Sako 1kva-5kva Inverter-charger User Manual

SAKO 1KVA-5KVA Inverter-Charger

Purpose
This manual describes the assembly, installation, operation and troubleshooting of this unit. Please read this manual carefully before installations and operations. Keep this manual for future reference.

Scope
This manual provides safety and installation guidelines as well as information on tools and wiring.

SAFETY INSTRUCTIONS

WARNING: This chapter contains important safety and operating instructions. Read and keep this manual for future reference .

1.  Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.
2.  CAUTION –To reduce risk of injury, charge only deep-cycle lead acid type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage .
3. Do not disassemble the unit. Take it to a qualified service center when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.
4. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning . Turning off the unit will not reduce this risk .
5. CAUTION – Only qualified personnel can install this device with battery .
6. NEVER charge a frozen battery .
7.  For optimum operation of this inverter/charger, please follow required spec to select appropriate cable size. It’s very important to correctly operate this inverter/charger.
8.  Be very cautious when working with metal tools on or around batteries. A potential risk exists to drop a tool to spark or short circuit batteries or other electrical parts and could cause an explosion.
9.  Please strictly follow installation procedure when you want to disconnect AC or DC terminals. Please refer to INSTALLATION section of this manual for the details.
10.  Fuses (3 pieces of 40A, 32VDC for lKVA, 4 pieces of 40A, 32VDC for 2KVA and 6 pieces for 3KVA, 1 piece of 200A, SBVDC for 4KVA and SKVA) are provided as over-current protection for the battery supply .
11.  GROUNDING INSTRUCTIONS -This inverter/charger should be connected to a permanent grounded wiring system. Be sure to comply with local requirements and regulation to install this inverter .
12.  NEVER cause AC output and DC input short circuited. Do NOT connect to the mains when DC input short circuits.
13.  Warning!! Only qualified service persons are able to service this device. If errors still persist after following troubleshooting table, please send this inverter/charger back to local dealer or service center for maintenance.

INTRODUCTION

This is a multi-function inverter/charger, combining functions of inverter, MPPT solar charger and battery charger to offer uninterruptible power support with portable size. Its comprehensive LCD display offers user-configurable and easy-accessible button operation such as battery charging current, AC/solar charger priority, and acceptable input voltage based on different applications.

Features

• Pure sine wave inverter
• Built-in MPPT solar charge controller
• Configurable input voltage range for home appliances and personal computers via LCD setting Configurable battery charging current based on applications via LCD setting
• Configurable AC/Solar Charger priority via LCD setting
• Compatible to mains voltage or generator power
• Auto restart while AC is recovering
• Overload/ Over temperature/ short circuit protection
• Smart battery charger design for optimized battery performance
• Cold start function

Basic System Architecture
The following illustration shows basic application for this inverter/charger. It also includes the following devices to have a complete running system:

• Generator or Utility.
•  PV modules (option)

Consult with your system integrator for other possible system architectures depending on your requirements.
This inverter can power all kinds of appliances in home or office environment, including motor-type appliances such as tube lights, fans, refrigerators,s, and air conditioners.

Product Overview

1.  LCD display
2.  Status indicator
3.  Charging indicator
4. Fault indicator
5.  Function buttons
6.  Power on/off switch
7.  AC input
8.  AC output
9. PV input
10.  Battery input
11.  Circuit breaker
12. RS232 communication port
13. Parallel communication cable (only for parallel model)
14. Current sharing cable (only for parallel model)
15.  Dry contact

INSTALLATION

Unpacking and Inspection
Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. You should have received the following items inside of package:

• The unit x 1
• User manual x 1
• Communication cable x 1

Preparation
Before connecting all wirings, please take off bottom cover by removing two screws as shown below.

Mounting the Unit
Consider the following points before selecting where to install:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface
• Install this inverter at eye level in order to allow the LCD display to be read at all times.
• The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
• The recommended installation position is to be adhered to the wall vertically.
• Be sure to keep other objects and surfaces as shown in the right diagram to guarantee sufficient heat dissipation and to have enough space for removing wires.

3KVA 24V, 1KVA/3KVA 48V model
3KVA 24V/48V Plus, 4-SKVA 48V model

Battery Connection

CAUTION: For safety operation and regulation compliance, it’s requested to install a separate DC over-current protector or disconnect device between battery and inverter. It may not be requested to have a disconnect device in some applications, however, it’s still requested to have over-current protection installed. Please refer to typical amperage in below table as required fuse or breaker size.  All wiring must be performed by a qualified personnel. WARNING! It’s very important for system safety and efficient operation to use appropriate cable for battery connection. To reduce risk of injury, please use the proper recommended cable and terminal size as below.

Recommended battery cable and terminal size:

Please follow below steps to implement battery connection:

1. Assemble battery ring terminal based on recommended battery cable and terminal size.
2. Connect all battery packs as units requires. It’s suggested to connect at least l00Ah capacity battery for 3KVA model and at least 200Ah capacity battery for 4KVNSKVA model.
3. Insert the ring terminal of battery cable flatly into battery connector of inverter and make sure the bolts are tightened with torque of 2-3 Nm. Make sure polarity at both the battery and the inverter/charge is correctly connected and ring terminals are tightly screwed to the battery terminals.

