Inverex AEROX 1.2KW, AEROX 3.2KW, AEROX 2.2KW Manual

SAFETY INSTRUCTIONS

This chapter contains important safety and operating instructions. Read and keep this manual for future reference.

1. Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.
2. 
   To reduce risk of injury, charge only deep-cycle lead acid type rechargeable batteries.
   Other types of batteries may burst, causing personal injury and damage.
3. 
   Do not disassemble the unit. Take it to a qualified service center when service or repair is required.
   Incorrect re-assembly may result in a risk of electric shock or fire.
4. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning. Turning off the unit will not reduce this risk.
5. 
   Only qualified personnel can install this device with battery.
6. NEVER charge a frozen battery.
7. For optimum operation of this inverter/charger, please follow required spec to select appropriate cable size. It's very important to correctly operate this inverter/charger.
8. Be very cautious when working with metal tools on or around batteries. A potential risk exists to drop a tool to spark or short circuit batteries or other electrical parts and could cause an explosion.
9. Please strictly follow installation procedure when you want to disconnect AC or DC terminals. Please refer to INSTALLATION section of this manual for the details.
10. One piece of 150A fuse is provided as over-current protection for the battery supply.
11. GROUNDING INSTRUCTIONS -This inverter/charger should be connected to a permanent grounded wiring system. Be sure to comply with local requirements and regulation to install this inverter.
12. NEVER cause AC output and DC input short circuited. Do NOT connect to the mains when DC input short circuits.
13. 
    Only qualified service persons are able to service this device. If errors still persist after following troubleshooting table, please send this inverter/charger back to local dealer or service center for maintenance.

INTRODUCTION

This is a multi-function inverter/charger, combining functions of inverter, solar charger and battery charger to offer uninterruptible power support with portable size. Its comprehensive LCD display offers user-configurable and easy-accessible button operation such as battery charging current, AC/solar charger priority, and acceptable input voltage based on different applications.

Features

• Pure sine wave inverter
• Configurable input voltage range for home appliances and personal computers via LCD setting
• Configurable battery charging current based on applications via LCD setting
• Configurable AC/Solar Charger priority via LCD setting
• Compatible to mains voltage or generator power
• Auto restart while AC is recovering
• Overload/ Over temperature/ short circuit protection
• Smart battery charger design for optimized battery performance
• Cold start function

Basic System Architecture

The following illustration shows basic application for this inverter/charger (See Figure 1). It also includes following devices to have a complete running system:

• Generator or Utility.
• PV modules

Consult with your system integrator for other possible system architectures depending on your requirements.
This inverter can power all kinds of appliances in home or office environment, including motor-type appliances such as tube light, fan, refrigerator and air conditioner.

Product Overview

1. LCD display
2. Status indicator
3. Charging indicator
4. Fault indicator
5. Function buttons
6. Power on/off switch
7. AC input
8. AC output
9. PV input
10. Battery input
11. Fuse or Circuit breaker
12. USB communication port
13. RS-232 communication port

INSTALLATION

Unpacking and Inspection

Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. You should have received the following items inside of package:

• The unit x 1
• User manual x 1
• Communication cable x 2
• Software CD x 1
• Battery cable x 1 (only for 1.2KW/2.2KW models)
• Power cord x 1 (only for 1.2KW/2.2KW models)

Preparation

Before connecting all wirings, please take off bottom cover by removing the screws (2pcs for 1.2KW/2.2KW, 4pcs for 3.2KW) as shown above.

Mounting the Unit

Consider the following points before selecting where to install:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface
• Install this inverter at eye level in order to allow the LCD display to be read at all times.
• For proper air circulation to dissipate heat, allow a clearance of approx. 20 cm to the side and approx. 50 cm above and below the unit.
  
• The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
• The recommended installation position is to be adhered to the wall vertically.
• Be sure to keep other objects and surfaces as shown in the diagram to guarantee sufficient heat dissipation and to have enough space for removing wires.

SUITABLE FOR MOUNTING ON CONCRETE OR OTHER NON-COMBUSTIBLE SURFACE ONLY.

