS is a train of non linear pulses instead of a sinusoidal wave These pulses are two to four milliseconds duration each with a very high Crest Factor of around 3 Crest Factor Peak value RMS value Many SMPS units incorporate Inrush Current Limiting The most common method is the NTC Negative Temperature Coefficient resistor The NTC resistor has a high resist ance when cold a...

Страница 15: ... Fig 4 1 Inrush current in an SMPS TIME Peak Current RMS Current Non linear Input Current Pulse Input Sine Wave Voltage Crest Factor Peak Current 3 RMS Current Voltage Voltage Current Current NOTE Voltage and current scales are different Fig 4 2 High Crest Factor of current drawn by SMPS SECTION 4 Powering Direct Embedded Switch Mode Power Supplies SMPS ...

Страница 16: ...eases in the Negative direction to a peak Negative value Vpeak 169 68V and then slowly drops back to 0V There are 60 such cycles in 1 sec Cycles per second is called the Frequency and is also termed Hertz Hz The Time Period of 1 Cycle is 16 66 ms TIME 0V Peak Negative Voltage VPEAK 169 68V VRMS 120 VAC Peak Positive Voltage VPEAK 169 68V Voltage Voltage 16 66 ms Fig 5 1 120 VAC 60 Hz Pure Sine Wav...

Страница 17: ... Air exhaust opening for cooling fan Fans are located behind the openings 7 Grounding Lug 8 Negative DC Input Terminal 9 Positive DC Input Terminal 10 Modular Jack for RC 200 Remote Control 11 Metal Strain Relief Clamp for AC Output Cable 12 Cover Plate for Compartment Containing AC Output Terminals 13 Compartment Containing AC Output Terminals for Hardwiring 14 Terminal for AC Output Ground Chass...

Страница 18: ... ON 6 Air exhaust opening for cooling fan Fan is located behind this opening 7 Grounding Lug 8 Negative DC Input Terminal 9 Positive DC Input Terminal 10 Modular Jack for RC 15A Remote Control 11 Air suction openings for the fan At the bottom of the unit not shown PST 600 PST 1000 12 24 Layout NEG WARNING Reverse polarity will damage the unit AVERTISSEMENT Inversion de polarité peut endommager l u...

Страница 19: ... second The Capacity C in Ah relates to the ability of the battery to provide a constant specified value of discharge current also called C Rate See Section 7 6 over a specified time in hours before the battery reaches a specified discharged terminal voltage Also called End Point Voltage at a specified temperature of the electrolyte As a benchmark the automotive battery industry rates batteries at...

Страница 20: ...lled the Capacity of the battery and is designated by the symbol C The time in Hours over which the battery is discharged to the End Point Voltage for purposes of specifying Ah capacity depends upon the type of application Let us denote this discharge time in hours by T Let us denote the discharge current of the battery as the C Rate If the battery delivers a very high discharge current the batter...

Страница 21: ...ging and discharging characteristics of a typical 12V 24V 48 Lead Acid battery at electrolyte temperature of 80 F 26 7 C The curves show the State of Charge X axis versus terminal voltage Y axis during charging and discharging at differ ent C Rates Please note that X axis shows State of Charge State of Discharge will be 100 State of Charge These curves will be referred to in the subsequent explana...

Страница 22: ...4V inverter However if it is discharged at a rate of 50 Amperes 500W output for a 12V inverter and 1000W output for a 24V inverter then theoretically it should provide 100 Ah 50 2 Hours However Table 7 3 shows that for 2 Hours discharge rate the capacity is reduced to 50 i e 50 Ah Therefore at 50 Ampere discharge rate 500W output for a 12V inverter and 1000W output for a 24V inverter the battery w...

Страница 23: ...input terminals considering that the DC input cables are thick enough to allow a negligible voltage drop between the battery and the inverter Inverters are provided with a buzzer alarm to warn that the loaded battery has been deeply discharged to around 80 of the rated capacity Normally the buzzer alarm is triggered when the voltage at the DC input terminals of the inverter has dropped to around i...

