Sensata Dimensions 24U15 User manual

Manufacturer of Dimensions™ Inverters
4467 White Bear Parkway
St. Paul MN 55110
Phone: [phone] Fax: [phone]
E-mail: inverteri[email protected]
Web: www.dimensions.sensata.com
ISO 9001:2000 Registered Company
DC to AC Standby Power System
Owners Manual for Models:
24U1
Including Options:
A: Emergency Vehicles
B3: 3-Step Battery Charger
R2: Remote “On/Off” Switch - Ground Start
T: Transfer Switch Relay
U: Utility Vehicles
Form:
122067
D
January 2007

2 Form 122067
Table of Contents:
Section
Description
Page
1
Safety Instructions
..…………………………………………………..…
3
1.1
Warning and Danger Symbols ……..……..…………….…….…..
3
1.2
Standby Power System Precautions
……………………….………
3
1.3
Battery Precautions
…………………….……..………………...……
3
2
Specifications ……..……………………..…...……………………..……
4
3
Technical description …..……………………………………………..…
3.1
Standby Power Systems …….……….…………………...……....…
5
3.1.1
Inverter Power Mode …………………………………….….
5
3.1.2
External Power Mode ….…………………………………….
5
3.2
Available Options
…………………………………………………….….
6
3.2.1
Emergency Vehicles
–
“A” Option .…………………..….
6
3.2.2
Battery Charger
–
“B3” Option ……….………………….
6
3.2.3
Remote “On/Off” Swtich Ground Start
-
“R2” Option
6
3.2.4
Transfer Switch
–
“T” Option
……………………..………
6
3.2.5
Utility Vehicles
–
“U” Option ………………………………
6
4
SPS Physical Description ..……….…………………………………….
7
4.1
SPS Module ………….…………………..……………….……………….
7
Installation ..………………………….……………………………………
9
5.1
Tools Needed for
Installation ..…………………………….……….
9
5.2
System Components ..………………………………….……………...
9
5.3
Mounting the SPS ….……………………………………………………
9
5.3.1
Chassis Bonding Lug .……………………………………..…
9
5.3.2
Temperature Compensation Sense Probe ..…………...
9
6
SPS
Wiring …………..……….…………………………………………….
10
6.1
DC Wiring …………………………………………………………….…….
10
6.1.1
Inverter Cable .…………………….…………………………..
10
6.1.2
Charge Cable ..……………………….……..……………..….
10
6.1.3
Connecting the DC Wires ………..…………………..…….
11
6.1.4
Remote “On/Off” Switch ……………………………………
11
6.1.5
Remote “On/Off” Switch Ground Start
-
“R2” Option
11
6.1.6
Deep Cycle Batteries .…………………………………..……
12
6.2
AC Wiring …………………………………………….…………….…..….
12
6.2.1
AC Output
…..…………………………….…………………….
12
6.2.2
AC Input ……..…………………………….……..…………….
12
6.3
DC Wiring Diagram ..……………………………………………………
13
DC Wiring Diagram “R2” Option …………………………………….
14
6.4
AC Wiring Diagram ….………………………….………………………
15
7
Operation and
Troubleshooting ..………………………………....….
16
7.1
Operation …..………………………………………………………………
16
7.1.1
Setting the Battery Size and Type ..….…………….…..
16
7.1.2
Turning the SPS On ………….…………..……………..…..
16
7.2
Troubleshooting
……………..………………..………………..….…..
17
8
Warranty ………………………………………..…………………….……
18

3 Form 122067
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 Standby Power System Precautions:
•
••
•Standby Power 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 Standby Power Systems should not be mounted in a location that may be
exposed to rain or spray.
•
••
•The Standby Power Systems should not be installed in a zero clearance enclosure.
•
••
•Damage to the Standby Power Systems will occur if correct polarity is not observed
when installing the DC input cables.
•
••
•Damage to the Standby Power Systems will occur if an external AC power source is
applied to the inverter’s AC hardwire output.
•
••
•The Standby Power Systems contains a circuit breaker and capacitor that may
produce a spark. Do not mount in a confined battery or gas compartment.
•
••
•Be sure the Standby Power Systems 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.

