Samlexpower PST-300S-12E User manual
DC-AC Power
Inverter
Pure Sine Wave
PST-300S-12E
PST-300S-24E
Please read this
manual BEFORE
installing your
inverter
Owner's
Manual
2 | SAMLEX AMERICA INC.
OWNER'S MANUAL | Index
SECTION 1 Safety Instructions ........................................3
SECTION 2 General Information .....................................6
SECTION 3
EMC (EMI/EMS) Compliance .............................................. 13
SECTION 4
Powering Direct / Embedded Switch Mode
Power Supplies (SMPS) ....................................................... 14
SECTION 5 Principle of Operation ............................... 16
SECTION 6 Layout........................................................ 17
SECTION 7
General Information on Lead-Acid Batteries ....................... 18
SECTION 8 Installation ................................................. 29
SECTION 9 Operation ...................................................42
SECTION 10 Protections ............................................. 44
SECTION 11 Troubleshooting Guide ........................... 48
SECTION 12 Specications ......................................... 50
SECTION 13 Warranty ..................................................52
Disclaimer of Liability
UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA, INC.:
1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION
PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDI-
RECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY
SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.
Samlex America reserves the right to revise this document and to periodically make changes to the content
hereof without obligation or organization of such revisions or changes.
Copyright Notice/Notice of Copyright
Copyright © 2016 by Samlex America, Inc. All rights reserved. Permission to copy, distribute and /or modify this
document is prohibited without express written permission by Samlex America, Inc.
2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
SECTION 1 | Safety Instructions
1.1 IMPORTANT SAFETY INSTRUCTIONS AND SYMBOLS
SAVE THESE INSTRUCTIONS. This manual contains important instructions for models
PST-300S-12E and PST-300S-24E that shall be followed during installation, operation and
maintenance.
The following safety symbols will be used in this manual to highlight safety
and information:
WARNING!
Indicates possibility of physical harm to the user in case of non-compliance.
!
CAUTION!
Indicates possibility of damage to the equipment in case of non-compliance.
i
INFO
Indicates useful supplemental information.
Please read these instructions before installing or operating the unit to prevent personal
injury or damage to the unit.
1.2 SAFETY INSTRUCTIONS - GENERAL
Installation and wiring compliance
must be done by a certied electrician.
Preventing electrical shock
-
tion 8.5.1 for details.
system.
with the unit. Turning the switch on the unit to OFF position may not entirely
remove dangerous voltages.
-
4 | SAMLEX AMERICA INC.
SECTION 1 | Safety Instructions
Installation environment
openings of the cooling fan.
Preventing re and explosion hazards
equipment. These areas may include spaces containing gasoline-powered machinery,
Precautions when working with batteries
the battery manufacturer’s recommendations.
The batteries can produce a short circuit current high enough to weld a ring or the
1.3 SAFETY INSTRUCTIONS - INVERTER RELATED
Preventing Paralleling of the AC Output
connection may result in parallel operation of the different power sources and AC power
the output section of the unit and may also pose a re and safety hazard. If an Electrical
4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 1 | Safety Instructions
!
CAUTION!
To prevent possibility of paralleling and severe damage to the unit, never
use a simple jumper cable with a male plug on both ends to connect the
Preventing DC Input Over Voltage
unit. Please observe the following precautions:
-
controller between the solar panel and the battery.
-
into the diversion load if there are no other loads. The charge controller will discon-
-
loads connected to the battery due to high voltages generated during conditions of
therefore, to be ensured that the diversion load is sized correctly to prevent the above
over voltage conditions.
Preventing Reverse Polarity on the Input Side
-
inverter will blow and may also cause permanent damage to the inverter.
!
CAUTION!
6 | SAMLEX AMERICA INC.
SECTION 1 | Safety Instructions
Use of External Fuse in DC Input Circuit
-
along the length of the cable. Please read instructions under Section 8.4.5 - Installation.
