Summary of Contents for Cenga Power BACKUP INVERTER
- Page 1 BACKUP INVERTER / BACKUP INVERTER-120 6kW Backup Inverter (Split Phase 120V/240V and Single Phase 120V) User’s Manual Version 1.0 Utility + Inverter + Charger + Transfer Switch + Solar Power + AGS...
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Page 2: Table Of Contents
Important Safety Information ...................... 3 General Safety Precautions ...................... 3 Precautions When Working with Batteries ................ 3 Introduction ........................... 4 General Information ........................ 4 Key Features ........................... 5 Electrical Performance ........................ 5 Inverter ............................ 5 Topology .......................... 5 AC Charger .......................... 6 De-sulfation .......................... 8 Transfer ............................ 8 Auto frequency adjust ........................ 9 Solar Charger .......................... 9 Maximum Power Point Tracking (MPPT) Function . -
Page 3: Important Safety Information
Important Safety Information WARNING! - This manual contains important instructions for all Inverter/Charger models that shall be followed during installation and maintenance of the inverter. General Safety Precautions 1. Before installing and using the BACKUP INVERTER, read all instructions and cautionary markings on the BACKUP INVERTER and all appropriate sections of this guide. Be sure to read all instructions and cautionary markings for any equipment attached to this unit. 2. This unit is designed for indoor use only. Do not expose the BACKUP INVERTER to rain, snow, or spray. 3. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the BACKUP INVERTER in a zero-clearance compartment. Overheating may result. 4. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk of fire, electric shock, or injury to persons. 5. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the BACKUP INVERTER with damaged or substandard wiring. 6. Do not operate the BACKUP INVERTER if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the BACKUP INVERTER is damaged, see the Warranty section. 7. Do not disassemble the BACKUP INVERTER. It contains no user-serviceable parts. See Warranty for instructions on obtaining service. Attempting to service the BACKUP INVERTER yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. 8. The BACKUP INVERTER contains more than one live circuit (batteries and AC line). Power may be present at more than one source. To reduce the risk of electrical shock, disconnect both AC and DC power from the BACKUP INVERTER before attempting any maintenance or cleaning or working on any circuits connected to the BACKUP INVERTER. Turning off controls will not reduce this risk. 9. Use insulated tools to reduce the chance of short-circuits when installing or working with the inverter, the batteries, or PV array. Precautions When Working with Batteries 1. -
Page 4: Introduction
work near a lead-acid battery. 7. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 8. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries. 9. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately. 10. If you need to remove a battery, always remove the grounded terminal from the battery first. Make sure all accessories are off so you don’t cause a spark. 11. Always use identical types of batteries. 12. Never install old or untested batteries. Check each battery’s date code or label to ensure age and type. 13. Batteries are temperature sensitive. For optimum performance, the should be installed in a stable temperature environment. 14. Always recycle old batteries. Contact your local recycling center for proper disposal information. Introduction General Information Thank you for purchasing the BACKUP INVERTER. The BACKUP INVERTER Pure Sine Wave Inverter is a combination of an inverter, charger, solar power and Auto-transfer switch into one complete system. It is packed with unique features and it is one of the most advanced inverter/chargers in the market today. The inverter features an AC pass-through circuit, powering your home appliances from utility or generator power while charging the battery. When utility power fails, the battery backup system keeps your appliances powered until utility power is restored. Internal protection circuits prevent over-discharge of the batteries by shutting down the inverter when a low battery condition occurs. When utility or generator power is restored, the inverter transfers to the AC source and recharges the batteries. Accessories allow the BACKUP INVERTER series to also serve as a central hub of a renewable energy system. Setting the BACKUP INVERTER inverter to battery priority mode designates that the load power is normally provided by the inverter. However, if the inverter output is interrupted, an internal transfer switch automatically transfers the load from the inverter to commercial AC power. The transfer time between inverter and line is short (6ms typical; 10ms max), and such transfers are normally not detected by even highly sensitive loads. Upon... -
Page 5: Key Features
