Cotek S1500-112 User manual

S1500 Series
Pure Sine Wave Inverter
User’s Manual

Table of contents
1. Important Safety Information.……………………………………………… 1
1-1 General Safety Precautions…………………………………………… 1
1-2 Batteries Precautions………………………………………………….. 1
2. Features………………………………………………………………………... 2
2-1 Applications.……………………………………………………………. 2
2-2 Electrical Performance………………………………………………… 3
2-3 Rear Panel Operation………………………………………………….. 4
3. Instructions………………………………………………….………………… 5
3-1 Front Panel Operation..………………………………………………... 5~7
3-2 Rear Panel Operation..………………………………………………… 8~9
3-3 Installation………………………………………………………………. 9
3-4 Quick Hook – up and testing.………………………………………... 10
3-5 AC Safety Grounding………………………………………………….. 11~12
3-6 DC Wiring Connections…………………….…………………………. 13
3-7 Inverter Operation……………………………………………………… 14~15
3-8 Power Output…………………………………………………………… 16
4. Troubleshooting……….……………………………………………………… 17
5. Maintenance…………………………………………………………………… 18
6. Warranty……………………………………………………………………….. 18
7. Appendices A…………………………………………………………………. 19
7-1 Dip Switch (110V)………………………………….…………………... 19
7-2 Dip Switch (220V)……………………………………………………… 19
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©Copyright ：This manual is the copyright of COTEK Electronic lnd. Co., Ltd. And may not be reproduced or copied
without the express permission of the owner.

Table of contents
8. Appendices B…………………………………………………………………. 20
8-1 Operation of RS232 serial port……………………………………….. 20
8-2 Interface Command………………………………………………….. 21~24
9. Appendices C………………….……………………………………………… 25
9-1 Remote Control Operation……...…………………………………… 25~26
9-2 Power Saving Mode...……………………………………………….. 27~29
10. Appendices…………………………………………………………………… 30
10-1 FCC (Class B) Declaration of Conformity…………………………... 30
10-2 CE (EMC EN55022B) Declaration of Conformity……………...…… 31
10-3 CE (LVD EN609050-1) Declaration of Conformity…………………. 32
10-4 e-mark (e13 020932) Declaration of Conformity…………………… 33
10-5 UL (UL458) Declaration of Completion………………….………….. 34
©Copyright ：This manual is the copyright of COTEK Electronic lnd. Co., Ltd. And may not be reproduced or copied
without the express permission of the owner.

1. Important Safety Information
WARNING!
Before installing and using the Inverter, you need to read
these safety instructions carefully.
1-1. General Safety Precautions
1-1-1. Do not expose the Inverter to water, mist, snow, or dust. To reduce
the risk of hazard, do not cover or obstruct the ventilation shaft.
Do not install the Inverter in a zero-clearance compartment.
Overheating may occur.
1-1-2. To avoid the risk of fire and electronic shock, make sure that existing
wiring is in good electrical condition and not undersize.
Do not operate the Inverter with damaged or substandard Wiring.
1-1-3. There are some components in the inverter can cause arcs and sparks.
To prevent from fire or explosion, do not put batteries, flammable
materials, or anything should be ignition–protected around the inverter.
1-2. Precautions When Working with Batteries
1-2-1. If battery acid contact your skin or clothing, you need to wash it out
immediately with soap and water. If acid enters into your eyes,
immediately flush your eyes with running cold water for at least 20
minutes and get medical attention immediately.
1-2-2. Never smoke or make a spark or flame in the vicinity of batteries or
Engines.
1-2-3. Do not drop a metal tools on the battery. The resulting spark or short-
circuit on the battery or other electrical parts 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 may produce a short-circuit current who’s
temperature is high enough to weld these metal items and cause a
severe burn.
1

2. Features
Pure sine wave output (THD < 3%)
Output frequency：50 / 60Hz switch selections
Low power “Power Saving Mode” to conserve energy
RS-232C interface / remote controls port
Built – in Voltage and watt meter
Thermostatically controlled cooling fan
Advanced microprocessor
Protection：Input low voltage Overload Short circuit
Low battery alarm Input over voltage Over temperature
2-1. Application
2-1-1. Power tools – circular saws, drills, grinders, sanders, buffers, weed and
hedge trimmers, air compressors, etc.
2-1-2. Office equipment – computers, printers, monitors, facsimile machines,
and scanners, etc.
2-1-3. Household appliances – vacuum cleaners, fans, fluorescent and
incandescent lights, shavers, sewing machines, etc.
2-1-4. Kitchen appliances – microwave ovens, refrigerators and freezers,
coffee makers, blenders, ice makers, toasters, etc.
2-1-5. Industrial equipment – metal halide lamp, high – pressure sodium lamp,
etc.
2-1-6. Home entertainment electronics – television, VCRs, video games,
stereos, musical instruments, satellite equipment, etc.
2

2-2. Electrical Performance
Specification Model No.
Item S1500-112 S1500-124 S1500-148 S1500-212 S1500-224 S1500-248
Continuous Output Power 1500W
Surge Rating 2000W
Input voltage 12V 24V 48V 12V 24V 48V
100 / 110 / 115 / 120V ± 3% 200 / 220 / 230 / 240V ± 3%
Output Voltage
Frequency 50 / 60Hz ± 0.05%
(Switch Selections)
Peak Output Current 25A 11A
Efficiency (full load) 85% 87% 88% 86% 89% 90%
No Load Current Draw ≦1.5W Saving Mode
Output Waveform Sine Wave <3% THD
100 / 110 / 115 / 120V RMS 200 / 220 / 230 / 240V RMS
Output voltage Regulation -10% / + 4% -10% / + 4%
10-16 20-32 42-62 10-16 20-32 42-62
Input Voltage Regulation VDC VDC VDC VDC VDC VDC
Overload, Short Circuit, Reverse Polarity (Fuse), Over/Under
Input Voltage, Over Temperature.
Protection
Power Saving Recovery Time 5 Second
Interface Control Port RS-232C With Baud Rate 1200,2400,4800 (Switch Selectable)
Remote Control Unit CR-5 Optional
Safety Certification UL458 EN60950-1
EN50081-1:1992
EN50082-1:1992 e-mark
EN55022B:1994
EMC FCC Class B EN61000-4-2:1995 e13 020932
EN61000-4-3:1996
ENV50204:1995
Operating Temperature Range 0 – 40℃
Storage Temperature Range -30℃to 70℃
Cooling Thermostatically controlled cooling fan (55℃ON, 45℃OFF)
Dimensions 390(L) x 275(W) x 105(H) mm / 15.4(L) x 10.8(W) x 4.1(H) Inch
Weight 7.0 kgs. / 15.5 Lbs.
Note: The specifications are subject to change without notice. 3

2-3. Mechanical Drawing
4

3. Instructions
This power inverter series is one of the most advanced line of mobile AC power
systems.
To get the most effective power inverter, it must be installed and used properly.
Please read the instructions of this manual before you install and operate this
model.
3-1. Front Panel Operation：
3-1-1. Front view：
3-1-2. ON / OFF switch：
Leave the power ON/OFF switch in the OFF position during installation.
3-1-3. Input Level：Display Input Voltage
The battery voltage bar graph indicates the voltage at the input
terminals of the power inverter. The voltage is very close to the
battery voltage at low input current. The voltage will be lower than the
battery voltage at high input current because the voltage drops across
the cable and connections. Ideally, the voltage should remain in the
green areas of the bar graph. If the voltage goes into the red area at
the top and bottom of the graph, the inverter may shutdown.
5

3-1-4. Battery Voltage indicator：
The AC load watt bar graph indicates the power drawn from the power
inverter by the load. For the long-term operation of the watt indicator,
it should remind in the green & orange area of the bar graph.
The short-term operation of the watt indicator may be in the red area.
If the value of the watt indicator increases highly, the bar will flash and
the inverter will shutdown to protect itself.
3-1-5. OVP (Over Voltage Protection indicator)：
The over voltage indicator indicates that the power inverter has shut
itself down because its input voltage exceeded 12 / 24 / 48VDC
version.
3-1-6. UVP：Under Voltage Protection indicator：
The under voltage indicator indicates that the power inverter has shut
itself down because its input voltage fell below 12 / 24 / 48VDC.
3-1-7. OTP：Over Temperature Protection indicator：
The over temp indicator indicates that the power inverter has shut itself
down because its temp has become overheated. The power inverter
may overheat because it has been operated at power levels above its
rating, or because it has been installed in a location which does not
allow it to dissipate heat properly. The power inverter will restart
automatically, once it has cooled off.
3-1-8. OLP：Over Load Protection indicator：
The overload indicator indicates that the power inverter has shut down
automatically because its output has been short-circuited or drastically
overloaded.
Switch OFF the power, correct the fault, and then switch the power
back ON to reset the unit.
3-1-9. Power Saving：
See appendix 9-2 for detailed information.
6

