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:

Model| Typical Amperage| Battery Capacity| Wire Size| Ring Terminal| Torque Value
---|---|---|---|---|---
Cable

mm 2

| Dimensions
D(mm)| L(mm)
lKVA 48V| 20A| l00AH| 114AWG| 2| | 21.8| 2~ 3 Nm
lKVA 24V, 2KVA 48V| 33A| lO0AH| 110AWG| 5| 6.4| 22.5| 2~ 3 Nm
3KVA 48V| S0A| lO0AH| 1*8AWG| 8| 6.4| 23.8| 2~ 3 Nm
2KVA 24V| 66A| l00AH

200AH

| 1*6AWG

2*10AWG

| 14

8

| 6.4

6.4

| 29.2

23.8

| 2~ 3 Nm
3KVA 24V| 100A| l00AH

200AH

| 1*4AWG

2*8AWG

| 22

14

| 6.4

6.4

| 33.2

29.2

| 2~ 3 Nm
4KVA| 66A| 200AH| 1*4AWG

2*8AWG

| 22

14

|

6.4

|

29.2

| 2~ 3 Nm
SKVA| 87A| 200AH| 1*4AWG

2*8AWG

| 22

14

| 6.4

6.4

| 33.2

29.2

| 2~ 3 Nm

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)

4. 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)

5. 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:

Solar Charging Mode

INVERTER MODEL

| lKVA24V 2KVA24V

3KVA24V

| 1KVA48V

3KVA48V

| 2KVA24V **2 KVA48V**

Plus/ 3KVA Plus/3KVA48V 24V Plus Plus/ 4KVA/5KVA

Max. PV Array Open Circuit Voltage| 75Vdc max| 102Vdc max| 145Vdc
PV Array MPPT Voltage Range| 30~66Vdc| 60~88Vdc| 30~115Vdc            60~115Vdc
Min. battery voltage for PV charge| 17Vdc| 34Vdc| 17Vdc 34Vdc

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.

Unit Status

| ****

Condition

| ****

Dry contact port:

---|---|---
NC&C| NO &C
Power Off| Unit is off and no output is powered.| Close| Open

Power On

| Output is powered from Utility.| Close| Open
Output   is powered from Battery or Solar.| Program 01 set as Utility| Battery voltage < Low DC warning

voltage

| Open| Close
Battery voltage > Setting value in Program 13 or battery charging

reaches floating stage

| ****

Close

| ****

Open

Program 01 is  set  as

SBU        or Solar first

| Battery voltage < Setting value in

Program 12

| Open| Close
Battery voltage > Setting value in Program 13 or battery charging

reaches floating stage

| ****

Close

| ****

Open

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

INVERTER MODEL

| lKVA 24V 2KVA 24V

3KVA 24V

1KVA48V

3KVA48V

| 2KVA 24V Plus

3KVA 24V Plus **4KVA**

2KVA48V Plus **SKVA**

3KVA48V Plus

---|---|---
Input Voltage Waveform| Sinusoidal (utility or generator)
Nominal Input Voltage| 120Vac or 230Vac
Low Loss Voltage| 95Vac±7V or 170Vac±7V (UPS)

65Vac±7V or 90Vac±7V (Appliances)

Low Loss Return Voltage| 100Vac±7V or 180Vac±7V (UPS);

70Vac±7V or 100Vac±7V (Appliances)

High Loss Voltage| 140Vac±7V or 280Vac±7V
High Loss Return Voltage| 135Vac±7V or 270Vac±7V
Max AC Input Voltage| 150Vac or 300Vac
Nominal Input Frequency| 50Hz / 60Hz (Auto detection)
Low Loss Frequency| 40±1Hz
Low Loss Return Frequency| 42±1Hz
High Loss Frequency| 65±1Hz
High Loss Return Frequency| 63±1Hz
Output Short Circuit Protection| Line mode: Circuit Breaker

Battery mode: Electronic Circuits

Efficiency (Line Mode)| >95% ( Rated R load, battery full charged )
Transfer Time| 10ms typical (UPS); 20ms typical (Appliances)

Output power derating:

When AC input voltage drops to 95V or 170V depending on models, the output power will be derated.

| 120Vac model:

Output Power

·::t?65!V 1 I 4 0V **Input Voltage**

230Vac model:

Output Power

— 9 ( 0V  170V ** 2I80V  Input Voltage**

Table 2 Inverter Mode Specifications

INVERTER MODEL

| lKVA24V 2KVA24V

3KVA24V

2KVA24V Plus

3KVA24V Plus

| 1KVA 48V

3KVA 48V

2KVA 48V Plus

3KVA 48V Plus

|

4KVA SKVA

---|---|---|---
Rated Output Power| 1KVA/0.8KW

2KVA/1.6KW

3KVA/2.4KW

| 1KVA/1KW

2KVA/1.6KW

3KVA/2.4KW

| 4KVA/3.2KW

5KVA/4KW

Output Voltage Waveform| Pure Sine Wave
Output Voltage Regulation| 110/120VAC±5% or 230Vac±5%
Output Frequency| 60Hz or SOHz
Peak Efficiency| 90%
Overload Protection| 5s@2:150%load; 10s@110%~150%load
Surge Capacity| 2 rated power for 5seconds
Nominal DC Input Voltage| 24Vdc| | 48Vdc
Cold Start Voltage| 23.0Vdc| | 46.0Vdc
Low DC Warning Voltage

@load< 20%

|

22.0Vdc

| |

44.0Vdc

@ 20% :5 load< 50%| 21.4Vdc| | 42.8Vdc
@load 2: SO%| 20.2Vdc| | 40.4Vdc
Low DC Warning Return Voltage| | |
@load< 20%| 23.0Vdc| | 46.0Vdc
@ 20% :5 load< 50%| 22.4Vdc| | 44.8Vdc
@load 2: 50%| 21.2Vdc| | 42.4Vdc
Low DC Cut-off Voltage

@load< 20%

|

21.0Vdc

| |

42.0Vdc

@ 20% :5 load< 50%| 20.4Vdc| | 40.8Vdc
@load 2: 50%| 19.2Vdc| | 38.4Vdc
High DC Recovery Voltage| 29Vdc| | 58Vdc
High DC Cut-off Voltage| 31Vdc| 62Vdc| | 60Vdc
No Load Power Consumption| <25W| <SOW
Saving Mode Power Consumption| <lOW| <15W

Table 3 Charge Mode Specifications

Utility Charging Mode

INVERTER MODEL

| lKVA24V 2KVA24V| 2KVA24V

3KVA24V

2KVA24V Plus

3KVA24V Plus

|

2KVA 48V

Plus 120Vac

| lKVA 48V 3KVA 48V

2KVA 48V Plus

3KVA 48V Plus

|

4KVA SKVA

Plus 120Vac
|
Charging Current (UPS)

@ Nominal Input Voltage

|

10/20A

|

20/30A

|

5/lOA

|

10/lSA

| 2/lOA/

20/30A/

�0/50/60A

Bulk Charging Voltage| Flooded Battery AGM / Gel

Battery

| 29.2

28.2

|

56.4

Floating Charging Voltage| 27Vdc| 54Vdc
Charging Algorithm| 3-Step

Charging Curve

|

Table 4 General Specifications

INVERTER MODEL

| ****

lKVA24V 1KVA48V

| ****

2KVA 24V

| ****

3KVA24V

| ****

3KVA48V

| 2KVA 24V Plus

3KVA24V Plus

2KVA48V Plus

3KVA48V Plus

| ****

4KVA

| ****

SKVA

---|---|---|---|---|---|---|---
Safety

Certification

| CE
Operating

Temperature Range

| ****

0°c to 55°C

Storage

temperature

| -15°C~ 60°C
Dimension

(DWH), mm

| 100 X 272 X 355| 140 X 295 X 479| 140 x295 x540
Net Weight, kg| 6.8| 7.0| 7.4| 11.5| 12.5| 13.5

TROUBLESHOOTING

Problem| LCD/LED/Buzzer| Explanation / Possible cause| What to do
---|---|---|---
Unit shuts down automatically

during startup process.

| LCD/LEDs and buzzer will be active for 3 seconds and then

complete off.

| The battery voltage is too low (<1.91V/Cell)| 1. Re-charge battery.

