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User Manual for SGP models including: LFP Series, LFP Series Pure Sine Wave Inverter Charger, Pure Sine Wave Inverter Charger, Sine Wave Inverter Charger, Wave Inverter Charger, Inverter Charger, Charger
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DocumentDocumentSun Gold Power Inc LFP Series Pure Sine Wave Inverter/Charger User's Manual Sun Gold Power Inc Table of Contents 1 Important Safety Information.............................................................................................................. - 2 1.1 General Safety Precautions..................................................................................................... - 2 1.2 Precautions When Working with Batteries...............................................................................- 2 - 2 Introduction......................................................................................................................................... - 3 2.1 General Information..................................................................................................................- 3 2.2 Application................................................................................................................................- 3 2.3 Features..................................................................................................................................... - 3 2.4 Mechanical Drawing................................................................................................................. - 4 2.5 Electrical Performance.............................................................................................................. -7 2.5.1 AC Charger............................................................................................................................ - 7 2.5.2 Inverter................................................................................................................................... - 9 2.5.3 Auto frequency adjust............................................................................................................ - 9 2.5.4 DIP Switches..........................................................................................................................- 9 2.5.5 Transfer................................................................................................................................ - 10 2.5.6 Power Saver Mode............................................................................................................... - 10 2.5.7 Protections............................................................................................................................- 11 2.5.8 LED Indicator & LCD......................................................................................................... - 12 2.5.9 Automatic Voltage Regulation(Optional)............................................................................- 12 2.5.10 LCD Display Details..........................................................................................................- 13 2.5.11 Audible Alarm....................................................................................................................- 14 2.5.12 FAN Operation...................................................................................................................- 14 2.5.13 Other features..................................................................................................................... - 14- 3 Installation......................................................................................................................................... - 16 3.1 Location.................................................................................................................................. - 16 3.2 DC Wiring recommendation...................................................................................................- 16 3.3 AC Wiring...............................................................................................................................- 16 3.4 Grounding............................................................................................................................... - 18 3.4.1 Automatic Neutral-to-Ground Connection.......................................................................... - 18 3.4.2 Disabling the Automatic Neutral-to-Ground Connection....................................................- 18 3.5 Install Flange...........................................................................................................................- 19 - 4 Troubleshooting Guide......................................................................................................................- 20 Appendix 1........................................................................................................................................... - 23 Appendix 2 - Installation Diagram.......................................................................................................- 25 - -1- Sun Gold Power Inc 1 Important Safety Information WARNING! This manual contains important instructions for all LFP Inverter/Charger models that shall be followed during installation and maintenance of the inverter. 1.1 General Safety Precautions 1-1-1.Do not expose the Inverter to rain, snow, spray, bilge or dust. To reduce risk of hazard, do not cover or obstruct the ventilation openings. Do not install the Inverter in a zero-clearance compartment. Overheating may result. Allow at least 30CM(11.81 inches) of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit. A minimum air flow of 145CFM is required. 