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SamplexPower PST-1000-12HD Owner's Manual

Dc-ac power inverter
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DC-AC Power
Inverter
Pure Sine Wave
PST-1000-12HD
PST-1000-24HD
Owner's
Please read this
manual BEFORE
Manual
installing your
inverter

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Summary of Contents for SamplexPower PST-1000-12HD

  • Page 1 DC-AC Power Owner's Please read this manual BEFORE Manual Inverter installing your Pure Sine Wave inverter PST-1000-12HD PST-1000-24HD...

  • Page 2: Table Of Contents

    OWNER'S MANUAL | Index SECTION 1 Safety Instructions ........3 SECTION 2 General Information ........10 SECTION 3 Limiting Electromagnetic Interference (EMI) ....... 17 SECTION 4 Powering Direct / Embedded Switch Mode Power Supplies (SMPS) ............18 SECTION 5 Principle of Operation ....... 20 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 18 VDC for PST-1000-12HD or 36 VDC for PST-1000-24HD 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 CONSIGNES DE SÉCURITÉ - GÉNÉRALES 1.5.1 Installation et Conformité du Câblage • L’installation et le câblage doivent conformer aux Normes Électriques Locales et Nationales; l’installation doit être faite par un(e) électricien(ne) CERTIFIÉ(E). 1.5.2 Prévention des Décharges Électriques •...
  • 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 18 VCC pour PST-1000-12HD ou 36 VCC pour PST-1000-24HD affin d'empêcher des dégâts permanents à l'appareil. Veuillez suivre les consignes suivantes: •...
  • Page 9 SECTION 1 | Safety Instructions l'onduleur et des dommages éventuels dus à une montée de la tension de la bat- terie proche du niveau de la tension de circuit ouvert du ou des panneaux solaires lorsque la batterie est complètement chargée et est en phase de flotteur. 1.6.3 Prévention de Polarités Inversées sur le Côté...

  • Page 10: 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 11 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 12 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 13 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 14 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 15 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 16 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 17: 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 18: 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 19 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 20: 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 21: Layout

    • Hole size: 5/16” for ON/OFF switching using external control signals (See Section 8.9) • Screw: 5/16” x 24TPI; 3/8” long 10. DIP Switch 1 (LVD) and DIP switch 2 (ALM) Fig. 6.1: Layout of PST-1000-12HD & PST-1000-24HD SAMLEX AMERICA INC. | 21...

  • Page 22: 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 23 SECTION 7 | General Information - Battery Related voltages (0.2 V or higher) and specific gravities of the individual cells (0.015 or more), the cells will have to be “equalized". 7.2.3 SLI (Starting, Lighting, and Ignition) Batteries: Everybody is familiar with the SLI batteries that are used for automotive starting, lighting, ignition and powering vehicular accessories.
  • Page 24 SECTION 7 | General Information - Battery Related 7.5 TYPICAL BATTERY SIZES The Table 7.1 shows details of some popular battery sizes: TABLE 7.1: POPULAR BATTERY SIZES BCI* Group Battery Voltage, V Battery Capacity, Ah 27 / 31 GC2** * Battery Council International; ** Golf Cart 7.6 C-RATE OF CHARGE / DISCHARGE 7.6.1 The rate of charge / discharge of a battery is normally expressed in “C-rate”...
  • Page 25 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 26 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 27 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 28 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36: 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 37 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 38 SECTION 8 | Installation 8.2 MOUNTING ORIENTATION The unit has air intake and exhaust openings for the cooling fans. It has to be mounted in such a manner so that small objects should not be able to fall easily into the unit from these openings and cause electrical / mechanical damage.
  • Page 39 The overall dimensions and the location of the mounting slots for PST-1500 and PST-2000 are shown at Fig. 8.1. NOTE: All dimensions are in mm Fig. 8.1: PST-1000-12HD and PST-1000-24HD Overall Dimensions & Mounting Slots SAMLEX AMERICA INC. | 39...
  • Page 40 8.4.1 Preventing DC Input Over Voltage It is to be ensured that the DC input voltage of this unit does not exceed 18 VDC for PST-1000-12HD or 36 VDC for PST-1000-24HD to prevent permanent damage to the unit. Please observe the following precautions:...
  • Page 41 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 42 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 43 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 cable 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 44 NEC on Column Installation Kit 0.91M 1.83M 3.05M (See (See (See Note 5) Note 1) Note 2) (See Note 3) PST-1000-12HD 160A 200A 160A AWG#2 DC-2500-KIT #1/0 #3/0 (2.5% voltage drop for 10ft) PST-1000-24HD 100A AWG#6 AWG#4 AWG#2 DC-1000-KIT NOTES FOR TABLE 8.2...
  • Page 45 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 46 SECTION 8 | Installation To ensure firm contact, a pair of pin type terminal lugs have been provided as follows: • PST-1000-12HD: For up to AWG#1/0 (Part No. PTNB50-20) • PST-1000-24HD: For up to AWG#4 (Part No. PTNB25-15) 8.4.7 Reducing RF Interference Please comply with recommendations given in Section 3.2.
  • Page 47 SECTION 8 | Installation 2. Pour empêcher la possibilité que l'onduleur se met en parallèle ou s'endommage sévèrement, n'utilisez pas un câble de raccordement avec un fiche de chaque côté pour brancher la sortie CA de l'onduleur à un réceptacle mural commode dans la maison / VR. 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) and neutral termi- nal for hardwiring (13, Fig 6.1) are internally bonded to the metal chassis of the inverter.
  • Page 48 SECTION 8 | Installation INFO Self Monitoring GFCI duplex sockets may have an indication schema that is not exactly the same as described above. Some Self Monitoring GFCI duplex sockets may have a separate Status LED to indicate available power and a separate LED to indicate a fault in the protection circuit or "End of Life".
  • Page 49 Use 3 conductor cable with at least 90 C insulation rating. Based on the maximum output current of 8.5A for PST-1000-12HD and for PST-1000-24HD, the minimum size of each of the 3 conductors of the AC output cable should be AWG #14 for both the inverters. This is the minimum size recommended in NEC (2014) Table 310.15(B)(16) for up to 15A over current...
  • Page 50 SECTION 8 | Installation For Line and Neutral wires: Nylon Insulated, Cord End Terminals for AWG #14 wire ................ 2 pieces For Neutral wire: Non Insulated Ring Terminal for #6 stud ....... 1 piece Use proper crimping Tool to crimp the terminals to the bare ends of the wire. Make sure that the connections are tight and firm.
  • Page 51 SECTION 8 | Installation 8.8 OPTIONAL WIRED REMOTE CONTROL MODEL RC-15A An optional Wired Remote Control Model No. RC-15A (with 16.5 ft. / 5 metre cable), is available for switching ON and switching OFF. The remote has LED indications similar to the indications on the front panel (2,3,4 in Fig.
  • Page 52 Toggle Switch 1A Fuse (10-36VDC) Toggle Switch +12V from 12V battery NOTE: Wiring Size: AWG #22 feeding PST-1000-12HD +24V from 24V battery feeding PST-1000-24HD 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 53 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 (9, figure 6.1) et la borne négative (-) de la source de courant continu externe doit être con- necté...
  • Page 54 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 (9, figure 6.1) et la borne négative (-) de la source de courant continu externe doit être connecté...