Inverter output. Once the qualified AC utility is restored, the relay is energized and the load is automatically reconnected to AC utility. The Inverter also features power factor corrected, sophisticated multi-stage charging and pure sine wave output with unprecedentedly high surge capability to meet demanding power needs of inductive loads without endangering the equipment. The BACKUP INVERTER is equipped with a powerful 40A charger. The overload capacity is 300% of continuous output for up to 20 seconds to reliably support tools and equipment longer – especially loads requiring extra power to start-up such as wells and other motors. Another important feature is that the inverter can be easily customized to Battery priority via a DIP switch, this helps to extract maximum power from the batteries in renewable energy systems. Thus, the BACKUP INVERTER is suitable for Renewable energy system, Utility, RV, Marine and Emergency backup applications. To get the most out of the power inverter, it must be installed, used and maintained properly. Please read the instructions in this manual before installing and operating. Key Features • Battery Temperature Sensor (BTS) (optional) • Automatic Generator Starting (AGS) (optional) • Supports Advanced Solar Charging with an Integrated MPPT Charger • Designed to Operate in Harsh Environments • DC Start & Automatic Self-Diagnostic Functions • Compatible with Both Linear & Non-Linear Loads • Easy to Install & Easy to Operate & Easy to Troubleshoot • Powerful Charge Rate Up to 40 Amps, Selectable From 0%-100% • High Efficiency Design & “Power Saving Mode” to Conserve Energy • Innovative Battery Priority Mode Designates the Preferred Operating Configuration • Low Voltage Battery Recover Point, Perfect for Renewable Energy Systems • 8 Pre-Set Battery Type Selectors plus De-sulfation for Totally Depleted Batteries • 4-step Intelligent Battery Charging with Power Factor Correction for Charger •... -
Page 6: Ac Charger
• AC Charger: Isolate Boost Topology • Solar Charger: MPPT PV Controller Because of the heavy-duty, high quality design, the BACKUP INVERTER is able to produce a pure sine wave suitable for all types of electrical loads – from motors to sensitive electronics equipment. The peak efficiency of the BACKUP INVERTER is 88%. Overload Capacity The BACKUP INVERTER has different overload capacities, making it ideal to handle demanding loads. • For 110%<Load<125%(±10%), no audible alarm in 14 minutes, beeps 0.5s every 1s in the 15th minute, and Fault(Turn off) after the 15th minute. • For 125%<Load<150%(±10%), beeps 0.5s every 1s and Fault (Turn off) after the 1 minute. • For 300% ≧ Load>150%(±10%), beeps 0.5s every 1s and Fault (Turn off) after 20s. AC Charger The BACKUP INVERTER is equipped with an active PFC (Power Factor Corrected) multistage battery charger. The PFC feature is used to control the amount of power used to charge the batteries in order to obtain a power factor as close as possible to 1. Unlike other inverters whose max charging current decreases according to the input AC voltage, the BACKUP INVERTER charger is able to output max current as long as input AC voltage is in the range of 164-243VAC (95-127VAC for 120V model), and AC frequency is in the range of 48 - 54Hz (58-64Hz for 60Hz model). The BACKUP INVERTER is equipped with a strong charging current of 40A, and the max charge current can be adjusted from 0%-100% via a liner switch at the right of the battery type selector. This will be helpful if you are using our powerful charger on a small capacity battery bank. The linear switch can effectively reduce the max charging current to 20% of its peak. Choosing “0” in the battery type selector will disable the charging function. There are 3 main charging stages: Bulk Charging: This is the initial stage of charging. While Bulk Charging, the charger supplies the battery with controlled constant current. The charger will remain in Bulk charge until the Absorption charge voltage (determined by the Battery Type selection) is achieved. A software timer will measure the time from AC start until the battery charger reaches 0.3V below the boost voltage. Absorb Charging: This is the second charging stage and begins after the absorb voltage has been reached. Absorb Charging provides the batteries with a constant voltage and reduces the DC charging current in order to maintain the absorb voltage setting. In this period, the inverter will start a T1 timer; the charger will keep the boost voltage in Boost CV mode until the T1 timer... - Page 7 has run out. Then drop the voltage down to the float voltage. The timer has a minimum time of 1 hour and a maximum time of 12 hours. Float Charging: The third charging stage occurs at the end of the Absorb Charging time. While Float charging, the charge voltage is reduced to the float charge voltage (determined by the Battery Type selection). In this stage, the batteries are kept fully charged and ready if needed by the inverter. If the AC power is reconnected or the battery voltage drops below 48Vdc, the charger will reset the cycle above. If the charge maintains the float state for 10 days, the charger will deliberately reset the cycle to protect the battery. Figure 1: Battery Charging Process Figure 2: Battery Type Selector http://www.cengapower.com/...