1-1-2. To avoid a risk of fire and electronic shock. Make sure that existing wiring is in good electrical condition; and that wire size is not undersized. Do not operate the Inverter with damaged or substandard wiring. 1-1-3. This equipment contains components which can produce arcs or sparks. To prevent fire or explosion do not install in compartments containing batteries or flammable materials or in locations which require ignition protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, or joints, fittings, or other connection between components of the fuel system. See Warranty for instructions on obtaining service. 1-1-4. Do not dis-assemble the Inverter/Charger. It contains no user serviceable parts. Attempting to service the Inverter/Charger yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected. 1-1-5. To reduce the risk of electrical shock, disconnect both AC and DC power from the Inverter/Charger before attempting any maintenance or cleaning. Turning off controls will not reduce this risk CAUTION: Equipment damage The output side of the inverter's AC wiring should at no time be connected to public power or a generator. This condition is far worse than a short circuit. If the unit survives this condition, it will shut down until corrections are made. Installation should ensure that the inverter's AC output is, at no time, connected to its AC input. Warning: Limitations On Use SPECIFICALLY, PLEASE NOTE THAT THE LFP SERIES INVERTER/CHARGER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. 1.2 Precautions When Working with Batteries 1-2-1. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 20 minutes and get medical attention immediately. 1-2-2. Never smoke or allow a spark or flame in vicinity of battery or engine. 1-2-3. Do not drop a metal tool on the battery. The resulting spark or short-circuit on the battery of other electrical part may cause an explosion. 1-2-4. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery produces a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 1-2-5. To reduce the risk of injury, charge only rechargeable batteries such as deep-cycle lead acid, lead antimony, lead calcium gel cell, absorbed mat, NiCad/NiFe or Lithium battery. Other types of batteries may burst, causing personal injury and damage. -2- Sun Gold Power Inc 2 Introduction 2.1 General Information This Series Pure Sine Wave Inverter is a combination of an inverter, battery charger and AC auto-transfer switch into one complete system with a peak conversion efficiency of 88%. It is packed with unique features and it is one of the most advanced inverter/chargers in the market today. It features power factor corrected, sophisticated multi-stage charging and pure sine wave output with unprecedentedly high surge capability to meet demanding power needs of inductive loads without endangering the equipment. For the regular model, when utility AC power cuts off(or falls out of acceptable range), the transfer relay is de-energized and the load is automatically transferred to the Inverter output. Once the qualified AC utility is restored, the relay is energized and the load is automatically reconnected to AC utility. The LFP Series Inverter is equipped with a powerful charger of up to110Amps (depending on model). The overload capacity is 300% of continuous output for up to 20 seconds to reliably support tools and equipment longer Another important feature is that the inverter can be easily customized to Battery priority via a DIP switch, this helps to extract maximum power from battery in renewable energy systems. Thus, the LFP Series Pure Sine Wave Inverter is suitable for Renewable energy system,Utility, RV, Marin and Emergency appliances. To get the most out of the power inverter, it must be installed, used and maintained properly. Please read the instructions in this manual before installing and operating. 2.2 Application Power toolscircular saws, drills, grinders, sanders, buffers, weed and hedge trimmers, air compressors. Office equipment computers, printers, monitors, facsimile machines, scanners. Household items vacuum cleaners, fans, fluorescent and incandescent lights, shavers, sewing machines. Kitchen appliances coffee makers, blenders, ice markers, toasters. Industrial equipment metal halide lamp, high pressure sodium lamp. Home entertainment electronics television, VCRs, video games, stereos, musical instruments, satellite equipment. 2.3 Features Smart Remote Control (RMT) Designed to Operate under HarshEnvironment DC Start & Automatic Self-DiagnosticFunction Compatible with Both Linear & Non-LinearLoad Easy to Install & Easy to Operate & Easy toSolve Low DC Voltage Supports Home & Office Appliances Powerful Charge Rate Up to 120Amp, Selectable From 0%-100% High Efficiency Design & "Power Saving Mode" to Conserve Energy Battery Priority Mode, Designates the Inverter-Preferred UPS Configuration 13 Vdc Battery Recover Point, Dedicated for Renewable Energy Systems 8 pre Set Battery Type Selector plus De-sulphation for Totally Flat Batteries 4-step Intelligent Battery Charging, PFC (Power Factor Correction) for Charger 8 ms Typical Transfer Time Between Utility & Battery, Guarantees Power Continuity 15s Delay Before Transfer when AC Resumes, Protection for Load when Used withGenerator -3- Sun Gold Power Inc 2.4 Mechanical Drawing LFP 1KW to 1.5KW Models -4- Sun Gold Power Inc LFP 2KW to 4KW Models -5- Sun Gold Power Inc LFP 5KW to 6KW Models -6- Sun Gold Power Inc 2.5 Electrical Performance 2.5.1 AC Charger LFP