3-1-10. AC Outlet (Outlet sockets are available for the following countries)：
North America (GFCI) North America (NEMA 5-15R)
Continental European (SCHUKO) Australia / New Zealand
Universal
United Kingdom
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3-.2 Rear Panel Operation：
3-2-1. Ventilation Shafts：
Be sure to keep it a distance (at least 3 inch) from surrounding things.
3-2-2. DC Terminals:
Connect DC input terminal to 12V / 24V / 48V battery or the other
power sources.
【＋】represents positive, and【－】represents negative. Reverse
polarity connection will blow the internal fuse and may damage the
inverter permanently.
Model voltage Min voltage Max. voltage
S1500-112 10.0 VDC 16.0 VDC
S1500-212
S1500-124 20.0 VDC 32.0 VDC
S1500-224
S1500-148 42.0 VDC 62.0 VDC
S1500-248
WARNING!
Do not connect the 12V model with 24V batteries or
the unit will be destroyed immediately.
8

3-2-3. RS-232C：
Connect to remote control unit (option accessory) or taken remote
controlled working status by computer.
3-2-4. Use wire #8 AWG to connects Chassis ground with Vehicle Chassis.
WARNING!
Operating the inverter without a proper ground
connection may cause an electrical safety hazard.
3-3. Protection Feature
DC Input
Over voltage Under Voltage
Over
Temperature
ProtectionModel Shut-
down Restart
Under
Voltage
Alarm Shut-
down Restart Shut- down Restart
S1500-112 16.7VDC 15.2VDC 10.2VDC 9.5VDC 12.6VDC
S1500-212
S1500-124 33.4VDC 30.4VDC 20.4VDC 19.0VDC 25.2VDC
S1500-224 85℃45℃
S1500-148 63.0VDC 61.8VDC 41.6VDC 42.0VDC 40.0VDC
S1500-248
9

3-4. Installation：
Where to install. The power inverter should be installed in a location that
meets the following requirements：
3-4-1. Dry －Do not expose the inverter to water.
3-4-2. Cool －The ambient temperature should be as cool as possible
between 0℃and 40℃.
3-4-3. Safe －Do not install batteries with flammable fumes close by.
3-4-4. Ventilated －Be sure to keep the inverter a distance (at least 2 to 3
inch) from surrounding things. Ensure the ventilation shafts located on
the rear and bottom side of the case are not obstructed.
3-4-5. Dust-free －Do not install the Inverter in a dusty environment. The
inverter can inhale the dust when the fan is working.
3-4-6. Close to batteries －Avoid excessive cable lengths. Do not install the
Inverter in the same compartment as batteries.
Use the recommended wire lengths and sizes (see section 2-10).
Do not mount the inverter where it will be exposed to the gases
produced by the battery.
These gases are very corrosive and prolonged exposure will also
damage the Inverter.
WARNING!
A spark may occur when you make this connection
since the current may flow to charge capacitors in the
power inverter.
Do not make this connection with Flammable fumes
close by. Explosion or fire may occur.
10

3-5. DC Wiring Connections：
The following procedure is for connections between the battery cables and
the DC input terminals on the Inverter. The cables should be high quality
copper wiring and keep cable length as short as possible. The maximum
length is 6 feet that is enough to handle the current, which is required by the
electrical code or regulations.
Cables that are not an adequate gauge (too narrow) or too long will
deteriorate inverter performance such as poor surge capability and frequent
low-input voltage warnings and shutdowns. The low input voltage warnings
are due to DC voltage drop across the cables from the inverter to the
batteries.
The longer or narrower the cables, the greater the voltage drop.
Increasing your DC cable size helps improve the situation.
Model No Wire AWG Inline Fuse
S1500-112 # 2 200A
S1500-212 # 2 200A
S1500-124 # 4 130A
S1500-224 # 4 130A
S1500-148 # 6 50A
S1500-248 # 6 50A
WARNING!
The installation of a fuse must be on positive cable.
Failure to place a fuse on “+” cables running between
the inverter and the battery may cause damage to the
inverter and will void warranty.
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The cables should be high quality copper wiring and keep cable length as
short as possible (a maximum of 3-6 feet).
S1500
INLINE FUSE
BATTERY
-+
12

