Cosuper CPT Series User manual

IMPORTANT: SPECIFICALLY, PLEASE NOTE THAT THE GLOBAL LF INVERTER CHARGER SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEM OR
OTHER MEDICAL EQUIPMENT OR DEVICES.
BEFORE USING THE INVERTER, YOU NEED READ AND SAVE THE SAFETY INSTRUCTIONS.
Thank you for purchasing a Cosuper product. Manufactured to a high standard, this product will, if used according to these instructions
and maintained properly, give you years of trouble free performance.
Refer to Instruction
Manual
INSTRUCTIONS FOR:
INVERTER CHARGERS PURE SINE WAVE
12V DC INPUT, 2000 & 3000 WATT
MODEL NO’s: CPT2000, CPT3000
1. SAFETY
CPT series Issue: 1 - 14/12/18


DANGER! - Beware, lead-acid batteries generate explosive gases during normal battery operation.
Wash with soap and water immediately if battery acid contacts skin or clothing. If acid enters eye, flush immediately with cool,clean running
water for at least 15 minutes and seek immediate medical attention.
 DO NOT smoke or allow a spark or flame in the vicinity of the battery or engine.
 If the battery terminals are corroded or dirty, clean them before attaching the leads.


WARNING! To prevent the risk of sparking, short circuit and possible explosion DO NOT drop metal tools in the battery area, or allow them to
touch the battery terminals.
 Before attaching to battery, remove personal metallic items such as rings, bracelets, necklaces and watches. A lead acid battery can produce
a short-circuit current which is high enough to weld such items and cause severe burns.
DO NOT expose inverter to rain, snow, spray, bilge or dust. DO NOT cover or obstruct ventilations.
2. INTRODUCTION
This pure sine wave inverter charger is the combination of inverter, battery charger and AC autotranser switch. This complete system with a peak
Power tools- circular saws, drills, grinders, sanders, buffers, weed and hedge trimmers, air compressor and etc.
Office equipment- computers, printers, monitors, facsimile machines, scanners and etc.
Household appliances- vacuum, fans, lights, TV, refrigerator, microwave, coffee machine, toaster, blender and etc.
Industrial equipment- metal halide lamp, high pressure sodium lamp and etc.
NOTE, The inverter working time with full loads cannot over 60 minutes.
conversion efficiency of 88%.
CPT is a inverter charger with backup UPS function. When utility AC power cuts off, the transfer relay is de-enegizered and the load is transferred
to inverter ouput. Once the qualified AC utility power is restored, the relay will be energized and the load is automatically reconnected to AC utility.
This inverter charger unit is easily customized to battery priority via a DIP switch which helps extract maximum power from battery in renewable
energy systems. Therefore this inverter charger is suitable for renewable energy system, RV, marnine and emergency appliances.
3. SPECIFICATION
>>Battery
>>General Information
>>Applications
>>Model Information
>>Inverter/Charger



MAKE SURE at least 10CM of clearance on DC terminal side and rear heat dissipation side, and 3CM of clearance on body side for air flow.
MAKE SURE existing wiring is in good electrical condition. DO NOT operate inverter charger with damaged or substandard wiring.
DO NOT install in compartments containing batteries or flammable materials or in locations which require ignition protected equipment.
DO NOT disassemble this inverter charger. Internal capacitors remain charged after all power is disconnected. Attempting to service this
inverter charger by yourself may cause electrical shock or fire.
WARNING! Disconnect both AC and DC power from the inverter charger before any maintenance. Turning off controls will not reduce risk.
DANGER! The output side of inverter’s AC wiring at no time be no connected to public power or a generator. Beware the wiring connection.


Typical part number ►
COSUPER inverter charger
Power range
2000=2000W
3000=3000W
Rated AC input& Output voltage
1=120VAC
DC range
12=12V

CPT series Issue: 2 - 14/12/18
Electrical Performance
SEALED LEAD ACID BATTERY CHARGING PROCESS LiFePO4 BATTERY CHARGING PROCESS
Topology
Inverter: Full bridge topology
Charger: Isolate boost topology
Because of high efficiency MOSFETS and 16bit, 4.9MHZ microprocessor and heavy transformer, it outputs PURE SINE WAVE AC with an average
THD of 15%(Min 5%, Max 25%) depending of load connected and battery voltage. Peak efficiency is 88%.
AC Charger
CPT inverter charger is equipped with an active PFC(Power Factor Corrected) multistage battery charger. The PFC 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.
Inverter charger is able to output max current as long as input AC voltage is in the range of 95-127VAC, and AC frequence is in range of 58-64Hz.
Before attempting to use ‘8’ position to do De-sulphation cycle you must clearly understand what it does, when and how you would use it.
De-sulphation can occur with infrequent use of batteries(nor), or if the batteries have been left discharged so low that they will not accept a charge.
This high voltage charge cycle is designed to tbreak down the sulphated crust that is preventing the plates taking a charge and allow the plates to
clean up and to accept charge once again.
*De-sulphation
CPT inverter charger allows start up only with utility power and power the depleted batteries.
For 12VDC battery bank, after battery voltage goes below 10V, if inverter charger is still working and battery voltage remain higher than 2 Vdc, then
inverter charger is able to charge the batteries once qualified AC inputs.
In DC priority model, the charging can be activated by restart inverter charger unit(turn off then turn on) manually before the battery voltage goes
down below 9Vdc.
CPT inverter charger unit allows adjust charge current manually by the switch on the top of inverter. Please note the pointer is between two grooves.
NEVER reverse the pointer back over 0% position(as the silver point indicate) or switch over 100% position.
Charge Current
14.4V
13.8V
12.8V
Charge at rated
constant current
Stay at
13.5-13.8V
Maintain battery
in 100% charge
Rated voltage charge until current
drops to 6.5% rated current
CURRENT
BULK CHARGE ABSORPTION FLOAT CHARGE RESET TO BULK CHG
VOLTAGE
CHARGING SPEC
* Charge hours will be a little changed accroding to different battery type and capacity
Battery selector
* Battery selector is operational only in AC priority
Switch setting 0 1 2 3 4 5 6 7 8 9
Battery type Gel USA AGM 1 AGM 2 Sealed lead acid Gel EURO Open Lead acid Calcium De-sulphation LiFePO4
Boost (Vdc) 14.0 14.1 14.6 14.4 14.4 14.8 15.1 13.6
Float (Vdc) 13.7 13.4 13.7 13.6 13.8 13.3 13.6 /
15.5
4 hours off
Charge off
Bypass only
model MAX Currents MAX Currentsmodel
3000W 12V 120V
2000W 12V 120V 50 ± 5 Amps 75 ± 5 Amps
14.4V
13.8V
Charge at constant current
& rising voltage Maintain battery in 100% charge
CURRENT
CONSTANT CHARGE
VOLTAGE
CHARGING SPEC