  • Page 55: 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 56 (900mA for PST-1000-12HD and 600mA for PST-1000-24HD). This is called the "idle current" or the "no load draw". Hence, when the load is not re- quired to be operated, turn OFF the ON/OFF switch on the inverter to prevent unneces- sary current drain from the battery.

  • Page 57: Protections

    More examples of such types of devices/ appliances are given at Section 2.5, Table 2.1. Surge Power rating of the PST-1000-12HD/PST-1000-24HD is 2000W. When the load attempts to draw in excess of the rated AC output current of 8.5A by 200%, output current limiting is carried out immediately resulting in a drop of the AC output voltage proportional to the load impedance.
  • Page 58 10.2 WARNING ALARM - LOW DC INPUT VOLTAGE (DIP SWITCH 2 - ALM) If the voltage at the DC input terminals drops to 10.7 ± 0.1V for the PST-1000-12HD or to 21.4V ± 0.2V for the PST-1000-24HD, a warning alarm buzzer will sound. The GREEN "POWER ON"...
  • Page 59 25.6V ± 0.5V 10.4 HIGH DC INPUT VOLTAGE SHUTDOWN If the voltage at the DC input terminals rises to 18V for PST-1000-12HD or 36V for PST- 1000-24HD, the inverter will be shut down temporarily. Buzzer alarm will be sounded. The GREEN "POWER" LED (2, Fig 6.1) will remain lighted. The Status LED on the GFCI (5C, Fig 6.1) will be OFF.
  • Page 60 SECTION 10 | Protections and then, press the "Reset Button" (5A, Fig 6.1) on the GFCI to reset (GFCI will not reset if the inverter is OFF and there is no AC voltage on the internal Line Side of the GFCI). (Refer to Section 8.5.2 for detailed information on the GFCI and it's operation).
  • Page 61 DC side. The fuses are 32V, Automotive Type Blade Fuses, Type "ATO" by Littel Fuse or equivalent: • PST-1000-12HD: 4 pieces of 40A fuses in parallel = 160A total • PST-1000-24HD: 4 pieces of 20A fuses in parallel = 80A total NOTE: The fuses are soldered to the PCB.

  • Page 62: Troubleshooting Guide

    • The AC output voltage will switch ON outlet (5C, Fig 6.1) is OFF automatically when the DC input voltage rises to 11.5V ± 0.3V or higher for PST-1000-12HD or, 23V ± 0.5V or higher for PST-1000-24HD. 62 | SAMLEX AMERICA INC.
  • Page 63 • DC input voltage is 18V or • The unit will reset automatically when lighted higher for PST-1000-12HD the DC input voltage drops below 18V for PST-1000-12HD or below 36V for • *Buzzer is sounded. • DC input voltage is 36V or PST-1000-24HD higher for PST-1000-24HD •...
  • Page 64 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 65: Specifications

    SECTION 12 | Specifications MODEL NO. PST-1000-12HD PST-1000-24HD OUTPUT OUTPUT VOLTAGE 120 VAC ± 3% 120 VAC ± 3% MAXIMUM OUTPUT CURRENT 8.5A 8.5A OUTPUT FREQUENCY 60 Hz ± 1% 60 Hz ± 1% TYPE OF OUTPUT WAVEFORM Pure Sine Wave...
  • Page 66 CAUTION! RISK OF FIRE Do not replace any vehicle fuse with a rating higher than recommended by the vehicle manufacturer. PST-1000-12HD is rated to draw 160 Amperes from 12V vehicle outlet and PST-1000-24HD is rated to draw 80 Amperes from 24V battery vehicle outlet.

  • Page 67: Warranty

    Warranty 3 YEAR LIMITED WARRANTY PST-1000-12HD / PST-1000-24HD manufactured by Samlex America Inc. (the “Warran- tor“) 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 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-1000-12HD-24HD-1122...

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Pst-1000-24hd

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