Sensata 24TX60 User manual

Form: 122189 © 2012 Sensata Technologies 1
DC to AC POWER INVERTERS
Quasi-Sine Wave 3-Phase Output
MODEL: 24TX60
OWNER’S INSTRUCTIONS

Form: 122189 © 2012 Sensata Technologies 2
OWNERS MANUAL
INVERTER MODEL
24TX60
Table of Contents
Page
1. Safety Instructions ……………. 3
2. Specifications …………………. 4
3. Technical Description ….…….. 5-6
4. Inverter Description…………… 7
5. Status Panel Description……... 8
6. Installation ……………............. 9-11
7. Operation & Troubleshooting... 12
8. Limited Warranty ……………… 13
9. Notes …………………………… 14

Form: 122189 © 2012 Sensata Technologies 3
1 Safety Instructions
Important: Read this manual before installation, it contains important safety, installation, and
operating instructions. Save this manual and keep it in a safe place.
1.1 Warning and Danger Symbols:
To reduce the risk of electrical shock and to ensure the safe operation of your Dimensions
power inverter, the following symbols are used throughout the manual.
ATTENTION:
Important operating instructions.
Follow them closely.
DANGER:
Risk of personal harm and/or
electrocution exists in this area.
Use extreme caution.
1.2 Inverter System Precautions:
Inverter Systems produce hazardous voltages. To avoid risk of harm or fire, the unit
must be properly installed.
There are no user serviceable parts inside, do not remove the cover.
The Inverter System should not be mounted in a location that may be exposed to rain
or spray.
The Inverter System should not be installed in a zero clearance enclosure.
Damage to the Inverter System will occur if correct polarity is not observed when
installing the DC input cables.
Damage to the Inverter System will occur if an external AC power source is applied to
the inverter’s AC hardwire output.
The Inverter System contains a capacitor that may produce a spark. Do not mount in a
confined battery or gas compartment.
Be sure the Inverter System is turned OFF during installation.
1.3 Battery Precautions:
Working in the vicinity of lead-acid batteries is dangerous. There is a risk of acid
exposure.
Batteries generate explosive gases during operation.
There is risk of high current discharge from shorting a battery that can cause fire and
explosion. Use insulated tools during installation.
Remove all rings, watches, jewelry or other conductive items before working near the
batteries.
Inspect the batteries once a year for cracks, leaks or swelling.
Dispose of the batteries according to local regulations. Do not incinerate batteries; risk
of explosion exists.

Form: 122189 © 2012 Sensata Technologies 4
Dimensions 3-Phase Power Inverters
Environmentally Friendly, Quiet, Reliable, AC Power
MODEL NUMBER
24TX60
Output Power
(Watts Continuous)
6,000
Output Current
(Amps AC per phase)
Up to 16
Peak Output
(Amps AC per phase)
40
Output Rating
(horsepower)
5
Input Current
(Amps DC)
Up to 300
Weight (lbs.)
164
Dimensions
in.(LxWxH)
18.4 x 27.2 x 10.8
Output Voltage (VAC)
220Y/120 RMS
Output Frequency:
60 Hz ± 0.02%’
3 phase/1 phase
Output Waveform:
Quasi-sine wave, single pulse per
phase, pulse width modulated
Input Voltage: (VDC)
22 to 28
Operating Temperature:
-20° to 40° C (-0° to 104° F)
Efficiency:
Better than 85%
Other Design Features:
Vent-less for moisture and dust resistance
Will withstand vibrating environment
Thermally controlled cooling fan
Elapsed time hour meter
Remote panel with LED indication for Inverter
Power, Low input voltage, Overload and High
temperature.
Remote ON/OFF switch hook up (12 VDC
input)
Unit Protection:
Automatic electronic short
circuit/overload protection
Automatic high temperature shutdown
Output circuit breaker
Battery Protection:
Automatic low battery shutdown at
22VDC (with 2.5 second delay)
Usage: Any 220VAC, 60 Hz, single or 3 phase product and/or 120VAC,
60Hz, single phase equipment within the inverter’s power rating that does
not require a pure sine waveform.
Warranty: Full 2 year parts and factory labor
Specifications are subject to change without notice.

