Sensata ADI-300/3000D User manual

DC to AC Power Inverters
OWNERS MANUAL for Model:
ADI-300/3000D
ADI-300/5000D
ADI-300/7000D
Form121208
Including Options T, T1
121208B
OWNERS MANUAL JANUARY 2007
Manufacturer of DimensionsTM Inverters
4467 White Bear Parkway
St. Paul, MN 55110
Phone: [phone] Fax: [phone]
E-mail: [email protected]
Web: www.dimensions.sensata.com

OWNERS MANUAL
FOR SENSATA TECHNOLOGIES
DIMENSIONS INVERTERS
Model ADI-300/3000D
Model ADI-300/5000D
Model ADI-300/7000D
Including options T, R
Table of Contents
Page
1. General . . . . . . . . . . . . . . 2
2. Description . . . . . . . . . . . 2
3. Installation . . . . . . . . . . . 2
4. Start Up/Operation. . . . . . 4
5. Troubleshooting. . . . . . . . 5
6. Wiring Diagram . . . . . . . . 6
7. Warranty . . . . . . . . . . . . 7
1. GENERAL
1.01 Dimensions inverters have been
designed and manufactured for many user
applications and long life. They utilize
patented construction methods and high
technology electronic parts and circuitry.
1.02 CAUTION: Inverters produce haz-
ardousvoltages,toavoid riskofharmorfire
theunitmustbeproperlyinstalled.Thereare
no user serviceable parts inside, do not
remove the cover.
CAUTION: The inverter should not be
installed in a zero clearance enclosure.
CAUTION: Damagetotheinverterwilloccur
if correct polarity is not observed when
installing the DC input cables.
CAUTION: Damage to the inverter will
occur if an external AC power source is
applied to the inverter’s AC output or it’s
hardwire output.
CAUTION: Working in the vicinity of lead-
acidbatteriesisdangerous.Batteriesgener-
ateexplosivegasesduringoperation. There
isa riskof acidexposure. Thereis alsoa risk
of high current discharge from shorting the
battery that can cause fire and explosion.
CAUTION: Be sure both the inverter and, if
used,theexternalACinputcircuitbreakeror
fuse are turned OFF during installation.
2. DESCRIPTION
2.01 The inverter converts 300 VDC to
120/240 VAC, 60 HZ, having a quasi-sine
wave form.
2.02 The inverter has internal protec-
tion against output short circuit, output
overload and high temperature conditions.
2.03 The enclosure is sealed to meet
Nema 12 requirements.
2.04 The inverter is designed to oper-
ate almost any 120/240 VAC, 60 HZ, single
phaseappliance,equipmentortoolwithinits
power ratings that does not require a pure
sine waveform.
3. INSTALLATION
3.01 The following instructions should
be thoroughly read and understood before
installation.
3.02 CAUTION: Inverters produce
hazardousvoltages,to avoidriskof harmor
Page 2

fire the unit must be properly installed.
CAUTION: Damage to the inverter will
occurifcorrectpolarityisnotobservedwhen
installing the DC input cables.
CAUTION: Damage to the inverter will
occur if an external AC power source is
applied to the inverter’s AC outlet or it’s
hardwire output.
CAUTION: Be sure both the inverter and, if
used, the external AC input circuit breaker or
fuse are 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.
NOTE: Usecare tosealall inputandoutput
connections to maintain the Nema 12
dustproof enclosure protection.
3.03 Mounting
3.03.1 Locate a suitable, secure flat
mounting surface. The maximum recom-
mended distance between the mounting
location and the power source is 40 feet.
3.03.2 The location should provide
adequateventilationandclearancetomain-
tain less than 400C while the unit is operat-
ing. At least 1/2 inch of clearance is required
on all sides.
3.03.3 Secure the unit with 1/4 inch
screws or bolts in the mounting slots on the
flanges of the chassis.
3.04 Chassis Bonding Lug - FIG. 1
3.04.1 Connect a #8 gauge or greater
copperwirebetweenthebondinglugonthe
inverter and the earth grounding system.
Page 3
3.05 D.C. Input Wiring - Fig. 1
3.05.1 Use stranded copper wire be-
tween the power source and inverter as
indicated. A line fuse must be installed
between the power source and the inverter.
DC Input Wire Lengths (maximum)
and Fusing Guide
Distance (feet) Line
Model 1-19 20-40 Fuse
300/3000 10 ga 8 ga 20
300/5000 8 ga 6 ga 40
300/7000 6 ga 4 ga 50
3.05.2 NOTE: Using smaller input
cable or longer length will greatly degrade
the inverter's surge performance.
3.05.3 Install the wires at the power
source,inverter andthenfuseholder. Make
surethatgood,cleanconnectionsaremade.
Use care not to touch the positive and
negative wires together. This will result in a
violent spark and fire.
3.05.4 CAUTION: Connecting the
inverter to the power supply with reverse
polarity will cause damage that is not cov-
ered under warranty.
3.05.5 The DC input terminals are
locatedinthewiringcompartment. Amount-
ing spark may result when connecting the
input wire, due to an initial charging of the
of the internal input capacitor.
3.07 120/240 VAC Output
3.07.1 CAUTION: Do not connect an
other 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!

