Cotek S1500-112 User manual

S1500 Series
Pure Sine Wave Inverter
User’s Manual

Contents
1. Important safety striations…………………………………………………...
1-1 General safety precautions……………………………………………. 1
1-2 Precautions when working with batteries…………………………….. 1
2. Features…………………………………………………………………………
2-1 Application………………………………………………………………. 2
2-2 Electrical performance…………………………………………………. 3
2-3 Rear panel operations…………………………………………………. 4
3. Introduction…………………………………………………………………….
3-1 Front panel operations…………………………………………………. 5~7
3-2 Rear panel operations………………………………………………….. 8~9
3-3 Installation……………………………………………………………….. 9
3-4
Quick hook －up and testing………………………………………….. 10
3-5 AC safety grounding……………………………………………………. 11~12
3-6 Making DC wiring connections………………………………………... 13
3-7 Inverter operation……………………………………………………….. 14~15
3-8 Power output……………………………………………………………. 16
4. Troubleshooting guide………………………………………………………. 17
5. Maintenance …………………………………………………………………… 18
6. Warranty ………………………………………………………………………... 18
7. Appendices A…………………………………………………………………..
7-1 Dip switch (110V)……………………………………………………….. 19
7-2 Dip switch (220V)………………………………………………………. 19
8. Appendices B…………………………………………………………………..
8-1 Operations of RS232 serial port………………………………………. 20
8-2 Interface command…………………………………………………….. 21~25
9. Appendices C…………………………………………………………………..
9-1 Remote control operations…………………………………………….. 26~27
9-2 Power saving mode…………………………………………………….. 28~31

Contents
10. Appendices…………………...………………………………………………...
10-1 FCC (Class B) declaration of conformity…………………………….. 32
10-2 CE (EMC EN55022B) declaration of conformity……………………. 33
10-3 CE (LVD EN60950) declaration of conformity………………………. 34
10-4 e-mark (e13 020932) declaration of conformity…………………….. 35
10-5 UL (UL458) declaration of conformity……………………………….. 36

1. Important Safety Instructions
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.
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.
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.
WARNING!
Before using the Inverter, read and save the safety
instructions.
1

2. Features
Pure sine wave output (THD < 3%)
Output frequency：50 / 60Hz switch selectable
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.
2-1-2. Office equipment－computers, printers, monitors, facsimile machines,
scanner.
2-1-3. Household items－vacuum cleaners, fans, fluorescent and
incandescent lights, shavers, sewing machines.
2-1-4. Kitchen appliances－microwave ovens, refrigerators and freezers,
coffee makers, blenders, ice markers, toasters.
2-1-5. Industrial equipment－metal halide lamp, high-pressure sodium lamp.
2-1-6. Home entertainment electronics－television, VCRs, video games,
stereos, musical instruments, satellite equipment.
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
Output Voltage 100 / 110 / 115 / 120V +/- 5% 200 / 220 / 230 / 240V +/- 3%
Frequency
(Switch Selectable) 50 / 60Hz +/- 0.05%
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
Output Voltage Regulation 100 / 110 / 115 / 120V RMS
-10% / +4%
200 / 220 / 230 / 240V RMS
-10% / +4%
Input Voltage Regulation 10-16
VDC 20-32 VDC 42-62 VDC 10-16 VDC 20-32 VDC 42-62 VDC
Protection Overload, Short Circuit, Reverse Polarity (Fuse), Over/Under
Input Voltage, Over Temperature.
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 UL458 EN60950
EMC FCC Class B
EN50081-1：1992
EN50082-1：1992
EN55022B：1994
EN61000-4-2：1995
EN61000-4-3：1996
ENV50204：1995
e-MARK
e13-020932
Operating Temperature Range 0 - 40℃
Storage Temperature Range -30℃to 70℃
Dimensions 390 (L) x 275 (W) x 105 (H) mm / 15.4 (L) x 10.8 (W) x 4.1 (H) Inch
Cooling Thermostatically controlled cooling fan ( 55℃ON , 45℃OFF)
Weight 7.0kgs / 15.5 lbs.
3

2-3. Mechanical Drawings
4

3. Introduction
This power inverter series is a the member of the most advanced line of mobile
AC power systems available.
To get the most out of the power inverter, it must be installed and used properly.
Please read the instructions in this manual before installing and using this model.
3-1. Front Panel Operations：
3-1-1. Front view：
3-1-2. ON / OFF switch：
Power ON/OFF switch, leave in the OFF position during installation.
3-1-3. Battery Voltage indicator：
The battery voltage bar graph indicates the voltage at the input
terminals of the power inverter. At low input current, this voltage is
very close to the battery voltage. At high input current, this voltage
will be lower than the battery voltage because of the voltage drop
across the cable and connections. Ideally, the voltage should remain
in the green Ares of the bar graph. If the voltage goes into the red
area at top and bottom of the graph, 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 long term operation, the watt indicator
should remind in the green & orange area of the bar graph.
Short term operation is possible with watt indicator in the red area.
If the watt indicator rises to high values the bar will flash and the
inverter will shutdown to protect itself.
3-1-5. OVP：Over Voltage 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 itself
down because its output has been short circuited or drastically
overloaded.
Switch the ON/OFF switch to OFF, correct the fault condition, and then
switch the ON/OFF switch back to ON to reset the unit.
3-1-9. Power Saving：Power energy saving enable.
See appendix 9-2 for detailed information.
6

3-1-10. AC Outlet (Outlet sockets available)：
North America (GFCI) North America (NEMA 5-15R)
Continental European (SCHUKO) Australia / New Zealand
United Kingdom Universal
7