4 Form 122067
Specifications
Millennium Series Standby Power Systems
24U1
MODEL NUMBER
24U1
Output Power
(Watts Cont.)
1 500
Output Current
(Amps AC)
Up to 12
Peak Output
(Amps AC)
45
Output Rating:
(hp)
¼
Input Current
(Amps DC)
Up to 75
Weight
(lbs.)
27
Dimensions
LxWxH
–
(In.)
13¼ x 11 x 6¾
BATTERY
CHARGER “B3”
(Optional)
3 step charger with automatic conditioning; Temperature compensated
output voltage; selectable between wet and sealed lead acid batteries;
selectable between small and large battery banks
Output Current
(Amps DC)
30
Input Current
(Amps AC)
Up to 15
TRANSFER RELAY “T”
(Optional)
Fail
-
safe shore power Transfer Relay
Current Rating
(Amps AC)
30
Transfer Time
(milliseconds)
Less than 16 typical
Output Voltage (VAC)
120 RMS ±5%
Output Frequency:
60 Hz ± 0.05%
Output Waveform:
Quasi
-
sine wave with waveform stabilizer
Input Voltage: (VDC)
22 to 28
Operating Temperature:
-
20° to 40° C
(0° to 104° F)
Efficiency:
Up to 93%
Other Design Features:
• Thermally-controlled cooling fan
• GFCI outlet protection
• Enclosed AC and DC cable connections with strain
relief
• Remote ON/OFF switch hookup
• LED for Inverter Power Low Input Voltage High
Temperature & Overload
• Battery voltage indicator with push-to-test “U” option.
• Optional Battery Charger “B3” and Transfer Relay “T”
• Optional one wire ground start “R2”
Unit Protection:
• Automatic electronic short
circuit/overload protection
• Automatic high temperature
shutdown
• Output circuit breakers
Battery Protection:
Automatic low battery shutdown at 21
VDC (with in-rush delay)
•Usage: Any 120 VAC 60 Hz single-phase products within the standby power system’s rating that does
not require a pure sine waveform.
Environmentally Friendly,
Quiet, Reliable, AC Power

5 Form 122067
Technical Description
3.1 Standby Power System:
A Standby Power System is a DC to AC power inverter with an optional battery charger
(“B3” option) and an automatic fast transfer switch (“T” option).
Note: In this manual we will use the acronym SPS when referring to a Standby Power
System.
The main “On/Off” switch controls the SPS and the LED lights built on the front of the
SPS provides system status. The SPS can also be controlled by a customer supplied
remote “On/Off” switch connected to the violet wire labeled “remote switch hook-up”
located in the field-wiring compartment.
The system has two operational modes when a transfer switch “T” option is included:
Inverter power mode and external power mode.
3.1.1 Inverter Power Mode: The SPS converts DC power from batteries to usable
120 VAC 60 Hz power. The direct current (DC) that enters the SPS 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 unit has a Digital System
Processor (DSP) to control the output voltage and frequency as the DC input voltage
and/or output load varies. The signal output waveform shape is not sinusoidal; it has a
total harmonic distortion of 31% and a maximum single harmonic distortion of 25%.
3.1.2 External Power Mode – “T” option only: 120 VAC 60 Hz external power
can be applied directly to the SPS by hardwire connections to the AC input wire leads
provided in the field-wiring compartment (available with the “T” option only). When
external power is present the internal transfer switch cannot be defeated; it
automatically turns the DC to AC inverter OFF and activates the three-step battery
charger if the “B3” option is included. At this time the loads attached to the SPS output
will operate directly from the external power line even if the SPS was turned OFF
manually. The internal transfer relay automatically switches the SPS back to “inverter
power” mode in the absence of external power whenever the SPS was previously set to
ON.

6 Form 122067
3.2 Available Options
3.2.1 Emergency Vehicles – “A” Option: The SPS has only one AC output
circuit with a 20A output breaker. With the “A” option 120VAC 60Hz AC outlets and the
set of hardwire leads are both GFCI protected.
3.2.2 Battery Charger – “B3” Option: The three-step battery charger feature
requires the transfer switch “T” option to operate. External power 120 VAC 60 Hz is
applied as explained in section 3.1.2 The internal transfer switch automatically turns the
DC to AC inverter OFF and turns the three-step built-in battery charger ON. The battery
charger cannot be defeated at this time and will engage even if the inverter has been
set OFF manually.
The 3-steps of the charging process are as follows:
a) Bulk mode: Charging current is passed through the batteries until a factory set
acceptance voltage limit is reached. The charger’s maximum output and the state of
charge of the batteries determine the amount of current.
b) Acceptance mode: Charging continues with the voltage held at the accept voltage
until current flow decreases to the factory set end value or the factory set
acceptance mode time limit is reached.
c) Float mode: Battery voltage is held at a factory set value which will neither charge
nor discharge the batteries.
Condition mode: Occurs every 10
th
charge cycle between Acceptance mode and Float
mode to ensure full restoration of active materials in all the plates of the battery cells.
The SPS has an automatic power sharing feature that automatically decreases the
battery charger output so that the total AC input current draw by the SPS for both the
AC loads and the battery charger does not exceed 15 amps AC. If the loads exceed 15
amps the charger will be at zero amp draw and the AC input circuit breaker will trip. The
battery charger draw will automatically increase when the external loads are reduced if
the batteries will accept more current.
3.2.3 Remote “On/Off Switch, Ground Start – “R2” Option: If the “R2”
option is included the SPS can be controlled by a customer supplied remote “On/Off”
switch connected to the 18-gauge black wire labeled “remote switch hook-up” which is
located in the field-wiring compartment the line side of the switch must be connected to
ground.
3.2.4 Transfer Switch – “T” Option: The transfer switch automatically switches
between “Inverter mode” and “External power mode” depending on the external power
line availability. External power 120 VAC 60 Hz can be applied directly to the SPS AC
input as explained in section 3.1.2.
3.2. Utility Vehicles – “U” Option: SPS having the “U” option are designed for
heavy-duty use on utility vehicle applications. The “U” option provides two AC output
circuits; one circuit is GFCI protected and has one 20A branch breaker. The second
circuit (lead hardwires) is non-GFCI protected and has a 30A output breaker. All SPS
having the “U” option come with a set of two heat sinks located at the back of the
chassis for heat dissipation purposes. A push to test LED battery voltage meter is also
included with the “U” option.

7 Form 122067
SPS Physical Description
4.1 SPS Module
FIGURE 1: SPS module physical description
Item #
Description
Function
1
“On/Off” Switch.
Switches the SPS on or off.
2
Branch Breaker
Not available
3
Output Breaker
–
15A
Trips to protect the SPS from hardwire AC output
short circuit or overload.
4
GFCI Outlets
Two outlets
120 VAC 60 Hz out put power.
5
Temperature Compensation Probe
Connector
Connects to the remote temperature sense probe.
Available with the “B3” option only.
6
Field Wiring Compartment Cover
Remove the faceplate to access the A
C output and/or
input lead wires and the DC input connectors.
7
Bonding Lug
Connects to the ground system.
8
DC input strain reliefs
Clamp the DC input cables for mechanical protection.
9
Battery Capacity Selector Switch
Sets the correct battery type
and the capacity of the
battery bank for proper charging. Available with “B3”
option only.
10
LED Status Control Panel
Provides system status
–
See next page
1
2
3
4
6
7
8
9
10

FIGURE 2:
LED Front Control Panel
(a) External power –
“T” option:
120 VAC 60 Hz connected to the unit.
(b) Inverter power:
The green LED indicates that the SPS is operating from
batteries in “inverter mode”.
(c) Low battery:
The red LED indicates that the SPS is in a low battery v
condition.
(d) Overload:
The red LED indicates that the SPS is in an overload condition.
(e) High temp:
The red LED indicates that the SPS has a high internal
temperature.
(f) Bulk mode –
“B3” option:
is in the bulk mode.
(g) Accept mode –
“B3” option:
charger is in the acceptance mode.
(h) Float mode -
“B3” option:
is in the float mode.
(i) Condition mode -
charger is in the condition mode.
(j) Check battery -
“B3” option:
battery bank or DC cables.
(k) Push to test –
“U” option:
battery voltage
LEDs as shown below.
(l) 28 –
30 VDC (Battery voltage):
(m) 26 –
28 VDC (Battery voltage):
(n) 24 –
26 VDC (Battery voltage):
(o) 22 –
24 VDC (Battery voltage):
(p) 20 –
22 VDC (Battery voltage):
c
b
e
a
d
f
g
h
i
j
8
LED Front Control Panel
“T” option:
The green LED indicates that there is external
120 VAC 60 Hz connected to the unit.
The green LED indicates that the SPS is operating from
batteries in “inverter mode”.
The red LED indicates that the SPS is in a low battery v
The red LED indicates that the SPS is in an overload condition.
The red LED indicates that the SPS has a high internal
“B3” option:
The green LED indicates that the battery charger
“B3” option:
The green LED indicates that the battery
charger is in the acceptance mode.
“B3” option:
The green LED indicates that the battery charger
“B3” option: The green LE
D indicates that the battery
charger is in the condition mode.
“B3” option:
The yellow LED indicates a possible fault in the
battery bank or DC cables.
“U” option:
Pressing this button enables the appropriate
LEDs as shown below.
30 VDC (Battery voltage):
Green LED.
28 VDC (Battery voltage):
Green LED.
26 VDC (Battery voltage):
Green LED.
24 VDC (Battery voltage):
Yellow LED.
22 VDC (Battery voltage):
Yellow LED.
28
-
30 VDC
26-28 VDC
24-26 VDC
22-24 VDC
20-22 VDC
Form 122067
The green LED indicates that there is external
The green LED indicates that the SPS is operating from
The red LED indicates that the SPS is in a low battery v
oltage
The red LED indicates that the SPS is in an overload condition.
The red LED indicates that the SPS has a high internal
The green LED indicates that the battery charger
The green LED indicates that the battery
The green LED indicates that the battery charger
D indicates that the battery
The yellow LED indicates a possible fault in the
Pressing this button enables the appropriate
k
l
m
n
o
p

Installation
.1
Tools for Installation:
Tools required for installation: Straight screwdriver connectors (butt type and
insulated) drill Crimpers (for insulated and non
#2 Phillips screwdriver wire cutters wire strippers cab
.2
System Components:
Picture
24U15 SPS
Temp. Comp. Cable 611440
XX: Length of the cable in feet
.3
Mounting the SPS:
The SPS mounting location should
to maintain room temperature during operation. At least 1/2 inch of clearance
is required on all sides.
•
Locate a suitable secure vertical or horizontal mounting surface as clo
batteries as possible without being in the same airtight compartment.
Figure 3: SPS footprints
.3.2
Temperature Compensation Sense Probe:
option is included connect the two
bank. Failure to connect the remote temperature sense probe correctly will result i
improper battery charging.
All dimensions are in inches
9
Installation
Tools for Installation:
Tools required for installation: Straight screwdriver connectors (butt type and
insulated) drill Crimpers (for insulated and non
-
insulated connectors) electrical tape
#2 Phillips screwdriver wire cutters wire strippers cab
le ties tape measure.
System Components:
Model and Description
Temp. Comp. Cable 611440
-XX (“B3” option only)
XX: Length of the cable in feet
Mounting the SPS:
The SPS 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.
Locate a suitable secure vertical or horizontal mounting surface as clo
batteries as possible without being in the same airtight compartment.
•
If mounting the SPS 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 SPS. See figure
3.
.3.1 Chassis Bonding Lug:
bonding lug located at the right side of the
SPS chassis to the earth grounding system
using an 8-gauge copper wire.
Temperature Compensation Sense Probe:
If the battery charger “B3”
option is included connect the two
-
conductor wire lug to a negative post of the battery
bank. Failure to connect the remote temperature sense probe correctly will result i
improper battery charging.
All dimensions are in inches
Form 122067
Tools required for installation: Straight screwdriver connectors (butt type and
insulated connectors) electrical tape
le ties tape measure.
Qty.
1
1
provide adequate ventilation and clearance
to maintain room temperature during operation. At least 1/2 inch of clearance
Locate a suitable secure vertical or horizontal mounting surface as clo
se to the
If mounting the SPS on a vertical
surface it is recommended that the front
control panel be pointing down whenever
Locate the mounting holes on the
and fasten them using ¼ inch
diameter screws to secure the SPS. See figure
.3.1 Chassis Bonding Lug:
Connect the
bonding lug located at the right side of the
SPS chassis to the earth grounding system
If the battery charger “B3”
conductor wire lug to a negative post of the battery
bank. Failure to connect the remote temperature sense probe correctly will result i
n