CPT series Issue: 3 - 14/12/18
Switch NO. Switch Fcuntion Position: 0 Position: 1
SW1: No Definition
SW2: Output frequence 50Hz 60Hz
SW3: AC output 120V (230V) 110V (220V)
SW4: DC/ AC priority AC DC
Automatic and uninterruptible transfer
In the case of a utility power failure or when the generating set is switched off, the CPT will switch over to inverter operation and take over the
supply of the connected devices. This is operated rapidly that operation of computers and other electronic devices are not disturbed (Uninterruptible
Power Supply or UPS functionality). This makes inverter highly suitable as an emergency power system in industrial and telecommunication
applications. This internal transfer switch is designed for heavy use when input utility supply is unstable.
PLEASE DO NOT MAKE ANY MODIFICATION ON THIS SWITCH WITHOUT AUTHORIZATION! FREQUENCY CHANGE CAUSES DANGER!
Default setting: SW2 - 1; SW3 - 1; SW4 - 0
DIP Switch
L.E.D Indicator
‘INV Mode’ green LED lit, buzzer beeps 0.5s every 5s
‘INV Mode’ green LED lit, buzzer beeps 0.5s every 1s and fault after 60s
Heat sink temp. ≥105℃, ‘Over Temp’ red LED lit, beeps 0.5s every 1s
(1) 110%<load<125%(±10%), no audible alarm in 14 mintues. Beeps 0.5s every 1s in 15th
minute and fault after 60s
(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
● Battery voltage low
● Battery voltage high
● Invert mode overload
● Over temperature
Audible alarm
AC Mode
● Utility power input
● CPT in fast charging
● CPT bypass AC to
connected loads
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
AC Mode
● Utility power input
● CPT in float charging
● CPT bypass AC to
connected loads
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
AC Mode
● Utility power input
● CPT in float charging
● CPT bypass AC to
connected loads
● Overload
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
DC Mode
● Battery power input
● CPT in inverting
DC Mode
● Battery power input
● CPT in inverting
● Over temperature
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
AC Mode
● Utility power input
● CPT in float charging
● CPT bypass AC to
connected loads
● Over temperature
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
AC Mode, fast chg blink
● Utility power input
● Fast charge is coming
to end
● CPT bypass AC to
connected loads
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector
DC Mode
● Battery power input
● CPT in inverting
● Overload
Line Mode
INV Mode
Fast CHG
Float CHG
Over Temp
Over Load
Save On
Battery Selector

CPT series Issue: 4 - 14/12/18
3. INSTALLATION
Auto gen start
Condition Enter condition Leave condition Speed
Heat sink temperature T< 85℃50%
T≥ 85℃100%
Charge current I≤ 50% MAX 50%
I> 50% MAX 100%
Load percantage
(INV Mode)
Load< 50% 50%
Load≥ 50%
T≥85℃
T< 80℃
I> 50% MAX
I≤ 40% MAX
Load≥ 50%
Load≤ 40% 100%
Battery goes to low voltage level and not be able to keep continuous output, inverter will alarm and send the boost signal to start the back generator.
And turen generator off after battery voltage recovers to rated level. Auto gen start only works with generators designed to work with this feature.
Getting Started
When a motorized appliance or a tool turns on, there is an initial surge of power to start. This surge of power is referred to as the "starting load" or
"peak load." Once started, the tool or appliance requires less power to operate. This is referred to as the "continuous load" in terms of power
requirements. You will need to determine how much power your tool or appliance requires to start up (starting load) and its continued running power
requirements (continuous load).
Power consumption is rated in watts, or it can be calculated from amperes (amps). This information is usually stamped or printed on most
appliances and equipment. If this information is not indicated on the appliance or equipment, check the owner's manual.
Multiply: AC AMPS X 110 (AC voltage) = WATTS
* This formula yields a close approximation of the continuous load of your appliance.
Multiply: WATTS X 1.5 = Starting Load
* This formula yields a close approximation of the starting load of most appliances. Exceptions are motorized appliances such as pumps, freezers and air conditioners. These appliances can have
startup loads of up to three to eight times the rated watts.
Determining the DC Power Requirement
Powering multiple appliances from the high-power CPT series inverter requires a 12 volt bank of batteries (several batteries). To calculate the a
pproximate power in amps a 12 volt battery bank has to supply you need. To know the current, or amps required for powering the continuous
AC load, a shortcut method is to divide the continuous AC load wattage by 12. For example, the continuous AC load is 1500 watts. The current (amps)
is: 1500/12 or 125 amps at 12 VDC.
Sizing the Battery Bank
To determine the minimum battery bank ampere-hour rating that you will need to operate appliances from the inverter, and any DC appliances
powered by the battery bank, follow these steps:
1. List the maximum wattage that the inverter has to provide (as above).
2. Estimate the number of hours the appliances will be in use between battery recharges. This will differ depending on appliances. As an example,
a typical home-use coffeemaker draws 500 watts during its brew time of 5 minutes; it maintains the temperature of the pot at about 100 watts.
Typical use of a microwave oven is only for a few minutes. Some longer operating time appliances are lamps, TVs, computers and refrigerator /
freezers.
3. Determine the total watt-hours of energy needed. Then multiply the average power consumption in watts by the number of hours of run time.
For example: 1500 watts for 10 hours = 15,000 watt hours. Using the 1500 watts (or 150 Amps) for 10 hours example as above, then 150 amps is
needed for 10 hours. This provides us with the basic amp-hours (AH) of battery that is required. Ten hours at 150 amps equals 1500 Amp Hours (AH).
This answer is just a beginning because there are other conditions that determine actual run time.
These include:
• AC appliance load and time in use (basic Amp Hour)
• Cable gauge and length (cable losses)
• Charge level of the batteries (between use, chargers have to be able to fully charge the batteries)
• Temperature of the batteries (colder batteries provide fewer amps)
• Age and condition of the batteries (older batteries lose capacity/amp hours)
• Compliance with turning off unnecessary AC and DC loads.If there is any doubt about sizing the battery bank, it is safe to overestimate the amp
hour requirements of the battery bank.
Note:
The type of batteries you use to power your high power inverter is important. Operating a high-power inverter will routinely discharge batteries and
they will require frequent recharging. Batteries used to start engines are not designed to repeatedly charge and discharge. KS recommends using
“deepcycle” or “marine” rated batteries.
Cable Gauges
When connecting the inverter to a battery bank use the thickest stranded insulated copper wire available, in the shortest length practical.
Recommended cable gauges are as follows:
Fan operation
CPT2000 and CPT3000, each model has one multiple controlled DC fan which starts working arrcoding to following logic.