3-2. Rear Panel Operations：
3-2-1. Ventilation Openings：
Do not obstruct, allow at least 3 inch for air flow.
3-2-2. DC Terminals:
Connect to 12V / 24 V / 48V battery or the other power sources.
【+】is positive, 【-】is negative. Reverse polarity connection will
blow internal fuse and may damage inverter permanently.
Model voltage Min voltage Max. voltage
S1500-112
S1500-212 10.0 VDC 16.0 VDC
S1500-124
S1500-224 20.0 VDC 32.0 VDC
S1500-148
S1500-248 42.0 VDC 62.0 VDC
WARNING!
Do not connect the 12V model to a 24 battery,
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. Connect chassis ground terminal to earth or to vehicle chassis using
#8 AWG wire.
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
S1500-212 17.1VDC 15.8VDC 10.2VDC 9.5VDC 12.4VDC
S1500-124
S1500-224 34.1VDC 31.5VDC 20.4VDC 19.3VDC 24.8VDC
S1500-148
S1500-248 63.0VDC 58.5VDC 41.6VDC 38.6VDC 49.6VDC
85℃45℃
WARNING!
Operation of the inverter without a proper ground
connection may result in an electrical safety hazard.
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 allow water to drip or splash on the inverter.
3-4-2. Cool －Ambient air temperature should be between 0°C
3-4-3. Safe －Do not install in a battery compartment or other areas where
flammable fumes may exist, such as fuel storage areas or engine
compartments.
3-4-4. Ventilated －Allow at least three inch of clearance around the inverter
for air flow. Ensure the ventilation openings on the rear and front of
the unit are not obstructed.
3-4-5. Dust-free －Do not install the Inverter in a dusty environments where
are dust, wood particles or other filings/shavings.
These dust can be pulled into the unit when the cooling fan is
operating.
3-4-6. Close to batteries －Avoid excessive cable lengths but do not install
the Inverter in the same compartment as batteries.
Use the recommended wire lengths and sizes (see section 2-10).
Also 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 damage
the Inverter.
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 in the presence of
Flammable fumes. Explosion or fire may result.
10

3-5. Making DC Wiring Connections：
Follow this procedure to connect the battery cables to the DC input terminals
of the Inverter. Your cables should be as short as possible ( ideally, less
than 6 feet / 1.8 meters ) enough to handle the required current in accordance
with the electrical codes or regulations application. Cables are not an
adequate gauge ( too narrow ) or too long will decrease the inverter
performances such as poor surge capability and low input voltage warnings
frequently and shutdowns. UVP warning presents 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 will help 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 battery may cause damage to the
inverter and will void warranty.
11

Also, use only high quality copper wiring and keep cable length short, a
maximum of 3-6 feet.
INLINE FUSE
BATTERY
-+
S1500
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 connect to the
incoming ground from your 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 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 wave form
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 AC
sources (such as inverter and generators) have their neutral
conductors tied to ground in the same way that the neutral
conductor from the utility is tied to ground at the AC breaker
panel. For models configured with a transfer relay, while AC
utility power is presenting and the Inverter is in bypass mode,
this connection (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 the safety
ground.
13

3-7. Inverter Operation：
To operate the power inverter, turn it on by using the ON/OFF switch on the
front panel. The power inverter is now ready to deliver AC power to your
loads. If you are operating several loads from the power inverter, turn them
on separately after the inverter has been turned on.
This will ensure that the power inverter does not have to deliver the starting
currents for all the loads at once.
3-7-1. Unpack and inspect the power inverter, check to see that the power
switch in the OFF position.
3-7-2. Connect the cables to the power input terminals on the year panel of
power inverter.
The terminal is positive (+) and black terminal is negative (-).
Insert the cables into the terminals and tighten allen nut to clamp the
wires securely.
3-7-3. Before proceeding further, carefully check that cable you have just
connected does tie negative terminal of inverter to the negative output
power source.
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.
WARNING!
Reverse polarity connection will blow a fuse in inverter
and may permanently damage the inverter.
Damage caused by reverse polarity connection is not
covered by warranty.
WARNING!
Make sure all the DC connections are tight (torque to
9-10 ft-lbs, 11.7-13Nm). Loose connections will
overheat and could result in a potential hazard.
14

3-7-5. Set the power switch to the ON position. Check the meters and
indicators on the front panel of the inverter. The voltage bar graph
should indicate 11 to 14 volts (22 to 28V when 24V version is used)
depending on the voltage of the power source. If does not, check
your power source and the connections to inverter.
The other indicators should be off.
3-7-6. Set power inverter switch to the 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 the 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
inverter, a meter such as FLUKE 45 BECKMAN 4410 or TRIPLETT
200 must be used.
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 in the presence of
flammable fumes Explosion or fire may result.
15

3-8. Power output：
The inverter will operate most AC loads within its power rating.
When deeming whether a microwave oven can be operated by the inverter,
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 will consume 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 will operate small microwave oven (0.2 to 0.3 cubic foot
capacity) that draws about 1700 watts. It will provide 3 minutes of cooking
time. 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 motor 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 guide：
Problems and Symptoms Possible Cause Solutions
Low output voltage Using average reading
voltmeter Use true RMS reading meter
and cable.
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 voltage indicator check connections
in lower red zone. and cable.
No output voltage. Thermal shutdown Improve ventilation,
Over Temp indicator Make sure ventilation
on, load less than openings in inverter
1500W. are not obstructed.
Reduce 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
WARNING!
Do not open or disassemble the Inverter.
Attempting to service the unit yourself may result in a risk of
electrical shock or fire.
17