Install the unit by screwing two screws. It's recommended to use M4 or M5 screws.

Battery Connection

For safety operation and regulation compliance, it's requested to install a separate DC over-current protector or disconnect device between battery and inverter. It may not be requested to have a disconnect device in some applications, however, it's still requested to have over-current protection installed. Please refer to typical amperage in below table as required fuse or breaker size.

All wiring must be performed by a qualified personnel.

It's very important for system safety and efficient operation to use appropriate cable for battery connection. To reduce risk of injury, please use the proper recommended cable as below.

Battery connection for 1.2KW/2.2KW:
Please follow below steps to implement battery connection:

1. Remove insulation sleeve 18 mm for positive and negative conductors.
   
2. Suggest to put bootlace ferrules on the end of positive and negative wires with a proper crimping tool.
3. 1.2KW model supports 12VDC system and 2.2KW model supports 24VDC system. Connect all battery packs as below chart. It's suggested to connect at least 100Ah capacity battery.
   
4. Insert the battery wires flatly into battery connectors of inverter and make sure the bolts are tightened with torque of 2 Nm in clockwise direction. Make sure polarity at both the battery and the inverter/charge is correctly connected and conductors are tightly screwed into the battery terminals.
   Recommended tool: #2 Pozi Screwdriver
   

Battery connection for 3.2KVA:
Please follow below steps to implement battery connection:

1. Assemble battery ring terminal based on recommended battery cable and terminal size.
2. Connect battery packs with 24VDC system. It's suggested to connect at least 100Ah capacity battery.
3. Insert the ring terminal of battery cable flatly into battery connector of inverter and make sure the bolts are tightened with torque of 5 Nm. Make sure the polarity at both the battery and the inverter/charge is correctly connected and ring terminals are tightly screwed to the battery terminals.
   

Shock Hazard
Installation must be performed with care due to high battery voltage in series.

Before making the final DC connection or closing DC breaker/disconnector, be sure positive (+) must be connected to positive (+) and negative (-) must be connected to negative (-).

AC Input/Output Connection

Before connecting to AC input power source, please install a separate AC breaker between inverter and AC input power source. This will ensure the inverter can be securely disconnected during maintenance and fully protected from over current of AC input. The recommended spec of AC breaker is 10A for 1.2KW, 20A for 2.2KW and 32A for 3.2KW.

There are two terminal blocks with "AC IN" and "AC OUT" markings. Please do NOT mis-connect input and output connectors.

All wiring must be performed by a qualified personnel.

It's very important for system safety and efficient operation to use appropriate cable for AC input connection. To reduce risk of injury, please use the proper recommended cable size as below.

Please follow below steps to implement AC input/output connection:

1. Before making AC input/output connection, be sure to open DC protector or disconnector first.
2. Remove insulation sleeve 10mm for 5 conductors for 3.2K model and 7mm for 3 conductors for 1.2KW/2.2KW models.
3. For 1.2KW/2.2KW models, simply connect AC utility to AC input of the inverter with a plug.
   For 3.2KW models, insert AC input wires according to polarities indicated on terminal block and tighten the terminal screws. Be sure to connect PE protective conductor ( ) first.
   → Ground (yellow-green)
   L → LINE (brown or black)
   N → Neutral (blue)
   

Be sure that AC power source is disconnected before attempting to hardwire it to the unit.

4. Then, insert AC output wires according to polarities indicated on terminal block and tighten terminal screws.
   Be sure to connect PE protective conductor ( ) first.
   → Ground (yellow-green)
   L → LINE (brown or black)
   N → Neutral (blue)
   
5. Make sure the wires are securely connected.

Appliances such as air conditioner are required at least 2~3 minutes to restart because it's required to have enough time to balance refrigerant gas inside of circuits. If a power shortage occurs and recovers in a short time, it will cause damage to your connected appliances. To prevent this kind of damage, please check manufacturer of air conditioner if it's equipped with time-delay function before installation. Otherwise, this inverter/charger will trig overload fault and cut off output to protect your appliance but sometimes it still causes internal damage to the air conditioner.