Series is equipped with an active PFC (Power Factor Corrected) multistage battery charger. The PFC feature is used to control the amount of power used to charge the batteries in order to obtain a power factor as close as possible to 1. Unlike other inverters whose max charging current decreases according to the input AC voltage, LFP series charger is able to output max current as long as input AC voltage is in the range of 164-243VAC (95-127VAC for 120V model), and AC freq is in the range of 48-54Hz(58-64Hz for 60Hz model). The LFP series inverter is with a strong charging current of 120Amp (for 4KW,12V), and the max charge current can be adjusted from 0%-100% via a liner switch at the right of the battery type selector. This will be helpful if you are using our powerful charger on a small capacity battery bank. Fortunately, the liner switch can effectively reduce the max charging current to 20% of its peak. Choosing "0" in the battery type selector will disable charging function. There are mainly 3 stages: Bulk Charging: This is the initial stage of charging. While Bulk Charging, the charger supplies the battery with controlled constant current. The charger will remain in Bulk charge until the Absorption charge voltage (determined by the Battery Type selection) is achieved. Software timer will measure the time from A/C start until the battery charger reaches 0.3V below the boost voltage, then take this time asT0 and T0×2 = T1. Absorb Charging: This is the second charging stage and begins after the absorb voltage has been reached. Absorb Charging provides the batteries with a constant voltage and reduces the DC charging current in order to maintain the absorb voltage setting. In this period, the inverter will start a T1 timer; the charger will keep the boost voltage in Boost CVmode until the T1 timer has run out. Then drop the voltage down to the float voltage. The timer has a minimum time of 1 hour and a maximum time of 12 hours. Float Charging: The third charging stage occurs at the end of the Absorb Charging time. While Float charging, the charge voltage is reduced to the fl oat charge voltage (determined by the Battery Type selection*). In this stage, the batteries are kept fully charged and ready if needed by the inverter. If the A/C is reconnected or the battery voltage drops below 12Vdc/24Vdc/48Vdc, the charger will reset the cycle above. If the charge maintains the float state for 10 days, the charger will deliberately reset the cycle to protect the battery. Table 2.5.1 Battery Charging Processes -7- Sun Gold Power Inc Switch Setting 0 1 2 3 4 5 6 7 8 9 Table 2.5.2 Battery Type Selector Description Gel USA AGM 1 Lithium/AGM2 Lithium/Sealed Lead Acid Gel EURO Lithium LiFePO4 De-sulphation Classic LFP Fast Mode/ VDC Float Mode / VDC Charger Off 14.0 13.7 14.1 13.4 14.6 13.6 14.4 13.6 14.4 13.8 12.6 12.0 14.0 13.8 15.5 for 4hrs 13.6 13.5 For 12Vdc Mode Series (*2 for 24Vdc Mode ; *4 for 48Vdc Mode) Use with Lithium Ion Battery Packs Our inverter charger can work with various lithium batteries like LiFePO4, LFP battery. Please check the battery specification to make sure the charging setting of inverter suits your lithium battery charge voltage and cut off voltages. If the charging setting of the inverter don' t match your lithium battery, please email your requirement to sales@sungoldpower.com for customization. De-sulphation The de-sulphation cycle on switch position 8 is marked in red because this is a very dangerous setting if you do not know what you are doing. Before ever attempting to use this cycle you must clearly understand what it does and when and how you would use it. What causes sulphation? This can occur with infrequent use of the batteries(nor), or if the batteries have been left discharged so low that they will not accept a charge. This cycle is a very high voltage charge cycle designed to try to break down the sulphated crust that is preventing the plates taking a charge and thus allow the plates to clean up and so accept charge once again. Charging depleted batteries The LFP series inverter allows start up and through power with depleted batteries. For 12VDC model, after the battery voltage goes below 10V, if the switch is still (and always) kept in "ON" position, the inverter is always connected with battery, and the battery voltage does not drop below 2V, the inverter will be able to charge the battery once qualified AC inputs are present. Before the battery voltage goes below 9VDC, the charging can be activated when the switch is turned to "Off", then to "ON". When the voltage goes below 9VDC, and you accidently turn the switch to OFF or disconnect the inverter from battery, the inverter will not be able to charge the battery once again, because the CPU loses memory during this process. Tabel 2.5.3 AC Charging Current for OIS model Model Watt 1.000 ~ 1.500 3.000 5.000 Battery Voltage 12 Vdc 24 Vdc 48 Vdc 12 Vdc 24 Vdc 48 Vdc 24 Vdc 48 Vdc AC Charger Current Max 45 ± 5 Amp 25 ± 5 Amp 15 ± 5 Amp 90 ± 5 Amp 40 ± 5 Amp 30 ± 5 Amp 80 ± 5 Amp 50 ± 5 Amp Model Watt 2.000 4.000 6.000 -8- Battery Voltage 12 Vdc 24 Vdc 48 Vdc 12 Vdc 24 Vdc 48 Vdc 24 Vdc 48 Vdc AC Charger Current Max 70 ± 5 Amp 25 ± 5 Amp 20 ± 5 Amp 120 ± 5 Amp 50± 5 Amp 40 ± 5 Amp 90 ± 5 Amp 60 ± 5 Amp Sun Gold Power Inc The charging capacity will go to peak in around 3 seconds. This may cause a generator to drop frequency, making inverter transfer to battery mode. It is suggested to gradually put charging load on the generator by switching the charging switch from min to max, together with the 15s switch delay, our inverter gives the generator enough time to spin up. This will depend on the size of the generator and rate of charge. 