Statpower PROwatt 1500/12 volt User manual

PROwatt 1500/12 volt

PROwatt 1500/24 volt

POWER INVERTER

Owner’s

Manual

Statpower Technologies Corporation Tel: (604) 420-1585

Fax: (604) 420-1591

Internet address: http://www.statpower.com

7725 Lougheed Highway

Burnaby, BC V5A 4V8

Canada

PROwatt is a trademark of Statpower Technologies Corporation.

Table of Contents

1 Introduction...........................................................................................................................................................1

2 How Your PROwatt 1500 Works.........................................................................................................................1

2.1 Principle of Operation .............................................................................................................................1

2.2 PROwatt 1500 Output Waveform...........................................................................................................3

3 Quick Checkout....................................................................................................................................................4

3.1 Power Source...........................................................................................................................................4

3.2 Cables......................................................................................................................................................4

3.3 Test Loads ...............................................................................................................................................5

3.4 Connections.............................................................................................................................................5

4 Installation ............................................................................................................................................................6

4.1 Where to Install.......................................................................................................................................6

4.2 Battery.....................................................................................................................................................6

Battery Type.....................................................................................................................................7

Battery Sizing...................................................................................................................................8

Using Multiple Batteries ..................................................................................................................9

Battery Tips....................................................................................................................................10

Alternators and Charging Systems.................................................................................................11

4.3 Cables....................................................................................................................................................12

4.4 Connections...........................................................................................................................................12

AC Wiring......................................................................................................................................12

Ground Wiring ..............................................................................................................................15

DC Wiring......................................................................................................................................16

4.5 Remote Panel.........................................................................................................................................17

Installation Instructions..................................................................................................................17

Operating Instructions....................................................................................................................17

5 Operation ............................................................................................................................................................18

5.1 Outlets, Controls and Indicators............................................................................................................18

5.2 Operating Limits...................................................................................................................................19

6 Troubleshooting..................................................................................................................................................20

6.1 Common Problems................................................................................................................................20

6.2 Troubleshooting Guide..........................................................................................................................21

7 Maintenance........................................................................................................................................................22

8 Warranty.............................................................................................................................................................22

8.1 Warranty Terms.....................................................................................................................................22

8.2 To Obtain Warranty Service.................................................................................................................22

9 Specifications ......................................................................................................................................................24

9.1 Electrical Performance ..........................................................................................................................24

9.2 Dimensions............................................................................................................................................24

1 Introduction

Your new PROwatt 1500 inverter is a member of the most advanced line of dc to ac inverters available today. It

will give you years of dependable service in your boat, RV, service vehicle or remote home.

To get the most out of your PROwatt 1500, it must be installed and used properly. Please read the installation and

operating instructions in this manual carefully before installing and using your PROwatt 1500. Pay special atten-

tion to the CAUTION and WARNING statements in this manual and on the PROwatt 1500. CAUTION state-

ments identify conditions or practices which could result in damage to your PROwatt 1500 or to other equipment.

WARNING statements identify conditions or practices that could result in personal injury or loss of life.

2 How Your PROwatt 1500 Works

An inverter is an electronic device that converts low voltage DC (direct current) electricity from a battery or other

power source to standard 115 volt AC (alternating current) household power. In designing the PROwatt 1500,

Statpower has used power conversion technology previously employed in computer power supplies to give you

an inverter that is smaller, lighter, and easier to use than inverters based on older technology.

2.1 Principle of Operation

The PROwatt 1500 converts power in two stages. The first stage is a DC-to-DC converter which raises the low

voltage DC at the inverter input to 145 volts DC. The second stage is the actual inverter stage. It converts the

high voltage DC into 115 volts, 60 Hz AC.

The DC-to-DC converter stage uses modern high frequency power conversion techniques that eliminate the bulky

transformers found in inverters based on older technology. The inverter stage uses advanced power MOSFET

transistors in a full bridge configuration. This gives you excellent overload capability and the ability to operate

tough reactive loads like lamp ballasts and induction motors.

Figure 1. PROwatt 1500 - Principle of Operation

2.2 PROwatt 1500 Output Waveform

The AC output waveform of the PROwatt 1500 is called a "quasi-sine wave" or a "modified sine wave". It is a

stepped waveform that is designed to have characteristics similar to the sine wave shape of utility power. A

waveform of this type is suitable for most AC loads, including linear and switching power supplies used in elec-

tronic equipment, transformers, and motors. This waveform is much superior to the square wave produced by

many other dc to ac inverters.