10 Form 122067
SPS Wiring:
6.1 DC Wiring:
1It is recommended in all cases to use stranded copper wires.
2Use SGX cross-linked polyurethane insulation type that complies with the high
temperature insulation requirements (125°C.) of SAE J-1127 and vehicle
manufacturer requirements.
3 Wire gauge recommendations are minimum. For higher temperature rated
applications inside engine spaces or large motor loads and other applications with
high surge currents use wire gauge 1 to 2 sizes larger than shown on table I.
4Keep the wire runs between battery and SPS as short as possible.
5Use Bussmann fuse type ANN-XXX and fuseblock # 3576 where XXX is the size of
the fuse.
6.1.1 Inverter Cable: This is the cable that runs from the SPS module to the
batteries. Estimate the “inverter cable” length and locate your SPS model on table I
cross-reference the wire gauge and fuse size.
Table I: Wire and Fusing Guide for 12VDC systems at 5% Voltage Drop at Full Output
Figure 4: Inverter cable assembly
6.1.2 Charge Cable: This is the cable that runs from the batteries to vehicle
alternator or OEM engine battery. Use 2-gauge cables and 250A fuse for small OEM
alternators and 1/0-gauge and 350A for heavy-duty alternators.
Inverter
Model
Full Load
(Amps DC)
Inverter to
battery estimated cable length in feet
1’
–
10’
11’
–
15’
16’
–
20’
24U15
75
6
-
gauge 150A fuse
4
-
gauge 200A fuse
2
-
gauge 250A fuse
To inverter
DC input
To
Batteries
Fuse
-
holder
Black wire (
-
)
A
20 feet maximum
B
18”
max.
Red wire (+)
A
B
Fuse
B terminal: 5/16” Ring
A terminal:
3/8” Ring

11 Form 122067
6.1.3 Connecting the DC wires:
Damage to the SPS not covered under warranty will occur if correct polarity is
not observed when installing the DC input cables.
•Refer to Figure 5A: DC wiring diagram.
•Open the SPS field-wiring compartment to access the DC input lugs.
•Unscrew the DC input lug POS (+) and NEG (-) screws.
•Remove the fuse from the fuseholder for cable installation.
•Remove 1 inch of insulation from the un-terminated ends of the red and black
cables.
•Insert the stripped end of the red wire into the DC input lug labeled POS (+) and the
stripped end of the black wire into the DC input lug labeled NEG (-). Tighten the lug
screws to 10 Ft. Lbs.
•Tighten the cover DC cable strain relief screws to 1 Ft. Lb.
•Connect the end of the short red cable to a POS (+) battery post.
•Connect the terminated end of the black cable (neg. return cable) directly to a
battery NEG (-) post (DO NOT connect to the chassis).
•Install the in-line fuse in the fuseholder that is within 18” of the positive post of the
battery bank (a one-time spark will occur when this final DC connection is made). To
determine the fuse size refer to section 6.1.1.
6.1.4 Remote “On/Off” Switch: An optional customer supplied “On/Off” switch
may be connected to the SPS. The remote switch will operate only if the main “On/Off”
switch on the face of the SPS is turned ON.
•Open the SPS field-wiring compartment to access the DC input connector.
•Locate the violet wire labeled “Remote Switch Hook-up” and remove it from the
positive battery connector.
•Connect the violet wire to the load side of the “On/Off” remote switch.
•Using an 18-gauge wire connect a fused (5 amp recommended) +24VDC battery
voltage to the line side of the switch.
•The fuse should be mounted within 18 inches of the battery’s positive post.
•All material used for the remote switch should be UL listed and installed per code.
6.1. Remote “On/Off” Switch, Ground Start – “R2” Option: An optional
customer supplied “On/Off” switch may be connected to the SPS. The remote switch will
operate only if the main “On/Off” switch on the face of the SPS is turned ON.
•Open the SPS field-wiring compartment to access the DC input connector.
•Locate the black wire labeled “Remote Switch Hook-up” and remove it from the
negative battery connector.
•Connect the black wire to the load side of the “On/Off” remote switch.
•Using an 18-gauge wire connect the line side of the switch to ground.
•All material used for the remote switch should be UL listed and installed per code.

