Toro SA41 Marine Battery User Manual
Contents
1. 19 APPENDIX I DIAGNOSTICS eed eae 20 APPENDIX FLOW DIAGRAM FOR DISPLAYS AND 21 21 MINIMUM CHARGE DISPLAY uhr y ted ema e tate mtra tee eda mes 22 BEING n ex eei epa tubi m arena Raat eb Mame 23 APPENDIX SA INVERTER 8 0 0 0402000 25 GENERA nee 25 SASSO INTERFACE ted te E utut 25 SA KP 01 OPTIONAL KEYPAD INSTALLATION tentent tette tent 27 SA S200 OPTIONAL CURRENT SHUNT 8 4 24 02 0 0 04 54 00410 28 deese e Mat PR et a gga ores uta Ct e MUR RH RD t quU 29 PRODUCT WARRANTY CONDITIONS 29 MOUNTING TEMPLATE FOR SA KP 01 KEYPAD 1 ente 30 Rev 5 INTRODUCTION Thank you for purchasing the Selectronic Sine wave inverter model SA41 with ENERGY MANAGEMENT Your 41 is a state of the art high performance TRUE SINE WAVE DC to AC Power Inverter incorporating ENERGY MANAGEMENT a unique energy monitoring and controlling system developed by Selectronic to enable you to maximise your limited energy resource Thousands of hours2. Ext Shunt YES Set Parameters Back to Readings if no Current Shunt 24 Zero DC Amps OFF Set Parameters Capacity 500AH Set Parameters AH In Batt 445 Set Parameters Min Charge 60 Set Parameters Lo Chg Alarm OFF Set Parameters Batt Effic 95 Set Parameters End Settings Set Parameters Back to Readings APPENDIX Ill SA INVERTER OPTIONS GENERAL The SA41 employs a rear chassis mounted 25 pin connector which allows you to add a selection of optional features to your power system Note that the software for these functions is already installed within the SA41 microcontroller The full range of features are a Remote Keypad low profile keypad with 2 line Liquid Crystal Display which be located up to 500 metres from your SA41 Wiring requirements 6 conductor shielded cable b DC Current Shunt Consists of a 200 Amp 75mV current shunt mounted on an insulated base and a twin flex loom for current sensing c Controller Outputs Two external relay or contactor coils can be energised for various AC or DC switching applications d Alarm Inputs Two digital inputs that can be programmed to monitor switch contact status or voltage levels refer to following circuits for examples SA SB 01 INTERFACE KIT The Interface Kit SA SB 01 plugs into the rear of the SA41 and provides a convenient termination point for the various options out
3. SET LOCKOUT START TIME Lockout on 22 00 This is the time the lockout for the controllers and buzzer commences Set Parameters After this time the buzzer will not sound and the controlled outputs will not come on If a control output is already on lockout will not turn it off Use the UP or DOWN keys to set the time SET LOCKOUT FINISH TIME L out off 6 00 This is the time the lockout for the controllers and buzzer ends Use the UP Set Parameters or DOWN keys to set the time LOW VOLTAGE TRIP Lo Volt Trip YES When set to YES the circuit breaker on the front panel will trip to Set Parameters completely disconnect the inverter from the batteries when the DC battery volts remains below the Lo DC Volts setting described below for more than 2 minutes Use the UP or DOWN keys to change the setting LOW DC VOLTS CUTOUT Lo DC Volts 40 0 The SA41 will cut out not tripping the breaker and a message displayed if Set Parameters the battery voltage falls below this setting for more than 10 seconds regardless of the setting of Lo Volt Trip The inverter will restart if reset or when the battery volts rise above the Lo DCV On setting next setting Please note that if the battery volts drop below 35V regardless of the Lo DC Volts setting then the breaker will trip instantly disconnecting the Lo DCV on 48 0 The SA41 will restart after a Low Battery Volts cut out when the battery Set Parameters
4. 34C This displays the operating temperature of the left heatsink Diagnostics HS2 Temp 34C This displays the operating temperature of the right heatsink Diagnostics DEMAND START CURRENT D S Current 48 This gives a reading of the value read by the demand start sense circuit and Diagnostics can be useful during advanced demand start troubleshooting SOFTWARE VERSION SELECTRONIC C This displays the revision of the software running your SA41 SA41 1 00 1996 Please note that this software is Copyright to SELECTRONIC AUSTRALIA P L and it is an offence to copy or duplicate any part of this program This is the last screen in the Diagnostics and pressing the NEXT DISPLAY key once more will return you to the readings 20 APPENDIX II FLOW DIAGRAM FOR DISPLAYS AND SETTINGS READINGS Status STANDBY Inverter OFF MON 15 06 Readings AC Volts 240V Readings AC Amps 2 5A Readings Batt Volts 49 2V Readings Not Installed Amps 23 6A OUT Battery Pk Amps 45 6 IN Battery Net AH 69 IN 87 In Battery 21 MINIMUM CHARGE DISPLAY Access to the next 5 screens is from the Readings screen Hold the Down and Up keys simultaneously for approximately 1 second then release the keys Min Charge 67 In Batt Today Min Charge 67 In Batt This Wk Weeks go 1 Min Charge 76 Days ago
5. Lo Press a Key Chg alarm setting is set to ON then this alarm will sound You are then able to take appropriate action such as removing loads or starting a generator to prevent further discharge and possible damage to your batteries FAULT FINDING 1 INVERTER STAYS ON EVEN WHEN NO APPLIANCE IS BEING USED This can be a common problem known as a phantom load but can be easily overcome with ENERGY MANAGEMENT Some appliances will need to be switched off at the power point as they may still represent a small load despite being switched off at the appliance Check again to make sure there are no appliances left on then sequentially switch off appliances at the wall and by watching your night light as described in Handy Hint on page 19 check to see if the 5 41 returns to pulsing mode after a 10 second delay Once you have found the offending appliance adjust the sensitivity of the demand start up see set parameters until the inverter turns off Once this is done re check that small loads will still bring the inverter on when required 2 INVERTER WILL NOT COME ON WHEN SMALL APPLIANCE IS SWITCHED ON This means that your demand start sensitivity is set too high With the appliance in question switched on adjust the demand start sensitivity until your SA41 turns on See Demand Start Sense on page 10 15 3 INVERTER SHUTS DOWN DURING MIDDLE OF THE DAY AND COMES BACK ON LATE IN THE AFTERNOON This is more than likely
