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SamplexPower PST-600-12 Owner's Manual

Dc-ac power inverter pure sine wave
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DC-AC Power
Inverter
Pure Sine Wave
PST-600-12
PST-600-24
Owner's
Please read this
manual BEFORE
Manual
installing your
inverter

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Summary of Contents for SamplexPower PST-600-12

  • Page 1 DC-AC Power Owner's Please read this manual BEFORE Manual Inverter installing your Pure Sine Wave inverter PST-600-12 PST-600-24...

  • Page 2: Table Of Contents

    OWNER'S MANUAL | Index SECTION 1 Safety Instructions ........3 SECTION 2 General Information ........9 SECTION 3 Limiting Electromagnetic Interference (EMI) ....... 16 SECTION 4 Powering Direct / Embedded Switch Mode Power Supplies (SMPS) ............17 SECTION 5 Principle of Operation ....... 19 SECTION 6 Layout ............

  • Page 3: Safety Instructions

    SECTION 1 | Safety Instructions 1.1 SAFETY SYMBOLS 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. INFO Indicates useful supplemental information.
  • Page 4 SECTION 1 | Safety Instructions equipment. These areas may include spaces containing gasoline-powered machinery, fuel tanks, and battery compartments. 1.2.5 Precautions when working with batteries • Batteries contain very corrosive diluted Sulphuric Acid as electrolyte. Precautions should be taken to prevent contact with skin, eyes or clothing. •...
  • Page 5 Safety Instructions 1.3.2 Preventing DC Input Over Voltage It is to be ensured that the DC input voltage does not exceed 16.5 VDC for PST-600-12 or 33.0 VDC for PST-600-24 to prevent permanent damage to the unit. Please observe the following precautions: •...
  • Page 6 SECTION 1 | Safety Instructions 1.3.4 Use of External Fuse in DC input Circuit Use Class-T or equivalent fuse of appropriate capacity within 7" of the battery Positive ter- minal. This fuse is required to protect DC input cable run from damage due to short circuit along the length of the cable.
  • Page 7 SECTION 1 | Safety Instructions 1.5.4 Prévention des Risques d’Incendie et d'Explosion • L'utilisation de l'appareil pourrait produire des arcs électriques ou des étincelles. Par conséquent, il ne devrait pas être utilisé dans les endroits où il y a des maté- riaux ou gaz nécessitant des équipements ignifuges, par exemple, des espaces contenant des machines alimentées par essence, des réservoirs d'essence ou, des compartiments à...
  • Page 8 1.6.2 Prévention d'une Surtension de l'Entrée CC II faut assurer que la tension d'entrée CC de cet appareil n'excede pas une tension de 16,5 VCC pour PST-600-12 ou 33.0 VCC pour PST-600-24 affin d'empêcher des dégâts permanents à l'appareil. Veuillez suivre les consignes suivantes: •...

  • Page 9: General Information

    SECTION 2 | General Information 2.1. DEFINITIONS The following definitions are used in this manual for explaining various electrical concepts, specifications and operations: Peak Value: It is the maximum value of electrical parameter like voltage / current. RMS (Root Mean Square) Value: It is a statistical average value of a quantity that varies in value with respect to time.
  • Page 10 SECTION 2 | General Information tance X to cause the current to lag the voltage by 90° and that of the capacitive reac- tance X to cause the current to lead the voltage by 90° are exactly opposite and the net effect is a tendency to cancel each other.
  • Page 11 SECTION 2 | General Information peres” (LRA) due to low DC resistance of the windings. For example, in motor driven loads like Air-conditioning and Refrigeration Compressors and in Well Pumps (using Pressure Tank), the Starting Surge Current / LRA may be as high as 10 times its rated Full Load Amps (FLA) / Maximum Continuous Running Power Rating.
  • Page 12 SECTION 2 | General Information Resistive Load: A device or appliance that consists of pure resistance (like filament lamps, cook tops, toaster, coffee maker etc.) and draws only Active Power (Watts) from the inverter. The inverter can be sized based on the Active Power rating (Watts) of resistive type of loads without creating overload (except for resistive type of loads with Tungsten based heating element like in Incandescent Light Bulbs, Quartz Halogen Lights and Quartz Halogen Infrared Heaters.
  • Page 13 SECTION 2 | General Information voltage crossing (for timing control) will not work properly from a voltage that has a Modified Sine Waveform. Also, as the Modified Sine Wave is a form of Square Wave, it is comprised of multiple Sine Waves of odd harmonics (multiples) of the fundamental frequency of the Modified Sine Wave.
  • Page 14 SECTION 2 | General Information • Some new furnaces with microprocessor control / Oil burner primary controls. • High intensity discharge (HID) lamps like Metal Halide Lamps. These may get dam- aged. Please check with the manufacturer of these types of devices for suitability. •...
  • Page 15 SECTION 2 | General Information Inverter TABLE 2.1: INVERTER SIZING FACTOR Sizing Factor Type of Device or Appliance (See note 1) Air Conditioner / Refrigerator / Freezer (Compressor based) Air Compressor Sump Pump / Well Pump / Submersible Pump Dishwasher / Clothes Washer Microwave (where rated output power is the cooking power) Furnace Fan Industrial Motor...

