DC-AC Power Inverter Pure Sine Wave PST-60S-12E / PST-60S-24E PST-100S-12E / PST-100S-24E PST-150S-12E / PST-150S-24E PST-200S-12E / PST-200S-24E Owner's Manual Please read this manual before installing your inverter
Owner's Manual | Index Section 1 Safety Instructions ................................................................. 3 Section 2 General Information .............................................................. 6 Section 3 Limiting Electromagnetic Interference (EMI) ........................ 11 Section 4 Powering Direct / Embedded Switch Mode Power Supplies (SMPS) ........................................................ 12 Section 5 Principle of Operation ..............................................
Section 1 | Safety Instructions 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. i INFO Indicates useful supplemental information. Please read these instructions before installing or operating the unit to prevent personal injury or damage to the unit.
Section 1 | Safety Instructions Preventing fire and explosion hazards • Working with the unit may produce arcs or sparks. Thus, the unit should not be used in areas where there are flammable materials or gases requiring ignition protected equipment. These areas may include spaces containing gasoline-powered machinery, fuel tanks, and battery compartments. Precautions when working with batteries • Batteries contain very corrosive diluted sulphuric acid as electrolyte.
Section 1 | Safety Instructions the 12V battery version and 33.0 VDC for the 24V battery version to prevent permanent damage to the unit. Please observe the following precautions: • Ensure that the maximum charging voltage of the external battery charger / alternator / solar charge controller does not exceed 16.5 VDC for the 12V battery version and 33.0 VDC for the 24V battery version • Do not use unregulated solar panels to charge the battery connected to this unit.
SECTION 2 | General Information 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. For example, a pure sine wave that alternates between peak values of Positive 325V and Negative 325V has an RMS value of 230 VAC.
SECTION 2 | General Information the net effect is a tendency to cancel each other. Hence, in a circuit containing both inductances and capacitances, the net Reactance (X) will be equal to the difference between the values of the inductive and capacitive reactances. The net Reactance (X) will be inductive if XL > XC and capacitive if XC > XL. Impedance, Z: It is the vectorial sum of Resistance and Reactance vectors in a circuit. Active Power (P), Watts: It is denoted as “P” and the unit is “Watt”.
SECTION 2 | General Information the inverter. The inverter can be sized based on the Active Power rating (Watts) without creating overload. Reactive Load: A device or appliance that consists of a combination of resistive, inductive and capacitive elements (like motor driven tools, refrigeration compressors, microwaves, computers, audio/ video etc.). These devices require Apparent Power (VA) from the inverter to operate. The Apparent Power is a vectorial sum of Active Power (Watts) and Reactive Power (VAR).
SECTION 2 | General Information frequency harmonic content in a modified sine wave produces enhanced radio interference, higher heating effect in inductive loads like microwaves and motor driven devices like hand tools, refrigeration / air-conditioning compressors, pumps etc. The higher frequency harmonics also produce overloading effect in low frequency capacitors due to lowering of their capacitive reactance by the higher harmonic frequencies.
SECTION 2 | General Information Power Rating of the Inverters The continuous output power rating of the inverter is specified in Active Power in Watts for resistive types of loads like heating elements, incandescent lamps etc. where Power Factor (PF) = 1. The Surge Power rating is for < 1 sec. Non resistive / reactive loads with Power Factor < 1 like motors (PF = 0.4 to 0.8), non Power Factor corrected electronics (PF = 0.5 to 0.6) etc, will draw higher Apparent Power in Volt Amps (VA).
SECTION 2 | General Information TABLE 2.1: INVERTER SIZING FACTOR Type of Device or Appliance Inverter Sizing Factor* Laser Printer / Other Devices using Quartz Lamps for heating 4 Switch Mode Power Supplies (SMPS): no Power Factor correction 3 Photographic Strobe / Flash Lights 4 (Note 1) * Multiply the Running Active Power Rating {Watts} of the appliance by this Factor to arrive at the Continuous Power Rating of the inverter for powering this appliance. TABLE 2.1: NOTES 1.
SECTION 4 | Powering Direct / Embedded Switch 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 various devices and circuits used in electronic equipment like battery chargers, computers, audio and video devices, radios etc. These power supplies use large capacitors in their input section for filtration.
SECTION 4 | Powering Direct / Embedded Switch Mode Power Supplies (SMPS) Input voltage RMS Current Inrush current Fig 4.1: Inrush current in an SMPS Peak Current Non-linear Input Current RMS Current Input Sine Wave Voltage TIME Fig. 4.2: High Crest Factor of current drawn by SMPS SAMLEX AMERICA INC.