CPT series Issue: 5 - 14/12/18
CPT inverter charger gives two different remote controllers by communication ports RJ45. Remote controller and inverter charger switch work in
parallel, inverter charger can be controlled by only one side. Never cut the communication cable during inverter working even if inverter is turned off.
It will damage the remote PCB inside if the cable is short circuited during cutting.
*Remote Controller
Preview of CPT Series Inverter
model DC Wire Gage DC Wire Gagemodel
3000W 12V 120V AWG 4/0
2000W 12V 120V AWG 1/0
WARNING:
DANGER OF BATTERY EXPLOSION – INSTALL A FUSE
Battery banks can deliver very high levels of current that can vaporize metal, start fires and cause explosions. It is recommended installing ANL
type fuse and fuse holder close to the positive battery bank terminal. This fuse protects the batteries from accidental DC cable shorts, which can
cause batteries to explode. ANL fuses and fuse holders are available at most marine supply stores
NOTE: Sparking is normal for the first connection. Make sure you have good secure connections – But do not over-tighten.
CR10
ON OFF
INVERTER
ALARM
REMOTE PANEL
AC CHARGER
DC input terminal
SW1
SW2
SW3
SW4
①
①AC input protection restoration
⑥
AC output protection restoration
⑦
AC input port
⑧
AC output port
⑨
GND terminal
Auto gen start terminal
⑩
RJ11 remote port for CR10
②
RJ45 remote port for PTM-12
③
TCP/IP(optional) port
④
DIP switch
⑤
②
③
④
⑥
⑤
⑦
⑧
⑨
⑩
GFCI
PTM-12
System Overview
Input AC
Alarm: NO
Fault : NO
Output AC
Output Freq
Work mode Inverter
Output Load