  • Page 16: Limiting Electromagnetic Interference (Emi)

    SECTION 3 | Limiting Electro-Magnetic Interference (EMI) 3.1 EMI AND FCC COMPLIANCE These inverters contain internal switching devices that generate conducted and radiated electromagnetic interference (EMI). The EMI is unintentional and cannot be entirely eliminated. The magnitude of EMI is, however, limited by circuit design to acceptable levels as per limits laid down in North American FCC Standard FCC Part 15(B), Class B.

  • Page 17: Powering Direct / Embedded Switch Mode Power Supplies (Smps)

    SECTION 4 | Powering Direct / Embedded Switch Mode Power Supplies (SMPS) 4.1 CHARACTERISTICS OF SWITCHED MODE POWER SUPPLIES (SMPS) Switch Mode Power Supplies (SMPS) are extensively used to convert the incoming AC power into various voltages like 3.3V, 5V, 12V, 24V etc. that are used to power vari- ous devices and circuits used in electronic equipment like battery chargers, computers, audio and video devices, radios etc.
  • Page 18 SECTION 4 | Powering Direct / Embedded Switch Mode Power Supplies (SMPS) NOTE: Voltage and current scales are di erent Input voltage Peak inrush current Rated steady state input RMS current Inrush current Fig 4.1: Inrush current in an SMPS NOTE: Voltage Peak Current and current scales...

  • Page 19: Principle Of Operation

    SECTION 5 | Principle of Operation 5.1 GENERAL This inverter converts 12 VDC battery voltage to AC voltage with an RMS (Root Mean Square) value of 120 VAC, 60 Hz RMS. 5.2 PURE SINE WAVE OUTPUT WAVEFORM The waveform of the AC voltage is a pure Sine Waveform that is same as the waveform of Grid / Utility power (Supplementary information on pure Sine Waveform and its advan- tages are discussed in Sections 2.2 to 2.4).

  • Page 20: Layout

    9. Positive (+) DC Input Terminal Set screw: • 5/16” x 24 TPI • 1/2” long ; Slotted Head 10. Modular Jack (6P6C) for RC-15A Remote Control (optional) Fig. 6.1: Layout of PST-600-12 & PST-600-24 20 | SAMLEX AMERICA INC.

