NOVA ELECTRIC CGL SERIES User manual

NOVA ELECTRIC CGL SERIES
PURE SINE-WAVE DC-AC INVERTERS
CGL 600W -SERIES INVERTER
USER MANUAL
NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS INC.
100 SCHOOL STREET
BERGENFIELD, NJ 07621-2915
PHONE [phone] / FAX [phone]
EMAIL: [email protected]
WEB ADDRESS: www.novaelectric.com

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 2
Features
Pure Sine Wave output (<4%THD)
Low power “Power Saving Mode” to conserve energy
Built-in voltage and load level display on front panel
Thermostatically controlled cooling fan
Advanced microprocessor design
Protection: • Input low voltage • Input over voltage
Low battery alarm • Short circuit
Applications
Electronic applications: communications equipment, commercial gear, etc.
Office equipment—computers, printers, monitors, facsimile machines, scanner.
Mobile equipment vans.
Household items – fans, fluorescent and incandescent lights, shavers, sewing machines.
Small Power tools
Home entertainment electronics – televisions, VCRs, video games, stereos, musical
instruments, satellite equipment.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 3
ELECTRICAL SPECIFICATIONS
PARAMETER 12V MODEL 24V MODEL 48 MODEL
INPUT VOLTAGE RANGE 10.7 – 15 VDC 21.5 – 32 VDC 42-58 VDC
OUTPUT VOLTAGE 110 MODEL (1) 100/110/120 VAC 100/110/120 VAC 100/110/120 VAC
OUTPUT VOLTAGE 230V MODEL (1) 220/230/240 VAC 220/230/240 VAC 220/230/240 VAC
OUTPUT FREQUENCY ALL UNITS (1) 50 OR 60 HZ Factory Selectable +/- 0.05% Accuracy
POWER RATING CONTINUOUS 600W / 700VA
SURGE RATING 800W / 1000VA
PEAK OUTPUT CURRENT 10A (110V Models) 5A (230V Models)
EFFICIENCY AT FULL LOAD 83% 110V Models
86% 220V Models
87% 110V Models
90% 220V Models
87% 110V Models
90% 220V Models
NO LOAD CURRENT 0.7A for 110V Models 0.35A for 230V Models
OUTPUT WAVEFORM Sine Wave <4% THD
OUTPUT REGULATION -10% / +4% All Models
PROTECTION Overload, Short Circuit, Reverse Polarity (Fuse), O..T, Over/Under Input
Voltage , Fan Failure
AMBIENT TEMPERATURE Operating: 0 to 500C Storage: -400C to 600C
SIZE & WEIGHT 270 X 180 X 72mm (10.6” x 7.1” x 2.8”) 3KG (6.6LB)
INDICATORS INPUT LEVEL, LOAD LEVEL, FAULT

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 4
1. Introduction:
This power inverter series are part of the most advanced line of mobile AC power
systems available.
This model is used in a wide range of applications including mobile equipment shelters,
remote homes, RVs, sailboats and powerboats. It will operate most televisions and VCRs
personal computers, small appliances and tools such as drills, sanders, grinders, mixers
and blenders, within the power ratings shown in the table on the prior page.
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.
1. Name and Main Function:
Front View:
2-1-1. ON / OFF Switch:
Power ON/OFF switch: Leave in the OFF position during installation.
2-1-2. Input Level: Displays Input Voltage
LED Status DC 12V DC 24 V DC 48V
RED Blink (slow) 10.5 ~ 10.9 21.0 ~ 21.8 42.0 ~ 43.6
RED 10.9 ~ 11.3 21.8 ~ 22.6 43.6 ~ 45.2
ORANGE 11.3 ~ 12.0 22.6 ~ 24.0 45.2 ~ 48.0
OFF 12.0 ~ 14.0 24.0 ~ 28.0 48.0 ~ 56.0
ORANGE Blink 14.0 ~ 14.7 28.0 ~ 29.4 56.0 ~ 58.8
OVER RED Blink 14.7 ↑29.4 ↑58.8 ↑
Load Level: Displays AC Load Watts
LED Status Load Condition
OFF 0 ~ 30W
GREEN 30W ~ 200W
ORANGE 200W ~ 450W
RED 450W ~ 580W
RED BLINK Over 580W
Fault Conditions:
OVP: over voltage protection
UVP: under voltage protection
OVER TEMP: over temperature protection
OVER LOAD: over load protection
INPUT LEVEL: display input voltage
LOAD LEVEL: display AC load watts

