Modtech PCCU-100 User manual

OPERATOR’S MANUAL
PCCU-100TM Lithium Ion
Power Conversion and Control Unit
7136 Eagle Rd. •Willoughby, OH 44094-9636
Tel: [phone] •Fax: [phone] •[email protected]
TO REDUCE THE RISK OF INJURY, YOU
MUST READ THIS OPERATOR’S MANUAL
AND COMPLY WITH ALL INSTRUCTIONS
AND PROCEDURES DESCRIBED HEREIN.
FAILURE TO DO SO MAY RESULT IN FIRE,
PERSONAL INJURY, AND/OR OTHER
DAMAGE.
Copyright © 2008, Modtech Corp., All rights reserved
2
GENERAL SAFETY RULES
This manual contains important safety and operating information for the
Modtech Corp. PCCU-100 24V Lithium-Ion battery to 115VAC 60Hz
power inverter. Before using the inverter, read this operator’s manual.
Also, read and observe all information on the labels attached to the
inverter.
1. CAUTION! TO REDUCE THE RISK OF INJURY AND/OR
EQUIPMENT DAMAGE, USE PCCU-100 ONLY WITH MODTECH
CORP. EM-100 LITHIUM ION BATTERY PACKS. The use of other
types of batteries or equipment may result in personal injury or
equipment damage. Under no circumstances connect the PCCU-100 to
power sources or other equipment not specifically and expressly
designated for use with this model inverter.
2. AVOID DANGEROUS CONDITIONS AND ENVIRONMENTS. Do
not connect a battery pack or operate the PCCU-100 in damp or wet
conditions. Avoid using the inverter in direct exposure to rain or snow.
Do not use the battery pack or inverter in the presence of explosive
gases or flammable materials because sparks will be generated
whenever a battery pack is plugged or unplugged from inverters or other
equipment.
3. USE PCCU-100 IN WELL VENTILATED AREA. Allow for adequate
airflow around inverter and battery pack to avoid overheating.
4. AVOID USING OR STORING THE PCCU-100 IN EITHER EXTREME
COLD OR EXTREME HOT TEMPERATURES. The battery pack will
shutdown and will not power the inverter under conditions of extreme
heat (above 60 °C) or extreme cold (below -20 °C). Performance may be
degraded with temperatures outside of the 0 °C to 45 °C recommended
operating range.
WARNING
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions may result in electrical shock, fire,
equipment damage, and/or serious personal injury.
SAVE THESE INSTRUCTIONS

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5. PCCU-100 IS RATED FOR 115 VAC 60 Hz OPERATION. Use the
inverter only to power appropriate appliances rated for this power input .
6. PCCU-100 IS RATED TO POWER LOADS OF 50 WATTS
CONTINUOUS. Do not connect high power loads (> 50 W) to your
inverter.
7. TO REDUCE USE OF ELECTRIC SHOCK always unplug any
appliances from the PCCU-100 and remove the battery pack from the
inverter before cleaning or maintaining the inverter or any appliance.
Use of a Ground Fault Circuit Interrupter between the inverter output and
the appliance is recommended to reduce shock hazards.
8. DO NOT DISASSEMBLE. The PCCU-100 contains no user
serviceable parts and should not be disassembled under any
circumstances. If faulty operation is suspected, return the inverter for
inspection and service if required.
9. NEVER CONNECT THE PCCU-100 TO AC DISTRIBUTION
WIRING. Connect the 115 VAC inverter output directly to the appliance
to be powered, preferably using a GFCI power cord / module.
10. STORE INVERTER IN A COOL, DRY PLACE. Avoid leaving the
inverter in direct sunlight, vehicle cabs, compartments, or unventilated
storage buildings during hot summer conditions. Under extreme
temperature conditions damage may occur. Avoid allowing inverter to
become wet or damp. Allow damp or wet inverter to dry thoroughly
before using.
11. TURN PCCU-100 OFF AND REMOVE BATTERY PACK when not
in use.
12. REPLACE FUSE ONLY WITH 10A 32V BLADE FUSE.
WARNING
READ AND SAVE THESE INSTRUCTIONS FOR
FUTURE USE.
Failure to follow all instructions may result in electrical shock, fire,
equipment damage, and/or serious personal injury.
4
FUNCTIONAL DESCRIPTION
If a battery pack is too hot or too cold, it will not power the PCCU-100
module. The lighted on/off power switch will illuminate when turned to
the on position with a charged battery within temperature limits attached.
If the switch does not illuminate, check that the fuse is intact and that the
battery does not show an error condition when connected to a CHG-50
charger. If the switch still does not illuminate, the PCCU-100 should be
retired from service and sent for inspection and repair if needed.
LIGHTED POWER
ON/OFF SWITCH
115 VAC 60 Hz
POWER
RECEPTACLE
FUSE
BATTERY
CONNECTOR
INFORMATION
LABEL
(NOT VISIBLE)
PCCU-100
24 Volt Lithium Ion Battery
to 115 VAC 60 Hz
Power Conversion and Control Unit