2.5.2 Inverter Topology The LFP inverter/charger is built according to the following topology. Inverter: Full Bridge Topology. AC Charger: Isolate Boost Topology Because of high efficiency Mosfets and 16bit, 4.9MHz microprocessor and heavy transformers, it outputs PURE SINE WAVE AC with an average THD of 10% (Min5%, Max 15%) depending of load connected and battery voltage. The peak efficiency of LFP series is 88%. Overload Capacity The LFP series inverters have different overload capacities, making it ideal to handle demanding loads. 1 For 110%<Load<125%(±10%), no audible alarm in 14 minutes, beeps 0.5s every 1s in the 15th minute, and Fault(Turn off) after the 15th minute. 2 For 125%<Load<150%(±10%), beeps 0.5s every 1s and Fault(Turn off) after the 1 minute. 3 For 300%Load>150%(±10%), beeps 0.5s every 1s and Fault(Turn off) after 20s. 2.5.3 Auto frequency adjust The inverter is with Auto Frequency adjust function. The factory default configuration for 220/230/240VAC inverter is 50Hz, and 60Hz for 100/110/120VAC inverter. While the output freq can be easily changed once a qualified freq is applied to the inverter. If you want to get 60Hz from a 50Hz inverter, just input 60Hz power, and the inverter will automatically adjust the output freq to 60Hz and vice versa. 2.5.4 DIP Switches On the rear panel of inverter, there are 5 DIP switches which enable users to customize the performance of the device. Dip Switch Function Setting Switch NO Switch Function Position: 0 Position: 1 SW1 SW2 SW3 SW4 SW5 Low Battery Trip Volt AC Input Range Power Saver Auto Setting O/P Frequency Setting Battery/AC Priority 10.0VDC 10.5VDC *2 for 24VDC, *4 for 48VDC 184-253VAC 140-270VAC 100-135VAC Night charger Function 90-135VAC Detect load Per 3Secs 50HZ 60HZ Utility Priority Battery Priority SW1: Low Battery Trip Volt: For 12VDC model, the Low Battery Trip Volt is set at 10.0Vdc by typical deep cycle lead acid battery. It can be customized to 10.5Vdc using SW1 for sealed car battery, this is to prevent batteries from over-discharging while there is only a small load applied on the inverter. (*2 for 24VDC, *4 for 48VDC) -9- Sun Gold Power Inc SW2:AC Input Range: There are different acceptable AC input ranges for different kinds of loads. For some relatively sensitive electronic devices, a narrow input range of 184-253VAC (100-135V for 120VAC model) is required to protect them. While for some resistive loads which work in a wide voltage range, the input AC range can be customized to 154-253VAC (90-135V for 120VAC model), this helps to power loads with the most AC input power without frequent switches to the battery bank. SW3:Power Saver Auto Setting : This cycle can be customized to 3 seconds through the SW3 on the DIP switch. SW4: Adjust 50hz/60hz The output frequency of the inverter can be set at either 50Hz or 60Hz by SW4. Kindly reminder: 4000W/12V machine doesn't have this function. SW5:Solar/AC Priority: Our inverter is designed with AC priority by default. This means, when AC input is present, the battery will be charged first, and the inverter will transfer the input AC to power the load. Only when the AC input is stable for a continuous period of 15 days, the inverter will start a battery inverting cycle to protect the battery. After 1 cycle normal charging and ac through put will be restored. The AC Priority and Battery Priority switch is SW5. When you choose battery priority, the inverter will inverting from battery despite the AC input. Only when the battery voltage is reaches low voltage alarm point(10.5V for 12V), the inverter transfers to AC Input, charges battery, and switches back to battery when battery is charged full. This function is mainly for wind/solar systems taking utility power as back up. 2.5.5 Transfer While in the Standby Mode, the AC input is continually monitored. Whenever AC power falls below the VAC Trip voltage (154 VAC, default setting for 230VAC,90VAC for 120VAC), the inverter automatically transfers back to the Invert Mode with minimum interruption to your appliances - as long as the inverter is turned on. The transfer from Standby mode to Inverter mode occurs in approximately 8 milliseconds. And it is the same time from Inverter mode to Standby mode. Though it is not designed as a computer UPS system, this transfer time is usually fast enough to keep your equipment powered up. There is a 15-second delay from the time the inverter senses that continuously qualified AC is present at the input terminals to when the transfer is made. This delay is built in to provide time for a generator to spin-up to a stable voltage and avoid relay chattering. The inverter will not transfer to generator until it has locked onto the generator's output. This delay is also designed to avoid frequent switching when input utility is unstable. 