SECTION 5 | Principle of Operation These inverters convert DC battery voltage to AC voltage with an RMS (Root Mean Square) value of 230 VAC, 50 Hz RMS. The waveform of the AC voltage is a pure sine wave form that is same as the waveform of grid power (Supplementary information on pure sine waveform and its advantages are discussed on pages 8 & 9). Fig. 5.1 below specifies the characteristics of 230 VAC, 50 Hz pure sine waveform.
SECTION 6 | Layout 600W Power Inverter 1 ON 2 3 4 POWER OVER OVER LOAD TEMP OFF 5 OUTPUT 230 VAC 50HZ 600W PST-60S: Front 6 7 NEG - 8 PST-60S: Back LEGEND 1. 2. Power ON/OFF Switch Green LED - Power Ouptut Status 3. 4. Red LED - Overload Red LED - Over temperature 5. 6. 7. “Schuko” type AC outlet Cooling Fan Opening Grounding Terminal 8. Negative (-) DC Input Terminal 9. Positive (+) DC Input Terminal 10. Modular Jack for RC-15 Remote Control (Bottom of Unit) POS + 9 10 Fig. 6.
SECTION 6 | Layout 2 TEMP LOAD ON I OUTPUT 230V 50Hz 3 OVER POWER O 4 OVER 1 OFF 10 6 Pure Sine Wave Inverter Remote PST-150S, PST-200S: Front 9 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Power ON/OFF Switch Green LED - Power Output Status Red LED - Over Load Red LED - Over Temperature “Schuko” Type AC Outlets Cooling Fans Grounding Terminal DC Input “-” DC Input “+” Remote Control Jack 8 POS + NEG - 6 7 PST-150S, PST-200S: Back Fig. 6.
SECTION 7 | General Information on Batteries for Powering Inverters an electrical conductor in one second. The Capacity “C” in Ah relates to the ability of the battery to provide a constant specified value of discharge current (also called “C-Rate”) over a specified time in hours before the battery reaches a specified discharged terminal voltage (Also called “End Point Voltage”) at a specified temperature of the electrolyte.
SECTION 7 | General Information on Batteries for Powering Inverters as the “C-Rate”. If the battery delivers a very high discharge current, the battery will be discharged to the “End Point Voltage” in a shorter period of time. On the other hand, if the battery delivers a lower discharge current, the battery will be discharged to the “End Point Voltage” after a longer period of time. Mathematically: EQUATION 1: Discharge current “C-Rate” = Capacity “C” in Ah ÷ Discharge Time “T” Table 7.
SECTION 7 | General Information on Batteries for Powering Inverters 12 Volt Lead-Acid Battery Chart - 80˚F 16.5 C/5 C/10 16.0 CHARGE C/20 15.5 C/40 15.0 Battery Voltage in VDC 14.5 14.0 13.5 13.0 C/100 C/20 C/10 12.5 C/5 12.0 DISCHARGE C/3 11.5 11.0 10.5 Please note that X-axis shows % State of Charge. State of Discharge will be = 100% - % State of Charge. 10.0 9.5 9.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Battery State of Charge in Percent (%) Fig. 7.
SECTION 7 | General Information on Batteries for Powering Inverters Table 7.3 (page 19) will show that a 100 Ah capacity battery will deliver 100% (i.e. full 100 Ah) capacity if it is slowly discharged over 20 hours at the rate of 5 Amperes (50W output for a 12V inverter and 100W output for a 24V inverter). However, if it is discharged at a rate of 50 Amperes (500W output for a 12V inverter and 1000W output for a 24V inverter) then theoretically, it should provide 100 AH ÷ 50 = 2 hours.
SECTION 7 | General Information on Batteries for Powering Inverters the DC input cables are thick enough to allow a negligible voltage drop between the battery and the inverter) . Inverters are normally provided with a buzzer alarm to warn that the loaded battery has been deeply discharged to around 80% of the rated capacity. Normally, the buzzer alarm is triggered when the voltage at the DC input terminals of the inverter has dropped to around 10.7V for a 12V battery or 21.
SECTION 7 | General Information on Batteries for Powering Inverters In the example given above, the 10.7V Low Battery / DC Input Alarm would trigger at around 80% discharged state (20% SOC) when the C-Rate discharge current is C/5 Amps. However, for lower C-Rate discharge current of C/10 Amps and lower, the battery will be almost completely discharged when the alarm is sounded.
SECTION 7 | General Information on Batteries for Powering Inverters based on the actual application requirements. Please consider using the following Programmable Low Battery Cut-off / “Battery Guard” Models manufactured by Samlex America, Inc. www.samlexamerica.
SECTION 7 | General Information on Batteries for Powering Inverters terminal of Battery 4 is connected to the Positive terminal of Battery 3. The Negative terminal of Battery 3 is connected to the Positive terminal of Battery 2. The Negative terminal of Battery 2 is connected to the Positive terminal of Battery 1. The Negative terminal of Battery 1 becomes the Negative terminal of the 24V battery bank.
SECTION 7 | General Information on Batteries for Powering Inverters teries to form a 12V, 400 Ah battery bank. Two 6V, 200 Ah batteries, Batteries 1 and 2 are connected in series to form a 12V, 200 Ah battery (String 1). Similarly, two 6V, 200 Ah batteries, Batteries 3 and 4 are connected in series to form a 12V, 200 Ah battery (String 2). These two 12V, 200 Ah Strings 1 and 2 are connected in parallel to form a 12V, 400 Ah bank.
SECTION 7 | General Information on Batteries for Powering Inverters The first step is to estimate the total AC watts (W) of load(s) and for how long the load(s) will operate in hours (H). The AC watts are normally indicated in the electrical nameplate for each appliance or equipment. In case AC watts (W) are not indicated, Formula 1 given above may be used to calculate the AC watts by multiplying 120 VAC / 230 VAC by the AC current in Amperes.
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. Various recommendations made in this manual on installation will be superseded by the National / Local Electrical Codes related to the location of the unit and the specific application.
SECTION 8 | Installation The corrosive fumes will corrode and damage the unit and if the gases are not ventilated and allowed to collect, they could ignite and cause an explosion. Accessibility: Do not block access to the front panel. Also, allow enough room to access the AC receptacles and DC wiring terminals and connections, as they will need to be checked and tightened periodically. Preventing Radio Frequency Interference (RFI): The unit uses high power switching circuits that generate RFI.
SECTION 8 | Installation 400 4 16.5 Height: 82 mm 200 241 16.5 4 44 282 12 PST-100S Dimensions (mm): 400 x 241 x 82 Fig. 8.2: PST-100S-12E, PST-100S-24E Dimensions and Mounting Slots / Dimensions (mm): 400 x 241 x 82 3 3 80.5 225 Height: 101 mm 282 276 3 415 Fig. 8.3: Dimensions and Mounting Slots for PST-150S-12E, PST-150S-24E and PST-200S-12E, PST-200S-24E / Dimensions (mm): 415 x 282 x 101 PST-150S & PST-200S Dimensions (mm): 415 x 282 x 101 SAMLEX AMERICA INC.
SECTION 8 | Installation Mounting Orientation The unit has air intake and exhaust openings for the cooling fan(s). 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.
SECTION 8 | Installation into the diversion load if there are no other loads. The charge controller will disconnect the diversion load if the current rating of the controller is exceeded. Disconnection of the diversion load may damage the battery as well as the inverter or other DC loads connected to the battery due to high voltages generated during conditions of high winds (for wind generators), high water flow rates (for hydro generators).
SECTION 8 | Installation The size (thickness / cross-section) of the conductors is designated by AWG (American Wire Gauge). Please note that a smaller AWG # denotes a thicker size of the conductor up to AWG #1. Wires thicker than AWG #1 are designated AWG 1/0, AWG 2/0, AWG 3/0 and so on. In this case, increasing AWG # denotes thicker wire.
SECTION 8 | Installation WARNING! Use of an appropriately sized external fuse as described above is mandatory to provide safety against fire hazard due to accidental short circuit in the battery wires. Please note that the DC side fuse(s) inside the unit are designed to provide protection to the internal components of the inverter. These fuses will NOT blow if there is a short circuit along the length of wires connecting the battery and the inverter.
SECTION 8 | Installation i INFO 4 standard Models of Samlex America, Inc. DC Installation Kits are available to cover installation requirements of 600 to 3500W inverters. Voltage drop of 2% or less will be applicable for 3 ft. distance. In some cases, the kits may contain thicker cables and higher rated fuses than the minimum sizes recommended. Thicker cables will produce lower voltage drop and hence, will further improve the overall efficiency.
SECTION 8 | Installation center which is also fed from the utility power/ generator. Such a connection will result in parallel operation and AC power from the utility / generator will be fed back into the inverter which will instantly damage the output section of the inverter and may also pose a fire and safety hazard.
SECTION 8 | Installation tion and are internally connected to the metal chassis of the inverter. The metal chassis of the inverter is connected to the designated Ground. When the “Schuko” plug (1) of the power cord of the AC device is plugged into the corresponding “Schuko” receptacle on the inverter (2 in Fig. 8.4 or 5 in Figs. 6.1, 6.2 and 6.
SECTION 9 | Operation Powering On The Loads After the inverter is switched on, it takes a finite time to become ready to deliver full power. Hence, always switch on the load(s) after a few seconds of switching on the inverter. Avoid switching on the inverter with the load already switched on. This may prematurely trigger the overload protection. When a load is switched on, it may require initial higher power surge to start.
SECTION 9 | Operation Indications For Normal Operation When the inverter is operating normally and supplying AC load(s), the LED (2) will be green. In case of abnormal operation, other displays and alarms will be activated. Please see under “Protections Against Abnormal Conditions” . Optional Wired Remote On/Off Control – Model RC-15 An optional wired Remote Control Model, No. RC-15, is available to enable switching on and off from a distance of 15 ft. The remote on / off control comes with 15 ft. cable.
SECTION 10 | Protections The inverter has been provided with protections detailed below: Overload / Short Circuit Shut Down The inverter can provide a higher than normal instantaneous power (< 1 second) limited to the surge power rating of the inverter. Also, the inverter can provide continuous power limited to the continuous power rating of the inverter. If there is an overload beyond these specified limits, the AC output of the unit will be shut down permanently.
SECTION 10 | Protections The unit will automatically reset after the hot spot has cooled down to 70°C. Reverse Polarity at the DC Input Terminals The Positive of the battery should be connected to the Positive DC input terminal of the inverter (9) and the Negative of the battery should be connected to the Negative DC input terminal of the inverter (8).
SECTION 11 | Trouble Shooting Guide ISSUE When switched ON, Green LED “Power” (2) does not light. Buzzer is off. There is no AC output voltage. POSSIBLE CAUSE There is no voltage at the DC input terminals. REMEDY Check the continuity of the battery input circuit. Check that the external battery fuse is intact. Replace if blown. Check that all connections in the battery input circuit are tight. Low AC output voltage (No buzzer alarm).
SECTION 11 | Trouble Shooting Guide ISSUE AC output shuts down completely. Red LED “Overload” (3) is lighted. Green LED “Power” (2) is off. POSSIBLE CAUSE Permanent shut-down of the AC output due to continuous overload beyond the continuous power rating of the inverter. REMEDY Reduce the load. The load is not suitable as it requires higher power to operate. Use an inverter with higher power rating.
SECTION 12 | Specifications Model NO. PST-60S-12E PST-60S-24E output Power, Continuous 600 Watts 600 Watts Power, Surge (for <1 sec) 1000 Watts 1000 Watts Output Voltage 230 VAC +/- 3% 230 VAC +/- 3% Output Frequency 50 Hz 50 Hz Output Voltage Waveform Pure Sine Wave Pure Sine Wave Total Harmonic distortion < 3% < 3% INPUT Input Voltage 10.7 to 16.5 VDC 21.4 to 33 VDC MAXIMUM INPUT CURRENT 80 A 40 A Input Current at No Load < 800 mA < 600 mA LOW INPUT VOLTAGE WARNING ALARM 10.
SECTION 12 | Specifications Model NO. PST-100S-12E PST-100S-24E output Power, Continuous 1000 Watts 1000 Watts Power, Surge (for <1 sec) 2000 Watts 2000 Watts Output Voltage 230 VAC +/- 3% 230 VAC +/- 3% Output Frequency 50 Hz 50 Hz Output Voltage Waveform Pure Sine Wave Pure Sine Wave Total Harmonic distortion < 3% < 3% input Input Voltage 10.7 to 16.5 VDC 21.
SECTION 12 | Specifications Model NO. PST-150S-12E PST-150S-24E output Power, Continuous 1500 Watts 1500 Watts Power, Surge (for <1 sec) 3000 Watts 3000 Watts Output Voltage 230 VAC +/- 3% 230 VAC +/- 3% Output Frequency 50 Hz 50 Hz Output Voltage Waveform Pure Sine Wave Pure Sine Wave Total Harmonic distortion < 3% < 3% input Input Voltage 10.7 to 16.5 VDC 21.4 to 33 VDC maximum input current 200 A 100 A Input Current at No Load < 1.6 A < 1.
SECTION 12 | Specifications Model NO. PST-200S-12E PST-200S-24E 2000 Watts 2000 Watts output Power, Continuous Power, Surge (for <1 sec) 4000 Watts 4000 Watts Output Voltage 230 VAC +/- 3% 230 VAC +/- 3% Output Frequency 50 Hz 50 Hz Output Voltage Waveform Pure Sine Wave Pure Sine Wave Total Harmonic distortion < 3% < 3% input Input Voltage 10.7 to 16.5 VDC 21.
SECTION 13 | Warranty 2 Year limited warranty The PST-60S-12E / PST-60S-24E; PST-100S-12E / PST-100S-24E; PST-150S-12E / PST-150S-24E; and PST-200S-12E / PST-200S-24E Series Inverters are manufactured by Samlex America, Inc. (the “Warrantor“) is warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“).
Contact Information Toll Free Numbers Ph: 800 561 5885 Fax: 888 814 5210 Local Numbers Ph: 604 525 3836 Fax: 604 525 5221 Website www.samlexamerica.com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders@samlexamerica.
