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Samlexpower PST-300-12 Owner's Manual

Dc-ac power inverter pure sine wave
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DC-AC Power
Inverter
Pure Sine Wave
PST-300-12
PST-300-24
Owner's
Please read this
manual BEFORE
Manual
installing your
inverter

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Summary of Contents for Samlexpower PST-300-12

  • Page 1 DC-AC Power Owner's Please read this manual BEFORE Manual Inverter installing your Pure Sine Wave inverter PST-300-12 PST-300-24...

  • 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-300-12 or 33.0 VDC for PST-300-24 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-300-12 ou 33.0 VCC pour PST-300-24 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 12/24 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

    • 3/8” long ; Slotted Head 7. Negative (-) DC Input Terminal Tubular hole diameter: 5mm/ 0.22” 8. Positive (+) DC Input Terminal Set screw: #10, 24TPI, 5/16“ long, Hex Socket Head Fig. 6.1: Layout of PST-300-12 & PST-300-24 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 Overall dimensions and location of mounting slots are shown in Fig. 8.1 below: (See NOTE 2) 1.75 NOTES: 1. All dimensions are in mm 2. Dimension 246mm is 65.5 measured with 3-Terminal Mating Plug (3B, Fig 6.1) removed Fig. 8.1 PST-300-12/ PST-300-24 Overall Dimensions & Mounting Slots 38 | SAMLEX AMERICA INC.
  • 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-300-12 or 33V for PST-300-24 - 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 Current per NEC Column 2) 0.91M 1.83M 3.05M (See Note 1) (See Note 2) (See Note 3) PST-300-12 AWG#8 AWG#6 AWG#4 PST-300-24 AWG#12 AWG#12 AWG#10 NOTES FOR TABLE 8.2 1) Column 2 indicates the value of the rated continuous DC input current drawn from the battery.
  • Page 44 AWG #14 / 2mm suitable for Ampacity of 12.5A. • Cable set with Battery Clamp, 3ft - For PST-300-12: AWG#12 / 4mm - For PST-300-24: AWG#14 / 2mm 44 | SAMLEX AMERICA INC.
  • Page 45 SECTION 8 | Installation WARNING! Limiting Power Draw from 12V Power Outlet in Vehicles: - Check the Ampere rating of the vehicle fuse powering the 12 V outlet. - AC power drawn from the inverter should be less than 10 times the Ampere rating of the vehicle fuse.
  • Page 46 SECTION 8 | Installation MISE EN GARDE! Empêcher la Sortie CA de Se Mettre en Parallèle 1. La sortie CA de l'appareil ne peut pas être synchronisée avec une autre source CA et ainsi, ce n'est pas approprié de la mettre en parallèle. La sortie CA de l'appareil devrait jamais être directement branchée à...
  • Page 47 SECTION 8 | Installation is detected the load side is permanently disconnected with status LED (4C in Fig 6.1) turn- ing Red. The GFCI will be required to be replaced. Details of operation are given below: • As soon as the inverter is switched on and VAC is made available at the internal line side of the GFCI, status LED (4C in Fig 6.1) will turn Green, then Red &...
  • Page 48 SECTION 8 | Installation ATTENTION! 1. N'alimentent pas la sortie de la prise GFCI à un Panel de sélection / Charger Centre où la position neutre est lié à la terre. Ce qui déclenche le disjoncteur. 2. Si une rallonge est utilisée, veuillez vous assurer que le cordon est mise à la terre à...
  • Page 49 SECTION 8 | Installation When using the inverter in a mobile RV, connect a 10 mm or AWG #8 insulated stranded copper wire from the above equipment grounding lug to the appropriate ground bus of the RV (usually the vehicle chassis or a dedicated DC Ground Bus). The connections must be tight against bare metal.
  • Page 50 Relay Contact Source Toggle Switch 1A Fuse (10-33VDC) Toggle Switch +12V from 12V battery feeding PST-300-12 NOTE: Wiring Size: AWG #22 +24V from 24V battery feeding PST-300-24 Fig 8.2(a) − 2-Wire Fig 8.2(b) − 2-Wire Fig 8.2(c) − 1-Wire ON/OFF...
  • Page 51 SECTION 8 | Installation ATTENTION! 1. Veuillez vous assurer que la polarité de la liaison de câblage. La borne positive ( +) de la source de courant continu externe doit être connecté à la borne positive marquée " +" ; sur le bornier à 3 contacts (3A/B, figure 6.1) et la borne négative (-) de la source de courant continu externe doit être connecté...
  • Page 52 SECTION 8 | Installation ATTENTION! 1. Veuillez vous assurer que la polarité de la liaison de câblage. La borne positive ( +) de la source de courant continu externe doit être connecté à la borne positive marquée " +" ; sur le bornier à 3 contacts (3A/B, figure 6.1). 2.