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 5
2-1-3. AC Outlet:
Outlet sockets available: Australia/New Zealand
North America/US (Standard 5-15R on all 110 -110 VAC
Models)
Europe
UK/Ireland
GFCI(USType)
Rear View:
2-2-1. Ventilation window:
Do not obstruct; allow at least 1 inch for air flow.
2-2-2. DC input terminals:
Connect to a battery or other voltage power source of the correct voltage.
[+] is positive; [-] is negative. Reverse polarity connection will blow the internal fuse
and may damage the inverter permanently. The input wiring should be protected by an
appropriately rated input fuse as per NEC or equivalent codes.
2-2-3. Wire to Chassis ground or to vehicle chassis using #8 AWG wire, minimum.
Warning! Operation of the inverter without a proper ground connection may result
in an electrical safety hazard.
3. Quick Hook-up and Testing:
If you would like to hook-up the power inverter and check its performance before going ahead
with your permanent installation, please follow these guidelines:
3-1. Unpack and inspect the power inverter; check to see that the power switch is in the OFF
position.
3-2. Connect the cables to the power input terminals on the rear panel of the power inverter.
The red terminal is positive (+) and the black terminal is negative (-). Connect the cables
into the terminals and tighten the bolts to clamp the wires securely.
3-3. Connect the cable from the negative terminal of the inverter to the negative terminal of
the power source. Make a secure connection.
Caution! Loosely tightened connectors result in excessive drop and may cause
overheated wires and melted insulation, as well as other damage.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 6
3-4. Before proceeding further, carefully check that cable you have just connected is from the
negative terminal of the inverter to the negative output terminal of the power source.
Caution! 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 our warranty.
3-5. Connect the cable from the positive terminal of the inverter to the positive terminal of the
power source. Make a secure connection.
Warning! You may observe a small spark when you make this connection since
current will flow to charge capacitors in the power inverter. This can be avoided by
installing a properly rated switch or circuit breaker at the power source. Do not
make this connection in the presence of flammable fumes; an explosion or fire may
result.
3-6. Set the power switch to the ON position. Check that the Input level indicator on the front
panel of the inverter is green. If it is not, check your power source and the connections to
the inverter. The other indicators should be off.
3-7. Set the power inverter switch to the OFF position. The indicator lights may blink and the
internal alarm may sound momentarily. This is normal. Plug the test load into the AC
receptacle on the front panel of the inverter. Leave the test load switch off.
3-8. Set the 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 measure the true output RMS voltage of
inverter, a meter such as FLUKE 87, BECKMAN 4410, or TRIPLETT 4200 must be
used.
4. Installation:
4-1. Where to install.
The power inverter should be installed in a location that meets the following
requirements:
4-1-1. Moisture: Do not allow water to drip or splash on or in the inverter.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 7
4-1-2. Cooling: Ambient air temperature should be between 0°C. and 50°C.; the cooler,
the better.
4-1-3. Ventilation: Allow at least one inch of clearance around the inverter for air flow.
Ensure that ventilation openings on the sides, front and rear of the unit are not obstructed.
4-1-4. Safety: Do not install in a battery compartment or other areas where flammable
fumes may exist, such as fuel storage areas or engine compartments.
4-2. Cables:
DC to AC inverters require high amperage / low voltage DC power low amperage / high
voltage AC power. To operate properly, connect the inverter and generate DC input
terminals directly to battery through a fuse or circuit breaker. The different inverters in
this family require different wire sizes due to the wide input voltage choices.
4-3. Grounding:
The power inverter has a lug on the rear panel [ chassis ground ]. This is to connect the
chassis of the power inverter to the ground. The ground terminals in the AC outlets on
the front panel of the inverter are also connected to the ground lug.
