ECGSOLAX 4.2KW Solar Hybrid Inverter User Manual

1. Introduction

This ECGSOLAX 4.2KW Solar Hybrid Inverter is a multi-function inverter/charger, combining the capabilities of an inverter, solar charger, and battery charger to provide uninterruptible power support in a compact size. It features a comprehensive LCD display and user-configurable button operation for settings such as battery charging current, AC/solar charger priority, and acceptable input voltage, adapting to various applications.

1.1 Features

• Pure sine wave solar inverter (on/off Grid)
• WIFI & GPRS available for iOS and Android (optional module required)
• Inverter running without battery
• One-key restoration to factory settings
• Built-in lithium battery automatic activation
• Built-in 120A MPPT solar charge controller (for 4.2KW/6.2KW models)
• Max PV array power: 6200W (for 4.2KW model), 6500W (for 6.2KW model)
• High PV input voltage range (60~450VDC)
• Built-in anti-dust kit for harsh environments
• Smart battery charge design for optimized battery performance
• 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 with mains voltage or generator power
• Auto restart while AC is recovering
• Overload, over temperature, and short circuit protection
• Cold start function

1.2 Basic System Architecture

The following diagram illustrates a basic application for this inverter/charger, showing its connection with solar modules, a generator or utility, external battery packs, and home appliances.

Consult with your system integrator for other possible system architectures depending on your requirements. This inverter can power various appliances in home or office environments, including motor-type appliances such as tube lights, fans, refrigerators, and air conditioners.

2. Safety Instructions

WARNING: 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. CAUTION: 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. CAUTION: 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 specifications 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 procedures when you want to disconnect AC or DC terminals. Refer to the INSTALLATION section of this manual for 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 regulations 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. Warning!! 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.

3. Product Overview

This section provides a visual and functional overview of the inverter's components.

Key Components:

1. LCD display
2. Status indicator
3. Charging indicator
4. Fault indicator
5. Function buttons
6. Power on / off switch
7. AC input
8. Main output
9. Second output
10. Battery input
11. PV input
12. Anti dust kit
13. RS-232 communication port / WiFi-port

4. Installation

4.1 Unpacking and Inspection

Before installation, carefully inspect the unit. Ensure that nothing inside the package is damaged. The package should contain one inverter unit and one user manual.

4.2 Preparation

Before connecting any wiring, remove the bottom cover by unscrewing the two retaining screws.

4.3 Mounting the Unit

When selecting a mounting location, consider the following:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface.
• Install the inverter at eye level for easy LCD display readability.
• For proper air circulation and heat dissipation, allow approximately 20 cm clearance to the sides and 50 cm above and below the unit.
• The ambient temperature should be between 0°C and 55°C for optimal operation.
• The recommended installation position is vertically adhered to the wall.
• Ensure sufficient space for heat dissipation and wire removal.

CAUTION: Suitable for mounting on concrete or other non-combustible surfaces only.

Install the unit by screwing two M6 screws into the wall.

4.4 Battery Connection

CAUTION: For safety and regulation compliance, install a separate DC over-current protector or disconnect device between the battery and inverter. Over-current protection is always required. Refer to the table below for typical amperage and required fuse/breaker size.

WARNING: All wiring must be performed by qualified personnel. It is crucial for system safety and efficient operation to use appropriate cables for battery connection. To reduce risk of injury, use the proper recommended cable sizes.

Battery Connection Steps:

1. Remove 18 mm of insulation sleeve from the positive and negative conductors.
2. It is recommended to put bootlace ferrules on the end of positive and negative wires using a proper crimping tool.
3. Connect all battery packs as shown in the system architecture diagram (Figure 1).
4. Insert the battery wires flatly into the inverter's battery connectors. Ensure the bolts are tightened with a torque of 2 Nm in a clockwise direction. Verify correct polarity at both the battery and the inverter/charger, and ensure conductors are tightly screwed into the battery terminals. Recommended tool: #2 Pozi Screwdriver.

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

CAUTION: Before making the final DC connection or closing the DC breaker/disconnector, ensure positive (+) is connected to positive (+) and negative (-) is connected to negative (-).