Страница 24: ...ompletely Discharged 0 SOC 12V 24V 48V 12V 24V 48V C 3 A 10 45V 20 9V 41 8V 09 50V 19 0V 38 0V C 5 A 10 90V 21 8V 43 6V 10 30V 20 6V 41 2V C 10 A 11 95V 23 9V 47 8V 11 00V 22 0V 44 0V C 20 A 11 85V 23 7V 47 4V 11 50V 23 0V 46 0V C 100 A 12 15V 24 3V 48 6V 11 75V 23 5V 47 0V In the example given above the 10 5V 21 0V 42 0V Low Battery DC Input Alarm would trigger at around 80 discharged state 20 SO...

Страница 25: ...battery capacity varies with temperature Battery capacity is also a function of age and charging history Older batteries have lower capacity because of shedding of active materials sulfation corrosion increasing number of charge discharge cycles etc Hence the State of Discharge of a battery under load cannot be estimated accurately However the low DC input voltage alarm and shut down functions are...

Страница 26: ...he Negative terminal of Battery 2 is connected to the Positive terminal of Battery 1 The Negative terminal of Battery 1 becomes the Negative terminal of the 48V battery bank 7 15 2 Parallel Connection 48V 100 Ah NOTE Each of the 48V 100 Ah battery banks will consist of i 8 pieces of 6V 100 Ah batteries in series or ii 4 pieces of 12V 100 Ah batteries in series 48V 100 Ah 48V Battery Bank 1 48V Bat...

Страница 27: ...rm a 48V 200 Ah Battery Bank String 2 These two 48V 200 Ah Strings 1 and 2 are connected in parallel to form a 48V 400 Ah bank CAUTION When 2 or more batteries battery strings are connected in parallel and are then connected to an inverter or charger See Figs 7 3 and 7 4 attention should be paid to the manner in which the charger inverter is connected to the battery bank Please ensure that if the ...

Страница 28: ...e electrical nameplate for each appliance or equipment In case AC Watts W are not indicated Formula 1 given above may be used to calculate the AC Watts The next step is to estimate the DC current in Amperes A from the AC Watts as per Formula 2 above An example of this calculation for a 48V inverter is given below Let us say that the total AC Watts delivered by the inverter 1000W Then using Formula...

Страница 29: ...onstant Voltage Float Charging In case Wet Cell Flooded Batteries are being used a 4 stage charger is recommended Constant Current Bulk Charging Stage Constant Voltage Boost Absorption Stage Constant Voltage Equalization Stage Constant Voltage Float Stage SECTION 8 Installation WARNING 1 Before commencing installation please read the safety instructions explained in Section 1 titled Safety Instruc...

Страница 30: ... Protection Against Fire Hazard The unit is not ignition protected and should not be located under any circumstance in an area that contains highly flammable liquids like gasoline or propane as in an engine compartment with gasoline fueled engines Do not keep any ﬂammable combustible material i e paper cloth plastic etc near the unit that may be ignited by heat sparks or ﬂames Closeness to the Bat...

Страница 31: ...dimensions and the location of the mounting slots for PST 1500 48 are shown at Fig 8 1 105 6 415 34 107 5 1 2 263 107 5 1 2 5 253 5 19 2 200 468 2 5 105 10 Fig 8 1 PST 1000 PST 2000 Overall Dimensions and mounting slots NOTE Dimensions are in mm Fig 8 1 PST 1500 48 Overall Dimensions Mounting Slots ...

Страница 32: ...re shown in Fig 8 2 PST 600 dimensions 200 15 2 3 8 15 2 3 8 32 12 162 32 12 1 6 9 5 5 276 2 NEG WARNING Reverse polarity will damage the unit AVERTISSEMENT Inversion de polarité peut endommager l unité NEG POS 238 82 NOTE Dimensions are in mm Fig 8 2 PST 600 48 Overall Dimensions Mounting Slots SECTION 8 Installation ...

Страница 33: ...ined above this is to prevent falling of objects into the unit through the fan opening when the fan opening faces up If fan opening faces down hot damaged component may fall out The surface of the unit is likely to be at elevated temperature in conditions of higher load and higher ambient temperature Hence the unit should be installed in a manner where it is not likely to come in contact with any ...

Страница 34: ...permanent damage to the inverter 8 4 3 Connection from Batteries to the DC Input Side Sizing of Cables and Fuses CAUTION The input section of the inverter has large value capacitors connected across the input terminals As soon as the DC input connection loop Battery terminal Ò External Fuse Ò Positive input terminal of the Inverter Ò Negative input terminal of the Inverter Ò Battery terminal is co...

Страница 35: ...er resistance per unit length Cables can be bought at a marine welding supply store Effects of low voltage on common electrical loads are given below Lighting circuits incandescent and Quartz Halogen A 5 voltage drop causes an approxi mate 10 loss in light output This is because the bulb not only receives less power but the cooler filament drops from white hot towards red hot emitting much less vi...

Страница 36: ... side overloading These fuses will NOT blow if there is a short circuit along the length of wires connecting the battery and the inverter 8 4 5 Recommended Sizes of Battery Cables and Fuses Sizes of cables and fuses are shown in Table 8 2 Sizing is based on safety considerations speci fied in NEC 2014 Please refer to Notes for Table 8 2 for details Table 8 2 Recommended Sizing of Battery Cables an...

Страница 37: ...s of Positive and Negative cable conductors ii Resistance of the cable is based on Table 8 1 5 Fuse in the battery circuit is primarily required for protection against short circuit in the battery cable run The size of this fuse has to be equal to or larger than the Rated DC Input Current of the inverter at Column 2 Further the Amp rating of the fuse used for protecting a battery cable against sho...

Страница 38: ...with a male plug on both ends to connect the AC output of the inverter to a handy wall receptacle in the home RV 8 5 1 Bonding of AC Output Neutral to Chassis Ground The Neutral slots of the NEMA5 20R GFCI Duplex Receptacles i 5 Fig 6 1 for PST 1500 48 and ii 5 Fig 6 2 for PST 600 48 are internally bonded to the metal chassis of the inverter 8 5 2 AC Output Connection Through Ground Fault Circuit ...

Страница 39: ...emain OFF The Green LED 5c in Fig 6 1 and Fig 6 2 will switch ON indicating that AC power is available at the Load Side outlets Plug a test lamp into the outlet and switch ON the test lamp Press the Test Button 5b in Fig 6 1 and 6 2 The Reset Button 5a in Fig 6 1 and 6 2 will pop out The GFCI will be forced to trip and cut off AC power to the load side outlets Green LED 5d in Fig 6 1 and 6 2 will ...

Страница 40: ...6 1 Stud 6 UNC 32 Threads Per Inch Neutral to Chassis Ground Bonding Neutral N 16 Fig 6 1 is bonded to the metal chassis of the inverter through a loop of wire connecting the N terminal on the Line side of the GFCI to the chassis of the inverter 8 5 3 2 AC Output Cable Sizing Conductor Termination for Hard wiring For PST 1500 48 only Use 3 conductor cable with at least 90 C insulation rating Based...

Страница 41: ...t V A Hz W VA and Power Factor PF It also has LED indications similar to the indications on the front panel 2 3 4 in Fig 6 1 Read Remote Control Manual for details NOTE For the Remote Control RC 300 to operate the ON OFF switch on the inverter 1 Fig 6 1 should be in ON condition 8 7 2 Optional Wired Remote Control for PST 600 48 An optional Wired Remote Control Model No RC 15A with 16 5 ft 5 metre...

Страница 42: ...iver 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 mul tiple loads are being powered they should be switched on one by one so that the inverter is...

Страница 43: ... low current Therefore to prevent any drain from the battery switch OFF the inverter from the ON OFF switch 1 Fig 6 1 for PST 1500 48 and 1 in Fig 2 for PST 600 48 provided on the front panel of the inverter SECTION 10 Protections 10 PROTECTIONS The inverters have been provided with protections detailed below 10 1 POWER SURGE OVERLOAD SHORT CIRCUIT SHUT DOWN i INFO Please refer to definitions of A...

Страница 44: ...g will occur near the peak portion of the voltage waveform during every half cycle half cycle lasts for 8 33 msec at 60Hz 3000W is the value of surge power averaged over 1 to 2 msec during every half cycle of 8 33msec If this situation continues for 2 to 2 5 sec overload condition is activated and the AC output is shut down Overload Condition If there is a continuous overload of 110 to 115 for 2 t...

Страница 45: ... indication light on the GFCI will be OFF The unit will reset automatically when the DC input voltage rises to 46 0V 0 5V or higher 10 4 HIGH DC INPUT VOLTAGE SHUTDOWN If the voltage at the DC input terminals rises to 64 0V or higher the AC output voltage will be shut down temporarily Buzzer alarm will be sounded The Green LED marked POWER POWER ON 2 in Fig 6 1 for PST 1500 48 and 2 in Fig 6 2 for...

Страница 46: ...o the Negative DC input terminal of the inverter and the Negative of the battery wrongly connected to the Positive DC input terminal of the inverter will blow the external internal DC side fuses If the DC side fuse is blown the inverter will be dead The Green LED marked POWER 2 in Fig 6 1 for PST 1500 48 and 2 in Fig 6 2 for PST 600 48 and the Green indication light on the GFCI will be switched OF...

Страница 47: ...e required current over the required length Use thicker cables if required Tighten connections of battery input circuit Reduce load AC output voltage is available Buzzer alarm is sounded at no load or when load is switched ON The Green LED marked POWER 2 Fig 6 1 is lighted Indication light on the GFCI is Green Low DC input voltage alarm DC input voltage is 42 0 5 VDC or lower but higher than 40 0 ...

Страница 48: ...n condition and will require manual reset To reset switch OFF the power ON OFF switch 1 Fig 6 1 wait for 3 minutes and then switch ON again Before switching ON again remove the cause of the shut down There is no AC output Buzzer alarm is sounded Red LED marked OVER TEMP 4 Fig 6 1 is lighted The Green LED marked POWER 2 Fig 6 1 is lighted Green indica tion light on the GFCI is OFF Shut down due to ...

Страница 49: ...ired current over the required length Use thicker cables if required Tighten connections of battery input circuit Reduce load AC output voltage is available Buzzer alarm is sounded at no load or when load is switched ON The Green LED marked POWER ON 2 Fig 6 2 is lighted Indication light on the GFCI is Green Low DC input voltage alarm DC input voltage is 42 0 0 5 VDC or lower but higher than 40 0 0...

Страница 50: ...down condition and will require manual reset To reset switch OFF the power ON OFF switch 1 Fig 6 2 wait for 3 minutes and then switch ON again Before switching ON again remove the cause of the shut down There is no AC output Buzzer alarm is sounded Red LED marked OVER TEMP 4 Fig 6 2 is lighted The Green LED marked POWER ON 2 Fig 6 2 is lighted Green indica tion light on the GFCI is OFF Shut down d...

Страница 51: ... reset 64 0 VDC 64 0 VDC Auto reset 64 0 VDC SHORT CIRCUIT SHUTDOWN When output voltage drops to 80 VAC or lower for 1 to 1 5 sec OVERLOAD SHUTDOWN At overload of 110 to 115 for 2 to 2 5 sec GROUND FAULT SHUTDOWN Through GFCI outlets 5 to 6 mA leakage OVER TEMPERATURE SHUTDOWN 90 C 5 C Sensed at internal hot spot Auto reset at 65 C 5 C REVERSE POLARITY ON DC INPUT SIDE External internal DC sides f...

Страница 52: ...fter having a reasonable number of opportunities to do so Warranty service shall be performed only by the Warrantor Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void There shall be no warranty for defects or damages caused by faulty installation or hook up abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spr...

Страница 53: ...SAMLEX AMERICA INC 53 NOTES ...

Страница 54: ...54 SAMLEX AMERICA INC NOTES ...

Страница 55: ...SAMLEX AMERICA INC 55 NOTES ...

Страница 56: ...ee Numbers Ph 1 800 561 5885 Fax 1 888 814 5210 Local Numbers Ph 604 525 3836 Fax 604 525 5221 Website www samlexamerica com USA Shipping Warehouses Kent WA Plymouth MI Canadian Shipping Warehouse Delta BC Email purchase orders to orders samlexamerica com ...

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