The chassis ground lug must be connected to a grounding point, which will vary,
depending on where the power inverter is installed. In a vehicle, connect the chassis
ground to the chassis of the vehicle. In a boat, connect to the boat’s grounding systems.
In a fixed location, connect the chassis ground lug to earth ground.
On units with Ground Fault Circuit Interrupt (GFCI), the neutral (common)
conductor of the power inverter AC output circuit is connected to the chassis ground.
Therefore, when the chassis is connected to ground, the neutral conductor will also be
grounded. This conforms to national electrical code requirements that separately derived
AC sources (such as inverters and generators) have their neutral tied to ground in the
same way that the neutral conductor from the utility line is tied to ground at the AC
breaker panel. When the chassis ground lug on the rear panel is connected to an earth
ground in the user’s location, it provides shock hazard protection. The GFCI has a test
button and a reset button. Pushing in the test button will interrupt the output power.
Pushing in the reset button will restore the output power and the green light will be on.
Note: Repeated pressing/toggling of the GFCI test button may shut down the inverter AC
output. THIS IS NORMAL.
On units without GFCI, the neutral is floating. To conform to national electrical code
requirements, the neutral must be connected to ground, or other neutrals that are
grounded.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 8
Warning! Do not operate the power inverter without connecting the ground
terminal to ground. Electrical shock hazard may result, and the GFCI circuit will
not operate properly.
5. Operation:
To operate the power inverter, turn it on 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.
5-1. Controls and Indicators:
The front panel ON/OFF switch turns the control circuit in the power inverter on and
off. It does not disconnect power from the power inverter.
When the switch is in the OFF position, the power inverter draws no current from the
battery. When the switch is in the ON position but with no load, the power inverter
draws less than 1.65A / normal, 0.12A / power saving mode (12V version) from the
battery.
5-2. Input Level Indicator:
The input level indicator 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. If the voltage goes into the RED area, the inverter may shut down.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 9
5-3. Load Level Indicator:
The load level indicator indicates the power drawn from the power inverter output. It
will indicate total watts drawn by all loads.
For long-term operation, the level should be in the green and orange areas of the bar
graph. Short-term operation is possible with wattage in the red area. If the wattage
rise to the “Blinking Red” the inverter will protect itself, and may reduce its output
voltage or shut down entirely.
5-4. Fault Indicator:
The over voltage indicator indicates that the power inverter has shut itself down
because its input voltage has been over the high limit.
6. Operating Limits:
6-1. Power Output:
Some motors used in refrigerators, freezers, pumps and other motor-operated
equipment require very high surge currents to start, often as much as 6 – 7 times rated.
The power inverter may not be able to start some of these motors, even though their
rated current draw is within the power inverter.
If the motor refuses to start, observe the battery voltage indicator while trying to start
the motor. If the battery voltage indicator drops below the low input level while the
inverter is attempting to start the motor, this may be the reason the motor won’t start.
Make sure that the battery connections are good and that the battery is fully charged.
If the connections are good and the battery is charged, but the voltage still drops
below the low voltage level, you may need to use a larger battery, or larger wire.
6-2. Input Voltage:
The power inverter will operate from input voltages ranging from 10.9V – 14.7V (12V
version) 21.8V – 29.4V (24V version), or 43.6V - 58.5V (48V version). If the voltage
drops below 10.5V (12V version), 21V (24V version), an audible low battery warning
will sound and the voltage indicator will be in slow blinking red. The power inverter
will shut down if the input voltage drops below 10V (12V version), 20V (24V
version), or 40V (48V version). This protects your battery from being over
discharged.