4.5 AC Input/Output Connection

CAUTION: Before connecting to the AC input power source, install a separate AC breaker between the inverter and the AC input power source. This ensures the inverter can be securely disconnected during maintenance and is fully protected from over-current. Recommended AC breaker specs: 32A for 3.6KW/4.2KW models and 50A for 6.2KW models.

CAUTION: There are two terminal blocks marked 'IN' and 'OUT'. Do NOT mis-connect input and output connectors.

WARNING: All wiring must be performed by qualified personnel. It is very important for system safety and efficient operation to use appropriate cables for AC input connection. To reduce risk of injury, use the proper recommended cable sizes.

AC Input/Output Connection Steps:

1. Before making AC input/output connections, ensure the DC protector or disconnector is open.
2. Remove 10 mm of insulation sleeve for six conductors. Shorten phase L and neutral conductor N by 3 mm.
3. Insert AC input wires according to the polarities indicated on the terminal block (L→LINE (brown or black), N→Neutral (blue)) and tighten the terminal screws.

WARNING: Ensure the AC power source is disconnected before attempting to hardwire it to the unit.

4. Then, insert AC output wires according to the polarities indicated on the terminal block (L→LINE (brown or black), N→Neutral (blue)) and tighten the terminal screws.
5. Make sure all wires are securely connected.

CAUTION: Appliances like air conditioners require 2-3 minutes to restart to balance refrigerant gas. If a power shortage occurs and recovers quickly, it can damage connected appliances. Check if your air conditioner has a time-delay function. Otherwise, the inverter/charger may trigger an overload fault and cut off output, potentially causing internal damage to the air conditioner.

4.6 PV Connection

CAUTION: Before connecting to PV modules, install a separate DC circuit breaker between the inverter and PV modules.

WARNING: It is very important for system safety and efficient operation to use appropriate cables for PV module connection. To reduce risk of injury, use the proper recommended cable sizes.

PV Module Selection:
When selecting proper PV modules, consider the following parameters:

• The Open Circuit Voltage (Voc) of PV modules must not exceed the maximum PV array open circuit voltage of the inverter.
• The Open Circuit Voltage (Voc) of PV modules should be higher than the minimum battery voltage.

PV Module Wire Connection Steps:

1. Remove 10 mm of insulation sleeve for positive and negative conductors.
2. It is recommended to put bootlace ferrules on the end of positive and negative wires using a proper crimping tool.
3. Check the correct polarity of wire connection from PV modules and PV input connectors. Connect the positive pole (+) of the connection wire to the positive pole (+) of the PV input connector, and the negative pole (-) to the negative pole (-). Recommended tool: 4mm blade screwdriver.

4.7 Final Assembly

After connecting all wirings, replace the bottom cover by screwing the two screws back into place.

4.8 Communication Connection

The inverter supports communication for monitoring and control.

1. Wi-Fi Cloud Communication (Option): Use the supplied communication cable to connect to the inverter and the Wi-Fi module. Download the SmartESS APP from the App Store (iOS/Android). Refer to the "Wi-Fi Plug Quick Installation Guideline" to set up the network and register. The inverter status will be displayed on the mobile phone APP or a computer webpage.
2. GPRS Cloud Communication (Option): Use the supplied communication cable to connect to the inverter and the GPRS module. Apply external power to the GPRS module. Download the APP from the App Store and refer to the "GPRS RTU Quick Installation Guideline" to set up the network and register. The inverter status will be displayed on the mobile phone APP or a computer webpage.

5. Operation

5.1 Power ON/OFF

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

5.2 Operation and Display Panel

The operation and display panel is located on the front of the inverter. It includes three indicators, four function keys, and an LCD display, providing operating status and input/output power information.

5.3 LCD Display Icons

The LCD display uses various icons to convey information about the inverter's status and operation.

