AIMS Power PICOGLF3K12050BY User manual

Pure Sine Wave Inverter Charger
3000 Watt
User’s Manual
PICOGLF3K12050BY
ETL Listed to UL 458 and CSA 22.2 No. 107.1
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Table of Contents
1. Important Safety Information ............................................................................................................................................- 3 -
1.1 General Safety Precautions..............................................................................................................................................- 3 -
1.2 Precautions When Working with Batteries......................................................................................................................- 3 -
2 Introduction ........................................................................................................................................................................- 4 -
2.1 General Information ........................................................................................................................................................- 4 -
2.2 Application ......................................................................................................................................................................- 4 -
2.3 Mechanical Drawing .......................................................................................................................................................- 5 -
2.4 Features ...........................................................................................................................................................................- 7 -
2.5 Electrical Performance ....................................................................................................................................................- 7 -
2.5.1 Invert ....................................................................................................................................................................- 7 -
2.5.2 AC Charger...........................................................................................................................................................- 9 -
2.5.3 Transfer...............................................................................................................................................................- 11 -
2.5.4 Power Saver........................................................................................................................................................- 12 -
2.5.5 Protections ..........................................................................................................................................................- 13 -
2.5.6 Remote Control ..................................................................................................................................................- 14 -
2.5.7 LED Indicator.....................................................................................................................................................- 15 -
2.5.8 Audible Alarm ....................................................................................................................................................- 15 -
2.5.9 FAN Operation ...................................................................................................................................................- 16 -
2.5.10 DIP Switches ....................................................................................................................................................- 16 -
2.5.11 Auto Generator Start.........................................................................................................................................- 18 -
2.5.12 Battery Temperature Sensing............................................................................................................................- 18 -
2.5.13 Other Features ..................................................................................................................................................- 19 -
3 Installation ........................................................................................................................................................................- 19 -
3.1 Unpacking and Inspection .............................................................................................................................................- 19 -
3.2 Installation Location, Tools & Materials .......................................................................................................................- 19 -
3.3 DC Wiring .....................................................................................................................................................................- 20 -
3.4 AC Wiring......................................................................................................................................................................- 22 -
3.5 Grounding......................................................................................................................................................................- 23 -
3.6 Mounting the Inverter....................................................................................................................................................- 25 -
4 Troubleshooting Guide .....................................................................................................................................................- 27 -
5 Limited Warranty..............................................................................................................................................................- 30 -
Appendix 1 - PICOGLF Series Spec Sheet .........................................................................................................................- 32 -
Appendix 2 - Circuit Schematics.........................................................................................................................................- 34 -
Appendix 3 - Installation Diagram ......................................................................................................................................- 36 -
Appendix 4 - Inverter Efficiency.........................................................................................................................................- 38 -
Please record the unit’s model and serial number in case you need to provide this information in the
future. It is much easier to record this information now than try to gather it after the unit has been
installed.
Model Number:
Serial Number:
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1. Important Safety Information
Read this manual before installation, as it contains important safety, installation and operating
instructions. Keep it in a safe place for future reference.
All wiring must follow the National Electric Code, Provincial or other codes in effect at the time
of installation, regardless of suggestions in this manual. All wires should be copper conductors.
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 12" ofclearance around the inverter for airflow. Make sure that the air can
circulate freely around the unit. A minimum air flow of 145CFM is required.
1-1-2. To avoid risk of fire and electronic shock, make sure that existing wiring is in good electrical
condition and that the wire is not undersized. Do not operate the inverter with damaged or substandard
wiring.
1-1-3. This equipment contains components which may produce arcs and/or sparks. To prevent fire and/or
explosion do not install in compartments containing batteries or flammable materials orin a location that
requiresignition protected equipment. This includes any space containing gasoline-powered machinery, fuel
tanks, joints, fittings, or other connection between components of the fuel system.
See Warranty for instructions on obtaining service.
1-1-4. Do not disassemble the inverter. It contains no user-serviceable parts. Attempting to service the
inverter yourself may result inelectrical shock orfire. 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 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.
Installer should ensure that the inverter’s AC output is, at no time, connected to its AC input.
WARNING: LIMITATIONS OF USE
SPECIFICALLY, PLEASE NOTETHAT THE INVERTER/CHARGER SHOULD NOT BEUSED IN
CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES.