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 10
The power inverter will also shut down if the input voltage exceeds its rating. This
protects the inverter against excessive input voltage. The input level will be red
blinking. Although the power inverter incorporates protection against over voltage, it
may still be damaged if the input voltage is allowed to exceed 20V (12V version) or
40V (24V version). or 75V (48V version).
7. Troubleshooting:
7-1. Common Problems:
Television or other communication equipment interference:
Operation of the power inverter can interfere with television reception on some
channels. If this situation occurs, the following steps may help to alleviate the
problem.
•Make sure that the chassis ground lug on the back of the power inverter is solidly
connected to the ground system of your vehicle, boat, shelter, or home.
•Make sure the neutral is bonded to ground ( See page 7)
•Move the television as far away from the power inverter as possible.
•Keep the cables between the battery and the power inverter as short as possible
and twist them together with about 2 to 3 twists per foot. This minimizes radiated
interference from the cables.
Overheating:
Check for clean air intake and an exhaust opening, and check that the fan is
operating.
No Output:
Check the input fuses (remove cover).
Check for correct input voltage

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
4/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL:www.novaelectric.com FAX: [phone]
Page 11
7-2 Troubleshooting Guide:
Problem and Symptoms Possible Cause Solution
Low output voltage Bad readings caused by using average reading Use a true RMS meter
(110V: 95-105VAC, voltmeter (See paragraph 3.8 of manual )
220V:190-210VAC)
Load level LED is RED Overload Reduce load
Flashing
No output voltage Low input voltage Recharge battery, check connections
and Input level indicator is red blinking and cable.
No output voltage, Inverter switched off. Turn inverter on.
No voltage indication No power to the inverter. Check wiring to Inverter.
Internalfuseopen Havequalified service technician check and
replace.
Reverse DC Polarity Have qualified service technician check
and replace fuse, OBSERVE CORRECT
POLARITY
No output voltage. High input voltage Make sure that inverter is connected to a
Input level indicator is blinking fast proper input voltage source.
Checkregulationofchargingsystem.
Low battery alarm Poor DC wiring, poor Use proper cable and make solid connection.
ON all the time, battery condition Use new battery.
Voltage level indicator is blinking slowly
Below 10.5V (12V ver.),
21V (24V ver.), or 42V (48V ver.)

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
4/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL:www.novaelectric.com FAX: [phone]
Page 12
7.2 Troubleshooting Guide (cont’d.)
Problem and Symptoms Possible Cause Solution
No output voltage, Thermal shutdown Allow inverter to cool off. Reduce load if
Unit feels hot continuous operation required.
Input DC current in excess of:
600W: 60A (12V), 30A (24V), or 16A (48V)
No output voltage, Thermal shutdown Improve ventilation. Make sure ventilation
Unitfeelshot openings in inverter are not obstructed;
Loadlessthan: reduce ambient temperature. Check fan
600W: 60A (12V) or 30A (24V) or 16A (48V)
No output voltage GFCI Tripped (optional) Push in the RESET button on the GFCI
receptacle. It continues to trip, remove
theloadseeiftheloadisthecause.
No output voltage; Short circuit or Check AC wiring for short circuit or
wiring error. improper polarity (hot and neutral reversed)
VeryhighpowerloadRemoveload
__________________________________________________________________________________________________________________________

NOVA ELECTRIC
A DIVISION OF
TECHNOLOGY DYNAMICS, INC.
045670 100 SCHOOL STREET
04/11/2003 Revision - BERGENFIELD, NJ 07621-2915
CGL 600W INVERTER MANUAL PHONE [phone]
URL: www.novaelectric.com FAX [phone]
Page 13
8. Maintenance:
Very little maintenance is required to keep your inverter operating properly. You should
clean the exterior of the unit periodically with a damp cloth to prevent accumulation of dust
and dirt. At the same time, tighten the screws on the DC input terminals. ( Remove power
first)
9. The Output Voltage and Frequency is factory preset.
No external adjustments are available for these two parameters
10. Warranty:
All Nova Electric products are warranted against defects in material and workmanship for a
period of one year from shipping date. Our obligation includes replacing, repairing, or adjusting
products (excluding fuses) that prove to be defective during the warranty period. The unit must
be returned to us postage paid. Contact our Customer Service Manager at [phone]
(Extension 115 ) for a Return Material Authorization (RMA) number.
This warranty is fully transferable. If a product is sold to a manufacturer for use in a product for
resale, the complete warranty is in force, providing the power system is sold as original
equipment.
This warranty will be considered void if the unit has suffered any obvious physical damage or
alteration, either internally or externally, and does not cover damage arising from improper use,
such as plugging the unit into an unsuitable or reversed power source, attempting to operate
products with excessive power consumption requirements, or use in unsuitable climates.
Nova Electric assumes no liabilities for consequential damages of any kind through the use or
misuse of its products by the purchaser or others. No other obligations are expressed or implied.