6. DC Volts Cutout Delayed User Adjustable Low DC Volts Cut in Delayed User Adjustable High DC Volts Cutout Instantaneous User Adjustable High DC Volts Disconnect Instantaneous TOTAL APPLIANCE RATING AT Continuous 30 Minute rating 5 Minute rating 1 Minute rating Surge rating INVERTER EFFICIENCY Peak at 500W No load power consumption CONT mode MISCELLANEOUS SPECIFICATIONS Output Frequency Accuracy Output Voltage Accuracy 0 2200W Total Harmonic Distortion THD Control Outputs 1 amp 2 max DC sinking current Alarm Inputs 1 amp 2 input switching level Operating temperature range Weight 25 C 3000W 4700W 5300W 6500W 8500W DC Input is Electrically Isolated from AC Output Note notice The above specifications are based on unity power factor 18 Pulsing AC 3W to 20W 1 sec 60mA 34V 38 44V 44 4 52V 60 68V 70V 40 C 2800W 4400W 91 0 66 A 50Hz 0 001 240V 4 lt 4 50 mA HI gt 3 V LO lt 1V 10 C to 50 C 32 kg Through a policy of continued development specifications are subject to change without RADIO FREQUENCY INTERFERENCE For many years Radio Frequency Interference RFI has been an annoying problem for owners of Inverters RFI in a domestic situation causes noise or interference on a radio or TV receiver Most of the problems with RFI in a Remote Area Power Supply RAPS installation involve AM radio reception Considerabl
7. and return your reply paid warranty card within 30 days from date of purchase If service is required please return your inverter in its original carton with proof of purchase and a brief description of the fault to your point of service or any of the following service centres Selectronic Australia Burley TV Service Reid Technology Ltd Analysis 25 Holloway Drive 278 Edmondson Ave 3 5 Auburn Street Harness Cask Road Bayswater Austral Takapuna Dorrigo Victoria 3153 NSW 2171 North Shore City NSW 2453 Australia Australia Auckland NZ Australia Ph 03 9762 4822 Ph 02 606 0279 Ph 9 489 8100 Ph 066 57 8003 Fax 03 9762 9646 Fax 9 489 8585 Fax 066 57 8002 29 MOUNTING TEMPLATE FOR SA KP 01 KEYPAD Use this template when marking and cutting holes in plasterboard etc for the SA KP 01 keypad 30
8. of development time have been invested in the SA41 to provide you with a reliable high quality product The output from your SA41 is as good as if not better than mains power and if looked after properly the SA41 will give you many years of reliable service WARRANTY CARD Before proceeding any further it is extremely important that you complete your warranty card NOW This will enable us to immediately register your initial 24 month warranty period and also make you eligible for our free lifetime warranty extension Six months after the purchase date of the SA41 Selectronic will send you a questionnaire Simply complete and return the questionnaire to us and we will extend your warranty free of charge for a lifetime By accurately completing your warranty card and questionnaire you will provide us with valuable information that will assist us in keeping up with your alternative energy needs Please take a few moments to fill in the warranty card Your efforts will be greatly appreciated INSTALLATION The installation of your inverter is SELEC IRONIC SINE WAVE TNVERTER extremely important Failure to 2 follow the recommended teh oe installation instructions may void nn your warranty If in doubt ask your supplier After unpacking the SA41 check for any damage which may have 200mm occurred du
9. or DOWN keys to set the value 2 gt m 2 m a lt 5 00 gt z 5 a d MINIMUM CHARGE IN BATTERY Min Charge 60 If the charge in the battery bank drops below this level an alarm will sound Set Parameters if the low charge alarm the next setting is set ON Use the UP or DOWN keys to set the value Lo Chg Alarm OFF If set to ON an alarm will sound if the charge in the batteries drops below Set Parameters the Min Charge setting above Use the UP or DOWN keys to change the setting gt I gt m gt BATTERY CHARGE EFFICIENCY Batt Effic 95 This setting is determined by the system design and the type and age of the Set Parameters batteries used If the battery efficiency is unknown then we suggest that you use the default setting of 95 initially and adjust if the ampere hours in the batteries differs from the readings End Settings Press NEXT DISPLAY key to return to Readings Set Parameters m 2 i o m zi 2 o 13 OVERLOAD SHUTDOWN AND ALARMS The 5 41 has eight alarm and overload conditions These result from high or low battery volts high AC volts AC output overloaded transformer too hot heatsink too hot either of the two alarm inputs being active or low battery charge If any of these conditions occur a message will be displayed If there is more than one alarm condition the display will alternate between messages The alarm message
10. see page 8 b The DC Amps reading is not correct Adjust this by zeroing the meter see pages 13 and 28 16 SYSTEM MAINTENANCE To get the optimum performance from your SA41 power inverter particularly under heavy appliance loads it is essential that the battery bank and the DC wiring are all in good condition The small amount of time spent on the suggested maintenance tasks that follow will maximise the reliability of your system SA41 MAINTENANCE Periodic maintenance of the SA41 inverter involves little more than checking for unobstructed operation of the cooling fan which is located at the rear of the inverter Note that cooling air is drawn in through vents underneath the inverter Suggested inverter maintenance should include 1 Check for unobstructed fan operation Clear away dust or foreign matter from the fan grill using a soft bristled brush Do not direct high pressure compressed air at the fan blades Note that the fan is designed to come on during heavy power demand 2 Check between fins of the heatsinks and clean out any accumulated foreign objects for example insect nests 3 Verify that the air flow beneath the chassis is not restricted 4 Clean external surfaces of the SA41 using a soft lint free cloth with polish and wax e g Mr Sheen BATTERY MAINTENANCE 1 Every week carry out a thorough visual inspection of all battery wiring taking particular note of the condition of inter connec