CAUTION! RECHARGEABLE APPLIANCES

Certain rechargers for small nickel cadmium batteries can be damaged if connected to the PROwatt. Two

particular types of equipment are prone to this problem:

1) small battery operated appliances such as flashlights, razors, and night lights that can be plugged di-

rectly into an ac receptacle to recharge.

2) certain battery chargers for battery packs used in hand power tools. These chargers have a

WARNING label stating that dangerous voltages are present at the battery terminals.

Do NOT use the PROwatt with the above equipment.

This problem does not occur with the vast ma-

jority of battery operated equipment. Most of

this equipment uses a separate charger or trans-

former that is plugged into the ac receptacle

and produces a low voltage output. If the label

on the ac adapter or charger states that the

adapter or charger produces a low voltage ac or

dc output (less than 30 volts), the PROwatt will

have no trouble powering this charger or

adapter safely.

The modified sine wave produced by the

PROwatt 1500 is designed to have an RMS

(root mean square) voltage of 115 volts, the same as standard household power. Most AC voltmeters (both digital

and analog) are sensitive to the average value of the waveform rather than the RMS value. They are calibrated for

RMS voltage under the assumption that the waveform measured will be a pure sine wave. These meters will not

read the RMS voltage of a modified sine wave correctly. They will read about 2 to 20 volts low when measuring

the output of the PROwatt 1500. For accurate measurement of the output voltage of the PROwatt 1500, a true

RMS reading voltmeter, such as a Fluke 87, Fluke 8060A, Beckman 4410, or Triplett 4200, must be used.

Figure 2. Modified Sine Wave

3 Quick Checkout

This section will give you the information you need to quickly hook-up your PROwatt 1500 and check its per-

formance before going ahead with permanent installation. You will need the following:

a) a 12 volt DC power source (24 volt for PW1500/24)

b) two cables to connect the power source to the PROwatt 1500

c) a test load that can be plugged into the AC receptacle on the PROwatt 1500.

3.1 Power Source

The power source must provide between 11 and 15 volts (22 and 30 volts for PW1500/24) DC and must be able

to supply sufficient current to operate the test load. As a rough guideline, divide the wattage of the test load by 10

(by 20 for PW1500/24) to obtain the current (in amperes) the power source must deliver.

Example: Test load is rated at 250 watts. Power source must be able

to deliver 250 ÷ 10 = 25 amperes (or 12.5Amps for 24 volt model).

Battery

Use a fully-charged 12 volt (nominal) battery that can deliver the required current while maintaining its voltage

above 11 volts (22 volts for 24 volt battery system). A fully-charged (12 volt) automobile battery is capable of

delivering up to 50 amperes without an excessive voltage drop.

DC Power Supply

Use a well regulated DC power supply that has an output voltage between 11 volts and 15 volts (22-30 volts for

PW1500/24) and can deliver the required current. If the supply is adjustable, make sure that the output voltage is

adjusted to be between 11 volts and 15 volts (22-30 volts for PW1500/24) the inverter may shut down if the volt-

age is outside these limits and may be damaged if the voltage is above 16 volts (32 volts for PW1500/24). Also

ensure that any current limit control is set so that the power supply can deliver the required current.

3.2 Cables

Your cables must be as short as possible and large enough to handle the required current. This is to minimize the

voltage drop between the power source and the inverter when the inverter is drawing current from the power

source. If the cables introduce an excessive voltage drop, the inverter may shut down when drawing higher cur-

rents because the voltage at the inverter drops below 10 volts (20 volts on PW1500/24).

We recommend #2 AWG (#4 AWG on PW1500/24) stranded copper cable that is no longer than 4 ft (1.2 metres)

if you want to test the PROwatt 1500 to its maximum ratings. For short term testing at reduced power levels, the

guidelines below should be followed:

Test Load Power Minimum Cable Size Minimum Cable Size

Consumption For PW1500/12 volt PW1500/24 volt

Short Term Test

100 watts #16 AWG copper #18 AWG copper

250 watts #12 AWG copper #16 AWG copper

500 watts #8 AWG copper #12 AWG copper

Ideally, the cable should be no more than 4 ft (1.2 meters) long.

The end of the cable to be connected to the inverter must have its insulation stripped for about 1/2 inch (1.25 cm)

back from the end, exposing the bare copper conductor. The other end of the cable, which is connected to the

power source, must be terminated with a lug or other connector that allows a secure, low resistance connection to

be made to the power source. For instance, if the power source is a battery, the cable must be terminated with a

battery terminal that clamps to the post on the battery.