CPT series Issue: 6 - 14/12/18
4. INDICATE & ALARM
5. TROUBLE SHOOTING
Audible Alarm
ON
ON
ON beep 0.5 s
every 5 s
beep 0.5 s
every 5 s
beep 0.5 s
every 5 s
beep 0.5 s
every 5 s
beep 0.5 s
every 5 s
beep 0.5 s
every 5 s
beep
continuous
beep
continuous
beep
continuous
beep
continuous
beep
continuous
ON
ON
ON
ON
ON
ON
blink
blink
ON ON
ON
ON
ON
ON
ON ON
ON
ON
ON
ON
ON
ON
ON
ON
Line Mode Inverter AC charger FaultINV ModeFast CHGFloat CHGOver Temp
Over Load
Save On
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ONONON
ONON
ON
Charge
Function
Alarms
Fault
Mode
Inverter
Symptom Possible cause Solution suggested
Inverter will not turn on during initial
power up
Batteries are not connected; loose battery-
-side connections or low battery voltage
Check batteries and cable connection.
Check DC fuse and breaker; Charge Battery
Press the switch to ON position
Check battery condition and recharge if
possible
Check AC voltage for proper voltage and
frequency
Refer to section on adjusting the “charge
rate”; Source qualified AC power;
Check all DC/ AC connections
Load generator down with a heavy load;
Turn generator output voltage down
Inverter has been manually transitioned to
OFF mode
Low battery voltage and low capacity level
AC voltage drops out of inverter charger
AC input range
Charger controls are improperly yet. Low AC
input voltage; Loose battery or AC input
connection
High AC input voltage from the generator
Applying specific loads such as electrical
heater
Remove the loads
NO AC output voltage and no indicator
lights ON
AC output voltage is low and inverter turn
loads OFF in a short time
Charger is inoperative and unit will not
accept AC
Charger is supplying a lower charge rate
Charger turns OFF while charging from
a generator
*Noise from transformer/case
Connecting Inverter
1. Prepare all cable ends with cable lugs.
2. Install a circuit breaker or high current fuse and fuse holder in the positive line as close to the battery as possible.
3. Make sure the inverter On/Off switch is turned OFF.
4. Connect the cables to the DC input terminals on the rear of the inverter. The red terminal is positive (+) and the black terminal is negative (-).
a. Connect the positive cable to the inverter and battery positive terminals.
b. Connect the negative cable to the inverter and battery negative terminals.
e. Connect an insulated wired from the chassis-ground terminal at the front panel of the inverter to the vehicle’s chassis or any other ground point.
Mounting Instructions
Your CPT series Inverter should not be mounted under the hood of a vehicle.
If installing in a vehicle, choose a dry, cool, ventilated area closest to the battery as practical. Before drilling any mounting holes, make sure that
there are no wires, fuel lines, or tanks directly behind the surface to be drilled. To mount the inverter:
1. Inverter must be OFF.
2. The inverter should be mounted horizontally.
3. Position the inverter against the mounting surface and mark locations of the mounting screw openings.
4. Remove the inverter and drill four mounting holes.
5. Fasten the inverter to the mounting surface using corrosion-resistant fasteners sized #10 or larger.
Operation
1. Turn On the inverter.
2. Turn OFF the inverter.
3. When you have confirmed that the appliance to be operated is turned off, connect AC output to the distribution panel and to appliances.
4. Turn ON the inverter.
5. Turn the appliance on.
6. Plug in additional appliances and turn them on.