  • Page 21: General Information - Battery Related

    SECTION 7 | General Information - Battery Related INFO For complete information on Lead Acid Batteries and Charging Process, please visit www.samlexamerica.com > Support > White Papers > White Paper - Batteries, Chargers and Alternators. 7.1 LEAD ACID BATTERY – BASIC DESCRIPTION AND ELECTRO- CHEMICAL REACTIONS 7.1.1 A Lead Acid battery consists of a number of 2 V nominal cells (actual voltage of...
  • Page 22 SECTION 7 | General Information - Battery Related fully charged to 2.105 V will measure a standing voltage of 12.63 V at Standard Room Temperature of 77º F / 25º C. Also, in a healthy battery, all the individual cells will have the same voltage and same specific gravity.
  • Page 23 SECTION 7 | General Information - Battery Related 80ºF (26.7ºC) till the voltage drops to 1.75V / Cell i.e. 10.5V for 12V battery or 21V for 24V battery. Approximate relationship between the two units is: Capacity “C” in Ah = Reserve Capacity in RC minutes x 0.6 7.5 TYPICAL BATTERY SIZES The Table 7.1 shows details of some popular battery sizes:...
  • Page 24 SECTION 7 | General Information - Battery Related TABLE 7.2 TYPICAL “C-rates” OF DISCHARGE Examples of C-rate of Discharge C-rate of Discharge for 100 Ah capacity battery (Column 1) (Column 2) 200A 100A C/5 or 0.2C (Inverter application) C/8 or 0.125C (UPS application) 12.5A C/10 or 0.1C (Telecom application) C/20 or 0.05C (Automotive application)
  • Page 25 SECTION 7 | General Information - Battery Related Typical 12V/24V Flooded Lead-Acid Battery Chart - 80˚F / 26.7˚C 24V 12V 33.0 16.5 C/10 32.0 16.0 CHARGE C/20 31.0 15.5 C/40 30.0 15.0 29.0 14.5 28.0 14.0 27.0 13.5 26.0 13.0 C/100 C/20 25.0...
  • Page 26 SECTION 7 | General Information - Battery Related TABLE 7.3 BATTERY CAPACITY VERSUS RATE OF DISCHARGE – C-RATE C-rate Discharge Current Usable Capacity (%) C/20 or, 0.05C 100% C/10 or, 0.10C C/8 or, 0.125C C/6 or, 0.17C C/5 or, 0.20C C/3 or, 0.34C C/2 or, 0.50C Table 7.3 shows that a 100 Ah capacity battery will deliver 100% (i.e.
  • Page 27 SECTION 7 | General Information - Battery Related Check the individual cell voltages / specific gravity. If the inter cell voltage difference is more than a 0.2V, or the specific gravity difference is 0.015 or more, the cells will require equalization.
  • Page 28 SECTION 7 | General Information - Battery Related TABLE 7.5 TERMINAL VOLTAGE AND SOC OF LOADED BATTERY Terminal Voltage at 80% State Terminal Voltage When Completely of Discharge (20% SOC) Discharged (0% SOC) Discharge Current: C-rate C/3 A 10.45V 20.9V 09.50V 19.0V C/5 A...
  • Page 29 SECTION 7 | General Information - Battery Related It is seen that at DC input voltage of 10V/ 20V, the battery is completely discharged for C-rate discharge current of C/5 and lower. In view of the above, it may be seen that a fixed Low DC Input Voltage Shutdown is not useful.
  • Page 30 SECTION 7 | General Information - Battery Related 7.15.1 Series Connection Cable “A” Battery 4 Battery 3 Battery 2 Battery 1 24V Inverter or 24V Charger 200Ah 200Ah 200Ah 200Ah Cable “B” Fig 7.2 Series Connection When two or more batteries are connected in series, their voltages add up but their Ah capacity remains the same.
  • Page 31 SECTION 7 | General Information - Battery Related 7.15.3 Series – Parallel Connection 12V String 1 12V String 2 Battery 1 Battery 2 Battery 3 Battery 4 Cable “A” 12V Inverter or 12V Charger 200 Ah 200 Ah 200 Ah 200 Ah Cable “B”...
  • Page 32 SECTION 7 | General Information - Battery Related If the Positive output cable of the inverter/charger (Cable “A”) is connected to the Positive battery post of the first battery (Battery 1 in Fig. 7.3) or to the Positive battery post of the first battery string (Battery 1 of String 1 in Fig.
  • Page 33 SECTION 7 | General Information - Battery Related - Les résistances des câbles interconnectés seront pas équilibrées - Tous les batteries/ fils de batterie dans la série n’auront pas la même résistance - Toutes les batteries individuelles vont recharger à des courants différentes, ainsi elles atteindront un état de rechargement complèt mais en décalage.
  • Page 34 SECTION 7 | General Information - Battery Related Now, the capacity of the batteries is determined based on the run time and the usable capacity. From Table 7.3 “Battery Capacity versus Rate of Discharge”, the usable capacity at 3 Hour discharge rate (C/3) is 60%. Hence, the actual capacity of the 12V batteries to deliver 300 Ah will be equal to: 300 Ah ÷...