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PCCU-100 INVERTER OPERATION
The PCCU-100 is a lithium ion battery to 115 VAC power inverter
targeted to power predominately low power electronic appliances.
Operationis as follows:
1. The recommended power connection sequence is as follows:
With PCCU-100 power switch inoff position, first connect a charged EM-
100 battery pack to the PCCU-100. Next, connect the appliance to be
powered to the PCCU-100 power receptacle using an appropriate GFCI
power cord / module. If the appliance has its own power switch, it should
be in the off position as well. Next turn the PCCU-100 power switch to
the on position and visualize that it illuminates. Power is now being
supplied to the appliance. Finally, turn the appliance power switch to the
on position.
2. If appliance operation is intermittent it may be drawing too much
power for the PCCU-100. Verify that the appliance is operating properly
and that its power level is 50 W or less.
3. Turn off the PCCU-100 power switch before plugging or unplugging
appliances or before plugging or unplugging battery packs. Whenever
power is not needed, turn off the PCCU-100 power switch for safety and
to maximally conserve battery power.
4. An audible tone is provided when battery power is depleted and the
PCCU-100 is about to or has shut down. ALWAYS ASSUME HIGH
VOLTAGE IS PRESENT AT THE POWER RECEPTACLE. Turn off the
PCCU-100 before plugging or unplugging appliances or battery packs.
5. External fuse: The PCCU-100 has a fuse protecting against input
(battery) over current conditions. The SIPSTM Scalable Intelligent Power
Systems components are designed to shutdown electronically in
advance of fuses opening. Should the fuse become blown, a damaged
unit may be indicated and it is recommended that the PCCU-100 be
returned for inspection and repair if needed. In no event should the
external fuse be replaced with any fuse other thanone identical to the
factory supplied type, 10A, 32V blade type fast acting.
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MAINTENANCE AND STORAGE
Moisture, extreme heat and extreme cold should be avoided when
storing (or using) the PCCU-100. Refrain from exposing the
inverter to rain, snow, or moisture of any kind. When storing the
inverter, a cool, dry location is best. All appliances should be
unplugged from the inverter and the battery pack removed prior to
storing.
SPECIFICATIONS
Nominal Input Power 24 VDC, 3 A
External Fuse 10 A, 32 V
BLADE TYPE, FAST ACTING
Nominal Output Power 115 VAC, 0.5 A, 60 Hz
Output Waveform Modified Sine Wave
Recommended Battery Pack Modtech Corp. EM-100
Minimum Operating Temperature -20 °C
Maximum Operating Temperature 45 °C
Dimensions 7” x 3-1/4” x 2-1/2”
(178 x 83 x 64 mm)
Weight 20 oz. (567 g)

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PCCU-100 Inverter with EM-100 Lithium Ion Battery Pack
7136 Eagle Rd. •Willoughby, OH 44094-9636
Tel: [phone] •Fax: [phone] •[email protected]
Copyright © 2008, Modtech Corp., All rights reserved
8
NOTES: