DC-AC Inverters PSE-12125A PSE-12175A PSE-12275A Owner's Manual Please read this manual before installing your inverter
Owner's Manual | Index Section 1: Safety Instructions........................................................................... 3 Section 2: General Information on Inverters.................................................... 6 Section 3: Characteristics of Sinusoidal AC Power .......................................... 9 Section 4: AC Power Distribution & Grounding ............................................ 10 Section 5: Limiting Electromagnetic Interference (EMI)...................................
Section 1 | Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important Safety and Operating Instructions. Please read before using this unit. The following safety symbols will be used in this manual to highlight safety and information: ! ! WARNING! Indicates possibility of physical harm to the user in case of non-compliance. CAUTION! Indicates possibility of damage to the equipment in case of non-compliance.
Section 1 | Safety Instructions Preventing Fire and Explosion Hazards - Working with the inverter may produce arcs or sparks. Thus, the inverter should not be used in areas where there are inflammable materials or gases requiring ignition protected equipment. - These areas may include spaces containing gasoline powered machinery, fuel tanks, battery compartments Precautions when Working with Batteries. - Batteries contain very corrosive diluted Sulphuric Acid as electrolyte.
Section 1 | Safety Instructions Connecting to Multi-Wire Branch Circuits Do not directly connect the Hot side of the 120 VAC of the inverter to the two Hot legs of the 120 / 240 VAC electrical breaker panel / load centre where multi-wire (common Neutral) branch circuit wiring method is used for distribution of AC power. This may lead to overloading / overheating of the Neutral conductor and is a risk of fire.
Section 2 | General Information on Inverters INVERTER GENERAL INFORMATION Why an Inverter is Needed The utility grid supplies you with alternating current (AC) electricity. AC is the standard form of electricity for anything that “plugs in” to the utility power. Direct current (DC) electricity flows in a single direction. Batteries provide DC electricity. AC alternates its direction many times per second. AC is used for grid service because it is more practical for long distance transmission.
Section 2 | General Information on Inverters Loads that Require “Surge Power” to Start Resistive types of loads (like incandescent lamps, toaster, coffee maker, electric range, iron etc) do not require extra power to start. Their starting power is the same as their running power. Some loads like induction motors and high inertia motor driven devices will initially require a very large starting or “surge” power to start from rest.
Section 2 | General Information on Inverters Power Rating of Microwaves The power rating of the microwave oven specifies its output or cooking power in Watts. Microwaves are not very efficent devices – efficiency is around 50%. Therefore, its input power is almost 2x its output / cooking power. Hence, Watt rating of the inverter should be at least 2x the Watt rating of the microwave oven. Powering a Water Supply Pump A water well or pressure pump often places the greatest demand on the inverter.
Section 3 | Characteristics of Sinusoidal AC Power Voltage, Current, Power Factor, Types of Loads The voltage waveform of 120 VAC, 60 Hz mains / utility power is like a sine wave (see Fig 8.1, page 30). In a voltage with a sine wave-form, the instantaneous value and polarity of the voltage varies with respect to time and the wave-form is like a sine wave.
Section 4 | AC Power Distribution & Grounding ! CAUTION! PLEASE NOTE THAT THE AC OUTPUT CONNECTIONS AND THE DC INPUT CONNECTIONS ON THESE INVERTERS ARE NOT CONNECTED (BONDED) TO THE METAL CHASSIS OF THE INVERTER. BOTH THE INPUT AND OUTPUT CONNECTIONS ARE ISOLATED FROM THE METAL CHASSIS AND FROM EACH OTHER. SYSTEM GROUNDING, AS REQUIRED BY NATIONAL / LOCAL ELECTRICAL CODES / STANDARDS, IS THE RESPONSIBILITY OF THE USER / SYSTEM INSTALLER.
Section 4 | AC Power Distribution & Grounding Grounded Electrical Power Distribution System The National Electrical Code (NEC) requires the use of a “grounded electrical distribution system”. As per this system, one of the two current-carrying conductors is required to be grounded. This grounded conductor is called the “Neutral/Cold/Return”. As this conductor is bonded to earth ground, it will be at near zero voltage or potential. There is no risk of electrical shock if this conductor is touched.
Section 4 | AC Power Distribution & Grounding AC output connections - PSE-12275A The AC output connections (n, Fig. 7.2) of inverter model PSE-12275A have three insulated conductors – one black and one white for carrying current and one green for “equipment grounding”. The green color “equipment grounding” conductor is connected to the metal chassis of the inverter. These three conductors exit through a pocket (n, Fig. 7.2) in the front side of the inverter.
Section 4 | AC Power Distribution & Grounding Grounding of PSE-12275A to earth or to other designated ground In case of hard wiring of the PSE-12275A inverter to a building’s service entrance /electrical breaker panel / load center, proper grounding and bonding have to be undertaken as per the applicable national / local electrical codes. In such cases, the electrical installation should be undertaken by a qualified electrician.
Section 5 | Limiting Electro-magnetic Interference (EMI) The inverter contains internal switching devices which generate conducted and radiated electromagnetic interference (EMI). The EMI is more pronounced in inverters whose output voltage has modified sine wave form as modified sine wave form is composed of odd harmonics of the fundamental frequency (60 Hz).
Section 6 | General Information on Lead Acid Batteries Lead-acid batteries can be categorized by the type of application: 1. Automotive service - Starting/Lighting/Ignition (SLI, a.k.a. cranking), and 2. Deep cycle service. Deep Cycle Lead Acid Batteries of appropriate capacity are recommended for powering of inverters.
Section 6 | General Information on Lead Acid Batteries Typical Battery Sizes Table 6.1 below shows details of some popular battery sizes: Table 6.1: Popular Battery Sizes BCI* Group Battery Voltage, V Battery Capacity, Ah 27 / 31 12 105 4D 12 160 8D 12 225 GC2** 6 220 * Battery Council International; ** Golf Cart Specifying Charging / Discharging Currents: C-Rate Electrical energy is stored in a cell / battery in the form of DC power.
Section 6 | General Information on Lead Acid Batteries Table 6.2 below gives some examples of C-Rate specifications and applications: Table 6.2: Discharge current rates - “C-Rates” "C-Rate" Discharge Current in Amps = Capacity "C" in Ah ÷ Discharge Time "T" in Hrs. Example of C-Rate Discharge Currents for 100 Ah battery 0.5 Hrs. 2C 200A 1 Hrs. 1C 100A C/5 or 0.2C 20A 8 Hrs. (UPS application) C/8 or 0.125C 12.5A 10 Hrs. (Telecom application) C/10 or 0.1C 10A 20 Hrs.
Section 6 | General Information on Lead Acid Batteries Lead-Acid Battery Chart - 80˚F / 26.7˚C 24V 12V 33.0 16.5 C/5 C/10 32.0 16.0 CHARGE C/20 31.0 15.5 C/40 Battery Voltage in VDC 30.0 15.0 29.0 14.5 28.0 14.0 27.0 13.5 26.0 13.0 C/100 C/20 C/10 25.0 12.5 C/5 24.0 12.0 DISCHARGE C/3 23.0 11.5 22.0 11.0 21.0 10.5 20.0 10.0 19.0 9.5 18.0 9.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Battery State of Charge in Percent (%) Fig. 6.
Section 6 | General Information on Lead Acid Batteries Table 6.3 (page 18) shows that a 100 Ah capacity battery will deliver 100% (i.e. full 100 Ah) capacity if it is slowly discharged over 20 Hours at the rate of 5 Amperes (50W output for a 12V inverter and 100W output for a 24V 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.
Section 6 | General Information on Lead Acid Batteries 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 10.5V for a 12V battery or 21V for 24V battery at C-Rate discharge current of C/5 Amps and electrolyte temp. of 80°F.
Section 6 | General Information on Lead Acid Batteries In the example given above, the 10.5V / 21.0V Low Battery / DC Input Alarm would trigger at around 80% discharged state (20% SOC) when the C-Rate discharge current is C/5 Amps. However, for lower C-Rate discharge current of C/10 Amps and lower, the battery will be almost completely discharged when the alarm is sounded.
Section 6 | General Information on Lead Acid Batteries Please consider using the following Programmable Low Battery Cut-off / “Battery Guard” Models manufactured by Samlex America, Inc. www.samlexamerica.
Section 6 | General Information on Lead Acid Batteries terminal of Battery 3 is connected to the Positive terminal of Battery 2. The 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 24V battery bank. Parallel Connection Cable “A” 12V Inverter or 12V Charger Battery 1 Battery 2 Battery 3 Battery 4 12V 12V 12V 12V Cable “B” Fig 6.
Section 6 | General Information on Lead Acid Batteries ! CAUTION! When 2 or more batteries / battery strings are connected in parallel and are then connected to an inverter or charger (See Figs 6.3 and 6.4 given above), attention should be paid to the manner in which the charger / inverter is connected to the battery bank. Please ensure that if the Positive output cable of the battery charger / inverter (Cable “A”) is connected to the Positive battery post of the first battery (Battery 1 in Fig 6.
Section 6 | General Information on Lead Acid Batteries The first step is to estimate the total AC watts (W) of load(s) and for how long the load(s) will operate in hours (H). The AC watts are normally indicated in the 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.
Section 6 | General Information on Lead Acid Batteries Batteries, alternators and isolators on vehicles / RVs It is recommended that for powering the inverter, one or more auxiliary deep cycle batteries should be used that are separate from the SLI batteries. The inverter should be powered from the deep cycle batteries.
Section 7 | Layout, Controls & Indications a b FRONT i LEGEND f d e c g h j K2 BACK a) ON/OFF Switch b) RED LED "Over Temp" c) RED LED "Overload" d) Colored, 10 level LED Bar Graph for Input Voltage "VOLTS" K1 e) Colored, 10 level LED Bar Graph for Input Current "AMPS" and output power "Watts" f) NEMA5-15R, 15A outlet g) Opening for cooling fan exhaust h) DC Input Terminals: PSE-12125A/PSE-12175A: 11mm hole with M-8 set screw.
Section 7 | Layout, Controls & Indications n b p q K1 o a c d e l m FRONT f K2 h (Negative - BLACK) i BACK g Fig. 7.2. Layout: PSE-12275A 28 | SAMLEX AMERICA INC.
Section 7 | Layout, Controls & Indications LEGEND (Fig 7.2) a) ON/OFF Switch b) RED LED "Over Temp" c) RED LED "Overload" d) Colored LED, 10 level LED Bar Graph for Input Voltage "VOLTS" e) Coloured, 10 level LED Bar Graph for Input Current "AMPS" f) NEMA5-15R, 15A outlet g) Opening for cooling fan exhaust h) DC Input Terminals: PSE-12125A/PSE-12175A: 11mm hole with M-8 set screw.
Section 8 | Principle of Operation The inverter converts 24V (nominal) DC voltage of the battery to 120V, 60 Hz AC voltage. The voltage conversion takes place in two stages. In the first stage, the 24V (nominal) DC voltage of the battery is converted to high voltage DC (155V to 170V) using high frequency switching and Pulse Width Modulation (PWM) technique. In the second stage, the high voltage DC is converted to 120V, 60 Hz. modified sine-wave AC. Note: 120V is the RMS value of the AC voltage.
Section 8 | Principal of Operation DEVICES THAT MAY NOT OPERATE ON MODIFIED SINE WAVE The output wave form of these inverters is a modified sine wave (see Fig. 8.1, page 30). In a sine wave, the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses 0 Volts. In a modified sine wave, the voltage rises and falls abruptly, the phase angle also changes abruptly and it sits at 0 Volts for some time before changing its polarity.
Section 9 | Installation The success of a DC to AC power inverter installation depends mainly on the methods and materials used for installation. Please read and comply with instructions given below. GENERAL Installation and Wiring Compliance - Installation and wiring must comply with the local and the national electrical codes and must be done by a certified electrician.
Section 9 | Installation Mounting Position of the Inverter The inverter may be mounted horizontally on the top of a horizontal surface or under a horizontal surface. The inverter may be mounted on a vertical surface only horizontally (the fan axis should always be horizontal i.e. the fan should not be pointing up or down). Cooling by Forced Air Fan Ventilation The inverters produce heat when operating. The amount of heat produced is proportional to the amount of power supplied by the inverter.
Section 9 | Installation - Do not use unregulated solar panels to charge a battery. Under cold ambient temperatures, the output of the solar panel may exceed 16.5 VDC. Always use a charge controller between the solar panel and the battery. - Do not connect to a battery system with a voltage higher than 12 VDC nominal.
Section 9 | Installation Distance up to 10 ft. Ampere rating of fuse Samlex Inverter Installation Kit PSE-12125A #2 AWG 175A to 200A DC-2000-KIT PSE-12175A #2/0 AWG 280A to 300A DC-2500-KIT PSE-12275A #4/0 AWG 360A to 400A DC-3500-KIT Model ! CAUTION! The input section of the inverter has large value capacitors connected across the input Fuse Inverter (+) terminals.
Section 9 | Installation Taping Battery Cables Together to Reduce Inductance. Do not keep the battery cables far apart. In case it is not convenient to twist the cables, keep them taped together to reduce their inductance. Reduced inductance of the battery cables helps to reduce induced voltages. This reduces ripple in the battery cables and improves performance and efficiency.
Section 9 | Installation ! CAUTION! In these NEMA 5-15R receptacles, the current carrying conductor connected to the longer rectangular slot is isolated from the metal chassis of the inverter. Hence, when the metal chassis of the inverter is connected to the earth ground, the longer rectangular slot is not grounded to earth ground. The longer rectangular slot is, therefore, not a “Neutral”.
Section 9 | Installation When using the inverter in a building , connect a #8 AWG insulated stranded copper wire from the above equipment grounding bolt to the earth ground connection (a connection that connects to the ground rod or to the water pipe or to another connection that is solidly bonded to the earth ground). The connections must be tight against bare metal. Use star washers to penetrate paint and corrosion.