11. will remain on the display until a key is pressed even if the alarm condition ends i e after a high voltage condition the battery volts comes back down again This allows you to determine the cause of the shutdown even if the inverter comes on again before you are able to read the display To reset the inverter after it has shutdown set the inverter Status to RESET and then back to STANDBY See page 5 DC VOLTS HIGH Hi DC Volts 66 0 This message is displayed and the inverter shuts down if the battery voltage Press a Key rises above the Hi DC Volts setting The inverter will automatically restart when the battery voltage drops below this value The present battery voltage is also displayed DC VOLTS LOW Lo DC Volts 38 0 This message is displayed and the inverter shuts down if the battery voltage Press a Key drops below the Lo DC Volts setting for more than 10 seconds inverter will automatically come on again when the battery voltage rises above the Lo ON voltage or if the inverter is manually reset via the STATUS display see page 5 The present battery voltage is also displayed AC VOLTS HIGH AC Volts Hi 0 If a system fault causes the AC voltage to go too high then this message is Press a Key displayed INVERTER OVERLOAD Inverter 0 An AC current overload or a short circuit on the AC output will cause the Press a Key inverter to shut down and display this mes
12. 1 Min Charge 76 End Min Charge Back to Readings SWITCHING BETWEEN READINGS MINIMUM CHARGE AND DIAGNOSTICS Press UP and Down together for 1 second Minimum charge displays Press UP and Down together for 1 second Diagnostic Displays 22 Pressing NEXT DISPLAY will return to Readings SETTINGS Access is from Readings screen Hold down Next Display key for approximately 1 second On with TIME INV CO LO A H or Set Control 1 CO LAH Start Day SUN Set Control 1 Start Hour 16 Set Control 1 Start Min 30 Set Control 1 Lockout ON Set Control 1 Duration 4 Hrs Set Control 1 Duration 30 Min Set Control 1 Buzzer ON Set Parameters Buzz Lockout OFF Set Parameters DS Sense 6W Set Parameters Back to Any key to end Add or DOWN for more Readings if DOWN Day MON not pressed Set Parameters Hour 15 Set Parameters un 3g AE A 29 o gs N Minute 30 Set Parameters Continue on to next page 23 From previous page Lockout on 22 00 Set Parameters L out off 6 00 Set Parameters Lo Volt Trip YES Set Parameters Lo DC Volts 40 0 Set Parameters Lo DCV on 48 0 Set Parameters Hi DC Volts 68 0 Set Parameters AC Volts 240V Set Parameters Alarm1 active HI Set Parameters Alarm2 active Hl Set Parameters Ext Keypad YES Set Parameters
13. MP IN2 2 3 1 OIL PRESS SWITCH ov 4 _ 77 SET ALARM Figure 2 3 26 48 1 IN2 2 3 SET ALARM INPUT 1 HI Figure 2 2 NORMALLY OPEN MONITORING OF SWITCH CLOSURE WHERE ONE SIDE COMMITTED TO EARTH 48 a 4 7K 2W mi 5 ov 4 77 SET ALARM INPUT 1 LO Figure 2 4 INSTALLATION SA KP 01 OPTIONAL KEYPAD Installation of the optional keypad requires the interface board SA SB 01 plus a suitable length of 6 conductor 3 pair shielded 7 0 2 data cable A 1 Carefully unpack the Keypad Kit The front cover has been left loose to allow access to the 4 mounting holes as shown 2 Prior to attaching the keypad to the wall bulkhead etc complete the electrical connections to the user screw connector as shown in Diagram 1 on page 26 Please take careful note of the orientation Plug the screw connector into the back of the keypad and secure the keypad chassis in its intended location 3 Clip the grey plastic front cover over the chassis applying firm E pressure at the points shown at right aa 4 At the SA41 end of the shielded cable connect the 6 wires to the SA SB 01 Interface Board using screw terminals 4 to 9 as shown in Diagram 1 Connect the cable shield to the terminal No 4 Black to reduce radiated electrical noise from the cable 5 Ensure that the SA41 is switched off at t
14. MUM CHARGE With the optional current shunt SA S200 installed the minimum charge in your batteries today this week or for a number of weeks or days can be logged Minimum daily discharge Minimum charge readings are accessed by pressing the UP and DOWN keys together for 1 second These vital readings give you the information you need to maximise your battery life This is done by managing your loads to maximise this figure e g using heavier loads later in the day or at other times when the battery charge is high MINIMUM CHARGE TODAY MIN CHARGE 76 The minimum charge in the battery since midnight last In Batt Today MINIMUM CHARGE THIS WEEK MIN CHARGE 76 The minimum charge in the battery since midnight last Saturday In Batt This Wk MINIMUM CHARGE WEEKLY LOG Weeks ago 1 This displays a log of the minimum weekly charge in the battery for up to Min Charge 76 52 weeks The logged weeks may be stepped through by pressing the UP or DOWN key The weeks that have not logged AH as yet will display 255 MINIMUM CHARGE DAILY LOG Days ago 1 This displays a log of minimum daily charge in the battery for up to 30 Min Charge 76 days The logged days may be stepped though by pressing the UP or DOWN key The days that have not logged AH as yet will display 255 SETTINGS There are a number of settings within the SA41 that can be changed via the front panel push keys push buttons These allow you to tai
