CSW2012-X Pure Sine Wave Inverter Owner’s Manual
Thank you from all of us at Sensata Technologies for purchasing this CSW2012-X inverter. The CSW2012-X is under the Magnum-Dimensions brand from Sensata Technologies. We understand that you have many purchasing options in the marketplace and are pleased that you have decided on this product. At Sensata, we are committed to providing you with quality products and services, and hope that your experience with us is pleasant and professional.
IMPORTANT PRODUCT SAFETY INSTRUCTIONS This manual contains safety instructions that must be followed during the installation and operation of this product. Read all instructions and safety information on the inverter and in this manual before installing or using. Safety Symbols To reduce the risk of electrical shock, fire, or other safety hazard, the following safety symbols have been placed throughout this manual to indicate dangerous situations and important safety instructions.
Table of Contents 1.0 Introduction ............................................................................. 1 1.1 Features ................................................................................. 1 1.2 How this Inverter Works ............................................................ 4 1.3 Advantages of a Pure Sine Wave Inverter .................................... 4 2.0 Installation .............................................................................. 5 2.1 Pre-Installation .......
List of Figures Figure Figure Figure Figure 1-1, 1-2, 1-3, 1-4, Front Panel Features .......................................................... 1 Front Panel Features (Cover Removed) ................................. 2 Back Panel Features .......................................................... 3 AC Waveforms .................................................................. 4 Figure Figure Figure Figure Figure 2-1, 2-2, 2-3, 2-4, 2-5, Basic System Diagram ............................................
1.0 Introduction 1.0 Introduction 1.1 Features Congratulations on your purchase of the CSW2012-X inverter. The CSW2012-X is a “pure” sine wave inverter with an internal transfer switch and is sold under the Magnum-Dimensions brand from Sensata Technologies. This unit is designed to be powerful, yet simple to operate, and will provide you with reliable AC power for trouble-free use. Please read this chapter to familiarize yourself with the features and benefits of your CSW2012-X inverter.
1.0 Introduction The following front panel features are available on the CSW2012-X inverter when the access cover is removed (See Figure 1-2): Info: To access and view the AC terminal block and ground terminal, remove the four Phillips screws holding the AC wiring access cover. 7. AC Entry/Exit Openings – two 1/2” knockouts are provided to accommodate the inverter’s AC input and output wiring. 8. AC Ground Connection – used to connect all AC input and output grounds. To attach multiple ground wires (i.e.
1.0 Introduction The back panel of the CSW2012-X inverter is equipped with the following features (See Figure 1-3): 11. Model Number – the model number of the inverter and other information. 12. Cooling Fan(s) – intake cooling fans that automatically turn on when the inverter’s internal temperature rises above 122°F (50°C). The fan turns off when the inverter’s internal temperature falls below 122°F (50°C). 13. Mounting Flanges (front and rear) – used to mount and secure the inverter to a shelf/wall. 14.
1.0 Introduction 1.2 How this Inverter Works There are two modes of operation associated with the CSW2012-X inverter: • Inverter Mode: When the inverter is properly connected to batteries and turned on, the direct current (DC) from the batteries is transformed into a pure sine wave alternating current (AC). This AC is similar to the voltage provided by your utility and is used to power any electrical appliances (i.e., AC loads) connected to the inverter’s output.
2.0 Installation 2.0 Installation Review this section and all safety instructions before proceeding with the installation of your inverter. WARNING: Installations should be performed by qualified personnel, such as a licensed or certified electrician. The installer determines which safety codes apply and ensures all applicable installation requirements are followed. Applicable installation codes vary depending on the specific location and application.
2.0 Installation AC Main Panel AC Source (Branch Circuit Breaker to Inverter: 30A max) (120VAC, 60 Hz Sinewave) CSW2012-X Inverter AC IN AC OUT* AC Sub-Panel AC Outlet DC Disconnect DC Ground (Vehicle chassis, DC ground bus, or engine negative bus) AC Loads (L1/N1 = 30A max, L2/N2 = 20A max) Fuse TV DVD Battery Bank Tools * Maximum pass-thru current from AC output terminals: L1/N1 output terminals = 30 amps, L2/N2 output terminals = 20 amps (in series with GFCI outlet).
2.0 Installation 2.2 Locating and Mounting the Inverter WARNINGS: • Do not mount the inverter near any flammable or combustible fluid or components. • Provide adequate clearance/ventilation to the inverter. Do not cover or obstruct any air vent openings and/or install in a zeroclearance compartment.