CAUTION Do not place anything between the flat part of the inverter terminal and the ring terminal. Otherwise, overheating may occur. Do not apply anti-oxidant substance on the terminals before terminals are connected tightly. Before making the final DC connection or closing DC breaker/disconnector, be sure positive ( +) must be connected to positive ( +) and negative (-) must be connected to negative (-).

AC Input/Output Connection

• CAUTION!! Before connecting to AC input power source, please install a separate AC breaker between inverter and AC input power source. This will ensure the inverter can be securely disconnected during maintenance and fully protected from over current of AC input. The recommended spec of AC breaker is l0A for lKVA, 20A for 2KVA, 32A for 3KVA, 40A for 4KVA and S0A for SKVA.
• CAUTION!! There are two terminal blocks with “I N” and “OUT” markings. Please do NOT mis-connect input and output connectors.
• WARNING! All wiring must be performed by a qualified personnel.
• WARNING! It’s very important for system safety and efficient operation to use appropriate cable for AC input connection. To reduce risk of injury, please use the proper recommended cable size as below.
• Suggested cable requirement for AC wires
  

  Model	Gauge	Torque Value
  lKVA	16AWG	0.5~ 0.6 Nm
  2KVA 230VAC	14 AWG	0.8~ 1.0 Nm
  2KVA 120VAC 3KVA	12 AWG	1.2~ 1.6 Nm
  4KVA	l0 AWG	1.4~ 1.6Nm
  SKVA	BAWG	1.4~ 1.6Nm

Please follow below steps to implement AC input/output connection: 

1.  Before making AC input/output connection, be sure to open DC protector or disconnector first.
2. Remove insulation sleeve 10mm for six conductors. And shorten phase Land neutral conductor N 3 mm.
3. Insert AC input wires according to polarities indicated on terminal block and tighten the terminal screws. Be sure to connect PE protective conductor ( ) first.
   -+Ground (yellow-green)
   L–+LINE (brown or black)
   N–+Neutral (blue)
5. Then, insert AC output wires according to polarities indicated on terminal block and tighten terminal screws.
   Be sure to connect PE protective conductor ( ) first.
   -+Ground (yellow-green)
   L–+LINE (brown or black)
   N–+Neutral (blue)
6. Make sure the wires are securely connected.
   CAUTION: Appliances such as air conditioner are required at least 2~3 minutes to restart because it’s required to have enough time to balance refrigerant gas inside of circuits. If a power shortage occurs and recovers in a short time, it will cause damage to your connected appliances. To prevent this kind of damage, please check manufacturer of air conditioner if it’s equipped with a time-delay function before installation. Otherwise, this inverter/charger will trig overload fault and cut off output to protect your appliance but sometimes it still causes internal damage to the air conditioner.

PV Connection
CAUTION: Before connecting to PV modules, please install separately a DC circuit breaker between inverter and PV modules.
WARNING! All wiring must be performed by a qualified personnel.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable for PV mod ule connection. To reduce risk of injury, please use the proper recommended cable size as below.

PV Module Selection:
When selecting proper PV modules, please be sure to consider below parameters:

1. Open circuit Voltage (Voe) of PV modules not exceeds max. PV array open circuit voltage of inverter.
2. Ooen circuit Voltaae (Voe) of PV modules should be hiaher than min. batterv voltaae.

Please follow below steps to implement PV module connection: 

1. Remove insulation sleeve 10 mm for positive and negative conductors.
2. Check correct polarity of connection cable from PV modules and PV input connectors. Then, connect positive pole ( +) of connection cable to positive pole ( +) of PV input connector. Connect negative pole (-) of connection cable to negative pole (-) of PV input connector.
3. Make sure the wires are securely connected.

Final Assembly
After connecting all wirings, please put bottom cover back by screwing two screws as shown below.

Communication Connection
Please use supplied communication cable to connect to inverter and PC. Insert bundled CD into a computer and follow on-screen instruction to install the monitoring software. For the detailed software operation, please check user manual of software inside of CD.

Dry Contact Signal
There is one dry contact (3A/250VAC) available on the rear panel. It could be used to deliver signal to external device when battery voltage reaches warning level.

OPERATION

Power ON/OFF
Once the unit has been properly installed and the batteries are connected well, simply press On/Off switch (located on the button of the case) to turn on the unit.

Operation and Display Panel
The operation and display panel, shown in below chart, is on the front panel of the inverter. It includes three indicators, four function keys and a LCD display, indicating the operating status and input/output power information.

Function Keys

LCD Display Icons
LCD Setting

After pressing and holding ENTER button for 3 seconds, the unit will enter setting mode. Press “UP” or “DOWN” button to select setting programs. And then, press “ENTER” button to confirm the selection or ESC button to exit.

Setting Programs:
Display Setting

The LCD display information will be switched in turns by pressing “UP” or “DOWN” key. The selectable information is switched as below order: input voltage, input frequency, PV voltage, MPPT charging current, MPPT charging power, battery voltage, output voltage, output frequency, load percentage, load in VA, load in Watt, DC discharging current, main CPU Version and second CPU Version.

Operating Mode Description
Fault Reference Code
Warning Indicator

SPECIFICATIONS

Table 1 Line Mode Specifications

Table 2 Inverter Mode Specifications

Table 3 Charge Mode Specifications

Table 4 General Specifications

TROUBLESHOOTING

Appendix: Approximate Back-up Time Table

Note: Backup time depends on the quality of the battery, age of battery, and type of battery. Specifications of batteries may vary depending on different manufacturers.