15. RANTY CONDITIONS Selectronic Australia Pty Ltd warrants your SA41 inverter to be free from defects in materials and workmanship under normal use and service for two 2 years This warranty is applicable from the date of original purchase All parts will be replaced or repaired free of charge within this period Travelling time for field service personnel is not covered under this warranty The unit shall be returned at no cost to the owner if no authorised field service personnel are available After you have completed our post installation questionnaire you will receive a lifetime warranty applicable to the original purchaser only The provision of this warranty shall not apply if the unit has been subject to misuse neglect accidental damage damage from external influences e g corrosion used for a purpose it is not intended acts of God or has not been installed in accordance with the manufacturers latest installation requirements Any installation updates will be mailed to your last known address Lifetime warranty is dependant on the supply of raw materials from suppliers above and beyond Selectronic Australia s legal obligation Freight charges to the point of purchase and the cost of any repairs resulting from damages occurring during this freighting will be borne by the owner Any alterations or repairs by unauthorised parties will void your warranty To ensure fast efficient handling of any warranty claims please complete
16. SELECTRONIC AUSTRALIA SA41 OWNERS MANUAL Contents Page INTRODUCTION deett qaid dila 2 WARRANTY CARD iioc ete t ober ie bue Pee eb 2 INSTALLATION sci lt t Ee ea tct dean hasty eed que o UR E Se 2 CONNECTION OF AC AND DG WIRINGI 3 OPERATION uates 5 ENERGY MANAGEMENT eG eee ey trad a es deme ee 5 Search sigh Saat 5 READINGS 6 TE 8 CONTROLLER OUTPUTS tuc qtue teen it eria unite be qe eb tud 8 ALARM INPU ce E 12 CURRENT SHUNT SETTINGS diae tauri be tp 12 OVERLOAD SHUTDOWN AND ALARMS eere 14 FAULT FINDING eeu ERE ipte Ret re estie 15 SYSTEM MAINTENANCE iere ere aos Spee ae ib nds 17 SASEMAINTENANCE a is Sa eid ated Ra aah ee EA E E eq 17 BATTERY MAINTENANCE 2 al Sat at ta mele doute de bit anc lc cael Souci 17 SA41 ELECTRICAL SPECIFICATIONS 2 1 18 RADIO FREQUENCY 19 HANDY HINT
17. Y Day MON Sets the current Day Use the UP and DOWN keys to set the value Set Parameters SET HOUR TIME OF DAY Hour 15 Set the hours in the current time of day 24 hour time Use the UP or Set Parameters DOWN keys to set the value SET MINUTE TIME OF DAY Minute 30 Sets the minutes in the current time of day Use the UP or DOWN keys to Set Parameters set the value DEMAND START SENSE DS Sense 6W This sets the minimum load which will bring the SA41 ON when the Set Parameters inverter Status is set to STANDBY mode demand start or pulsing See page 5 In most cases the default setting of 6W would be suitable If there is a load which the SA41 won t sense then reduce this value until the SA41 starts Alternatively if there is small load that keeps the SA41 on then increase this value You may need to try a few different settings to find the most appropriate value for your installation Use the UP or DOWN keys to set the value 10 LOCKOUT Lockout is a feature which ensures that you are not disturbed during a specified period of time e g you do not want to start a generator in the middle of the night When set to ON lockout prevents the controller outputs coming on or the buzzer sounding during the lockout period The lockout start and finish times below affect both controller lockout and buzzer lockout See Buzzer Lockout on page 10 Buzzer lockout and controller lockout may be set ON or OFF individually
18. al must be an AM RADIO type A TV aerial will not work HANDY HINT It is very important that you become familiar with the functioning of your inverter Since most Inverters are remotely sited from the home it is not always easy to know if the inverter is ON or pulsing An easy way to determine this is to plug a small child s night light neon type into a power point which is easily visible or replace the power point with a safety type with a neon indicator This will indicate the inverter s operation by flashing when the inverter is pulsing and remaining on when the inverter is brought on by a load 19 APPENDIX I DIAGNOSTICS The Diagnostics is a special set of displays that give additional information about the SA41 These are normally only used when advanced troubleshooting is undertaken The Diagnostics section displays the transformer and heatsink temperature demand start current and software version information Diagnostics is accessed by holding both UP and DOWN buttons together twice for at least 1 second each time during the display of any Readings screen with the exception of Status The NEXT DISPLAY key takes you through the Diagnostics displays eventually returning to the Readings display See page 22 for more information TRANSFORMER TEMPERATURE TX Temp 75C This display is the operating temperature of the transformer inside the SA41 Diagnostics in degrees Celsius HEATSINK TEMPERATURE HS1 Temp
19. an optional external keypad SA KP 01 is connected Set Parameters Otherwise this is set to NO See page 27 Use the UP or DOWN keys to change the setting CURRENT SHUNT SETTINGS EXTERNAL SHUNT Ext Shunt YES This is set to YES if an optional external current shunt SA S200 1s Set Parameters connected Otherwise this is set to NO See page 28 Use the UP or DOWN keys to change the setting Ifthe current shunt is set to YES the following settings will be displayed 12 N m 2 O gt v gt i z Zero DC Amps OFF This setting is used to zero the current reading from the external current Set Parameters shunt See installation notes in Appendix III on page 28 Use the UP or DOWN keys to change the setting Note when this setting is set to ON a zero DC amps is performed taking about 1 to 2 seconds after which the display returns to OFF Capacity 500AH This is the capacity of the batteries in ampere hours at the system discharge Set Parameters rate For example a solar powered system will generally use the C 100 100 hour rate but a diesel recharge system may use a discharge rate of C 20 20 hour rate Your system designer will advise you on this figure Use the UP or DOWN keys to set your battery capacity AH IN Batt 445 This setting is used at setup to enter the initial charge in the battery in Set Parameters Ampere Hours or during use to bring the readings back in line Use the UP