2.0 Installation Flat on a horizontal surface (right side up or upside down). DC terminals to the right, left or top. Note: CSW2012-X cannot be mounted with DC terminals facing down. Figure 2-2, Approved Mounting Positions 8.6’’ (21.8 cm) 8 1/2" (21.6 cm) Top 9.1’’ (23 cm) 12.5’’ (31.8 cm) 17.1’’ (43.5 cm) Back (DC Side) Front (AC Side) 4.5’’ (11.
2.0 Installation 2.3 Wiring the Inverter – General Requirements This section describes the requirements and recommendations for wiring the CSW2012-X inverter. Before wiring the inverter, carefully read all instructions. The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC (Canadian Electrical Code) for Canada provide the standards for safely wiring residential and commercial installations.
2.0 Installation 2.4 DC Wiring This section describes the inverter’s required DC wire sizes, the recommended disconnect/overcurrent protection, and how to make the DC connections to the inverter and the battery bank. WARNING: Even though DC voltage can be regarded as “low voltage”, significant hazards may be present, particularly from short circuits of the battery system.
2.0 Installation 2.4.1 DC Wire Sizing It is important to use the correct sized DC wire to achieve maximum efficiency from the system and to reduce fire hazards associated with overheating. Always keep your wire runs as short as practical to prevent low voltage shutdowns and to keep the DC breaker from nuisance tripping (or open fuses) because of increased current draw. See Table 2-2 to select the minimum DC wire size (and corresponding overcurrent device) required based on your inverter model.
2.0 Installation 2.4.2 DC Overcurrent Protection For safety reasons and to comply with electrical code regulations, DC overcurrent protection must be provided as part of the installation. The DC overcurrent protection device must be installed in the positive DC cable line, it can be a fuse (with a disconnect switch) or a circuit breaker and must be DCrated.
2.0 Installation 2.4.5 Wiring the Battery Bank WARNING: Lethal currents will be present if the positive and negative cables attached to the battery bank touch each other. During the installation and wiring process, ensure the cable ends are insulated or covered to prevent touching/shorting the cables.
2.0 Installation 2.4.7 Wiring the Inverter to the Battery Bank CAUTION: The inverter is NOT reverse polarity protected—if the positive terminal of the battery is connected to the negative terminal of the inverter and vice versa, severe damage to the inverter will occur and this will void the warranty. Before connecting the DC wires from the batteries to the inverter, verify the correct battery voltage and polarity using a voltmeter.
2.0 Installation DC cable with ring lug nut lock washer BATTERY battery terminal flat washer battery post bolt Verify that the DC cable lugs are flush with the battery terminals. Figure 2-4, DC Cable to Battery Terminals M8-1.25 Hex nut Lock washer DC cable with ring lug Inverter’s DC + terminal CSW2012-X Inverter CAUTION: Ensure nothing is placed between the DC terminal and the ring lug.
2.0 Installation 2.5 AC Wiring This section provides information on how to make the AC connections to the inverter using the correct AC wire size and corresponding overcurrent protection. 2.5.1 Pre-AC Wiring Requirements WARNING: DO NOT connect the inverter’s output to an AC power source. This could cause severe damage to the inverter and is not covered under warranty. CAUTION: Before installing any AC wiring, review all safety information in this manual to ensure a safe and long-lasting system.
2.0 Installation 2.5.3 AC Neutral to Safety Ground Bonding Electrical safety standards for wiring RV/truck and marine installations in the United States require the neutral and safety ground to be connected at the AC source; whether it is the utility feed in the RV Park/Marina, an inverter, or a generator. This is to establish a specification that maximizes the possibility that a circuit breaker will activate if a hot wire-to-ground fault occurs.
2.0 Installation 2.5.4 AC Terminal Block Connections The CSW2012-X has a two-pole AC input terminal block, a four-pole AC output terminal block and one AC ground screw to connect the inverter’s AC input and output wiring. These terminal blocks (see Figure 1-2, Items 9 and 10) allow a service/distribution panel (main panel) to be wired to the inverter’s input, and also allows a dedicated panel (sub-panel) between the inverter’s output wiring and the AC loads.
2.0 Installation Wiring the Inverter AC Output WARNING: DO NOT connect the inverter’s output to an AC power source. This could cause severe damage to the inverter and is not covered under warranty. The AC Output has three types of AC connections: • Use the GFCI outlet to power AC loads – This configuration does not require AC output installation. Plug the AC load into the GFCI outlet. During By-Pass mode, the AC output is limited by the rating of the inverter’s 20A breaker.
