Sensata 12/800N User manual

DC to AC POWER INVERTERS

Pure Sine Wave Output

OWNER’S MANUAL

MODELS:

12/1800N

12/2400N

12/3000N

12/3600N

MODELS:

12/800N

12/1200N

12/1500N

TABLE OF CONTENTS

SAFETY INSTRUCTIONS

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2

Inverter Safety Instructions

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2

Battery Safety Instructions

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3

THEORY OF OPERATION

.............................................................................................................

3

Inverter Power Mode

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3

NOMENCLATURE

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4

MOUNTING THE INVERTER

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4

Installation Tools

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4

Inverter Mounting Recommendations

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4

DC WIRING GAUGE & FUSING

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5

Inverter Cable

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5

Cable Recommendations

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5

REMOTE ON/OFF SWITCH

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5

HARDWIRE OUTPUT

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6

WIRING DIAGRAMS

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6

Typical Wiring Diagram for 12/800N,12/1200N & 12/1500N

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6

Typical Wiring Diagram for 12/8000N, 12/2400N, 12/3000N, & 12/3600N

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7

Typical DC Cable Connections for 12/800N, 12/1200N & 12/1500N

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8

Typical DC Cable Connections for 12/1800N, 12/2400N, 12/3000N, & 12/3600N

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9

INVERTER TROUBLESHOOTING GUIDE

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10

Troubleshooting Steps

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11

SPECIFICATIONS

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12

OTHER DESIGN FEATURES

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12

UNIT PROTECTION

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12

BATTERY PROTECTION

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12

LIMITED WARRANTY TERMS & CONDITIONS

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13

IMPORTANT: Read this manual before installation, it contains important safety, installation,

and operating instructions. Save this manual and keep it in a safe place.

NOTE: This product is Listed to applicable UL Standards and requirements by Underwriters

Laboratories Inc., File E100666.

Sensata Technologies is an ISO 9001:2008 Registered Company.

Sensata uses the following special notices to provide warning of possible safety related

problems which could cause serious injury and to provide information to help prevent dam-

age to equipment.

DANGER indicates an imminently hazardous situation which, if not avoided will result

in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result

in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situa-

tion which, if not avoided, may result in property damage.

NOTE is used to notify of installation, operation, or maintenance information that is

important but not hazard related.

2

SAFETY INSTRUCTIONS

Inverter Safety Instructions:

WARNING: Power Inverters produce hazardous voltages. To avoid risk of harm or fire,

the unit must be properly installed.

WARNING: There are no user serviceable parts inside, do not remove the cover.

WARNING: Power Inverters should not be mounted in a location that may be exposed

to rain or spray.

WARNING: Power Inverters should not be installed in a zero clearance enclosure.

WARNING Damage to the Power Inverter will occur if correct polarity is not observed

when installing the inverter’s DC input cables.

WARNING: Damage to the Power Inverter will occur if an external AC power source is

applied to the inverter’s AC hardwire output.

WARNING: Power Inverters contain a circuit breaker and capacitor that may produce a

spark. Do not mount in a confined battery or gas compartment.

WARNING: Be sure the Power Inverter is turned OFF during installation.

WARNING: Working in the vicinity of lead-acid batteries is dangerous. There is a risk of acid

exposure.

WARNING: Batteries generate explosive gases during operation.

WARNING: There is risk of high current discharge from shorting a battery that can cause fire

and explosion. Use insulated tools during installation.

WARNING: Remove all rings, watches, jewelry or other conductive items before working near

the batteries.

WARNING: Inspect the batteries once a year for cracks, leaks or swelling.

WARNING: Dispose of the batteries according to local regulations. Do not incinerate

batteries; risk of explosion exists.

When the inverter is in “Inverter Power” mode, the green LED “Inverter” will come on. The AC

power produced by the inverter comes from the energy stored in the battery bank through a

sophisticated electronic inversion process. A transformer, a Metal Oxide Silicon Field Effect

Transistors (MOSFET), a filter capacitor and a waveform stabilizer circuit are used to generate

clean useful AC power.

Note: The signal output waveform produced by the inverter when in “inverter mode” is pure

sinusoidal. It has a total harmonic distortion of less than 5%.

3

Battery Safety Information:

THEORY OF OPERATION

Inverter Power Mode

The “Local On/Off Switch” located on front, or the “Remote On/Off Switch” if used controls the

inverter. Both the Local and “Remote On/Off” switches are configured in series. To control the

inverter remotely set the “Local On/Off switch” to ON.

The inverter will operate in “inverter mode” only.