Hard Wiring of AC Output to AC Panelboards in RVs / Motor Homes / Trailers /Campers
WARNING!
RISK OF ELECTRIC SHOCK
wiring connection is used to feed the AC output of the inverter to the AC
the AC output is fed to the Panel Board through appropriate Residual Current
SECTION 2 | General Information
2.1. DEFINITIONS
concepts, specications and operations:
Peak Value:
RMS (Root Mean Square) Value: It is a statistical average value of a quantity that varies
Voltage (V), Volts: It is denoted by “V” and the unit is “Volts”. It is the electrical force
-
Current (I), Amps, A: It is denoted by “I” and the unit is Amperes – shown as “A”. It is
Frequency (F), Hz: It is a measure of the number of occurrences of a repeating event per
Efciency, (η):
in Watts.
6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
Phase Angle, (φ): It is denoted by “φ” and species the angle in degrees by which the
current vector leads or lags the voltage vector in a sinusoidal voltage. In a purely induc-
φ
φ
a purely resistive load, the current vector is in phase with the voltage vector and hence,
φ-
φ
and may lag or lead the voltage vector.
Resistance (R), Ohm, :-
rent when a voltage is applied across it. In a resistance, the current is in phase with the
Inductive Reactance (XL), Capacitive Reactance (XC) and Reactance (X): Reactance is the
opposition of a circuit element to a change of electric current or voltage due to that
XL
of wire in resisting any change of electric current through the coil. It is proportional to
frequency and inductance and causes the current vector to lag the voltage vector by
φXC
oppose changes in voltage. XCis inversely proportional to the frequency and capacitance
φ
unit of both XLand XC-
tance XL-
tance XC
effect is a tendency to cancel each other. Hence, in a circuit containing both inductances
and capacitances, the net Reactance (X) will be equal to the difference between the
values of the inductive and capacitive reactances. The net Reactance (X) will be inductive
if XL> XCand capacitive if XC> XL.
Impedance, Z: It is the vectorial sum of Resistance and Reactance vectors in a circuit.
Active Power (P), Watts: It is denoted as “P” and the unit is “Watt”. It is the power that
is consumed in the resistive elements of the load. A load will require additional Reactive
Power for powering the inductive and capacitive elements. The effective power required
would be the Apparent Power that is a vectorial sum of the Active and Reactive Powers.
Reactive Power (Q), VAR: Is denoted as “Q” and the unit is VAR. Over a cycle, this power
is alternatively stored and returned by the inductive and capacitive elements of the load.
It is not consumed by the inductive and capacitive elements in the load but a certain
of one cycle, the net value of this power is 0. However, on an instantaneous basis, this
power has to be provided by the AC source. Hence, the inverter, AC wiring and over cur-
rent protection devices have to be sized based on the combined effect of the Active and
Reactive Powers that is called the Apparent Power.
SECTION 2 | General Information
8 | SAMLEX AMERICA INC.
Apparent (S) Power, VA:
Power in Watts and the Reactive Power in “VAR”. In magnitude, it is equal to the RMS
value of voltage “V” X the RMS value of current “A”. The Unit is VA. Please note that
Apparent Power VA is more than the Active Power in Watts. Hence, the inverter, AC wir-
ing and over current protection devices have to be sized based on the Apparent Power.
Maximum Continuous Running AC Power Rating: This rating may be specied as “Ac-
-
=1. Reactive types of loads will draw higher value of “Apparent Power” that is the sum
of “Active and Reactive Powers”. Thus, AC power source should be sized based on the
power source may be subjected to overload conditions when powering Reactive Type of
loads.
Surge Power Rating:
-
Electric Motors: At the moment when an electric motor is powered ON, the rotor is
-
proportional to the RPM is generated in the windings and the current draw reduces
Rating at the rated RPM.