Section 10 | Operation Powering on the loads After the inverter is switched on, it takes a finite time for it to become ready to deliver full power. Hence, always switch on the load(s) after a few seconds of switching on the inverter. Avoid switching on the inverter with the load already switched on. This may prematurely trigger the overload protection. When a load is switched on, it may require initial higher power surge to start.
Section 10 | Operation current will increase. At the same time, the value of voltage at the DC input terminals will decrease due to internal voltage drop in the battery and also due to external voltage drop in the DC input cables. Indications for Normal Operation When the inverter is operating normally and supplying AC load(s), only the voltage and current/power LED Bar Graphs will be on. In case of abnormal operation, other displays and alarms will be activated.
Section 11 | Protections Against Abnormal Conditions voltage will continue to be available. This warning alarm indicates that the battery is running low and that the inverter will be shut down after sometime if the voltage at the inverter terminals further drops to 10V. The alarm will reset automatically when voltage rises above 10.5V.
Section 11 | Protections Against Abnormal Conditions Switch (a, Fig 7.1 or 7.2), wait for 3 minutes and switch ON again. NOTE: If the unit goes into overload once again, remove all the loads, reset as above and switch ON. If it goes into overload condition again without any load, it is defective. Please call Technical Support. Section 12 | Troubleshooting Guide SYMPTOM On switching on, the input voltage LED Bar Graph (d, Fig. 7.1 or 7.2) does not light. There is no AC voltage.
Section 12 | Troubleshooting Guide SYMPTOM Low AC output voltage and the input current LED Bar Graph (d, Fig. 7.1 or 7.2) shows very high current (No buzzer alarm). Possible Cause Low voltage at the DC input terminals and the load is close to the maximum allowable power. Remedy: 1. Check that the battery is fully charged. Recharge, if low. 2. Check that the battery cables are thick enough to carry the required current over the required length. Use thicker cables, if required. 3.
Section 12 | Troubleshooting Guide SYMPTOM There is no AC output. The voltage LED Bar Graph (d, Fig. 7.1 or 7.2) shows DC input voltage reading of 15V (full Bar Graph is lighted up to the top RED LED). Possible Cause Shut-down due to high input DC voltage (>16.5V). The unit will re-set automatically when the voltage drops below 16.5V. Remedy: 1. Check that the voltage at the DC input terminals is less than 16.5V. 2.
Section 12 | Troubleshooting Guide SYMPTOM Buzzer alarm is sounded. Red Over Temp LED is on (b, Fig. 7.1 or 7.2). There is no AC output. Possible Cause Shut-down due to over temperature because of fan failure or inadequate cooling as a result of high ambient temperature or insufficient air exchange. Remedy: 1. Check that the fan is working. If not, the fan / fan control circuit may be defective. Call Technical Support. 2. If the fan is working, check that the ventilation slots on the suction side (l, Fig.
Section 13 | Specifications PARAMETER PSE-12125A PSE-12175A PSE-12275A Output OUTPUT VOLTAGE 120VAC +5% / - 10% OUTPUT FREQUENCY 60Hz ± 5% OUTPUT VOLTAGE WAVEFORM 60Hz ± 5% 60Hz ± 5% Modified Sine Wave MAXIMUM CONTINUOUS ACTIVE POWER OUTPUT (POWER FACTOR = 1) 1250 W* 1750W* 2750W* MAXIMUM ACTIVE SURGE POWER OUTPUT (< 2 SEC, POWER FACTOR =1) 2500W* 3500W* 4500W* 85% to 90% 85% to 90% 85% to 90% PEAK EFFICIENCY Input DC INPUT VOLTAGE 12V Battery System (> 10.5VDC to < 16.
Section 13 | Specifications PARAMETER PSE-12125A INTERNAL DC SIDE FUSES PSE-12175A PSE-12275A Automotive Type ATC, 32V 175A (35A x 5 pcs.) 280A (35A x 8 pcs.) 360A (30A x 12 pcs.) Input and Output Connections DC INPUT CONNECTIONS Terminal with 11 mm diameter tubular hole and M8 set screw AC OUTPUT CONNECTIONS 5/16” bolt and nut, 18 TPI • 3 x AWG #10 wires in covered pocket for hard wiring to panel • 2 Knock Outs (Hole diameter 22 mm / 0.
SECTION 14 | Warranty 2 Year limited warranty PSE-12125A, PSE-12175A, PSE-12275A manufactured by Samlex America, Inc. (the “Warrantor“) is warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“). Warranty outside of the United States and Canada is limited to 6 months.
NOTES SAMLEX AMERICA INC.
NOTES 50 | SAMLEX AMERICA INC.
NOTES SAMLEX AMERICA INC.
Contact Information Toll Free Numbers Ph: 800 561 5885 Fax: 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders@samlexamerica.