2.0 Installation CSW2012-X Series Inverter See NOTE below ON OFF ON ON OFF OFF ON OFF ON ON OFF OFF ON ON OFF OFF ON OFF OFF ON ON OFF ON OFF ON OFF 120 VAC ON OFF Maximum 20-amp breaker (single pole) required to inverter AC input 20 ON OFF NOTE: In mobile installations, the neutral is typically not connected to ground in main panel.
2.0 Installation CSW2012-X Series Inverter See NOTE below ON OFF ON ON OFF OFF ON OFF ON ON OFF OFF ON ON OFF OFF ON OFF OFF ON ON OFF ON OFF ON ON OFF 120 VAC OFF 120 VAC ON OFF Maximum 30-amp breaker (single pole) required to inverter AC input 30 ON OFF NOTE: In mobile installations, the neutral is typically not connected to ground in main panel.
2.0 Installation 2.5.6 Removing the Display Panel The display panel on the inverter can be removed and installed in a different location using a longer 6-pin standard telephony cable (also referred to as a RJ12 cable). See Figure 2-8. • Remove the 2 screws at the front of the display panel, and then disconnect the small cable from the inverter. • Install the remote cable in your desired location and connect one end of the remote cable to the inverter and the other end of the cable to the display panel.
2.0 Installation 2.6 Testing the Inverter Before proceeding, you must first test whether the inverter was successfully installed. Use the functional test below to ensure the inverter is functioning properly. 2.6.1 Inverter Functional Test After all electrical connections to the inverter, batteries, AC source, and loads (using a sub-panel) have been completed, follow these steps to test the installation and the inverter’s operation. 1.
3.0 Operation 3.0 Operation The CSW1012-X inverter has two normal modes of operation; Inverter mode, which powers your loads using the batteries, and By-Pass mode, which transfers the incoming AC power (i.e., shorepower or a generator) to power your loads. 3.1 Inverter Mode In Invert mode, the inverter supplies AC power to your appliances by inverting the DC power from the battery. The amount of time the inverter can provide power is directly related to the capacity of the battery (or battery bank).
3.0 Operation 3.3 Display Panel Operation This section provides information on the display panel (Figure 1-1, Item 5). Figure 3-1, Display Panel 3.3.1 LED Indicators The LED indicators on the front display panel are used to indicate the inverter’s status. Use Table 3-1 to determine the inverter status. Table 3-1, Display Functions/Statuses Status LED Display LED Display Green (solid) Green 12.5 Amber (solid) Green Amber 12.5 0.80 Function/Status By-Pass mode.
3.0 Operation 3.3.3 Inverter Settings (enter Setting Mode) To change an inverter setting, enter Setting mode by pressing the Power and Select buttons together for about 5 seconds until a beep is heard. Use Figure 3-2 to set the inverter settings. See Table 3-2 for information on the different settings available for the inverter. Unit in normal operation 12.8 = POWER pushbutton = SELECT pushbutton Display will EXIT menu mode if either or pressed within the last 5 seconds.
3.0 Operation Table 3-2, Inverter Settings Inverter Settings PS0 The inverter is disabled. The AC Output terminals are getting power from the utility (AC input) only. When utility power is not available, the unit will not provide an AC backup function from the inverter and the display will automatically turn off in approximately 10 seconds. When the Power button is pressed again, the display will turn on for another 10 seconds.
3.0 Operation 3.4 Understanding Loads The inverter can power most loads within its power rating, however, there are special conditions that can cause a load to behave differently than expected. Following are some common problems encountered when using this inverter. USB loads – When using the USB connector, be sure that the device you will be connecting will accept 5 volts (≤ 750mA) and can be charged or powered using another power source.
4.0 Troubleshooting 4.0 Troubleshooting When the inverter shows an error code, use Table 4-1 to determine what condition triggered the error/warning code and what corrective action is needed. Use Table 4-2 to troubleshoot your inverter based on the symptoms. Table 4-1, Inverter Error Codes Code Condition E01 Input battery voltage is too low (<10.5 VDC). If it happens in By-Pass mode, the unit continues supplying AC output power. Otherwise, the AC output is shut down.