Transformers (e.g. Isolation Transformers, Step-up / Step-down Transformers, Power Trans-
former in Microwave Oven etc.): At the moment when AC power is supplied to a transformer,
the transformer draws very heavy surge of “Magnetization Inrush Current” for a few millisecs
Devices like Infrared Quartz Halogen Heaters (also used in Laser Printers) / Quartz
Halogen Lights / Incandescent Light Bulbs using Tungsten heating elements: Tungsten
has a very high Positive Temperature Coefcient of Resistance i.e. it has lower resist-
ance when cold and higher resistance when hot. As Tungsten heating element will be
cold at the time of powering ON, its resistance will be low and hence, the device will
draw very heavy surge of current with consequent very heavy surge of power with a
SECTION 2 | General Information
8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 2 | General Information
AC to DC Switched Mode Power Supplies (SMPS): This type of power supply is used as
stand-alone power supply or as front end in all electronic devices powered from Util-
-
input side capacitors start charging resulting in very high surge of Inrush Current for a
Power Factor, (PF): It is denoted by “PF” and is equal to the ratio of the Active Power
purely inductive or purely capacitive loads. Practically, the loads will be a combination of
Load: Electrical appliance or device to which an electrical voltage is fed.
Linear Load: A load that draws sinusoidal current when a sinusoidal voltage is fed to it.
Non-Linear Load: A load that does not draw a sinusoidal current when a sinusoidal volt-
Resistive Load:
Reactive Load: A device or appliance that consists of a combination of resistive, inductive
The AC power source has to be sized based on the higher Apparent Power (VA) and also
based on the Starting Surge Power.
10 | SAMLEX AMERICA INC.
2.2 OUTPUT VOLTAGE WAVEFORMS
TIME
360
320
280
240
200
160
120
80
40
0
40
80
120
160
200
240
280
320
360
Modied Sine
Wave sits at
ZERO for some
time and then
rises or falls
VPEAK = 325.22V
Modied Sine Wave
Sine Wave
Pure Sine Wave
crosses Zero Volt
instantaneously
VPEAK = 280 to 320V
VRMS = 230 VAC
VOLTS (+)VOLTS (–)
20.00 ms for 50 Hz
16.66 ms for 60 Hz
Fig. 2.1: Pure and Modied Sine Waveforms for 230 VAC, 50/60 Hz
also shows Modied Sine Waveform for comparison.
In a Sine Wave, the voltage rises and falls smoothly with a smoothly changing phase
angle and also changes its polarity instantly when it crosses 0 Volts. In a Modied Sine
Wave, the voltage rises and falls abruptly, the phase angle also changes abruptly and
it sits at zero V for some time before changing its polarity. Thus, any device that uses a
Modied Sine Waveform.
Also, as the Modied Sine Wave is a form of Square Wave, it is comprised of multiple
frequency harmonic content in a Modied Sine Wave produces enhanced radio interfer-
frequency harmonics also produce overloading effect in low frequency capacitors due to
lowering of their capacitive reactance by the higher harmonic frequencies. These capaci-
single-phase induction motors as Start and Run Capacitors. Thus, Modied and Square
Wave inverters may shut down due to overload when powering these devices.
SECTION 2 | General Information
10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11
SECTION 2 | General Information
2.3 ADVANTAGES OF PURE SINE WAVE INVERTERS
and cooler.
Improvement Capacitors and single phase motors containing Start and Run Capacitors
glitches in monitors.
2.4 SOME EXAMPLES OF DEVICES THAT MAY NOT WORK PROPERLY WITH
MODIFIED SINE WAVE AND MAY ALSO GET DAMAGED ARE GIVEN BELOW:
-
tools. These may get damaged. Please check with the manufacturer of these types of
devices for suitability.
These may get dam-
aged. Please check with the manufacturer of these types of devices for suitability.
The inverter may shut down indicating overload.
2.5 POWER RATING OF INVERTERS
i
INFO
-
12 | SAMLEX AMERICA INC.