NOMENCLATURE

CASE “L”

16

1.5 2.5 4 5 2.5

15

15.5

CASE “I”

393

8.2

15

CASE “O”

17

1.5 25.5 4.5 2.5

16

MOUNTING THE INVERTER

Installation Tools

Inverter Mounting Recommendations

The following tools are required for inverter installation: Crimper, Cable Ties, Cutter, Drill, #2

Phillips Screw Driver, Tape Measure, Wire Cutters, and Wire Strippers.

Inverter Mounting Footprints (Dimensions are in inches)

Inverter Models

12/800N & 12/1200N,

& 12/1500N

Inverter Models

12/1800N, 12/2400N

& 12/3000N

Inverter Model

12/3600N

4

NOTE: The inverter mounting location should provide adequate ventilation and clearance to

maintain room temperature during operation. A minimum of 1/2 inch of clearance is required

on all sides.

1. Locate a suitable vertical or horizontal mounting surface as close to the batteries as

possible without being in the same airtight compartment.

2. If mounting the inverter on a vertical surface, the front control panel should be pointing

down whenever possible.

3. Locate the mounting holes on the chassis flanges and fasten them using the 1/4 inch

diameter screws to secure the inverter.

DC WIRE GAUGE, FUSING & BATTERIES

Inverter Cable

An “Inverter Cable” kit (positive cable, negative cable, and proper fuse) is required to connect the

inverter to a battery pack. An 8-guage cable is also required to connect the inverter’s bonding

lug to ground.

The inverter cable length and the size of the inverter will determine the cable gauge and the size

fuse to use. The maximum inverter cable recommended is 20-ft; it must be fused within 18-in from

the positive (+) terminal of the battery.

Table 1: Cable and Fusing Guide at 5% Voltage Drop at Full Output

Inverter

Model

Full Load

(Amps DC) Fuse Size

Inverter to Battery Estimated Cable Length in Feet

1 ft. to 10 ft. 11 ft. to 15 ft. 16 ft. to 20 ft

12/800N 80 150A 4-gauge 4-gauge 2-gauge

12/1200N 120 200A 4-gauge 2-gauge 1-gauge

12/1500N 150 200A 2-gauge 1-gauge 1/0-gauge

12/1800N 180 300A 2-gauge 1/0-gauge 2/0-gauge

12/2400N 240 400A 1/0-gauge 2/0-gauge 4/0-gauge

12/3000N 300 500A 2/0-gauge 4/0-gauge 4/0-gauge

12/3600N 360 600A 4/0-gauge 4/0-gauge NR

*Proper cable gauge must be used to prevent excessive voltage drop at the inverter DC input

*Some motor starting may require the use of the next larger size cable

Cable Recommendations

1. Use stranded copper cable.

2. Use SGX cross-linked polyurethane insulation type that complies with the high temperature

insulation requirements (125º C) of SAE J-1127 and vehicle manufacturer requirements.

3. Cable gauge recommendations are minimum. For higher than normal temperature

applications or large motor loads, and other applications with high surge currents, use cable

gauge 1 to 2 sizes larger than recommended in Table 1.

4. Keep the cable lengths between the battery and inverter as short as possible.

5. UL requires that a line fuse be installed within 18 inches of the battery. Use only Bussmann

ANN type fuses to 500A and Bussmann ANL for 600A.

Cross reference the inverter model, and the estimated cable length in Table 1 to determine the

proper cable gauge and fuse size. The Inverter Cable kit may be purchased directly from Sensata

Technologies.

REMOTE “ON/OFF” SWITCH

An optional customer supplied remote “On/Off” switch can be connected to the remote

On/Off switch hookup lead extending from the inverter (violet wire). Use an 18-gauge cable, single

pole single throw switch, and a 5-amp in-line fuse installed within 10 inches from the positive (+)

terminal of the battery. 5

Recommended Battery Sizes & Quantities @ full hp rating

12/1800N 12/2400N 12/3000N 12/3600N

1 Deep Cycle 2-8D 2-8D 1 or 2-8D

HARDWIRE OUTPUT

The hardwire A.C output is not ground fault interrupt, (GFCI) protected unless the inverter has

option “A”. GFCI outlets should be installed at all appropriate locations per NEC 551. The GFCI

outlet should be Leviton Type 7899 or N7899, 20Amp., 125VAC.

WIRING DIAGRAMS

Typical Wiring Diagram for 12/800N, 12/1200N & 1500N

6

Typical Wiring Diagram for 12/1800N, 12/2400N, 12/3000N, 12/3600N

7

8

Typical DC Cable Connections for 12/800N, 12/1200N & 12/1500N

Typical DC Cable Conn’s for 12/1800N, 12/2400N, 12/3000N, &12/3600N

9

Sensata 12/800N User manual

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