4.0 Troubleshooting Table 4-2, Troubleshooting Problem Possible Cause/ Condition Solution AC output turns on and off. Search mode (PS2) enabled, and the AC load is <10W. Normal condition when in Search mode. The load connected must be below the AC load sense threshold of 10W; so the power output will be pulsed every 10 sec for checking the load. No AC output. Status LED is red. Unit has shut down. Check the error code shown on the display.
4.0 Troubleshooting Problem Possible Cause/ Condition Solution During AC input power outage, there is no AC output power when battery power is available. Unit is set to “NonBackup” mode (PS0) and AC input power is not available. Change the PS0 setting to a different setting if you want to turn the inverter on. With the PS0 setting, the inverter is completely off. When the AC input power is not available and the Power button is pressed once, the display and LEDs remain working for only about 30 seconds.
4.0 Troubleshooting Problem Possible Cause/ Condition Solution Heavy spark when connecting the battery power. This is a normal condition. It occurs when the internal DC input capacitors (filter) are discharged after the battery was disconnected for at least 30-40 seconds. Due to a sudden high DC surge (inrush) current that charges the internal big capacitors and quickly disappears (milliseconds) once capacitors get charged. Does not represent any drawing current from the battery.
4.0 Troubleshooting Problem Possible Cause/ Condition Solution The GFCI outlet trips as soon as the load is connected to either L2/ N2 AC Output terminals or into the GFCI outlet. There is a neutral-toground bonding in the load side. Locate and remove the neutral-to-ground bonding on the AC load side.
4.0 Troubleshooting Problem Possible Cause/ Condition The input battery undervoltage warning (E05) and/or shutdown alarm (E01) occurs in advance even when the battery voltage seems to be OK. (Cont.) Make sure to measure the battery voltage just before the E01 battery undervoltage shutdown in Battery (Inverter) mode occurs, and compare it with the corresponding voltage threshold in the specifications table (allow +/- 5% of tolerance).
5.0 Specifications 5.0 Specifications Table 5-1, CSW2012-X Specifications Model CSW2012-X Electrical Specifications Continuous Power1 2000 W 2 4000 W Surge Power (Peak) AC Output Voltage (12.5V) 120 VAC RMS ± 5% AC Output Current 16.6 AAC AC Output Voltage Range 104-127 VAC AC Output Frequency 60 Hz ± 0.5 Hz Pure sine wave (<3% THD) AC Output Waveform) AC Output Receptacle NEMA 5-15, Dual GFCI with LED Optimum Efficiency >90% DC Input Voltage (Nominal) 12.5 VDC 10.5 - 15.
Appendix Appendix A - Battery Information Battery Bank Sizing The size of the battery bank determines how long the inverter can power the AC loads without recharging. The larger the battery bank, the longer the run time. Size your battery bank to the system’s AC load requirements and the length of time required to run the load from the batteries. In general, the battery bank should not be discharged more than 50%.
Appendix Parallel Wiring Wiring the batteries in parallel increases the total run time the batteries can operate the AC loads. A parallel connection combines overall battery capacity by the number of batteries in the string. Even though there are multiple batteries, the voltage remains the same. In the example below (Figure A-2), four 12 VDC/100 AHr batteries are combined into a single 12 VDC/400 AHr battery bank.
Appendix Appendix B - Preventive/Periodic Maintenance Recommended Inverter and Battery Care The CSW2012-X inverter is designed to provide you with years of trouble-free service. Even though there are no user-serviceable parts, it is recommended that every 6 months you perform the following maintenance steps to ensure optimum performance and extend the life of your batteries. WARNING: Prior to performing these checks, switch both the AC and DC circuits OFF.
Appendix Appendix C - Regulatory and FCC Information Regulatory Compliance The CSW2012-X has been tested and listed to UL 458, 5th Edition (Power Converters/Inverters for use in the US; and is also certified to CSA C22.2 No. 107.1-01 (General Use Power Supplies) for use in Canada. It has been tested and certified to these product safety standards by Intertek Testing Services (known as ETL), which is a Nationally Recognized Testing Laboratory (NRTL).
Appendix Appendix D - Limited Warranty Sensata Technologies warrants the CSW2012-X inverter to be free from defects in material and workmanship that result in product failure during normal usage, according to the following terms and conditions: 1. The limited warranty for this product extends for a maximum of 12 months from the product’s original date of purchase. 2. The limited warranty extends to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser. 3.
Magnum-Dimensions Products Manufactured by: Sensata Technologies 2211 West Casino Rd. Everett, WA 98204 Phone: 425-353-8833 Fax: 425-353-8390 Web: www.Magnum-Dimensions.