The power rating of inverters is specied as follows:
during start up of certain AC appliances and devices.
Please read details of the above two types of power ratings in Section 2.1 under
“DEFINITIONS”
i
INFO
The manufacturers’ specication for power rating of AC appliances and devices
short duration surge of power required during start up of some specic types
manufacturer. This may not be possible in all cases and hence, can be guessed
at best, based on some general Rules of Thumb.
duration surge of power during start up. An “Inverter Sizing Factor” has been recom-
-
mum Continuous Running Power Rating of the inverter.
TABLE 2.1: INVERTER SIZING FACTOR
Type of Device or Appliance
Inverter
Sizing Factor
(See note 1)
5
Air Compressor 4
3
3
2
Furnace Fan 3
Industrial Motor 3
3
3
3
4
2
SECTION 2 | General Information
12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13
NOTES FOR TABLE 2.1
SECTION 3 | EMC (EMI / EMS) Compliance
3.1 EMC (EMI / EMS) COMPLIANCE
These inverters contain internal switching devices that generate conducted and radiated
eliminated. The magnitude of EMI is, however, limited by circuit design to acceptable
levels as per limits laid down in European Standard EN 55022, Class A. These limits are
designed to provide reasonable protection against harmful interference when the
equipment is operated in business / commercial / industrial environments. These invert-
ers can conduct and radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio com-
munications.
Section 12 for relevant European Standards.
3.2 REDUCING EMI THROUGH PROPER INSTALLATION
- Ensure that the inverter is rmly grounded to the ground system of the building or
the vehicle
devices as possible
inductance and induced voltages. This reduces ripple in the battery wires and im-
proves performance and efciency.
- Shield
- Use high quality shielded cables to attach audio and video devices to one another
SECTION 2 | General Information
14 | SAMLEX AMERICA INC.
4.1 CHARACTERISTICS OF SWITCHED MODE POWER SUPPLIES (SMPS)
-
audio and video devices, radios etc. SMPS use large capacitors in their input section for
ltration. When the power supply is rst turned on, there is a very large inrush cur-
turn-on is several to tens of times larger than the rated RMS input current and lasts for
given in Fig. 4.1. It will be seen that the initial input current pulse just after turn-on is >
15 times larger than the steady state RMS current. The inrush dissipates in around 2 or 3
Further, due to the presence of high value of input lter capacitors, the current drawn
in Fig 4.2. The steady state input current of SMPS is a train of non-linear pulses instead
of a sinusoidal wave. These pulses are two to four milliseconds duration each with a very
-
ance when cold and a low resistance when hot. The NTC resistor is placed in series with
the input to the power supply. The cold resistance limits the input current as the input
capacitors charge up. The input current heats up the NTC and the resistance drops
on, the NTC resistor will be hot so its low resistance state will not prevent an inrush
current event.
The inverter should, therefore, be sized adequately to withstand the high inrush current
and the high Crest Factor of the current drawn by the SMPS. Normally, inverters have
Hence, it is recommended that for purposes of sizing the inverter to accommodate
Crest Factor of 3, the Maximum Continuous Power Rating of the inverter should be > 2
times the Maximum Continuous Power Rating of the SMPS. For example, an SMPS rated
at 100 Watts should be powered from an inverter that has Maximum Continuous Power
Rating of > 200 Watts.
SECTION 4 | Powering Direct / Embedded Switch
Mode Power Supplies (SMPS)
14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15
Input voltage
Inrush current
Peak inrush
current Rated steady state
input RMS current
NOTE: Voltage
and current scales
are dierent
Fig 4.1: Inrush current in an SMPS
TIME
Peak Current
RMS Current
Non-linear
Input Current
Pulse
Input Sine
Wave Voltage
Crest Factor = Peak Current = 3
RMS Current
Voltage (+)Voltage (–)
Current (+)Current (–)
NOTE: Voltage
and current scales
are dierent
Fig. 4.2: High Crest Factor of current drawn by SMPS
SECTION 4 | Powering Direct / Embedded Switch
Mode Power Supplies (SMPS)
16 | SAMLEX AMERICA INC.