Form: 122189 © 2012 Sensata Technologies 5
3 Technical Descriptions:
3.1 Inverter System:
The remote “On/Off” switch controls the inverter and the remote status LED’s provides the
system status.
3.1.1 Inverter Power Mode: The inverter converts 24VDC power from batteries to usable 220
VAC, 3-phase; or 220 VAC single phase; or 120 VAC, single phase; all at 60 HZ, having a
quasi-sine wave form. The direct current (DC) that enters the inverter is filtered by a large input
capacitor and switched “On” and “Off” by the Metal Oxide Silicon Field Effect Transistors
(MOSFET) at a rate of 60 cycles per second, and directed into the transformer which steps the
voltage up to 120 volts. The signal output waveform shape is not sinusoidal; it has a total
harmonic distortion of 35% and a maximum single harmonic distortion of 25%.
3.2.1 Inverter Remote On/Off: The remote On/Off control circuitry requires +12VDC volts to
operate.
3.3.1 Inverter Circuit Protection: The inverters have internal protection against output short
circuit, output overload low input voltage and high temperature conditions. Also, there are
thermally controlled cooling fans.
3.4.1 Inverter Cable assembly kit: The inverter has a cable kit that includes several parts that
are required to be installed to maintain the chassis seal. Please see the picture below for piece
parts. The kit also includes an orange wire (not pictured).

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3.5.1 Inverter chassis is “designed to meet”Nema 4X: This chassis requires special
handling and attention if the design objectives are to be met. We need to install the chassis
system correctly or water will find a way to get inside. The inverter has silicone seals for the top,
side and DC cover plate. There is NO reason to take off the top or side cover plates!
The DC cover plate will need to be installed correctly. The DC box has DC power cables that
have Heyco strain relief connectors that are to be tightened as follows: Sealing nut (outside of
the DC box) is to be at 80 in lbs. and the locking nut (inside the box) is to be set at 60 in lbs.
The AC cable has the same Heyco strain relief that is connected to the chassis end at the
factory to the same specs. There is a special pressure release valve installed at the factory.
! NOTE: The DC cover plate screws must be started by HAND first to make sure that you have
the correct orientation for the screws and then tightened to 16 in lbs in a specific sequence.
! NOTE: The inverter serial number and date code are inside the DC box.
FIGURE 1: DC COVER PLATE (Tightening sequence and torque specification.)

Form: 122189 © 2012 Sensata Technologies 7
4 Inverter Physical Descriptions:
4.1 Inverter Module
FIGURE 2: Chassis physical description and installations dimensions.
FIGURE 3: DC Box (! See torquing requirements for cover plate; round seal goes on outside
of box DC cable Heyco strain reliefs)

Form: 122189 © 2012 Sensata Technologies 8
5 Status Panel Descriptions:
5.1 LED Remote Status Panel (Sensata Part Number 245035)
FIGURE 4: LED Status Panel
(a) Inverter power: Green LED that indicates the inverter is operating from in “Inverter Mode”.
(b) Low battery: Red LED that indicates the inverter is in a “Low Battery”voltage condition.
(c) Overload: Red LED that indicates the inverter is in an “Overload”condition.
(d) High Temperature: Red LED that indicates the inverter has a “High Temperature” condition.
a
b
c
d

Form: 122189 © 2012 Sensata Technologies 9
6 Installation
6.1 Tools for Installation:
Tools required for installation: 3/4” socket wrench, connectors (butt type and insulated), drill, Crimpers (for
insulated and non-insulated connectors), volt meter with probes, electrical tape, #2 Phillips screwdriver,
wire cutters, wire strippers, cable ties, and a tape measure.
6.2 Mounting the inverter:
Figure 5 (Inverter Footprint)
Locate a suitable, secure vertical or horizontal mounting surface as close to the batteries as
possible without being in the same airtight compartment.
If mounting the inverter on a vertical surface, it is recommended that the front control panel
be pointing down whenever possible.
Locate the mounting holes on the chassis flanges and fasten them using ¼ inch diameter
screws to secure the inverter. See figure 5.
6.2.1 The following instructions should be thoroughly read and understood before installation.
6.2.2 CAUTION: Inverters produce hazardous voltage, and to avoid risk of harm or fire the unit must be
properly installed.
CAUTION: The inverter should not be mounted in a location that may be exposed to rain or spray.
CAUTION: The inverter should not be installed in a zero clearance enclosure.
CAUTION: When working near batteries, safety goggles should be worn.
CAUTION: Be sure the inverter is turned "OFF" during installation. NOTE: All wiring must follow the
National Electric Code, provincial or other codes in effect at the time of installation, regardless of
suggestions in this manual. All wires should be copper conductors.
The inverter mounting location should provide adequate ventilation and clearance to maintain
room temperature during operation. At least 1/2 inch of clearance is required on all sides.