2.5.6 Power Saver Mode There are 3 different working status for LFP inverter: "Power Saver Auto" "Power Saver Off" and "Power Off". When power switch is in "Unit Off" position, the inverter is powered off. When power switch is turned to either of "Power Saver Auto" or "Power Saver Off", the inverter is powered on. Power saver function is designed to conserve battery power when AC power is not or rarely required by the loads. In this mode, the inverter pulses the AC output looking for an AC load (i.e., electrical appliance). Whenever an AC load (greater than 25 watts) is turned on, the inverter recognizes the need for power and automatically starts inverting and output goes to full voltage. When there is no load (or less than 25 watts) detected, the inverter automatically goes back into search mode to minimize energy consumption from the battery bank. In "Power saver on" mode, the inverter will draw power mainly in sensing moments, thus the idle consumption is significantly reduced. - 10 - Sun Gold Power Inc This cycle can be customized to 3 seconds turn SW3 on the DIP switch. Power saver on Power saver off Power saver on (Load detected) Note: The minimum power of load to take inverter out of sleep mode (Power Saver On) is 25 Watts. When in the search sense mode, the green power LED will blink and the inverter will make a ticking sound. At full output voltage, the green power LED will light steadily and the inverter will make a steady humming sound. When the inverter is used as an "uninterruptible" power supply the search sense mode or "Power Saver On" function should be defeated. Exceptions Some devices when scanned by the load sensor cannot be detected. Small fluorescent lights are the most common example. (Try altering the plug polarity by turning the plug over.) Some computers and sophisticated electronics have power supplies that do not present a load until line voltage is available. When this occurs, each unit waits for the other to begin. To drive these loads either a small companion load must be used to bring the inverter out of its search mode, or the inverter may be programmed to remain at full output voltage. 2.5.7 Protections The LFP series inverter is equipped with extensive protections against various harsh situations/faults. These protections include: AC Input over voltage protection/AC Input low voltage protection Low battery alarm/High battery alarm Over temperature protection/Over load protection Short Circuit protection (1s after fault) Back feeding protection When Over temperature /Over load occur, after the fault is cleared, the master switch has to be reset to restart the inverter. The Low batter voltage trip point can be customized from defaulted value 10VDC to 10.5VDC thru the SW1 on DIP switch. The inverter will go to Over temp protection when heat sink temp. 105ºC, and go to Fault (shutdown Output) after 30 seconds. The switch has to be reset to activate the inverter. The LFP series Inverter has back feeding protection which avoids presenting an AC voltage on the AC input terminal in Invert mode. After the reason for fault is cleared, the inverter has to be reset to start working. - 11 - Sun Gold Power Inc 2.5.8 LED Indicator & LCD SHORE POWER ON INVERTER ON FAST CHARGE FLOAT CHARGE OVER TEMP TRIP OVER LOAD TRIP POWER SAVER ON Table 2.5.8 LCD 1 Greeting message GREEN LED lit in AC Mode GREEN LED lit in Inverter Mode Yellow LED lit in Fast Charging Mode GREEN LED lit in Float Charging Mode RED LED lit in Over Temperature RED LED lit in Over Load GREEN LED lit in Power Saver Mode (Power Saver Load 25W) Indicator 2 AC Status & Input Voltage 3 Output Voltage/Frequency and Battery voltage "AC: abnormal" will be displayed when AC input is not qualified. 4 Output Current( in percentage) 2.5.9 Automatic Voltage Regulation(Optional) The automatic voltage regulation function is for full series of LFP Pure Sine Wave Inverter/ Charger except split phase models including LFP 1000W~6000W. Instead of simply bypassing the input AC to power the loads, the LFP series inverter stabilizes the input AC voltage to a range of 230V/120V±10%. Connected with batteries, the LFP Series inverter will function as a UPS with max transfer time of 10 ms. With all the unique features our inverter provides, it will bring you long-term trouble free operation beyond your expectation. - 12 - Sun Gold Power Inc Function Introduction Table 2.5.5 Input Voltage Transfer Points OIS Function Acceptable Input Voltage Range (Vac) Nominal Input Voltages (Vac) (A) Line low loss N/W (On battery) (B) Line Low comeback N/W (On Boost) (C) Line 2nd boost threshold (On Boost) (D) Line 2nd boost comeback (On Normal) (E) Line 1st boost threshold (On Boost) (F) Line 1st boost comeback (On Normal) (G) Line buck comeback (On Normal) (H) Line buck threshold (On Buck) (I) Line high comeback (On Buck) (J) Line high loss (On Battery) 2.5.10 LCD Display Details Connection Diagram OIS LV (NA/JPN) 0-160 100 110 120 220 75/65 84/72 92/78 168/143 80/70 89/77 97/83 178/153 ** ** ** ** ** ** ** ** 90 99 108 198 93 103 112 205 106 118 128 235 110 121 132 242 115 127 139 253 120 132 144 263 HV (INTL) 0-300 230 176/150 186/160 ** ** 207 215 246 253 266 276 240 183/156 193/166 ** ** 216 225 256 264 278 288 LCD Display Detail (1) Shore/ Generator voltage (2) DC voltage on inverter (3)Load when inverting % (4)Low/high voltage, over temp, overload (5)Fault condition (6) AC Output voltage (7) Output frequency (8) Bypass (online) / inverter mode (9) Battery state of charge graph WARNING Never cut the telephone cable when the cable is attached to inverter and battery is connected to the inverter. - 13 - Sun Gold Power Inc Even if the inverter is turned off. It will damage the remote PCB inside if the cable is short circuited during cutting. 