  • Page 53: 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 54 (<500mA for PST-300-12 and <400mA for PST-300-24). 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 55: Protections

    More examples of such types of devices/ appliances are given at Section 2.5, Table 2.1. Surge Power ratings of PST-300-12/ PST-300-24 is 500W (166% of its rated continuous power of 300W) for < 1 sec.
  • Page 56 10.3 LOW DC INPUT VOLTAGE SHUT DOWN If the voltage at the DC input terminals drops to 10V for PST-300-12 or to 20V for PST- 300-24, the AC output is shut down. Buzzer alarm is sounded. The Status LED on the front panel of the unit (2, Fig 6.1) will turn Orange.
  • Page 57 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 58 DC side. The fuses are 32V, Automotive Type Blade Fuses, Type "ATO" by Littel Fuse or equivalent: • PST-300-12: 40A, 32V • PST-300-24: 20A, 32V NOTE: The fuses are installed in Fuse Holders. Hence, these can be removed and replaced easily.

  • Page 59: Troubleshooting Guide

    (4C, Fig 6.1) is OFF • The AC output voltage will switch ON auto- matically when the DC input voltage rises to 11.5V ± 0.3V or higher for PST-300-12 or, 23V ± 0.5V or higher for PST-300-24 SAMLEX AMERICA INC. | 59...
  • Page 60 Orange • DC input voltage is • The unit will reset automatically when the DC 16.5V or higher for PST- input voltage falls below 16.5V for PST-300-12 • Buzzer is on. 300-12 or below 33V for PST-300-24 • Status LED on the GFCI •...
  • Page 61 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 for the GFCI outlet (4, Fig 6.1) leakage or due to Neutral Neutral to Ground bond and remove this to Ground bond on the ground fault condition.

  • Page 62: Specifications

    SECTION 12 | Specifications MODEL NO. PST-300-12 PST-300-24 OUTPUT OUTPUT VOLTAGE 120 VAC ± 3% 120 VAC ± 3% MAXIMUM OUTPUT CURRENT 2.54A 2.54A OUTPUT FREQUENCY 60 Hz ± 1% 60 Hz ± 1% TYPE OF OUTPUT WAVEFORM Pure Sine Wave...
  • Page 63 (du véhi- cule) est fabriqué pour plus que 40A pour PST-300-12 ou supérieur à 20A pour PST-300-24. Si le fusible s'ouvre plusieurs fois, ne continuez pas de le remplacer.

  • Page 64: Warranty

    Warranty 3 YEAR LIMITED WARRANTY PST-300-12/ PST-300-24 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 65 NOTES: SAMLEX AMERICA INC. | 65...
  • Page 66 NOTES: 66 | SAMLEX AMERICA INC.
  • Page 67 NOTES: SAMLEX AMERICA INC. | 67...
  • Page 68 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 Richmond, BC Email purchase orders to orders@samlexamerica.com 11001-PST-300-12-24-1221...

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Pst-300-24

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