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Page 8: De-Sulfation
De-sulfation The de-sulfation cycle on switch position 8 is marked in red because this is a very dangerous setting if you 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. Sulfation can occur with infrequent use of the batteries, or if the batteries have been left discharged so low that they will not accept a charge. This cycle is a very high voltage charge cycle designed to try to break down the sulfated crust that is preventing the plates taking a charge and thus allow the plates to clean up and so accept charge once again. Charging depleted batteries: The BACKUP INVERTER inverter allows start-up and through power with fully depleted batteries. After the battery bank voltage goes below 40V, if the switch is still (and has always) kept in "ON" position, the inverter is continuously connected with battery, and the battery bank voltage does not drop below 32V, the inverter will be able to charge the battery once qualified AC inputs are present. Before the battery voltage goes below 36VDC, the charging can be activated when the switch is turned to “Off”, then to “ON”. When the voltage goes below 36VDC, and you accidently turn the switch to OFF or disconnect the inverter from battery, the inverter will not be able to charge the battery once again, because the CPU loses memory during this process. AC Charging Current: The Inverter has an AC charging current of 40A (+/- 5A). The charging capacity will go to peak in around 3 seconds. This may cause a generator to drop frequency, making the inverter transfer to battery mode. It is suggested to gradually put charging load on the generator by switching the charging switch from min to max, together with the 15s switch delay, the inverter gives the generator enough time to spin up. This will depend on the size of the generator and rate of charge. Transfer While in Standby Mode, the AC input is continually monitored by the Inverter. Whenever AC power falls below the VAC Trip voltage (90VAC for each 120VAC phase), the inverter automatically transfers back to the Invert Mode with minimum interruption to your appliances - as long as the inverter is turned on. The transfer from Standby mode to Inverter mode occurs in approximately 6 ms (10ms max). The transfer time is the same from Inverter mode to Standby mode. Though it is not designed as a computer UPS system, this transfer time is usually fast enough to keep sensitive electronics equipment powered up. There is a 15-second delay from the time the inverter senses that continuously qualified AC is present at the input terminals to when the 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 switching when input power is unstable. http://www.cengapower.com/... -
Page 9: Auto Frequency Adjust
Auto frequency adjust The inverter is equipped with an Auto Frequency adjust function. The factory default configuration for 220/230/240VAC inverter is 50Hz, and 60Hz for 100/110/120VAC inverter. While the output frequency can be easily changed once a qualified frequency is applied to the inverter. If you want to get 60Hz from a 50Hz inverter, just input 60Hz power, and the inverter will automatically adjust the output frequency to 60Hz and vice versa. Solar Charger NOTE: The optional battery temperature sensor automatically adjusts the charging process of the controller according to the type of battery that is selected by user through battery type selector. With the battery temperature sensor installed, the controller will increase or decrease the battery charging voltage depending on the temperature of the battery to optimize the charge to the battery and maintain optional performance of the battery. Maximum Power Point Tracking (MPPT) Function Maximum Power Point Tracking, frequently referred to as MPPT, is an electronic system that operates the Photovoltaic (PV) modules in a manner that allows the modules to produce all the power they are capable of. The advanced Charge controller is a microprocessor-based system designed to implement the MPPT and can increase charge current up to 30% or more compared to traditional charge controllers. The qualified DC input volt range is 55v-110VDC. If the voltage falls out of this range, the charger will not work properly. Special attention should be paid to this when configuring the solar array. Power Saver Mode There are 3 different working status for PE inverter: “Power Saver Auto”, “Power Saver Off”, and “Power Off”. When power switch is in “Unit Off” position, the inverter is powered off. When power switch is turned to either of “Power Saver Auto” or “Power Saver Off”, the inverter is powered on. Power saver mode is designed to conserve battery power when AC power is not or rarely required by the loads. In this mode, the inverter pulses the AC output looking for an AC load (i.e., electrical appliance). Whenever an AC load (greater than 25 watts) is turned on, the inverter recognizes the need for power and automatically starts inverting and output goes to full voltage. When there is no load (or less than 25 watts) detected, the inverter automatically goes back into search mode to minimize energy consumption from the battery bank. In “Power saver on” mode, the inverter will draw power mainly in sensing moments, thus the idle consumption is significantly reduced. The inverter is factory defaulted to detect load for 250ms every 30 seconds. This cycle can be customized to 3 seconds by turning SW3 on the DIP switch. http://www.cengapower.com/... -