2.5.11 Audible Alarm Battery Voltage Low Battery Voltage High Invert Mode Over-Load Over Temperature Table 2.5.9 OIS Series Audible Alarm Spec Inverter green LED lit, and the buzzer beeps 0.5s every 5s. Inverter green LED lit, and the buzzer beeps 0.5s every 1s and Fault after 60s. (1) 110%<load<125%(±10%), No audible alarm in 14 minutes, Beeps 0.5s every 1s in 15th minute and Fault after 15 minutes; (2) 125% <load<150%(±10%), Beeps 0.5s every 1s and Fault after 60s; (3) Load>150%(±10%), Beeps 0.5s every 1s and Fault after 20s; Heatsink temp. 105ºC, Over temp red LED Lighting, beeps 0.5s every 1s; 2.5.12 FAN Operation For 1-3KW,4KW 24V/48V there is one multiple controlled DC fan which starts to work according to the following logic. For 4KW 12V and 6KW , there is two multiple controlled DC fan, the DC fan at the DC terminal side will work in the same way as the one on 1-3KW. So when the inverter is in power saver mode, the AC fan will work from time to time in response to the pulse sent by the inverter in power saver mode. The Operation of the DC fan at the DC terminal side is controlled by the following logic (Refer to Table 2.5.10): Table 2.5.10 OIS Series Fan Operation Logic Condition HEAT SINK TEMPERATURE CHARGER CURRENT LOAD% (INV MODE) Enter condition T 60 65 T <85 T > 85 I 15% 20%< I 50% I > 50% Load < 30% 30% Load < 50% Load 50% Leave condition T > 65 T 60 / T 85 T 80 I 20% I 15% / I 50% I 40% Load 30% Load 20% / Load 50% Load 40% Speed OFF 50% 100% OFF 50% 100% OFF 50% 100% Allow at least 30CM of clearance around the inverter for air flow. Make sure that the air can circulate freely around the unit. Variable speed fan operation is required in invert and charge mode. This is to be implemented in such a way as to ensure high reliability and safe unit and component operating temperatures in an operating ambient temperature up to 50°C. Speed to be controlled in a smooth manner as a function of internal temperature and/or current. Fan should not start/stop suddenly. Fan should run at minimum speed needed to cool unit. Fan noise level target <60db at a distance of 1m. 2.5.13 Other features Battery Temperature Sensing Applying the proper charge voltage is critical for achieving optimum battery performance and longevity. The ideal charge voltage required by batteries changes with battery temperature. - 14 - Sun Gold Power Inc The battery temperature sensor allows the charge controller to continuously adjust charge voltage based on actual battery temperature. Temperature compensation of charge voltage assures that the battery receives the proper charge voltage as battery temperature varies. The entire line is equipped with Battery Temperature Sensing for increased charging precision. It sends precise information to the charger, which automatically adjusts voltage to help ensure full battery charge depending on the ambient temperature of your battery installation. When the battery voltage is over 40(104), it will reduce the charging voltage by 0.1Vdc with every degree of temperature rise. We recommend that you install Battery Temperature Sensors on all banks to protect your batteries and to provide optimal charging of each bank. The battery temperature sensor mounts on the side of a battery. The specification is as below Inverter Condition Charger Mode Temp on BST BTS 122 BTS 104 Inverter Mode 104 BTS 122 BTS 122 Operation Automatically turns off charger Automatically turns on charger Increases the low voltage shut down point by 0.5Vdc Over Temp Fault A Battery Temperature Sensor has been provided as a separate accessory. It comes with 32.8'/10m cable. Battery voltage recover start After low battery voltage shut off (10V for 12V model/20V for 24V model/40V for 48V model), the inverter is able to restore operation after the battery voltage recovers to 13Vdc/26Vdc/52Vdc (with power switch still in the "On" position). This function helps to save the users extra labor to reactivate the inverter when the low battery voltage returns to an acceptable range in the renewableenergy systems. The built in battery charger will automatically reactivate as soon as city/generator ac has been stable for 15 seconds. WARNING Never leave the loads unattended, some loads (like a Heater) may cause accident in such cases. It is better to shut everything down after low voltage trip than to leave your load on, due to the risk of fire. Auto Gen Start The inverter can be customized to start up a generator when battery voltage goes low. When the inverter goes to low battery alarm, it can send a signal to start a generator, and turn the generator off after battery charging is finished. (Generator must have auto start function.) The auto gen start feature will only work with generators designed to work with this feature. There is an open/close relay that will short circuit the positive and negative cable from a generator. The input DC voltage can vary, but the Max current the relay can carry is 16Amp. Conformal Coating The entire line of inverters have been processed with a conformal coating on the PCB, making it water, rust, and dust resistant. While these units are designed to withstand corrosion from the salty air, they are not splash proof - 15 - Sun Gold Power Inc 3.1 Location 3 Installation Follow all the local regulations to install the inverter. Please install the equipment in a location that is Dry, Clean, Cool and that has good ventilation. Working temperature: -10-40 Storage temperature: -40-70 Relative Humidity: 0%-95%non-condensing Cooling: Forced air 3.2 DC Wiring recommendation It is suggested the battery bank be kept as close as possible to the inverter. The following able is a suggested wiring option for 3 meter DC cable. Please find the following minimum wire size. In case of DC cable longer than 3m, please increase the cross section of cable to reduce the loss. Power 1KW 1KW 1.5KW 1.5KW 2KW 2KW 2KW 3KW 3KW 3KW 4KW 4KW 5KW 5KW 6KW 6KW DC Input voltage 12V 24V 12V 24V 12V 24V 48V 12V 24V 48V 24V 48V 24V 48V 24V 48V Wire Gage AWG 1/0 AWG 4 AWG 1/0 AWG 4 AWG 1/0 AWG 1/0 AWG 4 AWG 4/0 AWG 1/0 AWG 4 AWG 1/0 AWG 1/0 AWG 4/0 AWG 1/0 AWG 4/0 AWG 1/0 Please follow the above minimum wire size requirement. One cable is always best, but if there is a problem obtaining the recommended size or larger cable, multiple smaller cables will work. Performance of any product can be improved by thicker cable and shorter runs, so if in doubt round up and keep the length as short as possible. 