20. before proceeding any further NOTE IF THE 5 41 EMITS PULSING BUZZER SOUND THE BATTERY LEADS HAVE BEEN CONNECTED IN REVERSE IMMEDIATELY DISCONNECT THE LEADS AND RECONNECT WITH THE CORRECT POLARITY DO NOT UNDER ANY CIRCUMSTANCES TURN ON THE BREAKER WHEN THE BUZZER IS PULSING AS PERMANENT DAMAGE TO THE SA4I WILL RESULT If all is well turn the breaker ON 1 switch lever UP If after two 2 attempts the circuit breaker does not turn on then check that the battery voltage is between 40 and 68V DC If the breaker still won t switch on refer to the FAULT FINDING section of this manual NEX T DOWN UP DISPLAY PROUDLY DESIGNED amp MADE IN AUSTRALIA 25 PIN D CONNECTOR gain more understanding of these operational notes it is suggested that they be read in conjunction with hands on access to an inverter with DC power applied When you first apply power to the SA41 with default factory settings the SA41 should be in STANDBY mode There may be a quiet pulsing sound and the red neons on the power point will flash if turned on The SA41 is now ready for use with no further adjustments necessary using the factory settings If the display shows TIME the default settings have been changed and the day and time will need to be set before the display will return to STATUS ENERGY MANAGEMENT The SA41 incorporates ENERGY MANAGEMENT which allows you to monitor and control your energ
21. caused by high battery volts during peak charging times from solar panels To overcome this adjust the high voltage cutout of your SA41 see High DC Volts Cutout on page 11 the maximum voltage allowable being 34 Volts If this is still not high enough you may have a problem with either your batteries or your regulator This could be potentially dangerous so we advise you to consult your system designer immediately 4 INVERTER SHUTS DOWN WITH LOW VOLTS If your SA41 has shut down because of low DC volts it could be due to the following 1 sustained large load could be causing the battery volts to drop to a low enough point to cause the SA41 to cut out This is not normally a fault with the SA41 but could be due to the following a Battery bank is too small consult your system designer b A bad connection between the batteries and inverter due to a loose or corroded terminal In this case please refer to the maintenance section of this manual c One or more battery cells could be faulty consult your installer 2 If your battery volts are below 47V with no loads connected the batteries may require charging Use a hydrometer to check the specific gravity of each cell Consult your battery manual for the correct specific gravity SG readings 5 INVERTER SHUTS DOWN DUE TO HEATSINK TOO HOT This is likely under heavy sustained load conditions since the SA41 shuts down to protect its internal components If you believe that the
22. e development time has resulted in a reduction of the RFI produced by the SA41 to a level that complies with Australian Standard AS1044 Compliance to this standard means RFI is low but how well the inverter performs in a particular installation can vary Below are some suggestions to help reduce the effects of RFI in your installation It is recommended that the power system including the inverter is housed at least 15 metres from the home Ensure a good earth stake is placed as close to the inverter as possible See installation on page 3 for wiring Avoid running DC wiring into the home if at all possible If this cannot be avoided run DC and AC in separate conduits separated by as much distance as practicable All DC wiring should also be kept as short as possible To further reduce the effects of RFI it is important that your AM radio has good signal strength This will enable your radio to reject any noise being produced by your inverter regulator controllers or DC lighting If possible try moving the radio around to improve signal strength or use an external aerial Some of today s building materials such as steel roofs and foil insulation may form a barrier to incoming radio signals If an external aerial is required it should be on the outside of the home mounted as high as practicable and as far from the battery shed as possible Connection from the aerial to the radio should be via a low loss coaxial cable PLEASE NOTE The aeri
23. he front panel circuit breaker 6 Plug the SA SB 01 Interface Board into the rear DB25 connector of the SA41 7 Switch on the SA41 at the circuit breaker The keypad will not display any information at this stage 8 Via the SA41 front panel access the Settings menu as described in Page 8 of the manual Scroll slowly through the screens until the following display is seen Ext Keypad NO Set Parameters Select YES using UP key Scroll through the remainder of the Settings screens until the Readings screen is reached 9 The external keypad will now display the same information as appears on the SA41 front panel 27 INSTALLATION SA S200 OPTIONAL CURRENT SHUNT Installation of the current shunt requires the SA SB 01 interface board 1 200 Amp 75mV precision current shunt must be fitted between the negative black lead of the SA41 and battery negative as shown on diagram 1 Please ensure that cables are kept as short as possible At least 120 Amp continuously rated battery cable should be used Attach the shunt and insulated base securely to a solid structure Using the twin flex supplied wire up the current sensing wires to the SA SB 01 Interface Board as shown in Diagram 1 terminals 10 and 11 being used for the current sensing Take careful note of the polarity Ensure that the SA41 Status is in RESET mode which ensures that the SA41 is not drawing any DC current through t