5.1 GENERAL
5.2 PURE SINE WAVE OUTPUT WAVEFORM
The waveform of the AC voltage is a pure Sine Waveform that is same as the waveform
(Supplementary information on pure Sine Waveform and its
advantages are discussed in Sections 2.2 to 2.4).
The instantaneous value and polarity of the voltage varies cyclically with respect to time.
-
TIME
0V
Peak Negative Voltage
- VPEAK = - 325.22V
VRMS = 230 VAC
Peak Positive Voltage
+ VPEAK = + 325.22V
Voltage (+)Voltage (–)
20.00 ms for 50 Hz
16.66 ms for 60 Hz
Fig. 5.1: 230 VAC, 50/60 Hz Pure Sine Waveform
5.3 PRINCIPLE OF OPERATION
-
frequency and the pulse width of this switching is modulated with respect to a refer-
ence sine wave.
SECTION 5 | Principle of Operation
16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17
SECTION 6 | Layout
WARNING: REVERSE POLARITY
WILL DAMAGE THE UNIT
! !
Fig 6.1 (a) PST-300S, Front
Fig 6.1 (b) PST-300S, Front - Showing
compartment with terminals for hardwiring
Fig 6.1 (c) PST-300S, Back
1. Three Position Rocker Switch
•– ON-PushtopendtoswitchONlocally
•0 OFF–CenteredtoswitchOFFlocally
•= EXTSwitch-Pushbottomendto
enable switching ON and OFF by
external switching control
2. Green LED marked “POWER”
3. Red LED marked “OVER LOAD”
4. RED LED marked “OVER TEMP”
5. Air inlet slots for cooling fan
6. European "Schuko" CEE 7/3 Receptacle
7. Metal strain relief clamp for AC output cable
(for hardwiring)
•Size:TradeSize:¾”
•Wiresizeaccommodated:3-Conductor
“Loomex” cable - AWG #14/3 to AWG #8/3
8. Cover plate for compartment containing
L1, L2 and G terminals for hardwiring of AC
output to 230VAC Panelboard
9. Modular Jack RJ-50 (10P10C) marked
“Remote” for connecting optional wired
Remote Control Model RC-300
10. Terminal Block marked “EXT Switch” with
4 terminals for ON / OFF switching using
external control signals
11. Compartment containing L1, L2 and G
terminals for hardwiring of AC output to
230VAC Panelboard
12. Nut and bolt terminal (size 6x32) for
Ground “G” for hardwiring of AC output
to 230VAC Panelboard
13. Terminal Block for Line Terminals L1 and L2
for hardwiring of AC output to 230VAC
Panelboard
•Terminalholediameter:4.15mm
•Terminalsetscrewsize:M3.5
14.BlackNegative(-)DCinputterminal–Nut
and bolt: 5/16 in, 18 TPI
15. Black removable plastic cover for Negative
(-) DC input terminal
16.RedPositive(+)DCinputterminal–Nut
and bolt: 5/16 in, 18 TPI
17. Red removable plastic cover for Positive (+)
DC input terminal
18. Opening for air outlet from internal fan (fan
is located behind the opening)
19. Chassis Grounding Terminal
•HoleDiameter:5/16”
•Setscrewsize:5/16x24TPI
20. 50/60 Hz Selector Switch
To Schuko
Ground
To
Schuko
}
18 | SAMLEX AMERICA INC.
7.1 GENERAL
i
INFO
White Paper - Batteries, Chargers and Alternators.
1.
2.
of inverters.
7.2 DEEP CYCLE LEAD ACID BATTERIES
sources, to have a constant discharge rate, to have the capability to be deeply dis-
powering these inverters.
