Sterling Power Products DAI-1500C-12xx User manual

3 in 1 COMBINED
PURE SINE WAVE INVERTER
UPS / BATTERY CHARGER
(SOLAR & SHORE)
USER MANUAL
Sterling Power Products
England Tel.[phone]
Fax [phone]
www.sterling-power.com
[e-mail]
STERLING
POWER PRODUCTS

Content
A. General Information------------------------------------------------------- 1
B. Warranty----------------------------------------------------------------------- 2
C. Introduction------------------------------------------------------------------ 4
D. Installation-------------------------------------------------------------------- 8
E. Operation---------------------------------------------------------------------- 11
F. Disabling Functions ------------------------------------------------------ 17
G. Charger Information------------------------------------------------------- 19
H. n/a
I. Auxiliary Contacts---------------------------------------------------------- 21
J. The Remote control unit-------------------------------------------------- 21
K. n/a
L. Programming Aux Contacts (AUX1, AUX2)------------------------ 22
M. Maintenance------------------------------------------------------------------ 23
N. Specifications---------------------------------------------------------------- 24

General：
 “ 3 in 1” It is a powerful pure sine wave inverter, a sophisticated battery
charger that features adaptive charge technology and a high-speed AC
transfer switch in a single compact enclosure.
 Besides all this functions ,however, the “3 in 1” has several advanced
features that provides a range of new applications as outlined bellow：
In the event of a grid failure ,or shore or generator power being
disconnected, the inverter within the “3 in 1” is automatically In less than 20
milliseconds activated and takes over supply to the connected loads.
 Allowed them to continue to operate without disruption. The “3 in 1” is very
powerful battery charger. It will therefore draw a lot of current from the
generator or shore side supply.
 INVERTER：
 Pure Sine Wave AC output.
 Very low total harmonic distortion (< 2 % )
 High surge capacity and soft-start design for heavy inductive loads such as air
conditioning
 Load detection system for “power saving” mode
 Extremely high efficiency.
 Battery Charger ：
 The “3 in 1” series is built around a bi-directional converter , that operates as
an inverter or as a battery charger high capacity three-stage Battery charger
Equalization mode conditions Battery for longer life
 Multistage charger-power factor corrected for superior
 Charging temperature sensitive charging for optional
 Care of all batteries ( temperature sensor optional ) Built in solar charge
regulator.
 Bypass Function：
 Automatic 60 A (3000W ) / 30 A ( 1500W ) transfer relay turns inverter and
charger on / off.
 Fast ( UPS ) mode or delay mode of the Bypass switch.
Power sharing prevent tripping of shore power breaker.
 Basic Remote Control：
 Power output on / off
 Function mode select
 Programming Battery charging voltage
 Error message display
 Programming auxiliary relay (x2 )
 Programming input current limit for power share

A. General Information
Operating instructions
This manual is a part of the delivery package of every inverter-charger. It serves as
Guidelines for safe and efficient operation of the unit. The instructions are only
valid for use with the following models and accessories.
 DAI-1500C-12xx / DAI-3000C-12xx
 DAI-1500C-24xx / DAI-1500C-24xx
 Temperature BTS-A-15 (m)
 Remote controller RCC-A-03 (3m) / RCC-A-15 (15m)
Any personnel who install the unit and / or works with it must be fully familiar with
the contents of this manual and must follow exactly all the warnings and safety
instructions. A qualified and trained personnel must carry out installation of , or any
work on the unit . Installation and application must comply with the respective local
installations codes and safety regulations.
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-2-
B. Warranty
During production and assembling, all Sterling Inverter / Chargers go through
many testing procedures. Every Sterling has its own serial number,which helps to
refer back to its original data in the event of controls or repairs. That is why you
should never remove the identification plate showing the serial number and must
ensure you return your warranty card as soon as possible.
The warranty period for your Sterling is 2years.
Sterling Warranty Terms and Conditions
Sterling warrants this product against defects in material or workmanship, to the
original purchaser only for an initial period of 60 days from date of purchase, when
in normal use and service. The warranty period will be extended to a total of one (1)
year if a completed warranty card is received within 60 days of purchase. No
warranty will be provided on units which have not been paid for in full.
Some models may have the option of purchasing an extended warranty period,
see elsewhere in this manual for details. This manufacturers warranty is in addition
to your consumer rights under local trade practices act.
This warranty does not extend to products which have been opened, altered or
repaired by persons other than authorized by Sterling or to products which
become defective due to acts of God, fire, sabotage, vandalism, contaminated
fluids, negligence or failure to operate, house and maintain the product in
accordance with instructions provided in this manual. It is extremely important
that all installation instructions contained within this manual are strictly
adhered to , failure to do so will void your warranty. Except for the foregoing
expressed warranty Sterling makes no warranty,expressed or implied,
including but not limited to, the warranty of merchantability or fitness for a particular
purpose.
Sterling will repair or replace the defective product in accordance with its best
judgment, For service under warranty, , if the product is found to be defective,
within the terms of the warranty. Repair or replacement of any unit does not extend
the original warranty terms in any way.
This warranty does not cover repairs made necessary due to the product coming in
contact with dirt, abrasives, moisture, rust, corrosion, varnish or other similar, or
failure due to poor quality or poor condition batteries.

-3-
Sterling reserve the right with some models to supply an accredited installer with
replacement parts, this may allow the unit to become operable much quicker.In
this case Sterling are not responsible for any costs of the installer’s time or
traveling expenses. Replacement parts are sent at Sterling's discretion.
Sterling will in no way be held responsible for any losses incurred
due to the malfunctioning or failure of a product.
Suitably qualified personnel must carry out wiring, failure to do so will void
warranty.
If you have any questions about this warranty please do not hesitate
to contact us.
Caution: Even when a unit has been completely disconnected, there can
Still be deadly voltages present at the OUTPUT. To remove these voltages you
must switch the unit ON with the ON/OFF switch. After one minute the
electronics are discharged and any work can now be safely carried out.
Caution: In normal use lead-acid and lead-gel batteries give out explosive gases.
Never smoke or allow a spark or flame in the vicinity of batteries. The batteries
must always be stored or placed in a well ventilated area, they should be placed in
such a way that there is no danger of short circuiting through carelessness. Never
charge frozen batteries.
This unit is not to be used or sold for life support equipment or applications.
B.1 Special Precautions
While working on batteries there should always be a second person close to you or
within your voice range, in case help is needed.
Plenty of fresh water and soap must be ready at hand so that in case of acid
coming in contact with skin, eyes and clothes, the areas in question can be
thoroughly washed.
If acid enters the eyes, you must thoroughly wash the eyes with cold running water
for at least 15 minutes. It is recommended that you immediately consult a medical
doctor.
Baking powder neutralizes battery acid electrolyte. Always keep some at hand.
Special care must be taken when working with metal tools near or on the batteries.
With tools such as screwdrivers, spanners etc. short-circuits can result. Sparks
produced by the short-circuit can cause an explosion.
When working on batteries all personal metal items such as rings, necklaces and
bracelets must be removed. Batteries are so powerful that short-circuit with these
items can melt them and thus cause severe burns. Always follow the battery
manufacturers instructions.
Under certain conditions this unit or a connected generator can start
automatically. While working on an electrical installation you must ensure that
these appliances are disconnected before commencing any work.

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C. Introduction
C.1 Basic schematic
This unit is a a sine wave inverter with integrated battery charger and AC Bypass
switch with many additional functions.
Bidirectional Inverter
(Inverter / Charger)
PV Arra
y
Solar Controller
BATTERY
Home / Boat / Motohome
DC BUS AC BUS
AC Load
C.1.1 The Inverter
The sinewave-inverter section of your Combi generates a sinewave AC voltage
with an exceptionally precise voltage and stabilized frequency, In order to start
large electric motors, the user has the possibility to employ a short-start-power
which is 3-times the nominal power of the Combi
The inverter is protected against overload and short-circuit. A power-stage with the
latest MOS-FET power transistors, a toroidal transformer, and a fast regulating
system make-up a robust and reliable inverter with very high efficiency. A load
detection system serves to provide the smallest energy consumption and ensures a
long life for the battery.
C.1.2 The Bypass switch
This unit can be connected to an AC input source. For example a stand-by motor
generator or the AC grid, such as shore power or a caravan park. With the
transfer system, on one side you have AC voltage which is used to run the load,
on the other side the batteries are being charged. The distribution of energy
between the AC loads and battery charger is automatic.

-5-
C.1.3 The Battery charger
The built-in battery charger is capable of charging the batteries quickly and
completely. A microprocessor controlled, 3 to 4 Step charging process ensures
the optimum charging of the batteries. The desired charging current can be set.
The battery charger can be used for lead-acid or gel batteries. Thanks to the
floating charge ability ofthis unit, the batteries can remain continuously connected.
C.1.4 The solar charge regulator (opetional)
With the built-in solar regulator, the unit is a complete solar-power-center. In a
solar installation this regulator ensures that the batteries are charged correctly.
With the unit, batteries can be charged with a generator and with the solar
modules at the same time. The charging of batteries with both energy sources is
carried out fully automatically.
C.1.5 Remote control
As an option, a remote control can be connected to this unit. The
remote control is supplied with a 3m long cable. This cable canbe up to 15m long.
(RS-485 interface) On the remote control output current and charging current are
also shown.
C.2 Battery connections
Lead-acid batteries are normally available in blocks of 2V, 6V or 12V. In most
cases, to generate the necessary operating voltage and the capacity of the
batteries for the unit many batteries have to be connected together in parallel
and or in series. Following three examples are shown:

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C.2.1 Parallel Connection:
C.2.2 Series Connection:

-7-
C.2.3 Parallel-Series Connection:

-8-
D. Installation
D.1 Location
The location of the Combi must be chosen by the following criteria:
Protection from unauthorized handling.
Dry dust free room, no condensation, no rodents.
Never install directly over the battery and never in a cabinet together
with the batteries.
Keep ventilation holes free. The ventilation of the Combi is designed in such a
way that it will work most efficiently when mounted vertically.
In mobile installation it is important to keep vibrations to a minimum.
D.2 Rear Panel
Connections
A Battery +/- Battery cables.
B SOLAR +/- Connections for Solar modules.
C AUX1 contact Connecting terminal for Auxiliary contact 1.
D AUX2 contact Connecting terminal for Auxiliary contact 2.
E BTS (Battery temp. sensor) Connecting terminal for Temperature sensor.
F EXT AC IN Connecting terminal for AC input.
G AC OUT Connecting terminal for AC output.

-9-
D.3 Cabling / wiring
When making connections to the unit you must ensure that all connections
are carried out in a clean and correct manner and under no circumstances that a
cable is connected to a wrong terminal.
Connecting the unit must be carried out in the following order.
D.3.1Connection to battery
Prepare the batteries for connection. Prepare battery cables, if necessary press
on cable tabs/shoes. Connect the red cable to the Battery positive fuse/circuit
breaker and the black cable to battery Minus (-) Take care when connecting the
second cable to the battery, as a spark is produced, this is caused for a short time
due to high current flowing in the unit to charge the capacitors. This is another
reason to install a battery fuse/circuit breaker. For this reason follow strictly the
safety measures described in this manual.
DO NOT INSERT THE BATTERY FUSE AT THIS STAGE.
D.3.2Connection to the AC OUTPUT.
The AC output must be connected to the screw terminal AC OUTPUT. For this,
use a 3-core cable with a conductor cross section of 2,5mm². Connections are
marked as follows “OUT / N”=Neutral, “GND”=Earth, “OUT / L”=Live or Active.
Caution: High voltage can be at the AC output, ensure the unit is not
connected when making AC connections.
D.3.3Connection to the AC INPUT
The AC input supply from the electricity grid or from a generator must be
connected to the screw terminals AC INPUT. For this use a 3-core cable with a
conductor cross section of 2,5mm². Connections are marked as follows
“IN / N”=Neutral, “GND”=Earth, “IN / L”=Live or Active.

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D.3.4Connect the Solar modules: SOLAR IN +/-
Solar modules are connected on these terminals. Under no circumstances should
any other energy source i.e. wind generator be connected to these terminals.
Depending on the power of the modules, the cable cross section should be 2.5 up
to 6mm². Before connecting it is necessary to check with a Voltmeter that the
voltage of the Module meets the following values:
Invertek DAI -1500C -12xx / DAI - 3000C -12xx 17-25V / 30A
Invertek DAI -1500C -24xx / DAI - 3000C - 24xx 34-45V / 30A.
D.3.5Connection to Aux1 & AUX2:
On these three terminals is a potential free change-over contact capable of
switching a maximum current and voltage of 16A/250V ac. The “ multi-display “
on the front of Combi can show the status of these contacts.
D.3.6Connection to Remote control unit ( optional ):
The Remote control unit RCC-A is connected in the “Remote control” of front
panel with a RJ11 / 6 connector. The Remote Control can be plugged IN at any
time. Push in the connector, without forcing it, until you hear the ”click:, now the
connector is locked in place. The same applies to the plug at the Remote control
unit. The length of the cable for the Remote control should not exceed 15m, is
comes standard with 3m cable.

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E. Operating
E.1 Front Panel Display And Operating Description
Sterling Power Products
85
69
7
12
PB6 PB5 PB7
PB4 PB1
10
PB3 PB2
11
2 1 3 4
E.2 Push buttons
Push buttons Name Description
PB1 RUN/STOP RUN/STOP key
PB2 FUNC k Operation mode select key.
PB3 AUX1Auxiliary contract (aux1, aux2) Manual / Active change. And Function
programming key
PB4 DSPL Multi-display select key
PB5 UP（△ ） △Increment key.
PB6 DOWN （▽ ） ▽Decrement key.
PB7 ENTER Data write key.

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E.3 LED INDICATOR:
LED Name L ED ON LED Blink LED OFF
1 AC IN 1. Input voltage normal, and
position”transfer
Voltage Level”
(150VAC~240VAC)
2. Input voltage frequency
range in between(45~60Hz)
Has input power, but
voltage or frequency is not
in the allowance range.
No input power
2 CHARGER Green : Battery charger is
working.
Green Blink : Battery
charger is standby.
Orange Blink : Battery
charger is disable.
--------------
3 SOLAR PANEL Solar module is delivering
energy.
-----------------------------
1. Solar module
aren’t connect
or
2. Day or Night /
(cloudy day)
4 SOLAR
CHARGER
Solar charger is working.
------------------------------
Solar charger is
disabled.
5 AC OUT There is voltage at the “AC OUT”
terminal.
No voltage at the “AC
OUT” terminal.
-------------
6 INVERTER Green : Inverter is working. Green Blink : Inverter is
standby
Orange Blink : Inverter is
disable.
--------------
7 EQUALIZE In Equalize charging
Process
------------------------------
Disable Equalize
charging function
8 BATTERY Approx state of charge or discharge of Battery.
9 BYPASS Green : BYPASS switch is active
AC IN voltage is being sent
directly to AC OUT terminal
Green Blink :BYPASS
switch standby.
Orange Blink : BYPASS
switch disable
---------------
10 RUN/STOP Green : Invertek turn on.
Red : Invertek turn off.
Red Blink : Auto-Restart
is in use ---------------

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11 MULTI-DISPLAY
LED In Inverter Mode In Charger Mode
9.1 Battery Voltage Battery Voltage
9.2 Output Voltage Input Voltage
9.3 Output Frequency Charging Phase
9.4 AC output current Battery charging current
9.5 Indicator of parameter setting or modify or monitor.
9.6 Indicator of error message
12 POWER
MONITOR
Displays the value of the output power in % of max continuous
power (in Inverter Mode) and the charge current in Amps. (in
Charger Mode) In this mode the 200% LED indicate that power
sharing is in use.
LED 9.1 LED 9.4
LED 9.5
LED 9.2
LED 9.6
LED 9.3
Display
monitoring
values or set
values of each
parameter.
：Battery under voltage trip.
：Battery over voltage trip.
：AC out overload trip.
：Heatersink overtemperature trip.

Fn00 Fn01 Fn02 Fn03 Fn04 Fn05 Fn06 Fn07 Fn08 Fno9
DSPL FUNC
ENT AUX
Battery type
0= Open lead acid
1= Gel ( exide ) setting
2= Gel u.s.a setting
3= Agm sealed
inverter voltage
0) 200 v 50 hz
1) 220 v 50 hz
3) 240 v 50 hz
2) 230 v 50 hz
power saver mode
1) power saver on
2) power saver off
system fuctions
0) all functions normal
1) inverter off, charger and bypass on
2)charger and bypass off, inverter on
3) inverter and charger off, bypass on
aux 1 setup
0) on when charger on
1) on when charger off
2) on when inverter on
3) on when inverter off
aux 2 setup
0) on when charger on
1) on when charger off
2) on when inverter on
3) on when inverter off
input current limit setup
0) 25 % power 4 amps
1) 50% power 7 amps
2) 75% power 11 amps
3) 100% power 15 amps
charging current reduction
0) 25% reduction
1) 50% reduction
2) 75% reduction
3) full current
solor charger
1) on
2) off
low voltage cut out
0) 10.0 v
1) 10.5 v
2) 11.0 v
3) 11.5 v
4) 12.0 v
System Adjustments
To adjust any of the unit’s preset parameters ) the unit must be in STOP mode! Select the
function you wish to change from the list of light blue boxes below. Select the parameter in the box you wish to change. For example, if you wish to switch the power saver
function off, you find that the power saver function is attached to (function 2) and that selection means “off”. To select this desired option go to the main key pad on the
front of the unit. Push the pad marked FUNC (function) for 2 seconds and use up/down keys to scroll through the functions. (The display will show up to ) Stop at
the function you require. (For power saver stop at .) With on the screen push ENT on the keypad and use the up/down arrows to select the parameter
required. The display will show from to (depending on which parameter you wish to change). Then select the parameter number you wish (in this case the power saver
off function which is ), by using the up/down keys and push the ENT key to enter that selection. After the selection has been made the display will show and this will
complete the parameter change. Then press DSPL to return to the function heading (one level upwards). Either continue to next function or press DSPL again to
return to the voltage display mode. The unit will also automatically return to the voltage display after about 20 seconds if left alone. Don’t forget to return to RUN mode!
(factory settings are highlighted in dark blue in each function box/default
Fn02 2
Fn00 Fn09.
Fn02 Fn02
00 06
2 End
(”enter”)
adjusting the
screen example Fn09