  • Page 35: Installation

    SECTION 8 | Installation WARNING! 1. Before commencing installation, please read the safety instructions explained in the Section titled “Safety Instructions” on page 3. 2. It is recommended that the installation should be undertaken by a qualified, licensed / certified electrician. 3.
  • Page 36 SECTION 8 | Installation Clean: The area should be free of dust and fumes. Ensure that there are no insects or rodents. They may enter the unit and block the ventilation openings or short circuit electrical circuits inside the unit. 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.
  • Page 37 SECTION 8 | Installation - Mount on a non-combustible material. - The mounting surface should be able to support the weight of the unit - Mount horizontally on a horizontal surface - above a horizontal surface (e.g. table top or a shelf). - Mount horizontally on a vertical surface –...
  • Page 38 SECTION 8 | Installation 8.3 OVERALL DIMENSIONS Overall dimensions and location of mounting slots are shown in Fig. 8.1 below: 14.0 14.0 276.2 NOTE: Dimensions are in mm NEG – NEG – POS + WARNING: Reverse polarity will damage the unit. AVERTISSEMENT : Inversion de polarité...
  • Page 39 - Ensure that the maximum charging voltage of the external battery charger / alternator / solar charge controller does not exceed 16.5 VDC for PST-600-12 or 33V for PST-600-24 - When using Diversion Charge Control Mode in a Charge Controller, the solar / wind / hydro source is directly connected to the battery bank.
  • Page 40 SECTION 8 | Installation 8.4.3 Connection from the Batteries to the DC Input Side of the Unit – Cable and External Fuse Sizes WARNING! The input section of the inverter has large capacitors connected across the input terminals. As soon as the DC input connection loop (Battery (+) terminal ►...
  • Page 41 SECTION 8 | Installation Table 8.1 Battery Cable Resistance per Foot WIRE SIZE, RESISTANCE IN OHM (Ω) PER FOOT AT 25°C / 77°F AWG#2 0.000159 Ω per Foot AWG#1/0 0.000096 Ω per Foot AWG#2/0 0.000077 Ω per Foot AWG#4/0 0.000050 Ω per Foot Conductors are protected with insulating material rated for specific temperature e.g.
  • Page 42 SECTION 8 | Installation cables that connects the battery to the inverter, thousands of Amperes of current can flow from the battery to the point of shorting and that section of the wire will become red-hot, the insulation will melt and the cable will ultimately break. This interruption of very high current will generate a hazardous, high temperature, high-energy arc with ac- companying high-pressure wave that may cause fire, damage nearby objects and cause injury.
  • Page 43 3.05M (See (See Column 2) Installation Kit Note 1) Note 2) (See (See Note 5) Note 3) PST-600-12 100A AWG#6 AWG#4 AWG#2 DC-1000-KIT PST-600-24 AWG#10 AWG#10 AWG#6 DC-1000-KIT NOTES FOR TABLE 8.2 1) Column 2 indicates the value of the rated continuous DC input current drawn from the battery.
  • Page 44 SECTION 8 | Installation b) Voltage drop across the length of cables limited to 2% of 12V / 24V. i) Voltage drop has been calculated by multiplying the Rated Continuous DC Input Current (Column 2) and the resistance of the total length of Copper con- ductor (the total length of conductor has been taken as 2 times the running distance between the unit and the battery to cover 2 lengths of Positive and Negative cable conductors).
  • Page 45 Installation To ensure firm contact, a pair of pin type terminal lugs have been provided as follows: • PST-600-12 : For up to AWG#4 (Part No. PTNB25-15) • PST-600-24 : For up to AWG#10 (Part No. DBNYB5-14) 8.4.7 Reducing RF Interference Please comply with recommendations given in Section 3.2.
  • Page 46 SECTION 8 | Installation 8.5.1 Bonding of AC Output Neutral to Chassis Ground The Neutral slots of the NEMA5-20R GFCI Duplex Receptacles (5, Fig 6.1) are internally bonded to the metal chassis of the inverter. 8.5.2 AC Output Connection Through Self Monitoring Ground Fault Circuit Interrupter (GFCI) An un-intentional electric path between a source of current and a grounded surface is referred to as a “Ground Fault”.
  • Page 47 SECTION 8 | Installation • Press the “Reset Button” (5A in Fig 6.1). The GFCI will reset and AC power to the load side outlets will be restored. Status LED (5C in Fig 6.1) will turn Green. The test lamp will also switch ON.
  • Page 48 SECTION 8 | Installation Hot and Neutral of the Utility power to the Hot and Neutral in the Sub-Panel. The Neutral of the Sub-Panel will be bonded to the Earth Ground through the Main Utility Supply Panel. As the Neutral of the inverter will be isolated from the Neutral of the utility power, the Neutral of the GFCI output will not be bonded to the Earth Ground and the GFCI will not trip - When the Utility power fails or is interrupted, the Hot and the Neutral of the GFCI will be...
  • Page 49 Toggle Switch 1A Fuse (10-33VDC) Toggle Switch +12V from 12V battery NOTE: Wiring Size: AWG #22 feeding PST-600-12 +24V from 24V battery feeding PST-600-24 Fig 8.2(a) − 2-Wire Fig 8.2(b) − 2-Wire Fig 8.2(c) − 1-Wire ON/OFF ON/OFF control using...
  • Page 50 SECTION 8 | Installation 8.9.1.1 2-Wire ON/OFF Control from Remote Location Using Switch/Relay Contact, Fig 8.2(a): In this arrangement, external voltage source is NOT required. The inverter will switch ON when potential free relay contact / switch is closed and terminals "S" and "–" of the Terminal Block (4A, Fig 6.1) are shorted.
  • Page 51 SECTION 8 | Installation The inverter will switch ON when the external relay contact / switch is closed [External DC voltage (10-33VDC) is fed to terminals marked "+" and "–" on the 3-Way Terminal Block (4A, Fig 6.1)]. The inverter will switch OFF when the external relay contact / switch is opened [External DC voltage (10-33VDC) is removed from terminals marked "+"...