12 Form 122067
6.1.6 Deep Cycle Batteries:
Do not use vehicle-starting batteries; deep discharge cycles typical with SPS
applications can shorten the life of this type of batteries.
•Install at least one 24 VDC auxiliary deep cycle battery set to feed the SPS directly.
Depending on the application running time more batteries could be added if
necessary. The vehicle alternator will recharge the batteries.
•It is recommended to mount the battery bank close to the SPS. The maximum
recommended distance between the SPS and the battery bank is 20 feet.
•The battery compartment must be vapor-tight to the interior of the vehicle and
vented directly to the exterior.
•Install several vent-plugs within one inch of the top of the battery compartment to
allow for ventilation. Install a ventilation assembly as needed.
•Allow space around the battery and especially above the battery for inspection and
maintenance purposes.
•The battery should not be able to move more than 1 inch in any direction.
6.2 AC Wiring:
Remove the SPS field-wiring compartment cover plate to access the 120VAC 60Hz input
and output hardwire leads and follow the color code connections: Hot - Black wire
Neutral - White wire Ground - Green wire.
6.2.1 AC Output: The 120 VAC 60 Hz current produced by the SPS is provided at
the GFCI receptacle outlets located on front of the SPS (“A” and “U” options only). The
output is also presented behind the wiring compartment panel for direct hardwire leads.
•If option “A” is included the hardwire leads are GFCI protected; remote outlets do
not need to be GFCI outlets.
•If option “A” is not included the hardwire leads are not GFCI protected and require
the installation of remote GFCI outlets. The GFCI outlet
• model recommended is Hubbell # GFR 5352XX (20A) or GFR 5252XX (15A).
Do not connect another source of AC power directly to the output of the SPS.
This will result in damage to the SPS that is not covered under warranty.
6.2.2 AC Input: If the transfer switch “T” option is included the AC input hardwire
leads can be connected to an external power line 120VAC 60Hz source. The cable
clamp strain relief should be used to secure the field wires. The input circuit should have
a maximum 30 amps circuit protection from the distribution panel.

13 Form 122067
6.3 DC Wiring Diagram
Figure 5A: DC wiring diagram
-
+
Aux.
24 Volt
Battery
Fuse
Charge Cable
Black (-)
Remote
On/Off Switch
Vehicle Alternator
OEM
24 Volt
Battery
Fuse
Fuse
AC Output AC Input
“T” Option
Engine Compartment
Fuse
Temperature Compensation
Probe cable
“B3” Option
Red (+)
Black (-)
Charge Cable
Red (+)
• Connect the charge cables directly to the
vehicle alternator.
• Remote “On/Off” switch and fuse is
customer supplied.
2
-
pin
Connector
“B3” Option
Violet wire

14 Form 122067
Figure 5B: DC wiring diagram – “R2” Option
-
+
Aux.
24 Volts
Battery
Fuse
Charge Cable
Black (-)
Remote
On/Off Switch
Vehicle Alternator
OEM
24 Volts
Battery
Fuse
Fuse
AC Output AC Input
“T” Option
Engine Compartment
Temperature Compensation
Probe Cable
“B3” Option
Red (+)
Black (-)
Charge Cable
Red (+)
• Connect the charge cables directly to the
vehicle alternator.
• Remote “On/Off” switch and fuse is
customer supplied.
2
-
pin
Connector
“B3” Option
Black wire
(“R2” Option)
Ground start

15 Form 122067
6.4 AC Wiring Diagram
Figure 7: AC wiring diagram
1
Output
Breaker
Branch
Breaker
AC Output AC Input
30A
Black wire – Hot
White wire – Neutral
Green wire - Ground
GFCI Outlets
Available with the
“U” or “A” options only
Black White Green
Wire Wire Wire
Hot
Neutral Ground
•“U” option: Install external GFCI
outlets Hubbell # GFR5352XX (20A)
or Hubbell # GFR5252XX (15A)
120VAC 60Hz
Output
Not used
AC Input
Fuse (maximum)
Remote GFCI outlet