WE MAKE NO WARRANTY OR REPRESENTATION IN CONNECTION WITH THEIR PRODUCTS
FOR SUCH USES. USING THE INVERTER/CHARGER WITH THIS PARTICULAR EQUIPMENT IS
AT YOUR OWN RISK.
1.2 Precautions When Working with Batteries
1-2-1. If battery acid contacts skin or clothing immediately wash with soap and water. If acid enters eyes
immediately rinse eyes with running cold water and seek immediate medical attention.
1-2-2. Never smoke or allow a sparks or flames in the vicinity of a battery.
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1-2-3. Do not drop a metal tool on the battery. The resulting spark or short-circuit on thebattery can cause an
explosion.
1-2-4. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
battery. A battery produces a short-circuit current high enough to weld any metal objects and will cause a
severe burn.
1-2-5. To reduce the risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium gel cell,
absorbed mat, orNiCad/NiFe, lithium type rechargeable batteries. Other types ofbatteries mayswell or
burst causing personal injury and damage.
2 Introduction
2.1 General Information
The AIMS Power 3000 watt 50 amp bypass pure sine wave inverter isan inverter, battery charger
andACauto-transfer switch into one device with a peak conversion efficiency of 88%.
It is packed with unique features and it is one of the most advanced inverter chargers on the market today. It
features power factor correction, sophisticated multi-stage charging and pure sine wave output with
unprecedentedly high surge capability to meet demanding power needs of inductive loads without
damaging the equipment.
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 inverter mode. Once the qualified AC power is restored the relay is re-
energized and the load is automatically reconnected to AC bypass mode. The Global LF Series inverter is
equipped with a powerful smart charger. The overload capacity is 300% of continuous output for up to 20
seconds to reliably support tools and equipment.
The inverter can also be set to Battery Priority via a DIP switch. This helps to extract maximum power
from the battery in renewable energy systems such as solar and wind. The Global LF Series Pure Sine Wave
inverter is suitable for Renewable energy systems in work trucks, RV, Marine and Emergency appliances.
To get the most out of the power inverter, it must be operated and maintained properly. Please read the
instructions in this manual before installing and operating
2.2 Application
Power tools–circular saws, drills, grinders, sanders, buffers, weed and hedge trimmers, aircompressors.
Office equipment – computers, printers, monitors, facsimile machines, scanners.
Household items – vacuum cleaners, fans, fluorescent andincandescent lights, shavers, sewing machines.
Kitchen appliances – coffee makers, blenders, ice markers, toasters.
Industrial equipment – metal halide lamp, high – pressure sodium lamp.
Home entertainment electronics – televisions, DVRs, video games, stereos, musical instruments, satellite
equipment.
And much more...
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2.3 Mechanical Drawing
DC Side (Figure 1)
Figure 1
AC Side (Figure 2)
Figure 2
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AC Side (Figure 2-1)
Figure 2-1
Breaker Side (Figure 3)
Figure 3
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Breaker Side (Figure 3-1)
Figure 3-1
2.4 Features
•High surge ability up to 300% of rated power (20 sec)
•Powerful 100 amp battery charger for lead, gel, AGM, NiCAD/NiFe, and lithium
•Bypasses 30A 120Vac and 50A 240Vac
•Low quiescent current, low power “Power Saving Mode” to conserve energy
•Automatic Generator Start
•Battery temperature sensing for increased charging precision
•3-step intelligent battery charger, PFC (Power Factor Correction)
•8 pre-set battery type selector switch plus de-sulphation for totally flat batteries
•Powerful charge rate of up to 100Amps, selectable from 15%-100%
•10 ms typical transfer time between battery andAC, guarantees power continuity
•Optional LCD remote control panel (Part # REMOTELF)
•Automatic ground & neutral bonding with manual disability
•15s delay before transfer when ACresumes, extra protection for loads when used with
generator
•Allows start up and through power with depleted batteries
•Multiple cooling fans
•Extensive protections against various harsh situations
•13VDC battery recovery point, dedicated for renewable energy systems
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2.5.1 Invert
Topology
The Global LF inverter is built according to the following topology.
Invert: Full Bridge Topology.
Charge: Isolated Boost Topology.