3-6. AC Safety Grounding：
During the AC wiring installation, AC input and output ground wires are
connected to the inverter. The AC input ground wire must be connected to
the incoming ground from AC utility source.
The AC output ground wire should go to the grounding point for your loads
( for example, a distribution panel ground bus ).
Ground Fault Circuit Interrupters (GFCI)：
Installations in Recreational Vehicles (for North American approvals) will
require GFCI protection of all branch circuit connected to the AC output of
the hardwire terminal equipped with Inverter. In addition, electrical codes
require GFCI protection of certain receptacles in residential installations.
While the pure sine wave output of the Inverter is equivalent to the
waveform provided by utilities, compliance with UL standards requires us to
test and recommend specific GFCI.
Cotek has tested the following GFCI – protected 20A receptacles and found
that they functioned properly when connected to the output of the Inverter.
3-6-1. Neutral Grounding (GFCI’S)：
3-6-1-1. 120V models：The neutral conductor of the AC output circuit
of the Inverter is automatically connected to the safety ground
during inverter operation. This conforms to National
Electrical Code requirements that separately derived from AC
sources (such as inverters and generators) which have their
neutral conductors tied to ground in the same way as the
neutral conductors from the utility tied to ground at the AC
breaker panel. For models configured with a transfer relay,
while AC utility power is present and the Inverter is in bypass
mode, this connection (the neutral of the Inverter’s AC output
to input safety ground) is not present so that the utility neutral
is only connected to ground at your breaker panel, as required.
3-6-1-2. 230V models：There is no connection made inside the
inverter from either the line or neutral conductor to safety
ground.
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3-7. Inverter Operation：
To operate the power inverter, use the ON / OFF switch on the Front panel to
turn the power on. Then the power inverter is ready to deliver AC power to
the loads.
If you are operating several loads from the power inverter, turn them on
separately after the inverter is on.
This will ensure that the power inverter does not have to deliver the starting
currents for all the loads at one time.
3-7-1. To check its performance, unpack and inspect the power inverter when
the switch is OFF.
3-7-2. Connect the cables to the power input terminals on the rear panel of
power inverter. The red terminal represents positive (+) and black
terminal represents negative (-). Insert the cables into the terminals
and clamp the nuts and the wires securely.
WARNING!
Ensure all the DC connections are tight (torque to 9-10
ft-lbs, 11.7-13Nm). Loose connections will overheat
and could cause a potential hazard.
3-7-3. Before proceeding further, carefully check the cable you have
connected does tie negative terminal of inverter to the negative output
power source.
WARNING!
Reverse polarity connection will blow a fuse in the
inverter and may permanently damage the inverter.
Damage caused by reverse polarity connection is not
covered by warranty.
3-7-4. Connect the cable from the negative terminal of the inverter to the
negative terminal of the power source. Make a secure connection.
14

WARNING!
You may observe a spark when you make this
connection since current may flow to charge
capacitors in the power inverter.
Do not make this connection with flammable fumes
close by. Explosion or fire may occur.
3-7-5. Set the power switch to ON position. Check the meters and indicators
in the front panel of the inverter. The voltage bar graph should indicate
11V to 14V (22V to 28V when 24V version is used) depending on the
voltage of the power source. If it is not working, check your power
source and the connections to the inverter. The other indicators should
be off.
3-7-6. Set power inverter switch to OFF position, the indicator lights may blink
and the internal alarm may sound momentarily.
The is normal. Plug the test load into the AC receptacle on the front
panel of the inverter. Leave the test load switch off.
3-7-7. Set power inverter switch to ON position and turn the test load On.
The inverter should supply power to the load.
If you plan to accurately measure the true output r.m.s. voltage of the
inverter, a meter such as FLUKE 45 BECKMAN 4410 or TRIPLETT
200 must be used.
15

3-8. Power Output：
The inverter will operate most AC loads within its power rating. Considering
that whether a microwave oven can be operated by the inverter or not,
remember that the power commonly advertised for microwave ovens are the
cooking power (the power delivered to the food), not the power actually
consumed by the microwave oven. The microwave oven consumes 40% to
100% more than its advertised cooking power. Check the rating sticker on the
back of the oven to determine its actual power requirements.
The 1500W inverter can operate small microwave oven (0.2 to 0.3 cubic foot
capacity) that draws about 1700 watts. It provides 3 minutes for cooking.
Some induction motors used in refrigerators, freezers, pumps, and other
motor operated equipment require very high surge currents to start.
The Power Inverter may not be able to start some of these motors even
though their rated current requirement is within the power inverter.
If motor is refused to start, observe the battery voltage indicator while trying to
start the motor. If the battery voltage indicator drops below 11 volts while
inverter is attempting to start the motor, this may be why the motor won’t start.
Make sure that the battery connections are good and the battery is fully
charged.
16

4. Troubleshooting：
WARNING!
Do not open or disassemble the S600 Inverter.
Attempting to service the unit yourself may cause the risk
of electrical shock or fire.
Possible Cause Solutions
Problems and Symptoms
Low output voltage Using average reading Use true RMS reading meter
and cable
voltmeter
See page 15
Point 3-7-7. of manual
Load LED bar flash Overload Reduce load
No output voltage Low input voltage. Recharge battery
And the voltage indicator Check connections
in the lower red zone and the cable
No output voltage Thermal shutdown Improve ventilation
Over Temp indicator On Enure ventilation
Load less than 1500W shafts in the inverter
are not obstructed.
Lower ambient
temperature.
No output voltage, Short circuit or Wiring Check AC wiring
Over Load indicator error for short circuit or
On. improper polarity (hot
and neutral reversed).
Very high power load Remove load
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