Clayton Power G3 COMBI, 1012-50, 1312-80, 1512-80, 2012-100 User Manual

Clayton Power GmbH

www.claytonpower.com

G3 COMBI

Sine Wave Inverter + Battery Charger

Type

1012- 50
1024- 30
1312- 80
1512- 80
1524- 40
2012-100
2324- 50

Version 2.0

User Manual

G3-Combi

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Clayton Power GmbH

G3-Combi

Clayton Power GmbH

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IMPORTANT BASIC-INFORMATION

This User-Manual serves a guideline for safe and effective operation, for installation of
equipment and for equipment maintenance. – It is therefore obligatory that all persons
who work on or with the equipment are completely familiar with the content of this
manual and follow the instructions contained herein.
Installation of and work on the product may only be carried out by qualified, authorized
and trained staff, familiar with the locally applicable standards and taking into
consideration the safety guidelines and measures.

Attention

We from Clayton Power makes every effort to ensure that the information contained within this
document are correct. However, our equipment is continuously being improved and updated, so
we cannot assume liability for any errors which may occur.
The information may contain errors or inaccuracies and represents no commitment whatsoever.

Exclusion of liability

Clayton Power shall in no event be liable for loss, damages or costs arising from use of this
Clayton Power product, or in any way connected with faulty installation, improper operation or
incorrect utilization and maintenance.

Clayton Power shall in no event be liable for any direct or indirect damages, disablement or
death on persons who

- works with or are dependent on Clayton Power products,

- are connected to medical equipment or to any life support system, where Clayton Power
products is integrated as a component.

Copyright

The information contained within this document remains the sole property of Clayton Power
No part of this document may be copied or reproduced in any form or by any means, and
the information contained within is not to be communicated to a third party, without the
prior written consent of Clayton Power.

Clayton Power GmbH

Oberwolfhauserstr. 10

CH-8633 Wolfhausen ZH

Schweiz

Phone: [phone]

G3-Combi

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Clayton Power GmbH

Content----------------------------------------------------------------------------------Page

Important basic-information..................................................................................................................3

1. Features and operation-functions............................................................................................5

1.1 Inverter mode: .............................................................................................................................6

1.1.1 Switch ON and OFF the inverter..........................................................................................6

1.1.2 Load search mode..............................................................................................................6

1.2 Charger mode..............................................................................................................................7

1.2.1 Charger activation...............................................................................................................7

1.2.2 Charging steps....................................................................................................................7

1.2.3 Charge current adjust..........................................................................................................8

1.3 Backup-mode..............................................................................................................................8

1.4 LED-indicationsfor operation and failfunctions.............................................................................9

1.5 Device layout & status indicators................................................................................................10

1.6 Layout-description .....................................................................................................................10

2. Specifications..........................................................................................................................11

2.1 Electrical inverter specification...................................................................................................11

2.2 Batterycharger specification.......................................................................................................12

2.3 Mechanical specifications..........................................................................................................12

3. Installation...............................................................................................................................13

3.1 Environment..............................................................................................................................13

3.1.1 Mounting the device..........................................................................................................13

3.2 Cable Installation.......................................................................................................................13

3.2.1 Battery cable.....................................................................................................................13

3.2.2 AC cables..........................................................................................................................14

3.2.3 Fusing...............................................................................................................................15

3.3 Mechanical drawings & layout description..................................................................................16

3.3.1 Dimensions.......................................................................................................................16

3.4 Externel wiring...........................................................................................................................18

3.5 Device connection-plugs............................................................................................................19

3.5.1 Assembling of Neutrik-plugs..............................................................................................19

Annex A Information about acid-batteries...................................................................................20

1. Choosing the best battery..........................................................................................................20

1.1 Battery sizing ........................................................................................................................20

2. Battery-installation.....................................................................................................................21

3. Battery maintenance..................................................................................................................21

3.1 Check of electrolyte...............................................................................................................22

3.2 Sealed batteries....................................................................................................................22

3.3 Battery storage......................................................................................................................22

Annex B Warranty.........................................................................................................................23

G3-Combi

Clayton Power GmbH

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1. FEATURES AND OPERATION-FUNCTIONS

The Combi is a combination of a sine wave inverter and a intelligent battery charger. The unit
has a number of benefits thanks to its dual functionality. The Combi charges batteries, when it
is connected to the fixed 230 VAC grid. When it is disconnected, the sine wave inverter part
converts energy from the battery to 230 VAC. This function is particularly well-suited for
emergency power (UPS). The obvious advantage is of course that it is always possible to
charge and use batteries with one and same unit.

Clayton Power Combi, well-suited for emergency power (UPS)

 True Sine wave Inverter section
 Integrated UPS functions.
 Start up heavy duty loads with high peak power consumption.
 Fully automatic 3 step charge cycle control.
 Adjustable battery and charge settings
 Overload protection
 short circuit protection on output
 Over temperature shutdown
 High battery voltage shutdown
 Temperature controled fan
 Remote option
 Datacommunication
 Status indication LED in front panel
 Status LED (data, remote active) in DC input endplate
 Custom made to harsh environment with special lacquer coating and double galvanic

separation.