A solid, low resistance connection to the power source is essential for proper operation of the PROwatt

1500.

3.3 Test Loads

Use only equipment rated for 110-120 volt, 60 Hz AC operation that has a power consumption of 1500 watts or

less. We recommend that you start with a relatively low power load, such as 100 watt lamp, to verify your test

set-up before trying high power loads.

Figure 3. Connections to the PROwatt 1500

3.4 Connections

Follow the connection sequence described below.

STEP 1Ensure that the ON/OFF switch on the PROwatt 1500 is in the OFF position. If the power source is a DC

power supply, switch it off as well.

STEP 2Connect the cables to the power input terminals on the rear panel of the PROwatt 1500. The red terminal

is positive (+) and the white terminal is negative (-). Insert the bare ends of the cables into the terminals

and tighten the screws to clamp the wires securely.

STEP 3Connect the cable from the negative (white) terminal of the PROwatt 1500 to the negative terminal of the

power source. Make a secure connection.

CAUTION! Loosely tightened connectors result in excessive voltage drop and may cause overheated wires

and melted insulation.

STEP 4Before proceeding further, carefully check that the cable you have just connected connects the negative

terminal of the PROwatt 1500 to the negative output terminal of the power source. Power connections

to the PROwatt 1500 must be positive to positive and negative to negative.

CAUTION! Reverse polarity connection (positive to negative) will blow the fuses in the PROwatt 1500 and

may permanently damage the PROwatt 1500. Damage caused by reverse polarity connection is not cov-

ered by your warranty.

STEP 5Connect the cable from the positive (red) terminal of the PROwatt 1500 to the positive terminal of the

power source. Make a secure connection.

WARNING! You may observe a spark when you make this connection since current may flow to charge capaci-

tors in the PROwatt 1500. Do not make this connection in the presence of flammable fumes. Explosion or

fire may result.

STEP 6If you are using a DC power supply as the power source, switch it on. Set the ON/OFF switch on the

PROwatt 1500 to the ON position. Check the meters and indicators on the front panel of the PROwatt

1500. The voltage bar graph should indicate 11 to 14 volts (22-28 volts for PW1500/24), depending on

the voltage of the power source. If it does not, check your power source and the connections to the

PROwatt 1500. The other indicators should be off.

STEP 7Set the PROwatt 1500 ON/OFF switch to the OFF position. The indicator lights may blink and the inter-

nal alarm may sound momentarily. This is normal. Plug the test load into the AC receptacle on the

front panel of the PROwatt 1500. Leave the test load switched off.

STEP 8Set the PROwatt 1500 ON/OFF switch to the ON position and turn the test load on. The PROwatt 1500

should supply power to the load. If it does not, refer to the troubleshooting section of this manual. If

you plan to measure the output voltage of the PROwatt 1500, refer to Section 2.2 of this manual.

4 Installation

4.1 Where to Install The PROwatt 1500 should be installed in a location that meets the following requirements:

a) Dry - do not allow water to drip or splash on the PROwatt 1500.

b) Cool - ambient air temperature should be between 0oC and 40oC (30oF and 105oF) the cooler the bet-

ter.

c) Ventilated - allow at least 1 inch (2.5cm) of clearance around the PROwatt 1500 for air flow. Ensure

that ventilation openings on the rear and bottom of the unit are not obstructed.

d) Safe - do not install the PROwatt in the same compartment as batteries or in any compartment capable

of storing flammable liquids such as gasoline.

e) Close to Battery - install as close to the battery as possible in order to minimize the length of cable re-

quired to connect the inverter to the battery. It is better and cheaper to run longer AC wires than

longer DC cables.

CAUTION! To prevent fire, do not cover or obstruct ventilation openings. Do not install the PROwatt

1500 in a zero-clearance compartment. Overheating may result.

WARNING! This equipment contains components which tend to produce arcs or sparks. To prevent fire

or explosion do not install in compartments containing batteries or flammable materials or in locations

which require ignition protected equipment.

Mount the PROwatt on a flat surface using the mounting bracket on the bottom. Mounting hardware should be

corrosion resistant and #10 or larger. The PROwatt may be mounted horizontally or vertically.

4.2 Battery

The battery you use strongly affects the performance you can expect from your PROwatt 1500. It is important to

connect the PROwatt 1500 to the correct size and type of battery. The following information will help you select

the appropriate batteries for your application.