16 Form 122067
Operation and Troubleshooting
7.1 Operation
The battery voltage must be higher than 18 volts for the SPS to operate.
7.1.1 Setting the Battery Size and Type: The battery selector switch located at
the right side of the chassis must be set according to the type and size of the battery
bank the SPS is connected to as shown in table II below.
TABLE II: BATTERY SELECTOR SWITCH POSITION
BATTERY BANK SIZE
(Amp-Hour)
DEEP CYCLE BATTERY
TYPE
SEALED LEAD ACID
WET LEAD ACID
More than 200
A
C
Less than 200
B
D
TABLE III: BATTERY CHARGER VOLTAGES
BATTERY
TEMPERATURE
WET CELL BATTERIES
SEALED BATERIES
ACCEPT
(Volts)
FLOAT
(Volts)
CONDITIONING
(Volts)
ACCEPT
(Volts)
FLOAT
(Volts)
CONDITIONING
(Volts)
°F
°C
78
25
28.8
26.4
29.4 to 30 max.
28.4
26.4
28.8 to 30 max.
TABLE IV: BATTERY CHARGER TIME PERIODS
BATTERY BANK SIZE
(Amp-Hour)
WET CELL TYPE BATTERIES
SEALED TYPE BATTERIES
BULK
(max.)
ACCEPT
(max.)
CONDITIONING
(max.)
BULK
(max.)
ACCEPT
(max.)
CONDITIONING
(max.)
Less than 200
6
-
hrs.
2
-
hrs.
4
-
hrs.
6
-
hrs.
2
-
hrs.
3
-
hrs.
Greater than 200
8
-
hrs.
3
-
hrs.
6
-
hrs.
8
-
hrs.
3
-
hrs.
4
-
hrs.
If the bulk mode times-out the charging process will go to the float mode
immediately bypassing the acceptance mode.
7.1.2 Turning the SPS “ON”: To turn the SPS ON set the Inverter On/Off switch
to the “On” position. The green LED “Inverter Power” will come on. If the “T” option is
included the green LED “Inverter Power” will come only if no external power 120VAC 60
Hz is applied to SPS AC input otherwise the green LED “External Power” LED will come
on. If the remote switch is used the inverter is turned ON or OFF by the remote switch.
Turn the SPS OFF if not in use. There is an approximately 1 to 2 amps DC
draw from the batteries at idle or no load.

17 Form 122067
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: [e-mail]
•A TRUE RMS voltmeter is required for accurate AC output voltage readings on a
quasi-sine SPS. A voltmeter that uses averaging circuitry will give a false reading.
•Unplug all loads and connect a 100-watt light bulb to the inverter output. Observe
the LEDs light coming on at the control panel then check the troubleshooting table.
Troubleshooting Table V
PROBLEM POSSIBLE CAUSES OR SOLUTIONS
No LEDs: No power output. The SPS is not connected
to the Battery Disconnect Switch; the battery voltage
is below 18 volts DC the SPS is not connected to the
Module Disconnect Switch or 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 SPS DC input.
Check or bypass the remote On/Off circuit.
Low battery: Red LED indicator light on steady.
Indicates that the SPS has shut off due to a low
battery voltage condition.
Fault in the battery wiring battery capacity and voltage or an in-
line fuse. This message will automatically clear or the SPS will
shut off.
Overload: Red LED indicator light on steady.
Indicates that the SPS has shut off due to an overload
condition.
The SPS output wiring is shorting or loads exceed the inverter
rating. This message will automatically clear or the SPS will shut
off. Remove the short circuit or excessive load from the output
and then switch the SPS off then on.
High Temp: Red LED indicator light on steady.
Indicates that the SPS has shut off due to high internal
temperature. The unit will automatically turn back on
when it has cooled to 40°C (104°F).
Red LED indicator light blinking. Indicates that the SPS
has shut off due to high battery temperature (117-
120°F).
Verify that the SPS 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.
Battery compartment is too hot and needs to cool down.
Overload & High Temp: Both of these red LED
indicator lights are on steady. Indicates that there is a
problem with the battery charger’s temperature
compensating cable. It could be open or shorted.
Check to make sure the temperature compensating cable is
connected to the inverter. If the cable is connected then you
possibly need to replace the temperature compensating cable.
Contact Dimensions.
Check battery - “B3” Option: Green LED indicator
light. Indicates that the charger is operating in a low
DC output voltage condition. The battery voltage must
be higher than 9 volts for the charger to operate.
Shorted or defective battery. Make sure that the DC cable
connections are tight and clean and not shorted and that the
proper wire gauge is used.
Indicates that the charger is operating in a high DC
output voltage condition.
There is another source of battery charging or there is a
defective battery charger. Disconnect and reconnect the external
AC power to restart the battery charger.
Indicates that the SPS has shut off due to high battery
voltage.
Check battery wiring or remove other source of battery charging
such as the vehicle alternator. Disconnect and reconnect the
external AC power to restart the battery charger.

18 Form 122067
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 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.
RETURN GOODS POLICY:
• No returned materials will be accepted without an accompanying Returned Materials Authorization Number (RMA) from
the factory.
• 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 Authorization (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.
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PRODUCT EXCEPT AS STATED IN THIS LIMITED WARRANTY. SENSATA TECHNOLOGIES WILL IN NO EVENT BE LIABLE
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
WARNING: LIMITATIONS 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.