5. TROUBLESHOOTING
5.01 Sensata offers free phone consulta-
tion (no collect calls) concerning installation
or troubleshooting. Call the Customer Ser-
vice Department at:
1-651- 653-7000 or 1-800-553-6418
fax number: 651-653-7600
e-mail: [email protected]
NOTE: Since the inverter has a quasi-sine
waveform, a TRUE RMS volt meter is re-
quired for an accurate reading. Other volt
meters that use averaging circuitry will give
incorrect readings.
5.02 Iftheinverterfailstooperate,usethe
following troubleshooting procedure.
5.02.1 Connect a 100 watt light bulb to
the inverter output.
5.02.2 Make sure inverter is turned
“On”, and the circuit breakers are reset.
5.02.3 Observe the fault indicating
lights on the front of the inverter.
a) TheLowinputvoltagelightindicates
a low power source condition. Switch the
inverter“Off”for5seconds,then“On”again.
Thelight comingonagainindicatesafaultin
the D.C. wiring, power source capacity and
voltage or the line fuse.
b) The Overload light indicates an
outputwiringshortcircuitoraloadthatistoo
large for the power rating of the inverter.
Switch the inverter “Off”, remove the short
circuitorexcessiveloadfromtheoutput,then
switch the inverter back “On”.
c) TheHightemperaturelightindicates
the inverter has overheated. The unit will
automaticallyturnbackonwhenithascooled
Page 4
3.07.2 The 120/240 VAC output is
presented behind the wiring compartment
panel for direct hardwire connection. The
black wires are hot, the white wire is neutral
and the green wire is ground. The cable
clamp strain relief should be used to secure
the field wires.
3.07.3 The remote AC outlets should
be mounted at a convenient location in a
listed outlet box with approved strain relief.
3.08 120/240 VAC Input (T or T1
option)
3.08.1 120/240 VAC, 60 HZ power
from the electric utility or generator can be
connectedtothe inverterwithhardwirecon-
nections at the AC Input wire leads provided
in the hardwire compartment. The black
wires are hot, the white wire is neutral, and
the green wire is ground. The cable clamp
strainreliefshouldbeusedtosecurethefield
wires.
3.08.2 The input circuit should have
30 amp (50 amp for T1) circuit protection
from the distribution panel.
3.08.3 Ifprovidedwiththe"T"or"T1"
option, when external 120/240 VAC is sup-
plied,theinternaltransferswitchisautomati-
cally activated, the inverter is turned "Off",
and the inverter's loads will operate from
external AC.
4. START UP/OPERATION
4.01 To operate the inverter, turn the
inverter switch to “ON”. Assure that the
breakers are reset.

to 40 degrees C. Verify that the inverter is
not in a closed air tight compartment.
5.03 Call Sensata for technical
assistanceand/orareturnauthorizationnum-
beriftheabovestepsarecompletedandthe
inverter still will not operate satisfactory.
Page 5

DCFUSEAND
DISCONNECT
300VDCBUSS
INPUT
A.C.INPUT
(T or T1 OPTION)
A.C.OUTPUT
FIGURE 1 INSTALLATION WIRING
Positive(+)
Negative(-)
WARNING: Connecting the power supply with the wrong polarity to the
inverter will cause damage that is not covered under the warranty.
Page 6

Page 7
Limited Warranty Terms & Conditions
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 are 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, Power Controls White Bear, 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.
RETURNGOODSPOLICY:
•No returned materials will be accepted without an accompanying Returned Materials Authorization Number (RMA) from the factory.
The RMA number must be clearly printed outside the inverter box.
•Credit will be issued for returned goods to the original purchaser within 60 days of purchase, provided the inverter is returned to
Sensata unused and not mounted. The amount of credit will be issued at Sensata's discretion based on the condition of the product.
•Customer must be in good standing with Sensata Technologies.
•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 Sensata vendors will be covered under that manufacturer's credit return policy.
•Customer pays return freight.
PLEASE SHIP AUTHORIZED RETURNS TO:
Sensata Technologies / Power Controls White Bear / 4467 White Bear Parkway / St. Paul, MN 55110
Return Freight Prepaid
LIMITED WARRANTY:
Sensata Technologies extends the following warranty to the original purchaser of those goods subject to the qualifications indicated.
Sensata warrants to the original purchaser for use that the goods or any component thereof manufactured by Sensata 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. Damages caused by the misuse, undue care or
obvious wear through use will not be covered by this warranty.
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.
To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material Authori-
zation (RMA). Once obtained, send the Return Material Authorization Number along with the defective part or goods to: Sensata
Technologies, Power Controls White Bear, 4467 White Bear Parkway, St. Paul, MN 55110, Return Freight Prepaid.
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A 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. SENSATA TECHNOLOGIES WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
WARNING: LIMITAIONS ON USE: DIMENSIONS brand products are not intended for use in connection with Life Support Systems and
for Avionic use. Sensata Technologies makes no warranty or representation in connection with their products for such uses.
R