2. Replace battery.

No response after power on.|

No indication.

| 1. The battery voltage is far too low. (<1.4V/Cell)

2.  Battery polarity is connected reversed.

| 1. Check if batteries and the wiring are connected well.

2. Re-charge battery.

3. Replace battery.

Mains exist but the unit works in battery mode.

| Input voltage is displayed as O on the LCD and green LED is

flashino.

|

Input protector is tripped

| Check if AC breaker is tripped and AC wiring is connected well.

Green LED is flashing.

Green LED is flashing.

|

Insufficient quality of AC power. (Shore or Generator)

Set “Solar First” as the priority of outout source.

| 1. Check if AC wires are too thin and/or too long.

2. Check if generator (if applied) is working well or if input voltage range setting is correct. (UPS➔Appliancel Change output source priority

to Utilitv first.

When the unit is turned on, internal

relay is switched on and off repeatedly.

| LCD display and LEDs are flashing|

Battery is disconnected.

| Check if battery wires are connected well.

Buuer beeps continuously and red LED is on.

| Fault code 07| Overload error. The inverter is overload 110% and time is up.| Reduce the connected load by

switching off some equipment.

Fault code 05

| Output short circuited.

Temperature of internal converter

component is over 120°C. (Only available for 1-3KVA models.)

| Check if wiring is connected well and remove abnormal load.

Check whether the air flow of the unit is blocked or whether the ambient temperature is too high.

Fault code 02| Internal temperature of inverter comoonent is over 100°C.

Fault code 03

| Battery is over-charged.| Return to repair center.
The battery voltage is too high.| Check if spec and quantity of batteries are meet

requirements.

Fault code 01| Fan fault| Replace the fan.
Fault code 06/58| Output abnormal (Inverter voltage

below than 190Vac or is higher than 260Vacl

| 1. Reduce the connected load.

2. Return to reoair center

Fault code 08/09/53/57| Internal components failed.| Return to repair center.
Fault code 51

Fault code 52

| Over current or surge.

Bus voltage is too low.

| Restart the unit, if the error happens again, please return to repair center.
Fault code 55| Output voltage is unbalanced.
Fault code 56| Battery is not connected well or fuse is burnt.| If the battery is connected well, please return to repair center.

Appendix: Approximate Back-up Time Table

lKVA

| 200| 766| 1610
400| 335| 766
600| 198| 503
800| 139|
1000| 112| 269

2KVA

| 200| 766| 1610
400| 335| 766
600| 198| 503
800| 139|
1000

1200

| 112

95

| 269

227

1400| 81| 176
1600| 62| 140
1800| | 125
2000| 50| 112

3KVA

| 300| 449| 1100
600| 222| 525
900| 124| 303
1200| | 227
1500

1800

| 68

56

| 164

126

2100| 48| 108
2400| |
2700| 31| 74
3000| 28|
Model| Load (VA)| Backup Time@ 48Vdc 100Ah (min)| Backup Time@ 48Vdc 200Ah (min)
---|---|---|---

lKVA

| 100| 2529| 5058
200| 1264| 2529
300| 843| 1686
400| 608| 1279
500

600

| 482

406

| 1035

872

700| 310| 710
800| 268| 615
900| 231| 540
1000| 186| 471
Model| Load (VA)| Backup Time@ 48Vdc 100Ah (min)| Backup Time@ 48Vdc 200Ah (min)
---|---|---|---

2KVA

| 200| 1581| 3161
400| 751| 1581
600| 491| 1054
800| 331| 760
1000

1200

| 268

221

| 615

508

1400| 172| 387
1600| 136|
1800| 120| 295
2000| 106| 257

3KVA

| 300| 1054| 2107
600| 491| 1054
900| 291| 668
1200| 196|
1500

1800

| 159

123

| 402

301

2100| 105| 253
2400| | 219
2700| 71| 174
3000| 63| 155

4KVA

| 400| 766| 1610
800| 335| 766
1200| 198| 503
1600| 139|
2000

2400

| 112| 269

227

2800| 81| 176
3200| 62| 140
3600| 55| 125
4000| 50| 112

5KVA

| 500| 613| 1288
1000| 268| 613
1500| 158| 402
2000| 111| 271
2500

3000

| 90

76

| 215

182

3500| 65| 141
4000| 50| 112
4500| | 100
5000| | 90

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.

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