24. he shunt Also disable all charging sources such as Solar Panels and wind generators Via the SA41 front panel access the Settings menu as described on Page 8 of the manual Scroll slowly through the screens until the following display is seen Ext Shunt NO Set Parameters Select YES using the UP key Scroll to the next screen and the following display will be seen Zero DC Amps OFF Set Parameters Select ON using the UP key Note when this setting is set to ON a zero DC amps is performed taking about 1 to 2 seconds after which the display returns to OFF Scroll through the remainder of the Settings screens until the Readings screen is reached Scroll through the Readings screen until the following screen is displayed Note that when the battery current is zero the screen may flicker between IN and OUT this is quite normal Apply an AC load to the inverter s output and verify that the DC current reading is OUT If not then reverse the sensing wires to the current shunt 28 WARNING THE OUTPUT VOLTAGE FROM AN INVERTER IS AS LETHAL AS LANDLINE POWER It is therefore absolutely necessary for your safety to ensure that all Remote Area power installations meet and comply with the relevant provisions and requirements of wiring standards It is imperative that you ensure that only Electrical contractors are permitted to install any AC wiring in your system PRODUCT WAR
25. lined above The screw terminals are numbered from 1 to 14 and the connections are as follows TERMINAL NO DESCRIPTION 2o o oe RE Fo 3 5 oo Kopay Please refer also to Diagram 1 overleaf 25 SA SB 01 INTERFACE CONNECTIONS FOR ALARM INPUT APPLICATIONS SA SB 01 REFER BELOW EXAMPLES INTERFACE BOARD TOP VIEW 48V INT FUSE IN 2 ALARM INPUTS BLU WH YELL RED DO 7 SA41 INVERTER SHIELD 48 pe ba RELAY SPDT 50mA 50 CONTROLLER RELAY SPDT OUTPUTS 1A FUSE INSIDE INVERTER REAR VIEW FUSE BATTERY NEGATIVE IF IT IS NOT EARTHED INVERTER i 1 TO INVERTER POSITIVE CHARGER SA S200 48V SYSTEM ALL CHARGING 200 AMP 75mV BATTERY FUSE AND DISCHARGING CURRENT SHUNT SOURCES NEG LEAD GROUND Figure 1 ALARM INPUTS Examples Alarm input 1 shown only ALARM FITTED TO BATTERY ROOM DOOR REED SWITCH NORMALLY CLOSED 48V 1 IN2 2 INI 3 SET ALARM INPUT 1 LO Figure 2 Figure 2 1 GENERATOR OIL PRESSURE MONITOR 48V 1 69 LA
26. load is not excessive check around the inverter case and heatsinks for obstructions to air flow as this will cause the inverter to heat up much quicker and shut down sooner than normal Also check that the clearances around the SA41 are as specified in INSTALLATION on page 2 6 CHARGE IN BATTERY APPEARS INCORRECT It is possible that this figure can accumulate errors as battery charging discharging is a very complex procedure with many variances a hydrometer is always the most accurate method of determining a battery s state of charge If your system regulator is showing FLOAT then you should be able to presume your batteries are close to or actually 100 charged You can confirm this with a hydrometer If the CHARGE IN BATTERY figure is not reading correctly adjust it by the method shown in page 13 If the figure is consistently too low e g 90 when the system shows FLOAT you should increase the battery charge efficiency figure as described in page 13 Alternatively if your system is not in float and the reading is already 100 you should reduce the battery efficiency 7 INVERTER PULSES SLOWER THAN NORMAL WHEN IN STAND BY This means that the inverter has not been switched on for approximately 20 minutes and has gone into a power saving mode thus pulsing at about half the normal rate 8 NETT AMP HOUR APPEARS INCORRECT This could be caused by one or both of the following a The clock is not adjusted correctly
27. lor the SA41 inverter and ENERGY MANAGEMENT sections to suit your system requirements Settings are accessed by holding down the NEXT DISPLAY key for at least 1 second whilst in any Readings display The value of the parameter displayed can be modified by pressing the UP or DOWN keys Pressing the NEXT DISPLAY key will take you to the next parameter to be set Pressing the NEXT DISPLAY key after the last parameter is displayed will take you back to the Readings displays Please note If DC power is disconnected from the inverter the Settings which have been entered will be saved and held in permanent memory However these settings are not saved until the display is returned to Readings CONTROLLER OUTPUTS SA41 ENERGY MANAGEMENT has 2 control outputs as mentioned on page 25 each of which can be activated with time inverter cutout and or low ampere hours The six settings are displayed as OFF ON TIME INV CO LO A H and CO LAH respectively For simplicity the displays shown are for control output 1 only Control output 2 settings are identical to control output 1 Pressing the UP or DOWN keys will change the setting On with OFF The control 1 output will remain off at all times Set Control 1 On with ON The control 1 output will remain on at all times Set Control 1 On with TIME The control 1 output will come on at the Start Day Start Hour and Start Set Control 1 Minute that is set in the three screens bel
28. mall loads such as VCRs or digital clocks that require 24 hour power or if loads are too small to be sensed in the STANDBY mode The only disadvantage is that when no appliances are operating the SA41 will be drawing more power than it would in STANDBY mode RESET mode electronically shuts down the inverter When placed in this mode any overload or shutdown conditions are also reset READINGS The SA41 ENERGY MANAGEMENT has six Readings displays to give you vital information about your inverter and your batteries By pressing the NEXT DISPLAY key on the front panel the screen information rotates through displays of inverter Status Time AC Volts AC Amps and Battery Volts When the optional current shunt SA S200 15 installed four additional readings are available these being Nett DC Current Peak Charge Current Nett Daily Amp Hours and Battery percentage Charge TIME AC VOLTS AC Volts 240V Readings AC AMPS AC Amps 2 5A Readings BATTERY VOLTS Batt Volts 49 2V Readings Displays the Current Time as a 24Hr clock and day This time is set as described in Settings see Page 8 This screen gives an approximate indication of the AC voltage produced by the inverter The AC volts would normally read between 230V and 245V except under high load or low battery conditions The AC current reading shows the total current drawn from the AC output by the appliances connected t