PV Connection

Before connecting to PV modules, please install separately a DC circuit breaker between inverter and PV modules.

It's very important for system safety and efficient operation to use appropriate cable for PV module connection. To reduce risk of injury, please use the proper recommended cable size as below.

When selecting proper PV modules, please be sure to consider below parameters:

1. Open circuit Voltage (Voc) of PV modules not exceeds max. PV array open circuit voltage of inverter.
2. Open circuit Voltage (Voc) of PV modules should be higher than min. battery voltage.

Take 300Wp PV module as an example. After considering above two parameters, the recommended module configurations listed as below table.

PV Module Wire Connection
Please follow below steps to implement PV module connection:

1. Remove insulation sleeve 10 mm for positive and negative conductors.
   
2. Suggest to put bootlace ferrules on the end of positive and negative wires with a proper crimping tool.
3. Check correct polarity of wire connection from PV modules and PV input connectors. Then, connect positive pole (+) of connection wire to positive pole (+) of PV input connector. Connect negative pole (-) of connection wire to negative pole (-) of PV input connector. Screw two wires tightly in clockwise direction.
   Recommended tool: 4mm blade screwdriver
   

Final Assembly

After connecting all wirings, please put bottom cover back by screwing the screws as shown above.

Communication Connection

Please use supplied communication cable to connect to inverter and PC. Insert bundled CD into a computer and follow on-screen instruction to install the monitoring software. For the detailed software operation, please check user manual of software inside of CD.

OPERATION

Power ON/OFF

Once the unit has been properly installed and the batteries are connected well, simply press On/Off switch (located on the button of the case) to turn on the unit.

Operation and Display Panel

The operation and display panel, shown in below chart, is on the front panel of the inverter. It includes three indicators, four function keys and a LCD display, indicating the operating status and input/output power information.

LED Indicator
LED Indicator			Messages
	Green	Solid On	Output is powered by utility in Line mode.
		Flashing	Output is powered by battery or PV in battery mode.
	Green	Solid On	Battery is fully charged.
		Flashing	Battery is charging.
	Red	Solid On	Fault occurs in the inverter.
		Flashing	Warning condition occurs in the inverter.
Function Keys
Function Key		Description
	ESC	To exit setting mode
	SCROLL	To go to next selection
	ENTER	To confirm the selection in setting mode or enter setting mode

LCD Display Icons

LCD Setting

After pressing and holding " " button for 3 seconds, the unit will enter setting mode. Press " " button to select setting programs. And then, press " " button to confirm the selection or " " button to exit.

Setting Programs:

Display Setting

The LCD display information will be switched in turns by pressing " " button. The selectable information is switched as the following table in order.

Operating Mode Description

Operation mode	Description	LCD display
Standby mode Note: *Standby mode: The inverter is not turned on yet but at this time, the inverter can charge battery without AC output.	No output is supplied by the unit but it still can charge batteries.	Charging by utility and PV energy.
		Charging by utility.
		Charging by PV energy.
		No charging.
Fault mode Note: *Fault mode: Errors are caused by inside circuit error or external reasons such as over temperature, output short circuited and so on.	PV energy and utility can charge batteries.	Charging by utility and PV energy.
		Charging by utility.
		Charging by PV energy.
		No charging.
Line Mode	The unit will provide output power from the mains. It will also charge the battery at line mode.	Charging by utility and PV energy.
		Charging by utility.
Battery Mode	The unit will provide output power from battery and PV power.	Power from battery and PV energy.
		Power from battery only.

Battery Equalization Description

Equalization function is added into charge controller. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top. Equalization also helps to remove sulfate crystals that might have built up on the plates. If left unchecked, this condition, called sulfation, will reduce the overall capacity of the battery. Therefore, it's recommended to equalize battery periodically.

• How to Apply Equalization Function
  You must enable battery equalization function in monitoring LCD setting program 30 first. Then, you may apply this function in device by either one of following methods:
  1. Setting equalization interval in program 35.
  2. Active equalization immediately in program 36.
• When to Equalize
  In float stage, when the setting equalization interval (battery equalization cycle) is arrived, or equalization is active immediately, the controller will start to enter Equalize stage.
  