Form: 122189 © 2012 Sensata Technologies 10
6.3 Mounting
6.3.1 Locate a suitable, secure flat mounting surface as close to the 24 volt auxiliary batteries as possible
without being in the same air tight compartment. The maximum recommended distance between the
mounting location and the battery is 10 feet.
6.3.2 The location should provide adequate ventilation and clearance to maintain room temperature while
the unit is operating. At least 1/2 inch of clearance is required on all sides.
6.3.3 Secure the unit with 1/4" screws or bolts in the mounting holes on the legs of the unit.
6.4 DC Wiring
6.4.1 CAUTION: Assure that hydrogen gas does not accumulate near the battery by keeping the area
well ventilated. A spark may result when connecting the final battery wiring due to initial charging of the
internal input capacitor.
6.4.2 Use stranded copper cable between the battery and the inverter as indicated. Keep the distance to
less than 10 feet. A line fuse must be installed between the battery and the inverter. UL requires that the
fuse be within 18 inches of the battery.
Cable gauge Line fuse
24TX60 4/0 500 amp
6.4.3 Use only an approved fuse holder with a U.L. listed fuse as indicated above.
6.4.4Using smaller input cable or longer length will greatly degrade the inverter peak performance.
IMPORTANT NOTE FOR VEHICLE INSTALLATION: Do not use the vehicle chassis as the negative
return in place of a return cable. Use the same size cable as the positive connection and run directly to
the battery.
6.4.5 Install the cables at the battery, inverter and then fuse holder. Make sure that clean, tight
connections are made. Use care not to touch the positive and negative cables together. A violent spark
will result and could result in exploding batteries and fire.
6.4.6 The battery input terminals are located in the wiring compartment. A mounting spark may result
when connecting the battery wire, due to an initial charging of the internal input capacitor.
6.4.7 CAUTION: Connecting the inverter to the wrong polarity of the battery will cause damage that is not
covered under warranty.
6.4.8 3-phase DC Input Lug Torque; UL 486E states 30 ft/lbs. for brass, therefore, the recommended
torque is or 30 ft. lbs. (360 in. lbs.).

Form: 122189 © 2012 Sensata Technologies 11
6.5 Remote ON/OFF Switch
NOTE: The inverter will not switch on unless the violet wire has +12 VDC applied to it.
6.5.1 All material used for the remote switch should be U.L. listed and installed per low voltage, Class 2,
wiring code. The remote switch hookup can not provide additional current to operate an indicating lamp.
6.5.2 The remote switch should be single pole and have at least a 5 amp rating, such as Leviton No.
1330-2. The wire used should be at least 18 gauges.
6.5.3 The switch should be mounted at a convenient location.
6.5.4 The remote switch should be connected to the violet wire marked “Remote Switch Hookup” in the
wiring compartment. Positive (+) 12 battery voltage must be connected to the other side of the switch.
Cable clamp strain relief should be used to secure the field wires.
6.5.5 This model designation has a remote On/Off switch circuit modified to accept +12 VDC. The remote
switch must be connected to the violet wire marked "Remote Switch Hookup".
6.6 220Y/120 VAC Output
6.6.1 CAUTION: Do not connect another source of AC power directly to the output of the inverter. This
will result in damage to the inverter that is not covered under warranty!
6.6.2 The A.C. output is presented at the A.C. wiring compartment. The 3 phase outputs are labeled “L1”,
“L2”, “L3”. There is also an A.C. neutral labeled “N” and a chassis ground labeled “G”.
6.6.3 To obtain 220 VAC, 3 phase output, a connection must be made to L1, L2, and L3.
6.6.4 To obtain 220 VAC, single phase output, a connection should be made to any two of the hot leads,
as L1 and L2, or L1 and L3, or L2 and L3.
6.6.5 To obtain 120 VAC, single phase output a connection should be made to any one hot lead and to
AC neutral “N”; as L1 and N, or L2 and N, or L3 and N.
6.6.7 Remote AC outlets should be mounted at a convenient location in a listed outlet box with approved
strain relief, if used.

Form: 122189 © 2012 Sensata Technologies 12
7 Operation and Troubleshooting
7.1 Operation To operate the inverter, switch the output circuit breaker switch to “ON”. Also switch
“ON” the remote on/off switch (if used).
7.1.2 Turning the inverter “ON”: To turn the inverter ON, set the On/Off switch to the “On”
position. The green “Inverter Power” LED will light.
7.2 Troubleshooting
Call or e-mail Customer Service Department for free consultation during business hours (central time
zone) at: 1-800-553-6418 or 1-651-653-7000; fax: [phone];
E-mail: inverteri[email protected]
A TRUE RMS voltmeter is required for accurate AC output voltage measurements on a quasi-sine
inverter. A voltmeter that uses averaging circuitry will give incorrect measurements.
Unplug all loads and connect a 100-watt light bulb to the inverter output. Observe the LED Status
Panel then check troubleshooting Table V.
Table V
PROBLEM
POSSIBLE CAUSES OR SOLUTIONS
No LEDs: No power output. The
inverter is not connected to the
batteries; the battery voltage is
below 9 volts DC or there is a
fault in the remote On/Off circuit.
Check the in-line fuses for continuity. Make sure the DC wires are
clean and tight. Check the DC voltage at the inverter DC input.
Check or bypass the remote On/Off circuit.
Low battery: Red LED indicator.
Indicates that the inverter has
shut off due to a low battery
voltage condition.
Fault in the battery wiring, battery capacity and voltage or the in-line
fuse. The inverter will shut off after 2.5 seconds. Switch the inverter
off then on to clear the error.
Overload: Red LED indicator.
Indicates that the inverter has
shut off due to an overload
condition.
The inverter output wiring is shorting or loads exceed the inverter
rating. The inverter will shut off after 2.5 seconds. Switch the
inverter off to clear the error. Remove the short circuit or excessive
load from the output, and then switch the inverter on.
High Temp: Red LED indicator
light. Indicates that the inverter
has shut off due to high internal
temperature. The unit will
automatically turn back on when
it has cooled to 40°C (104°F).
Verify that the inverter is in a vented compartment and that the fan
is not blocked. High ambient temperatures combined with poor
ventilation may also contribute to the shut down.
The battery voltage must be higher than 9 volts for the inverter to operate.
Turn the inverter OFF when not in use. There is an approximated 1 to 2 amp DC
draw from the batteries at idle or no load.