29. nd operated to the battery manufacturer s recommendation To ensure operation to SA41 specification the battery bank should have a minimum capacity of 500 ampere hours at the 100 hour discharge rate ask your supplier if in doubt Smaller capacity batteries can be used but may result in degraded performance of the SA41 under heavy surge conditions CONNECTION OF AC AND DC WIRING IMPORTANT Before making any wiring connections check that the circuit breaker located on the front panel is in the OFF position i e LEVER DOWN Your electrician should firstly connect the AC wiring via the three terminal rear junction box Carefully observe the correct connections Please refer to the rear panel view of the SA41 on the following page BROWN ACTIVE dot top connector GREEN YELLOW EARTH centre connector BLUE NEUTRAL Bottom connector The lid of the junction box has knockouts to allow conduit entry Make sure the connections are tight and safe Re fit junction box cover NOTE ALL AC WIRING MUST BE CARRIED OUT BY A LICENSED ELECTRICIAN AND MUST CONFORM TO AS 3000 WIRING REGULATIONS OR RELEVANT STANDARDS Verify that the circuit breaker on the front panel is in the OFF position LEVER DOWN Now connect the battery cables RED BATTERY POSITIVE BLACK BATTERY NEGATIVE These connections should be tight If using nuts bolts and washers they should be stainless steel At this point re check the connections
30. o the inverter Displays the DC Battery volts This provides you with an indication of the condition of your battery bank WHERE THE OPTIONAL 200 AMP CURRENT SHUNT IS INSTALLED DC CURRENT Amps 23 6A OUT Battery PEAK AMPS Pk Amps 45 6 IN Battery This reading gives a Nett current 1 either charging the battery IN or being taken out of the battery OUT The range for this reading is 0 100A IN and 0 200A OUT continuous or 0 400A OUT intermittent This reading gives the peak Nett charging current into the batteries for the present day today If no load has been present for the entire day this will indicate the peak combined charging current from your solar panels wind generator or other charging sources thus allowing you to monitor their operation During the first day after the inverter is turned on at the circuit breaker this screen will display a meaningless figure 6 AMP HOURS TODAY Net AH 69 IN This reading gives a nett figure of Amp Hours since midnight last night A Today nett AH reading of IN indicates more Amp Hours have gone into the battery than have been used The opposite applies for a Net AH reading of OUT 1 Amp Hour 1 amp for 1 hour or 2 amps for hour etc BATTERY CHARGE Charge 87 This reading shows the amount of charge present in you battery bank at any In Battery given time 1 100 means a fully charged battery MINI
31. ow The Start Day can be set to ALL which will turn the output on every day at the set time Pressing the UP or DOWN keys will change the setting The output will remain on for the time set in Duration see next page Start Day SUN Start Hour 16 Start Min 30 Set Control 1 Set Control 1 Set Control 1 On with INV CO Set Control 1 On with LO AH Set Control 1 On with CO LAH Set Control 1 Inverter Cut out The control 1 output will turn on when the inverter shuts down due to overload over temperature or low or high voltage The output will remain on for the time set in Duration below The output will not come on if the front panel circuit beaker 15 tripped Low Amp Hours If the charge in the batteries falls below the level set in the Minimum Charge setting see page 13 then the control output will come on for the time set in Duration below Cutout or Low Amp Hours This setting combines the previous two bring the output on with low amp hours or with the inverter cutting out The output will stay on for the time set in Duration below Note that the controller can only be set to LO A H and CO LAH if the optional external current shunt kit SA S200 is used Each controller output is capable of switching an external relay or contactor which can be used to switch AC or DC loads If the controller is set to INV CO LO A H or CO LAH and the condition still exists after the Duration time the ou
32. ring transit If there are any signs of damage contact your supplier immediately 300 The inverter must be installed in a 300mm dry cool dust free environment Please leave at least 300mm clearance at the left and right hand sides Black heatsink fins 300mm above the inverter and approx 200mm at the rear as this Front will aid the natural cooling of the inverter The air vents on the underside of the SA41 also need to be kept clear of obstructions mm circuit breakers for other circuits SUPPLY INSTALLATION Earths Earth Leakage Circuit Breaker E L C B Inverter System Fuse Rear 9 junction o Box GND Power Circuits Lightning Earth As close as possible to inverter MUST BE BONDED TO ALL OTHER EARTHS Neutral Link GND Safety Earth ALL AC AND DC WIRING mim Ground connection to MUST CONFORM TO general mass of earth RELEVANT STANDARDS We suggest that you house your inverter along with other power generating equipment in a remotely sited purpose built area Also make sure that the exhaust from your generator or other sources of heat or fumes are kept well away from the SA41 SEIAA Solar Energy Industries Association Of Australia installation guidelines must be followed You must have a suitable 48V DC battery bank which is maintained a
33. sage If the shutdown was due to an overload the SA41 will automatically reset after 1 minute or when a key is pressed If the shutdown was due to a short circuit the SA41 will have to be reset via the STATUS display see page 5 on the front panel TRANSFORMER TOO HOT TX Too Hot 122C If the transformer reaches its maximum operating temperature the SA41 Press a Key will shut down to protect the internal components The SA41 will restart again only when the temperature drops to a safe level The present temperature of the transformer is also displayed 14 HEATSINK TOO HOT HS Too Hot 82C If the heatsink reaches its maximum operating temperature the SA41 will Press a Key shut down to protect itself The SA41 will come on again only when the temperature drops to a safe level The present temperature of the heatsink is also displayed ALARM 1 ACTIVE Alarm 1 Active When the Alarm 1 input on the 5 41 is activated see Settings on page Press a Key 12 this message is displayed and the buzzer sounds The buzzer will continue to sound as long as the input is active ALARM 2 ACTIVE Alarm 2 Active When the Alarm 2 input on the SA41 is activated see Settings on page Press a Key 12 this message is displayed and the buzzer sounds The buzzer will continue to sound as long as the input is active LOW CHARGE ALARM Lo Charge 59 If the battery charge drops below the Min charge setting and the