3.3 AC Wiring We recommend using 10 to 6Awg wire to connect to the AC terminal block. When in AC mode the AC input power will supply both the loads and AC charger, a thicker wire gauge for AC Input is required. Please consult a qualified electrician about the specific wire gauge required in terms of wire material and inverter power. There are 3 different ways of connecting to the terminal block depending on the model. All the wirings are CE compliant, Call our tech support if you are not sure about how to wire any part of your inverter. - 16 - Sun Gold Power Inc Wiring Option 1 230V single phase/120V single phase Input: Hot line+Neutral+Ground Output: Hot line+Neutral+Ground Wiring Option 2 230V split phase Input: Hot line+ Hot line +Ground Output: Hot line+ Hot line +Neutral Wiring Option 3 230V split phase Input: Hot line+ Hot line +Ground Output: Hot line +Neutral Remark: In such cases, each output hotline can only carry a max of half the rated capacity. WARNING For split phase models, AC input neutral is not required in wiring. Never Connect Input Neutral to Output Neutral. Damage will result which is not covered under warranty. WARNING The output voltage of this unit must never be connected in its input AC terminal, overload or damage may result. Always switch on the inverter before plugging in any appliance. - 17 - Sun Gold Power Inc 3.4 Grounding Connect an AWG 8 gauge or greater copper wire between the grounding terminal on the inverter and the earth grounding system or the vehicle chassis. 3.4.1 Automatic Neutral-to-Ground Connection All single-phase 120Vac inverters are equipped with an automatic neutral-to-ground switch. These inverters use an internal relay that automatically connects the AC neutral output to the vehicle/ship's safety ground in inverter mode and cuts off when it is connected to a qualified external AC power source. This design avoids the simultaneous existence of two neutral-to-ground connections, thereby avoiding the risk of shock hazard between the vehicle/boat's neutral and the external AC source's neutral. 3.4.2 Disabling the Automatic Neutral-to-Ground Connection In some installations, this function must be disabled. In order to accommodate to these situations, the automatic neutral-to-ground system can be defeated, so the neutral will not be bonded in any operating mode. If you are not sure whether you must disable this function, please refer to the local code requirements. There is a section of green wire with insulated connector at the left side of the AC terminal block. The insulated connector connects the neutral wire and the ground wire inside the inverter during inverting. Pull two ends of the insulated connector apart to separate the green wire; this will prevent the neutral and ground wires from being connected to the inside of the inverter. If possible, please use tape to insulate the disconnected ends, separate the ends from each other and push back out of the way. Typically when connecting to the house panel (after disconnecting city power from it), it is when you want to disconnect this connection as the house panel already has the neutral to ground bond. Normally in a standalone system or in a vehicle, you need to maintain this connection. - 18 - Sun Gold Power Inc 3.5 Install Flange 1000W to 1500W Models 2000W to 4000W Models 2 5000W to 6000W Model Side View For LFP - 19 - Sun Gold Power Inc 4 Troubleshooting Guide Troubleshooting contains information about how to troubleshoot possible error conditions while using the LFP Series Inverter & Charger. The following chart is designed to help you quickly pinpoint the most common inverter failures. Indicator and Buzzer For LFP Status Line Mode Inverter Mode Inverter Mode Item CC CV Float Standby Inverter On Power Saver Battery Low Battery High Overload On Invert Mode Over-Temp On Invert Mode Over-Temp On Line Mode Over Charge SHOR E POWE R ON × × × × × × INVERT ER ON × × × × × × × Indicator on top cover FAST CHG FLOAT CHG OVER TEMP TRIP × × , blink × × × × × × × × × × × × × × × × × × × × × × × × × × × Fan Lock × × × × × Battery High × × × × Inverter Mode × × × × × Overload Fault Output × × × × × Mode Short Over-Temp × × × × Over × × × × Charge Back Feed Short × × × × × OVER LOAD TRIP POWER SAVER ON LED on Remote Swit BATT INVERTE Alarm CHG R × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × Buzzer × × × × × × Beep 0.5s every 5s Beep 0.5s every 1s Refer to "Audible alarm" Beep 0.5s every 1s Beep 0.5s every 1s Beep 0.5s every 1s Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous - 20 - Sun Gold Power Inc Indicator and Buzzer For LFP Status Item POWER SAVER 1 CC Line CV Mode Float Standby Inverter Inverter On Mode Power Saver OVER LOAD 2 Battery Low Battery High Overload On Invert Mode Inverter Over-Temp Mode On Invert Mode Over-Temp On Line Mode Over Charge Fan Lock Battery High Inverter Mode Overload Fault Mode Output Short Over-Temp Over Charge Back Feed Short LED Indicators on top cover OVER UNIT FLOAT FAST TEMP ALARM CHG CHD 3 4 5 6 , Flash LEDs on Remote Switch INVERTE LINE BATT INVER Alarm R MODE MODE CHG TER 7 8 1 2 3 Buzzer Beep 0.5s every 5s Beep 0.5s every 1s Refer to "Audible alarm" Beep 0.5s every 1s Beep 0.5s every 1s Beep 0.5s every 1s Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous Beep continuous - 21 - Sun Gold Power Inc *The reason