• Equalize charging time and timeout
  In Equalize stage, the controller will supply power to charge battery as much as possible until battery voltage raises to battery equalization voltage. Then, constant-voltage regulation is applied to maintain battery voltage at the battery equalization voltage. The battery will remain in the Equalize stage until setting battery equalized time is arrived.
  

However, in Equalize stage, when battery equalized time is expired and battery voltage doesn't rise to battery equalization voltage point, the charge controller will extend the battery equalized time until battery voltage achieves battery equalization voltage. If battery voltage is still lower than battery equalization voltage when battery equalized timeout setting is over, the charge controller will stop equalization and return to float stage.

Fault Reference Code

Fault Code	Fault Event	Icon on
02	Over temperature
03	Battery voltage is too high
04	Battery voltage is too low
05	Output short circuited or over temperature is detected by internal converter components.
06	Output voltage is abnormal.
07	Overload time out
08	Bus voltage is too high
09	Bus soft start failed
12	NTC temperature sensor on the heatsink is failed

Warning Indicator

Warning Code	Warning Event	Audible Alarm	Icon flashing
02	Temperature of inverter inside is high	1. No beep when temperature is in high level. 2. Beep once every 0.5 second when temperature is increased to close to over-temperature protection.
03	Battery is over-charged	Beep once every second
04	Low battery	Beep once every second
07	Overload	Beep once every 0.5 second
10	Output power derating	Beep twice every 3 seconds
	Battery equalization	None
20	Communication error between MPPT SCC board and main board	None
21	MPPT solar charger board cannot match with main board even communication is normal.	None

SPECIFICATIONS

Table 1 Line Mode Specifications

INVERTER MODEL	1.2KW	2.2KW	3.2KW
Input Voltage Waveform	Sinusoidal (utility or generator)
Nominal Input Voltage	230Vac
Low Loss Voltage	170Vac± 7V (UPS); 90Vac± 7V (Appliances)
Low Loss Return Voltage	180Vac± 7V (UPS); 100Vac± 7V (Appliances)
High Loss Voltage	280Vac± 7V
High Loss Return Voltage	270Vac± 7V
Max AC Input Voltage	300Vac
Nominal Input Frequency	50Hz / 60Hz (Auto detection)
Low Loss Frequency	40± 1Hz
Low Loss Return Frequency	42± 1Hz
High Loss Frequency	65± 1Hz
High Loss Return Frequency	63± 1Hz
Output Short Circuit Protection	Circuit Breaker
Efficiency (Line Mode)	>95% ( Rated R load, battery full charged )
Transfer Time	10ms typical (UPS); 20ms typical (Appliances)
Output power derating: When AC input voltage drops to 170V, the output power will be derated.

Table 2 Inverter Mode Specifications

Table 3 Charge Mode Specifications

Utility Charging Mode
INVERTER MODEL		1.2KW	2.2KW	3.2KW
Charging Algorithm		3-Step
AC Charging Current (Max)		20Amp (@VI/P=230Vac)		25Amp (@VI/P =230Vac)
Bulk Charging Voltage	Flooded Battery	14.6	29.2
	AGM / Gel Battery	14.1	28.2
Floating Charging Voltage		13.5Vdc	27Vdc
Charging Curve
MPPT Solar Charging Mode
INVERTER MODEL		1.2KW	2.2KW	3.2KW
Max. PV Array Power		700W	1400W	1800W
Charging Current		50Amp	50Amp	65Amp
PV Array MPPT Voltage Range		15Vdc~80Vdc	30~80Vdc
Max. PV Array Open Circuit Voltage		102Vdc
Max Charging Current (AC charger plus solar charger)		60Amp		80Amp

Table 4 General Specifications

TROUBLE SHOOTING

APPROXIMATE BACK-UP TIME TABLE

Note: Backup time depends on the quality of the battery, age of battery and type of battery.
Specifications of batteries may vary depending on different manufacturers.

Documents / Resources

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download Inverex AEROX 1.2KW, AEROX 3.2KW, AEROX 2.2KW Manual