The Combi devices can operate in three modes:

 Inverter mode

Energy is taken from the battery, inverted to 230VAC and delivered at output connector
(grey socket).

 Back up mode

In case of black out of AC public grid, the device will switch over automatically to inverter
function and the connected equipment will still run powered by the battery.

Important: for back up mode, the inverter section must be switched on!

 Charger mode

The charger switch on automatically when a public grid or an AC generator (185-265VAC) is
present at the AC input connector (blue socket). A relay bypasses the supplied AC voltage
to the output (grey socket). At the same time some of the energy (from grid or generator)
goes to recharge the battery bank.

G3-Combi

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Clayton Power GmbH

1.1 Inverter mode:

1.1.1 Switch ON and OFF the inverter

Switch ON the inverter

 Push down ON/OFF power switch for about 2 seconds. Both blue and red LED will light.
 After 2 seconds red LED stops and the power switch can be released.
 The blue LED will flash to indicate start up sequence
 Blue LED lights and 230VAC is present.

Note: If the battery is discharged, then the red LED will continue to light; - recharge battery and

try again!

Note: The fan is running at full speed, while the power supply is starting up for acoustic

detection of the fan!

Switch OFF the inverter

 Push down the ON/OFF power switch < 0.5 second

 The blue LED stops lightning and the device shuts down

Remote ON/OFF

 Use an external switch, to switch battery Plus to remote input terminal of Combi ON or

OFF.

1.1.2 Load search mode

In cases where it is preferable to leave the combi switched on and the load is periodically
inactive (switched OFF), the load search mode can be activated.

In this mode the Combi is partly active and generate a short pulse every 2 second, if a load
(>10W resistive) is detected, the device switches ON automatically. When a load is
disconnected again the device automatically returns to search mode (low consumption) after 1
min without load. - In load search mode the battery consumption is reduced to less than 2W in
order to save the battery during no load periods!

Activate load search mode

Switch OFF if the combi is activated; Push down the power switch for > 5 seconds; Release
only when the blue, green and red LED starts to light at the same time.

Note: in load search mode the battery consumption is reduced, while no load is active! The

device switch on automatically when a load is connected (> 10W resistive)
The load search mode will remain active, until deactivation or disconnection of the

battery longer than 15 minutes.

Note: there will be a small delay when connecting a load and until the device starts up

automatically!

Note: If load search mode is entered with a load connected, the blue LED flashes slowly only

for 5 seconds (to indicate entering of load search mode), then it lights continually!

Deactivate load search mode
Push power switch > 5 seconds; Release only when Blue, green and red LED start to flash at

the same time.

Note: The load search function will remain active if the device is switched ON/OFF by remote.
Note: Load search mode will also be deactivated, if battery is disconnected longer than 15

minutes.

G3-Combi

Clayton Power GmbH

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1.2 Charger mode

1.2.1 Charger activation

The charger will automatically switch on regardless of the ON/OFF power switch status, when
185-265VAC is connected to the AC input (blue Neutrik).

Note: If the inverter is switched OFF, the charger will operate at even lower voltage than

185VAC (down to 110VAC in this mode is accepted) but with reduced charge current!

1.2.2 Charging steps

The battery-charger is a fullautomatic
three-step-charger with IUoUo­characteristic. The charging para­meters can be set by the supplier
before delivery, adapting the
regarding batteries.

Charging with constant current (I­phase - quick blinking green LED)

In relation to actual battery charging
level, charging happens with maximal
charging current, to get the battery
loaded as quick as possible. In case
of a deep unloaded battery, the maximum current is limited during starting period, to prevent
damaging the battery

After arriving the set main charging voltage (14,2 to 14,7V, depending on battery-type), the
charge switches to next charging step.

Charging with constant voltage (U1-phase - slow blinking green LED)

During this phase, the main topping charging of battery happens. The voltage is kept on a
constant level of 14,4V (standard-value). In relation to approaching the full battery-capacity, the
current will decrease continuously and comes down to a minimum value, which depends on the
type of battery. As soon the current gets below of this minimum value, or a preset safetytime is
reached, the charger switches to phase 3.

Maintenance charging with reduced voltage (U2phase – steady green LED)

Charging voltage will be reduced to 13,5V (standard-value) to maintain full battery-capacity for a
unlimited period. So the physical caused self-unloading will be equalized. Additional connected
AC-consumers are than provided in parallel from AC-grid via the Combi without burden the
batteries.

Charge power reduction

2300W (10A) from the AC grid should not be exceeded! The charger reduces automatically the
charge current if the total power exceeds 2300W (charge power + AC output power)

Note: the regulation is slow in order to allow load peak currents, without disturbing the charging!

Important: The device has a build in fuse – see FUSING section -, do not exceed this
limit!

Deactivation of charger Disconnecting from AC Grid will stop charging.

Note: If the inverter was activated (ON) there will be 230VAC at the grey output connector
(discharging)