for the noise from transformer and/or case Symptom Inverter will not turn on during initial power up. Possible Cause Batteries are not connected, loose battery-side connections. Low battery voltage. No AC output voltage and no indicator lights ON. AC output voltage is low and the inverter turns loads OFF in a short time. Charger is inoperative and unit will not accept AC. Charger is supplying a lower charge rate. Inverter has been manually transitioned to OFF mode. Low battery. AC voltage has dropped out-of-tolerance Charger controls are improperly set. Recommended Solution Check the batteries and cable connections. Check DC fuse and breaker. Charge the battery. Press the switch to Power saver on or Power saver off position. Check the condition of the batteries and recharge if possible. Check the AC voltage for proper voltage and frequency. Refer to the section on adjusting the "Charger Rate". Low AC input voltage. Source qualified AC power.. Charger turns OFF while charging from a generator. Sensitive loads turn off temporarily when transferring between grid and inverting. Noise from Transformer/case* Loose battery or AC input connections. High AC input voltages from the generator. Inverter's Low voltage trip voltage may be too low to sustain certain loads. Applying specific loads such as hair drier Check all DC /AC connections. Load the generator down with a heavy load. Turn the generator output voltage down. Choose narrow AC voltage in the DIP switch, or Install a UPS if possible. Remove the loads When in inverter mode and the transformer and/or case of the inverter sometimes may vibrate and make noise. The noise may come from transformer. According to the characteristics of our inverter, there is one type of load which will most likely to cause rattles of transformer, that is a half-wave load, load that uses only a half cycle of the power(see figure 1). This trends to cause imbalance of magnetic field of transformer, reducing its rated working freq from 20KHz to, say, maybe 15KHz (it varies according to different loads). This way, the freq of noise falls exactly into the range (200Hz-20KHz) that human ear can sense. The most common load of such kind is hair drier. Figure 1 If the noise comes from case. Normally when loaded with inductive loads, the magnetic field generated by transformer keeps attracting or releasing the steel case at a specific freq, this may also cause noise. Reducing the load power or using an inverter with bigger capacity will normally solve this problem. The noise will not do any harm to the inverter or the loads. - 22 - Sun Gold Power Inc Appendix 1 Inverter Output DC Input Model Continuous Output Power Surge Rating(20s) Capable of Starting Electric Motor Output Waveform Nominal Efficiency Line Mode Efficiency Power Factor Nominal Output Voltage rms Output Voltage Regulation Output Frequency Short Circuit Protection Typical transfer Time THD Nominal Input Voltage Minimum Start Voltage Low Battery Alarm Low Battery Trip High Voltage Alarm & Fault High DC Input Recovery Low Battery voltage recover Idle Consumption-Search Mode Input Voltage Range Input Frequency Range Output Voltage Charger Breaker Rating (230Vac) Charger Breaker Rating (120Vac) Over Charge Protection Shutdown Inverter & AC Charger Electrical Specifications 1KW 1.5KW 2KW 3KW 1000W 1500W 2000W 3000W 3000W 4500W 6000W 9000W 4KW 4000W 12000W 5KW 6KW 5000W 6000W 15000W 18000W 1HP 1.5HP 2HP 3HP 4HP 5HP 6HP Pure Sine wave/Same as input(Bypass mode) >88%(Peak) >95% 0.9-1.0 100-110-120Vac / 220-230-240Vac ±10% RMS 50/60Hz ± 0.3Hz Yes, Current Limit Function (Fault after 1sec) 10ms(Max) < 10% 12.0Vdc ( *2 for 24Vdc, *4 for 48Vdc) 10.0Vdc 10.5Vdc / 11.0Vdc 10.0Vdc / 10.5Vdc 16.0Vdc 15.5Vdc 13.0Vdc < 25 W when Power Saver On Narrow: 100~135VAC / 194~243VAC; Wide: 90~135VAC / 164~243VAC; Narrow: 47-55±0.3Hz for 50Hz, 57-65±0.3Hz for 60Hz Wide:43±0.3Hz plus for 50Hz/60Hz Depends on battery type 10A 10A 10A 20A 20A 30A 30A 10A 20A 20A 30A 40A N/A N/A 15.7V for 12Vdc ( *2 for 24Vdc, *4 for 48Vdc) - 23 - Sun Gold Power Inc Charge Battery type Gel U.S.A A.G.M 1 Lithium Sealed Lead Acid Gel Euro Open Lead Acid LiFePO4 De-sulphation Classic LFP Remote Control Input Voltage Waveform Nominal Voltage Low Voltage Trip Low Voltage re engage Bypass & Protection High Voltage Trip High Voltage re engage Max Input AC Voltage Nominal Input Frequency Low Freq Trip Low Freq re engage High Freq Trip High Freq re engage Baypass Breaker Rating (230Vac) Baypass Breaker Rating (120Vac) Output Short circuit protection Mounting Inverter Dimensions(L*W*H) Inverter Weight Mechanical Shipping Specification Dimensions(L*W*H) Shipping Weight Display Standard Warranty Fast Vdc 14.0 14.1 13.8 14.4 14.4 14.8 14.0 15.5 for 4hrs 13.6 Yes. Optional Float Vdc 13.7 13.4 13.6 13.6 13.8 13.3 13.8 13.5 Sine wave (Grid or Generator) 120Vac 80V/90V±4% 90V/100V±4 % 140V±4% 135V±4% 150VAC 230Vac 184V/154V±4% 194V/164V±4% 253V±4% 243V±4% 270VAC 50Hz or 60Hz (Auto detect) Narrow: 47±0.3Hz for 50Hz, 57±0.3Hz for 60Hz Wide:40±0.3Hz for 50Hz/60Hz Narrow: 48±0.3Hz for 50Hz, 58±0.3Hz for 60Hz Wide:45±0.3Hz for 50Hz/60Hz Narrow: 55±0.3Hz for 50Hz, 65±0.3Hz for 60Hz Wide: No up limit for 50Hz/60Hz Narrow: 54±0.3Hz for 50Hz, 64±0.3Hz for 60Hz Wide: No up limit for 50Hz/60Hz 10A 15A 20A 30A 30A 40A 40A 20A 20A 30A 30A 40A N/A N/A 362*242*198mm 16KG 17KG 520x320x310mm 18KG 19KG Circuit breaker Wall mount 505*242*198mm 20KG 24KG 35KG 670x320x310mm 22KG 26KG 37KG Status LEDs 1 Year 597*242*198mm 45KG 45KG 760x320x310mm 47KG 47KG - 24 - Sun Gold Power Inc Appendix 2 - Installation Diagram - 25 - 614-00510-04