Form: 122189 © 2012 Sensata Technologies 13
8 Warranty
SHIPPING TERMS: F.O.B. St. Paul Minnesota. Freight prepaid and billed, subject to prior credit approval.
MINIMUM ORDER: $50.00 Net Price
LOSS OR DAMAGE: Loss or damage in transit is the responsibility of the carrier. Any claim should be filed with the delivering
transport company. Invoice, Bill of Lading and Delivery receipt with damage noted therein must accompany any claims for freight
damage. Claims for shortage and lost shipments must be made in writing to Sensata Technologies, St. Paul, MN within 10 days of
date of shipment. Claims not reported within this time frame will not be honored.
PRICES: Prices are subject to change without notice. All orders are subject to acceptance at the factory. We reserve the right to
invoice prices in effect at time of shipment.
TERMS: Net 30 days with approved credit, credit card or C.O.D.
RETURN GOODS POLICY
No returned materials will be accepted without an accompanying Returned Materials Authorization Number (RMA) from
factory.
Credit will be issued for returned goods to the original purchaser within 60 days of purchase, provided the inverter is returned
to Dimensions unused and not mounted. The amount of credit will be issued at Dimensions discretion based on the condition
of the product.
Customer must be in good standing with Dimensions.
Inverters that are discontinued, high-voltage (over 24vdc), special-order or used are excluded and will not be eligible for
credit. Non-inverter items such as cable assemblies, fuses and fuse holders, will not be eligible for credit
Support components supplied by Dimensions vendors will be covered under that manufacturer’s credit return policy.
Customer pays return freight.
PLEASE SHIP FREIGHT PREPAID AUTHORIZED RETURNS TO:
Sensata Technologies / 4467 White Bear Parkway / St. Paul, MN 55110
LIMITED WARRANTY: Sensata warrants to the original purchaser for use that the goods or any component thereof manufactured
by Dimensions will be free from defects in workmanship from the date of purchase for the period listed on the product label,
provided such goods are installed, maintained and used in accordance with Sensata and the original manufacturer’s written
instructions.
Components not manufactured by Sensata, but used within the assembly provided by Sensata, are subject to the warranty period
as specified by the individual manufacturer of said component, provided such goods are installed, maintained and used in
accordance with Sensata and the manufacturer’s written instructions.
Sensata’s sole liability and the Purchaser’s sole remedy for a failure of goods under this limited warranty and for any and all claims
arising out of the purchase and use of the goods shall be limited to the repair or replacement of the goods that do not conform to
this warranty. The return of the purchase price in cash is at the sole discretion of Sensata.
To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material
Authorization (RMA). Once obtained, send the Return Material Authorization Number along with the defective part or goods to:
Sensata Technologies, 4467 White Bear Parkway, St. Paul, MN 55110, freight prepaid.
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM
DATE OF PURCHASE.
SENSATA TECHNOLOGIES ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THE PRODUCT,
EXCEPT AS STATED IN THIS LIMITED WARRANTY. AIRPAX DIMENSIONS WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
WARNING: LIMITATIONS ON USE: Sensata products are not intended for use in connection with Life Support Systems and for
Avionic use. Sensata makes no warranty or representation in connection with their products for such uses.

Form: 122189 © 2012 Sensata Technologies 14
NOTES

Form: 122189 © 2012 Sensata Technologies 15
Important Notice: Sensata Technologies (Sensata) reserves the
right to make changes to or discontinue any product or service
identified in this publication without notice. Sensata advises its
customers to obtain the latest version of the relevant
information to verify, before placing any orders, that the
information being relied upon is current. Sensata assumes no
responsibility for infringement of patents or rights of others
based on Sensata applications assistance or product
specifications since Sensata does not possess full access
concerning the use or application of customers’ products.
Sensata also assumes no responsibility for customers’ product
designs