It works bi-directionally: in one direction it converts DC power from the battery to AC power (inverter
Mode) and in the other direction it converts external AC power to DC power to charge the batteries (AC
Mode). The same power components are used in both directions, resulting in high-energy transfer efficiency
with fewer components.
Please note that the inverter can only work in one direction at one time (i.e. it can not work as an inverter
andas a charger at the same time).
When operating in invert mode, thedirect current (DC) that enters theinverter from the batteries is filtered
by a large input capacitor and switched “On” and “Off” by the Metal Oxide Silicon Field Effect Transistors
(MOSFET) at a rate of 50 Hz or 60Hz, in this step the DC is converted to low voltage synthesized sine wave
AC using an H-bridge configuration and high frequency PWM (Pulse Width Modulation) technique.It is
then directed intothe transformer which steps the low AC voltage up to 230 or 120 volts.
The unit has a 16bit, 4.9MHZ microprocessor to control the output voltage and frequency as the DC input
voltage and/or output load varies.
Because of high efficiency MOSFETs and the heavy transformers, it outputs PURE SINE WAVE ACwith
an average THD of 10% (min 3%, max 20% under full linear loads) depending on load connected and
battery voltage.
The peak DC to AC conversion efficiency of the Global LF series is 92%.
Don’t parallel the AC output of the inverters to increase power capacity as they have no
stacking functionality.
Overload Capacity
The Global LF series inverters have high overload capacities, making it ideal to handle demanding loads.
1. For 110%<Load<125%(±10%), no audible alarm for 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 1 minute.
3. For 300%≧Load>150%(±10%), beeps 0.5s every 1s and Fault(Turn off) after 20s.
Caution:
After theinverter is switched on, it takes a set time for it to self diagnose and get 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 surgeto start. If multiple loads
are being powered, they should be switched on one by one so that the inverter is not overloaded by the high
starting surge if all the loads are switched on at once.
USE CARE
Turn the charge current control switch gently to avoid breakage due to over-turning.
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2.5.2 AC Charger
The 3000 watt inverter charger isequipped 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, this Global
LF series charger is able to output max current as long as the input AC voltage is in the range of
95-127VAC, and AC freq is in the range of 48-54Hz(58-64Hz for 60Hz model).
It has a very rapid charge current available, and the max charge current can be adjusted from 15%-100% via
a liner switch to theright of thebattery type selector. This will be helpful if you are using our powerful
charger on a small capacity battery bank. The liner switch can effectively reduce the max charging current
to 15% of its peak.
Choosing “0” in the battery type selector will disable the charging function.
There are 3 charging stages:
Bulk Charging: (fast charge LED solid) 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.
Asoftware timerwill measure the time from A/C start until the battery charger reaches 0.3V below the boost
voltage, thentake thistime asT0 and T0×10 = T1.
Absorb Charging: (fast charge LED blinking 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 CV mode
until the T1 timerhas 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: (float charge LED solid) The third charging stage occurs at the end of the Absorb Charging
time. While Float charging, the charge voltage is reduced to the float 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, the charger will restart the above
cycle.
If the charge maintains the float state for 10days, the charger will deliberately reset the cycle to protect the
battery.
Curves in Figure 5 show the current and voltage in the battery charging process.
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Figure 5
De-sulphation
The de-sulphation cycle, switch position 8, is marked in red because this is a very dangerous setting if you
do not know what you are doing. Before attempting to use this cycle you must clearly understand what it
does, when and how you would use it.
What causes sulphation? This can occur with infrequent use of the batteries, or if the batteries have been
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 from taking a charge and thus allow the
plates toclean upandaccept a charge once again.
Battery Type Selector Settings
Switch Position
Description
Boost / Vdc
Float / Vdc
0
Charger Off
1
Gel USA
14.0
13.7
2
AGM 1
14.1
13.4
3
AGM 2
14.6
13.7
4
Sealed lead acid
14.4
13.6
5
Gel EURO
14.4
13.8
6
Open lead acid
14.8
13.3
7
Calcium
15.1
13.6
8
De-sulphation
15.5 (4 Hours then Off)
9
Not used or customized*
Above figures based on 12Vdc models.
*For some customized models, position 9 is programmed with a customized algorithm. Please refer
to the product label or the manufacturer for more information.
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