CPT series Issue: 7 - 14/12/18
FAQ
Q. Why does the inverter turn itself off?
A. If the inverter’s audible alarm sounds and a fault L.E.D illuminates, this indicates that there is a fault or error, and the inverter may turn off. Most
commonly this would be caused by an appliance that is drawing too much power (overloading), low battery voltage or voltage drop due to
insufficient size cables or poor connections.
Q. The Inverter will not run my appliance even though the appliance draws less power (Watts) than the size of the inverter?
A. Electrical appliances can be divided into three groups by the way they draw energy (current) from their power supply. These groups are
“Resistive”, “Inductive” and “Capacitive” appliances or also called “loads”. Some appliances may draw all three types of power.
Resistive Loads such as normal incandescent lights (wire filament) always draw a constant power (watts) from the power supply, that is a 100 Watt
light will draw approximately 100 Watts from the power supply at all times. Resistive loads are the easiest appliances for an inverter to run.
Inductive Loads such as a refrigerator (Electric Motor) require a large rush of power (surge current) to start and then usually draw a more constant
power once running. Inductive loads contain coils of wire (motors, transformers, ballasts, solenoids). When the power is first turned on,these coils of
wire draw a large surge current which forms the magnetic flux (magnetic field) which allows these appliances to work. This magnetic flux is a kind of
stored energy.
The most common inductive appliances are: fridges, air compressors, transformers/ chargers, pumps, power tools and fluorescent lights. These
appliances may draw up to 10 times their normal running power to start up; that is to run a 80W fridge you may need a 600 or 1000 Watt inverter.
Capacitive Loads such as many TV’s or many electronic appliances require a large surge current to start only when they have not been used for a
while. This is often due to large capacitors in the power supply that must be quickly charged when the appliance is turned on. If the appliance is not
used for a few days these capacitors slowly go flat. Resetting the inverter a couple of times may allow these appliances to work.
Q. Why does it damage the inverter if the battery leads are reverse-connected?
A. Your inverter uses sophisticated electronics to convert DC battery power to AC mains power. If you accidentally connect the inverter to the
battery incorrectly (reverse polarity) a large current will be drawn by the inverter which will blow the protection fuse. As this occurs some of the high
current could damage sensitive electronic components. Because of this risk it is important to always double-check the battery polarity before making
any connections.
Q. How do I check or change the fuses?
A. CPT inverters contain internal fuses and should only be checked or replaced by a qualified electrical appliance repairer.
THE DC SUPPLY MUST BE DISCONNECTED BEFORE ANY REPAIR, THEN TURN THE ON/OFF SWITCH OF THE INVERTER “ON” TO
DISCHARGE THE CAPACITORS.
Q. Can I run laptop computers and other sensitive electrical appliances?
A. Yes. CPT pure sine wave output is suitable for medical equipment and sensitive electrical appliances. They allow you to watch television
without static, operate computers and gaming consoles and run fluorescent lights.
When in inverter mode sometimes the transformer and/ or case may vibrate and makes noise.
*If the noise is created by transformer;
This mainly caused by HALF BRIDGE LOAD, the load uses only half cycle of power (figure 1). This tends to cause an imbalance of magnetic
field of transformer, reducing its rated working freq from 20KHz to 15KHz(it varies according to different loads). In such a case the frequency
of noise falls exactly into the range 200Hz to 20KHz that human ear can hear.
The most common load of such kind is electrical heater and hair drier.
*If the noise is created by case;
Normally when loaded with inductive loads, the magnetic field generated by transformer keeps attracting or releasing the steel case at a speific
freq, this may also cause noise.
Reducing 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.
Figure 1
*Reason for noise from transformer/case
Full bridge
U
T
Half bridge
U
T

KS series Issue: 8 - 14/12/18
CPT2000 CPT3000
2000W 3000W
6000W 9000W
40W 80W
110VAC 86% 86%
110VAC 50±5 A 75±5 A
30A 40A
17/ 37 20/ 44
AC Charger/Bypass
Control & Signal
General Speci cation
E ciency
Power Input/Output
Output power
Surge ower
Output voltage
Output frequency
Waveform
DC input voltage
DC voltage range
AC input range
AC input frequency
DC output voltage
Charge current
Over charge protection
LED indicator
Dip switch
Network function
Battery type
Dry contact terminal
Pure sine wave ( THD<3% )
Idle consumption
(Fully loaded)
90-135 VAC
Weight(Kg/Ib)
Dimension(mm/in)
Safety
EMC
Operating / Storage temp
Woking humidity
100/110/120 VAC±5%;
50/60 HZ ± 0.5%
Transfer time
Input waveform
MAX bypass current
Remote control(optional)
Charge current; Output frequency; AC output voltage; DC/ AC priority
50/60 HZ ± 0.5%
Bulk( 13.0-14.9V ); Absorption( 14.9-15.1V ); Float charge( 13.3-13.8V )
12 VDC
10.5-16.0 VDC
15.7 VDC
< 10 ms
Pure sine wave ( Utility power or generator )
7-led for working mode
PTM-12; CR10
-20- 50 ℃/ -30- 70 ℃
Stand-alone, or TCP/ IP optional
Lithium, Gel, AGM, Wet or customized
By relay
UL458: 2015 Ed.6; CSA C22.2
FCC part15 Class A
-20- 90% RH
455*250*185/
18*10*7
6. SPECIFICATION

CPT series Issue: 9 - 14/12/18
7. DIMENSION
2000-3000W