Page 10: Protections
When in the search sense mode, the green power LED will blink and the inverter will make a ticking 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 or “Power Saver On” function should be defeated. Exceptions: Some devices when scanned by the load sensor cannot be detected. Small fluorescent lights are the most common example. (Try altering the plug polarity by turning the plug over.) Some computers and sophisticated electronics have power supplies that do not present a load until line voltage is available. When this occurs, each unit waits for the other to begin. To drive these loads either a small companion load must be used to bring the inverter out of its search mode, or the inverter may be programmed to remain at full output voltage. Protections The BACKUP INVERTER inverter is equipped with extensive protections against various harsh situations/faults. These protections include: • AC Input over voltage protection/AC Input low voltage protection • Low battery alarm/High battery alarm • Over temperature protection/Over load protection • Short Circuit protection (1s after fault) • Back feeding protection When Over temperature /Over load occur, after the fault is cleared, the master switch has to be reset to restart the inverter. The Low battery voltage trip point can be customized from defaulted value 10VDC to 10.5VDC thru the SW1 on the DIP switch. The inverter will go to Over temp protection when the heat sink temp. ≥105ºC, and it will go to Fault (shutdown the output) after 30 seconds. The switch has to be reset to reactivate the inverter. The Inverter has back-feeding protection which avoids presenting an AC voltage on the AC input terminal in Invert mode. Note: After the reason for fault is cleared, the inverter has to be reset to start working. LED Indicator & LCD http://www.cengapower.com/... -
Page 11: Audible Alarm
Line Mode Green LED lit in AC Mode Inverter Mode Green LED lit in Inverter Mode Fast Charge Yellow LED lit in Fast Charging Mode Float Charge Green LED lit in Float Charging Mode Alarm Mode Red LED lit in error state Over Temp Trip Red LED in Over Temperature Over Load Trip Red LED in Over Load Power Saver On Green LED lit in Power Saver Mode Audible Alarm Battery Voltage Low Inverter Green LED is lit and the buzzer beeps every 5s for .5s duration. Battery Voltage High Inverter Green LED is lit and the buzzer beeps ever 1s for .5s (Fault after 60s). Inverter Over-Load 1. Between 110% and 125%, no alarm for first 14min, beeps every 1s for .5s @ 15 min and fault after 15min. http://www.cengapower.com/... -
Page 12: Fan Operation
2. Between 125% and 150%, beeps every 1s for .5s and fault after 60s. 3. Greater than 150%, beeps every 1s for .5s and fault after 20s. Over Temperature When the heatsink temperature is greater than 105ºC, beeps every 1s for .5s (over temp LED is lit). FAN Operation There are two DC fans and one AC fan inside the inverter. While in inverter mode, the AC fan will run to dissipate heat. When the inverter is in power saver mode, the AC fan will work from time to time in response to the pulse sent by the inverter in power saver mode. The Operation of the DC fan at the DC terminal side is controlled by the following logic: Item Condition Speed T > 65℃ H E AT SIN K T ≤ 60℃ / T ≥ 85℃ TEMPERATURE 100% T ≤ 80℃ I ≥ 20% C H A RGER I ≤ 15% / I ≥ 50% CUR R EN T I ≤ 40%... -
Page 13: Other Features
SW 5 Solar/AC Priority Setting Utility Priority Solar Priority SW1 – Low Battery Trip Volt: The Low Battery Trip Volt is set at 40.0Vdc which is typical for a deep cycle lead acid battery. It can be customized to 42Vdc using SW1 for sealed AGM batteries, to prevent the batteries from over-discharging while there is only a small load applied on the inverter. SW2 – AC Input Range: There are different acceptable AC input ranges for different kinds of loads. For some relatively sensitive electronic devices, a narrow input range of 184-253VAC (100-135V for per phase) is required to protect them. While for some resistive loads which work in a wide voltage range, the input AC range can be customized to 154-253VAC (90-135V per phase), this helps to power loads with the most AC input power without frequent switches to the battery bank. SW3 – Power Saver Auto