  • Page 52: Operation

    SECTION 9 | Operation 9.1 SWITCHING THE INVERTER ON/OFF Before switching on the inverter, check that all the AC loads have been switched off. 3-Position Rocker Switch marked ON/OFF/EXT (1, Fig 6.1) is used to switch ON / switch OFF the unit locally and also to enable switching on/off by external switching control. Switching options are as follows: ON –...
  • Page 53 (<600mA for PST-600-12 and <450mA for PST-600-24). This is called the "idle current" or the "no load draw". Hence, when the load is not required to be operated, turn OFF the ON/OFF switch on the inverter to prevent unnecessary current drain from the battery.

  • Page 54: Protections

    More examples of such types of devices/ appliances are given at Section 2.5, Table 2.1. Surge Power ratings of PST-600-12/ PST-600-24 is 1000W (166% of its rated continuous power of 600W) for < 1 sec.
  • Page 55 10.3 LOW DC INPUT VOLTAGE SHUT DOWN If the voltage at the DC input terminals drops to 10V ± 0.1V for PST-600-12 or to 20V ± 0.2V for PST-600-24, the AC output is shut down. Buzzer alarm is sounded. The GREEN "POWER ON"...
  • Page 56 SECTION 10 | Protections 10.5 OVER-TEMPERATURE SHUT DOWN In case of failure of the cooling fan or in the case of inadequate heat removal due to higher ambient temperatures / insufficient air exchange, the temperature inside the unit will increase. The temperature of a critical hot spot inside the inverter is monitored and at 90°...
  • Page 57 DC side. The fuses are 32V, Automotive Type Blade Fuses, Type "ATO" by Littel Fuse or equivalent: • PST-600-12: 2 pieces of 40A fuses in parallel = 80A total; 32V • PST-600-24: 2 pieces of 20A fuses in parallel = 40A total; 32V NOTE: The fuses are installed in Fuse Holders.

  • Page 58: Troubleshooting Guide

    • The AC output voltage will switch ON auto- outlet (5C, Fig 6.1) is OFF matically when the DC input voltage rises to 11.5V ± 0.3V or higher for PST-600-12 or, 23V ± 0.5V or higher for PST-600-24 58 | SAMLEX AMERICA INC.
  • Page 59 16.5V or higher for PST- DC input voltage drops below 16.5V for 600-12 PST-600-12 or below 33V for PST-600-24 • Buzzer is on. • DC input voltage is 33V • Status LED on the GFCI or higher for PST-600-24 outlet (5C, Fig 6.1) is OFF...
  • Page 60 SECTION 11 | Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE REMEDY • There is no AC output from GFCI has tripped due to Check load side circuits for leakage or Neutral the GFCI outlet (5, Fig 6.1) leakage or due to Neutral to Ground bond and remove this ground fault to Ground bond on the condition.

  • Page 61: Specifications

    SECTION 12 | Specifications MODEL NO. PST-600-12 PST-600-24 OUTPUT OUTPUT VOLTAGE 120 VAC ± 3% 120 VAC ± 3% MAXIMUM OUTPUT CURRENT 5.1A 5.1A OUTPUT FREQUENCY 60 Hz ± 1% 60 Hz ± 1% TYPE OF OUTPUT WAVEFORM Pure Sine Wave...
  • Page 62 (du véhi- cule) est fabriqué pour plus que 80A pour PST-600-12 ou supérieur à 40A pour PST-600-24. Si le fusible s'ouvre plusieurs fois, ne continuez pas de le remplacer.

  • Page 63: Warranty

    Warranty 3 YEAR LIMITED WARRANTY PST-600-12/ PST-600-24 manufactured by Samlex America Inc. (the “Warrantor“) are warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 3 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“).
  • Page 64 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 11001-PST-600-12-24-1119...

This manual is also suitable for:

Pst-600-24Pst-300-12Pst-300-24

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