Battery Type

The lead-acid battery which is probably most famil-

iar is the starting battery in your automobile. An

automotive starting battery is designed to deliver a

large amount of current for a short period of time

(so it can start your engine). Only a small portion

of the battery's capacity is used when starting the

engine and it is quickly recharged by the running

engine. It is not designed for repeated charge-

discharge cycles where the battery is almost com-

pletely discharged and then recharged. If it is used

in this kind of deep discharge service, it will wear

out very rapidly.

Deep-cycle lead-acid batteries are designed for

deep discharge service where they will be repeat-

edly discharged and recharged. They are marketed for use in recreational vehicles, boats, and electric golf carts

so you may see them referred to as RV batteries, marine batteries, or golf cart batteries.

Figure 4. PROwatt 1500 Connected Directly to Engine Bat-

tery for Light-Duty Applications

For most applications of the PROwatt 1500, Statpower recommends that you use one or more deep-cycle batteries

that are separated from the starting battery in your vehicle by a battery isolator. A battery isolator is a solid-state

electronic circuit which allows equipment to be operated from an auxiliary battery without danger of discharging

the vehicle's starting battery. During vehicle operation, the battery isolator automatically directs the charge from

the alternator to the battery requiring the charge. Battery isolators can be obtained at marine and RV dealers and

most auto parts stores.

If your application involves relatively low power loads (i.e. power consumption of 300 watts or less) and rela-

tively short operating times before recharging (one hour or less), you may connect the PROwatt 1500 directly to

the vehicle starting battery.

CAUTION! The PROwatt 1500/12

must be connected only to batteries

with a nominal output voltage of 12

volts . The PROwatt 1500/12 will not

operate from a 6 volt battery, and will

be damaged if it is connected to a 24

volt battery. The PW1500/24 must be

connected only to a 24 volt battery

system. The PW1500/24 will not oper-

ate from a 6 or 12 volt battery.

Figure 5. Recommended Battery Configuration for Medium-Duty

Applications

Battery Sizing

Unfortunately, there are a number of different standards for rating battery energy storage capacity. 12 volt Auto-

motive starting batteries are normally rated by cranking amps. This is not a relevant rating for continuous use.

Deep-cycle batteries are rated either by reserve capacity in minutes or by ampere-hour capacity.

Battery reserve capacity is a measure of how long a battery can deliver a certain amount of current - usually 25

amperes. For instance, a battery with a reserve capacity of 180 minutes can deliver 25 amperes for 180 minutes

before it is completely discharged.

Ampere-hour capacity is a measure of how many amperes a battery can deliver for a specified length of time -

usually 20 hours. For example, a typical marine or RV battery rated for 100 ampere-hours can deliver 5 amperes

for 20 hours (5 amperes x 20 hours = 100 amp-hrs).

Actual battery capacity decreases as discharge current increases. A battery rated at 100 ampere-hours which can

deliver 5 amperes for 20 hours, may deliver 20 amperes for only 4 hours, resulting in an actual capacity of 80 am-

pere-hours. For this reason, it is difficult to compare rated ampere-hour capacity with battery reserve capacity.

For example a battery with a reserve capacity of 180 minutes has the following calculated ampere-hour capacity:

180 min.÷ 60 = 3 hr., 3 hr. x 25 amps = 75 amp-hrs

However its actual ampere-hour rating will be closer to 100 ampere-hours because it is rated at the discharge cur-

rent required to get 20 hours of operation (about 5 amperes).

To determine the battery capacity you require, follow these steps:

STEP 1 For each piece of equipment you will be operating from the PROwatt 1500, determine how many watts it

consumes. This can normally be found on a label on the product. If only the current draw is given, mul-

tiply the current draw by 115 to get the power consumption in watts.

STEP 2For each piece of equipment you will be operating from the PROwatt 1500, estimate how many hours it

will operate between battery charging cycles.

STEP 3Calculate total watt-hours of energy consumption, total hours running time, and average power consump-

tion as in the following example:

Equipment Power Consumption Operating Time Watt - Hours (Power x Operating Time)

TV & VCR 115 watts 3 hours 345

Sewing Machine 150 watts 1 hour 150

Waterpik 90 watts 0.25 hour 22.5

Blender 300 watts 0.25 hour 75

Coffee Maker 750 watts 0.3 hour 225

Coffee Grinder 100 watts 0.l hour 10

Microwave Oven 1500 watts 0.5 hour 750

Totals 5.4 hours 1577.5 watt-hours

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