Setting: The inverter is factory defaulted to detect load for 250ms in every 5 seconds. This cycle can be changed to 3 seconds thru the SW3 on the DIP switch. SW4 – Solar/AC Priority: The BACKUP INVERTER is designed with AC priority by default. This means that when AC input is present, the battery will be charged first, and the inverter will transfer the input AC to power the load. Only when the AC input is stable for a continuous period of 15 days, the inverter will start a battery inverting cycle to protect the battery. After 1 cycle normal charging and AC through power will be restored. The AC Priority and Battery Priority switch is SW4. When you choose battery priority, the inverter will invert from battery even when the AC input is present. Only when the battery voltage reaches the low voltage alarm point will the inverter transfer to AC Input, charge the battery, and switches back to battery when battery is charged full. This function is mainly for wind/solar systems using utility power as a back-up. Other features Battery voltage recover start After low battery voltage shut off (40V), the inverter is able to restore normal operation after the battery voltage recovers to 52Vdc (with power switch still in the “On” position). This function helps to save the extra effort to reactivate the inverter when the low battery voltage returns to an acceptable range in the renewable energy systems. The built in battery charger will automatically reactivate as soon as input AC power has been stable for 15 seconds. WARNING: Never leave the loads unattended, some loads (like a heater) may cause accidents in such cases. It is better to shut everything down after low voltage trip than to leave your load on, due to the risk of fire. -
Page 14: Conformal Coating
Auto Gen Start The inverter can be customized to start-up a generator when battery voltage goes low. When the inverter goes to low battery alarm levels, it can send a signal to start a generator, and turn the generator off after battery charging is finished. The auto gen start feature will only work with generators designed to work with this feature. There is an open/closed relay that will short circuit the positive and negative cable from a generator. The input DC voltage can vary, but the Max current the relay can carry is 16Amp. Conformal Coating The inverter has been processed with a conformal coating on the PCB making it water, rust, and dust resistant. Installation Location Follow all the local regulations to install the inverter. Please install the equipment in a location that is Dry, Clean, Cool and that has good ventilation. • Operating temperature: -10 ℃ -40 ℃ • Storage temperature: -40-70 ℃ • Relative Humidity: 0%-95% ， non-condensing • Cooling: Forced air DC Wiring recommendation It is suggested the battery bank be kept as close as possible to the inverter. For distances up to 1m (3ft), “0” wire gauge is recommended. For distances of 1-5m (3-15ft), “00” wire gauge si recommended. In case of DC cable longer than 5m, please increase the cross section of cable to reduce the loss. AC Wiring We recommend using 10-5Awg wire to connect to the AC terminal block. http://www.cengapower.com/... -
Page 15: Troubleshooting Guide
Troubleshooting Guide Troubleshooting contains information about how to troubleshoot possible error conditions while using the Inverter. The following chart is designed to help you quickly pinpoint the most common inverter failures: Indicator On Front Panel Indicator On Remote Module Inverter Utility Inverter Fast Float Alarm Over-Temp Over-Load Power Charger Status Buzzer Alarm Power On Charge Charge Trip Trip Save On C.C √ × √ × × × × × √ × × × Line C.V √... - Page 16 Beep 0.5s Battery Low × √ × × √ × × × × √ √ every 5s Beep 0.5s every Battery High × √ × × √ × × × × √ √ Overload On Refer to × √ × × √ × √ × × √ √ Inverter Mode Inverter “Audible alarm”...
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Page 17: Warranty
AC output voltage is low and the Low battery. Check the condition of the inverter turns loads OFF in a short batteries and recharge if time. possible. Charger is inoperative and unit AC voltage has dropped Check the AC voltage for will not accept AC. out-of-tolerance proper voltage and frequency. Charger is supplying a lower Charger controls are improperly Refer to the section on charge rate. set. adjusting the “Charger Rate”. Source qualified AC power.. Low AC input voltage. Loose Check all DC /AC battery or AC input connections. connections. Charger turns OFF while charging High AC input voltages from the Load the generator down from a generator. generator. with a heavy load. Turn the generator output voltage down. Sensitive loads turn off temporarily Inverter's Low voltage trip voltage Choose narrow AC voltage in the when transferring between grid may be too low to sustain certain DIP switch. power and inverter power. loads.