-15-
E.7.1 The Inverter
The Inverter section of the unit produces a high quality Sinewave output, the
quality of this output is compatible with any appliance, Thanks to the generous
dimensioning of the unit , you can operate appliances requiring higher power
than the nominal power of the unit for a short time. The unit provide up to
3-times the nominal power to start motors etc.
E.7.2 Power saving function (Fn02)
In order to avoid unnecessary discharge of the battery, the inverter switches OFF
automatically if no AC power is being used. The unit switches ON
automatically again if an AC load is switched ON. The AC Out LED blinks if the
inverter is in “Power Saving-Mode”.
If the “Power Saving-Mode” is not wanted, set the Fn02 "DISABLE" function.
This will keep the unit running continuously, but will alsodischarge your
batteries quicker.
E.7.3 Overload
If the unit is overloaded for too long or too heavily, it switches off. The
“Multi-display” will show “ ” and the “RUN/STOP” LED will RED Blink. After
approximately 10 seconds the Inverter switches on automatically. If the unit is
overloaded four times in quick succession, then it no longer switches back on
automatically. The “RUN/STOP” LED remains lit, and the multi-display show “ ”.
Press the push button 1(PB1) ”RUN/STOP” in order to switch the unit back ON.
E.7.4 Overheating (Over Temp)
If the Inverter has been overload for a long time or it has been working in a high
ambient temperature, it will switch OFF. The “Multi-display” will show “ ” and
the “RUN/STOP”LED RED blinks. After cooling down, the inverter switches back on
automatically. One minute before the inverter switches off due to high temperature
a buzzer will be heard. If the Auxiliary Contact has been programmed for “Over
Temp” then the contact will be active when the buzzer sounds. This could be used
for example to start an emergency back up generator, creating a no break energy
supply.

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E.7.5 Battery Condition
Deep discharging of batteries leads to high losses in capacity and early aging.
That is why the unit will constantly monitor the battery condition. When battery
voltage gets too low the Invertek switches OFF. The multi-display will show
“” or ” ” (Low voltage cut out P-12) the “RUN/STOP” LED RED blinks.
When the battery voltage returns to 12.1V resp..24.2V, the inverter switches ON
automatically. One minute before the Inverter switches OFF due to low voltage a
buzzer will be heard.
The low voltage is set to 11.8V resp. 23.6V. These settings are standard for
most batteries. The voltage levels are maintained by the built-in
Battery-Management-System of the Invertek which looks at the load and battery
condition and adjusts to suit.
This setting is comparable with the levels of 10.8V resp. 21.6V, which are given
for most batteries on nominal load.
Equalization Charging
Absorption Stage

-17-
F. Disabling Functions (Fn05)
Each different function, charger, inverter and transfer can be disabled. This is
useful for specific applications which are required to disable some of these three
functions. If you press the “FUNC” button for more than 2 seconds you can
have access to the different possibilities shown in the following diagram,.
In programming mode the display only shows the different types of program with
the “Charger”, Transfer” and “Inverter” functions. To change the type of
programming press the “△or ▽” button until the LED corresponding to the
desired function is lit, in to the table below, After 10 seconds or press “DSPL”
button the Invertek will exit the programming mode and function with the new
programming,. In normal user mode, the disabled functions are displayed by a
orange blinking LED.