7.3 RATED CAPACITY SPECIFIED IN AMPERE-HOUR (Ah)
-
ment for electrical current and is dened as a Coulomb of charge passing through an electri-
cal conductor in one second. The Capacity “C” in Ah relates to the ability of the battery to
over a specied time in hours before the battery reaches a specied discharged terminal
in this case will be the number of Amperes of current the battery can deliver for 20 Hours at
-
7.4 RATED CAPACITY SPECIFIED IN RESERVE CAPACITY (RC)
vehicle can be driven after the charging system fails. This is roughly equivalent to the
conditions after the alternator fails while the vehicle is being driven at night with the
headlights on. The battery alone must supply current to the headlights and the com-
SECTION 7 | General Information on Lead Acid
Batteries
18 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 19
SECTION 7 | General Information on Lead Acid
Batteries
Reserve capacity is the time in minutes for which the battery can deliver 25 Amperes at
battery and 42V for 48V battery.
Capacity “C” in Ah = Reserve Capacity in RC minutes x 0.6
7.5 TYPICAL BATTERY SIZES
TABLE 7.1: POPULAR BATTERY SIZES
BCI* Group Battery Voltage, V Battery Capacity, Ah
12 105
12
12 225
GC2** 220
* Battery Council International; ** Golf Cart
7.6 SPECIFYING CHARGING / DISCHARGING CURRENTS: C-RATE
stored energy is related to the amount of the active materials pasted on the battery
plates, the surface area of the plates and the amount of electrolyte covering the plates.
the battery and is designated by the symbol “C”.
The time in Hours over which the battery is discharged to the “End Point Voltage” for
as the “C-Rate”. If the battery delivers a very high discharge current, the battery will be
discharged to the “End Point Voltage” in a shorter period of time. On the other hand,
if the battery delivers a lower discharge current, the battery will be discharged to the
“End Point Voltage” after a longer period of time. Mathematically:
EQUATION 1: Discharge current “C-Rate” = Capacity “C” in Ah ÷ Discharge Time “T”
TABLE 7.2: DISCHARGE CURRENT RATES - “C-RATES”
Hours of discharge time “T” till
the “End Point Voltage”
"C-Rate" Discharge Current in Amps =
Capacity "C" in Ah ÷ Discharge Time
"T" in Hrs.
Example of C-Rate
Discharge Currents
for 100 Ah battery
0.5 Hrs. 2C 200A
1 Hrs. 1C 100A
20A
}
20 | SAMLEX AMERICA INC.
SECTION 7 | General Information on Lead Acid
Batteries
TABLE 7.2: DISCHARGE CURRENT RATES - “C-RATES” (continued from Previous page)
Hours of discharge time “T” till
the “End Point Voltage”
"C-Rate" Discharge Current in Amps =
Capacity "C" in Ah ÷ Discharge Time
"T" in Hrs.
Example of C-Rate
Discharge Currents
for 100 Ah battery
12.5A
10A
5A
100 Hrs. 1A
NOTE: When a battery is discharged over a shorter time, its specied “C-Rate” discharge current will
7.7 CHARGING / DISCHARGING CURVES
Please note that X-axis shows % State of Charge. State of Discharge will be = 100% - %
State of Charge
Lead-Acid Battery Chart - 80˚F / 26.7˚C
Battery Voltage in VDC
Battery State of Charge in Percent (%)
0 10 20 30 40 50 60 70 80 90 100 110 120 130
16.5
16.0
15.5
15.0
14.5
14.0
13.5
13.0
12.5
12.0
11.5
11.0
10.5
10.0
9.5
9.0
C/5
C/40
C/20
C/10
DISCHARGE
CHARGE
C/20
C/3
C/5
C/10
C/100
33.0
32.0
31.0
30.0
29.0
28.0
27.0
26.0
25.0
24.0
23.0
22.0
21.0
20.0
19.0
18.0
24V 12V
Fig. 7.1: Charging / Discharging Curves for 12V / 24V Lead Acid Battery
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