5.4 LCD Setting

To enter setting mode, press and hold the ENTER button for 3 seconds. Use the "UP" or "DOWN" buttons to select setting programs, then press "ENTER" to confirm or "ESC" to exit. The manual provides detailed tables for various settings, including output source priority, maximum charging current, AC input voltage range, battery type, auto restart options, output frequency, output voltage, and more. These settings allow customization for optimal performance based on your specific setup.

5.5 Display Setting

The LCD display information can be cycled through by pressing the "UP" or "DOWN" key. The selectable information includes input voltage, input frequency, PV voltage, charging current, charging power, battery voltage, output voltage, output frequency, load percentage, load in Watt, load in VA, load in Watt, DC discharging current, and main CPU Version. The display will show different information depending on the charged or discharged state and power levels.

5.6 Operating Mode Description

The inverter operates in various modes, each with specific display characteristics. These modes include Standby mode, Line mode, and Grid-Tie Operation. The LCD display will show relevant parameters and icons for each mode, indicating the power flow and system status.

5.7 Battery Equalization Description

The equalization function in the charge controller reverses the buildup of negative chemical effects like stratification and helps remove sulfate crystals from battery plates. This condition, if unchecked, can reduce battery capacity. Periodic equalization is recommended.

How to Apply Equalization Function:

1. Enable the battery equalization function in monitoring LCD setting program 30.
2. Apply this function by either:
• Setting the equalization interval in program 35.
• Activating equalization immediately in program 36.

When to Equalize:
In the float stage, when the set equalization interval (battery equalization cycle) is reached, or equalization is actively initiated, the controller will enter the Equalize stage.

During the Equalize stage, the controller charges the battery until it reaches the battery equalization voltage. Constant-voltage regulation then maintains this voltage. The battery remains in this stage until the set battery equalized time is reached. If the battery voltage does not reach the equalization voltage within the set time, the charge controller extends the equalization time. If the voltage still doesn't reach the target after the extended time, equalization stops, and the system returns to the float stage.

5.8 Fault Reference Code

The inverter provides fault codes to indicate specific issues. Refer to the table below for a list of fault codes, their events, and corresponding LCD icons.

5.9 Warning Indicator

The inverter provides warning codes and audible alarms for various conditions. Refer to the table below for details.

6. Maintenance

6.1 Clearance and Maintenance for Anti-Dust Kit

Every inverter comes with an anti-dust kit installed from the factory. The inverter automatically detects this kit and activates an internal thermal sensor to adjust the internal temperature. This kit also protects the inverter from dust, increasing product reliability in harsh environments.

Maintenance Steps:

1. Loosen the screws on the top of the inverter in a counterclockwise direction.
2. Remove the dustproof case and take out the air filter foam.
3. Clean the air filter foam and the dustproof case. After cleaning, re-assemble the dust-kit back into the inverter.

NOTICE: The anti-dust kit should be cleaned from dust every one month.

7. Specifications

Detailed technical specifications for the ECGSOLAX Hybrid Inverter are provided in the tables below.

Table 1: Line Mode Specifications

INVERTER MODEL	3.6KW	4.2KW	6.2KW
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.

8. Troubleshooting

This section provides guidance for common issues and their solutions. If problems persist, contact qualified service personnel.

9. User Tips

• Always ensure proper ventilation around the inverter to prevent overheating, especially in enclosed spaces.
• Regularly check and clean the anti-dust kit (monthly recommended) to maintain optimal performance and prolong the inverter's lifespan.
• For battery connections, double-check polarity before making final connections to avoid damage.
• When configuring settings via the LCD, take note of the default values before making changes, as these are often optimized for general use.
• If using the optional WiFi/GPRS module, ensure the SmartESS app is updated to the latest version for best monitoring and control experience.
• In case of any fault or warning, consult the troubleshooting section immediately. If the issue persists, contact a qualified service technician.

10. Warranty and Support

For warranty information, technical support, or service inquiries, please contact your authorized ECGSOLAX dealer or the manufacturer directly. Always refer to the complete user manual (PDF) for detailed warranty terms and conditions, as well as comprehensive support resources.

A PDF version of this user manual is available for download: ECGSOLAX Hybrid Inverter User Manual (PDF)