34. tions between cells IMPORTANT When working on batteries of such high capacity it is essential that you wear protective clothing some form of eye protection and rubber soled work boots Please regard your batteries with a great deal of caution and if in any doubt entrust this work to your installer 2 Check that the stainless steel inter connecting bolts are tight and have minimal corrosion If corrosion is evident carefully follow the following procedure a Disconnect the system battery fuse before working on the battery bank b Unbolt the stainless steel bolts and nuts of any corroded connections and thoroughly clean the join with a wire brush or file taking extreme care not to short circuit any battery cells with any tools c Re assemble and smear a small amount of Vaseline or similar grease over the surface of the joint to slow down any future corrosion 3 Every month measure the specific gravity SG of each cell using your hydrometer to ensure that all cells are performing correctly Any serious imbalance should be reported to your system designer in case remedial action needs to be taken 17 SA41 ELECTRICAL SPECIFICATIONS INVERTER TYPE PWM Full bridge power stage with true sine wave AC output DEMAND START SECTION Type Minimum Load Power to start User adjustable Maximum response time Standby current from battery Average BATTERY VOLTAGE RANGE Low DC Volts Disconnect Instantaneous Low
35. tput will stay on until the condition ends Also with these settings a Lockout option can be set ON or OFF See lockout below and on page 11 LOCKOUT Lockout ON Set Control 1 DURATION Duration 4 Hrs Set Control 1 Duration 30 Min Set Control 1 If set to ON lockout prevents the controller output coming on during the lockout period See notes on lockout on page 11 Pressing the UP or DOWN keys will change the setting This screen sets the duration hours the control 1 output will stay on Pressing the UP or DOWN keys will change the setting This screen sets the duration minutes the control 1 output will stay on Pressing the UP or DOWN keys will change the setting Buzzer This display allows you to select whether the audio alarm sounds during an Set Parameters overload or other alarm conditions If set to OFF the buzzer will not sound during an alarm condition The alarm condition will still be displayed Pressing the UP or DOWN keys will change the setting 00 N m A it 2 T T BUZZER LOCKOUT Buzzer Lockout OFF If set to ON lockout prevents the buzzer from sounding during the lockout Set Parameters period See lockout on page 11 Pressing the UP or DOWN keys will change the setting MORE SETTINGS Any key to end Pressing NEXT DISPLAY or UP keys will save the settings entered and go or DOWN for more back to Displays If the DOWN key is pressed more settings will be displayed SET DA
36. volts rise above this setting Use the UP or DOWN keys to set the value r g lt o 2 HIGH DC VOLTS CUTOUT Hi DC Volts 68 0 When the battery volts exceeds this setting the SA41 will cut out Set Parameters instantaneously Please note that if the battery volts rise above 70V regardless of the Hi DC Volts setting the breaker will instantly trip and the inverter will be totally disconnected 11 VOLTS SETTING AC Volts 240V Allows the output voltage to be set from 220V to 240V if an output voltage Set Parameters other than 240V is required Use the UP or DOWN keys to set the value NZ users should set this to 220VAC ALARM INPUTS The ENERGY MANAGEMENT has 2 alarm inputs shown on pages 25 and 26 which can be set to trigger an alarm condition See page 15 Use the Lo setting if the input is connected to a normally closed set of contacts see fig 2 1 on page 26 of when the voltage falls below 1V on alarm see fig 2 4 Use the Hi setting if the input is connected to a normally open set of contacts see fig 2 2 on page 26 or when the voltage rises above 3V on alarm see fig 2 3 ALARM INPUT 1 Alarm 1 active Hi Set alarm input 1 to HI or LO active Use the UP or DOWN keys to change Set Parameters the setting ALARM INPUT 2 Alarm 2 active Hi Set alarm input 2 to HI or LO active Set Parameters EXTERNAL KEYPAD Ext Keypad YES This is set to YES if
37. y system by displaying information on the Liquid Crystal Display Settings can be adjusted via the front panel keys STATUS Status STANDBY Status CONT Status RESET Inverter OFF Inverter ON Inverter OFF The first screen will display the Status of the SA41 There are three status conditions STANDBY CONT continuous and RESET which are explained in more detail below When this screen is displayed the Status can be changed by pressing the UP or DOWN keys Each time the UP key is pressed the status will change from STANDBY to CONT then RESET and back to STANDBY whereas the DOWN key will change the Status in the reverse order The second line indicates whether the inverter is ON or OFF i e if there is 240V available or not During pulsing OFF is displayed on the second line reverting to ON when a load is connected and the inverter starts The STANDBY mode means that the 5 41 is producing pulses of power while waiting for an appliance to be switched on This is frequently called the demand start because as soon as the appliance is operated the SA41 will turn on and remain on until the appliance is switched off After a 10 second delay the SA41 will return to STANDBY mode awaiting another load This feature is extremely important as it conserves valuable battery power when no appliances are on CONT mode continuous means the inverter will be on at all times regardless of the load This situation is useful if you have s
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