Quantum Harvest 3000-60 TSW Owner's Manual
®
®
Faraday
Enclosures
Portable Solar
Power Stations
Owner's Manual
Quantum Harvest Model 3000-60 TSW
quantumharvest.net
Introduction
Congratulations on your purchase of a Quantum Harvest EMP protected* portable solar
power station! These units have been carefully designed and hand-crafted to provide many
years of trouble-free operation. In the unlikely event of malfunction, we offer a 1 year warranty
on the batteries (if provided by us.); 3 years on the inverter and charge controllers; 5 years on
everything else. For warranty details, see page 34.
To obtain maximum performance and long life from your new power station, it is
important to gain a basic understanding of how such units operate and their limitations. The
heart of the unit, and it's main component, is the battery bank. This is where the energy from
the solar panels or the included 120 volt AC battery charger is stored for later use. The
particular batteries I have selected are state of the art deep-cycle Absorbed Glass Mat (AGM)
medical-grade batteries. These batteries are maintenance free and can be stored and used in any
position. Since they do not give off gases as they charge, there is no danger of fire and they
never need to have water added.
To obtain maximum life from these, or any other batteries, it is important to try to avoid
deep cycling, that is, drawing them down flat before allowing them to recharge. Sometimes this
cannot be avoided, but if at all possible, strive to avoid doing so.
Another important component is the inverter. This is the device that converts the low
voltage DC current from the batteries into the high voltage AC current that we are familiar
with. (All Quantum Harvest power stations also have 12 volt DC receptacles and USB charging
sockets for the appropriate devices, in addition to standard 120 volt AC house current.) The
inverter is protected internally from overheating and low battery voltage, and externally from
over-current draw by a 400 ampere ANL type fuse. The Model 3000 will sustain a continuous
3000 watts of current, and will briefly provide up to 6000 surge watts, to start motors and other
inductive loads. The inverter relies on air flow around and through the unit to cool it, therefore
it is imperative that the inverter not be used with the enclosure door closed.
Another important part is the solar panels. We currently offer a choice of a 100 watt
single-panel mobile assembly, as well as a 200 watt dual-panel mobile assembly, and a 300
watt, three panel assembly. All our models of power stations can also be purchased without
solar panels, allowing the client to supply their own panels, if they so desire. We recommend an
absolute minimum of 100 watts rated panel capacity, and 200 or even 300 watts would be
better. If unsure, email us at support@quantumharvest.net with the specifications of the
proposed panels and we can quickly look them up and confirm whether or not they will work.
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*A quick note on EMP
An EMP, or Electro-Magnetic Pulse is a devastating phenomenon that, while harmless to living
things, absolutely destroys anything electronic. It consists of extremely powerful electromagnetic fields
building and collapsing hundreds of thousands of times per second. This induces potentially huge
electric currents in anything that conducts electricity, causing components connected to said conductor
to burn out. An EMP can be caused by either a deliberate, high-altitude nuclear warhead detonation,
or can be caused naturally by a solar event called a Coronal Mass Ejection, or CME.
All Quantum Harvest power units are built into a specially designed enclosure, more
properly called a Faraday Cage, named after Michael Faraday, an early pioneer in
electromagnetic research. The purpose of a Faraday cage is to intercept and divert
electromagnetic energy away from the box's interior, thus protecting the contents.
The principles involved are fairly simple, but the proper execution is critical. In order
for the enclosure to be useful, it must have a door, but any opening larger than a square
centimeter or so allows too much energy to penetrate the interior, thus defeating the purpose of
the Faraday cage.
The solution to this conundrum is to gasket the door with a special type of conductive
gasket, mated to a copper or silver strip that is electrically bonded to the main box. The key is
to have very low electrical resistance between the door and the enclosure, with no gaps. This is
not as easy as it sounds, and requires special materials designed specifically for this
application.
My experience with Faraday apparatus comes from 8 years experience with very
powerful industrial machines called RF welders. These machines use extremely powerful and
focused bursts of electromagnetic energy to weld and form plastic parts. These machines
basically create a local EMP every time they fire, and it is critical that stray energy be confined
and dissipated safely to avoid damage to other sensitive electrical machinery.
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Table of Contents
Specifications.......................................................................................Page 4
Note on Batteries.................................................................................Page 5
Section 1............Capacities and recommended usages.....................Page 6-7
Section 2............Controls/Circuit Protection Devices.......................Page 8-10
Section 3.............External Ports and Connectors..............................Page 11-13
Section 4A.....General Operation and Routine Maintenance..........Page 14
Section 4B..........Using the 220 volt sub-system................................Page 15
Section 4C..Using the Solar Panel Assembly(s) and AC charger....Page 16-19
Section 5.............Using Booster Cables..............................................Page 20-22
Section 6A.....Power Board Removal, Re-installation......................Page 23-25
Section 6B......Battery Removal, Re-installation...............................Page 26-28
Section 6C.....Soft-start Module Removal, Re-installation..............Page 29
Section 6D...........Control Panel Removal, Re-installation..............Page 30-32
Troubleshooting...................................................................................Page 33
Contact Information...........................................................................Page 33
Warranty Information........................................................................Page 34
Addendum A....Replacement of Solar Panel Diodes........................Page 35-36
Addendum B....Bypassing the Soft-start Module.............................Page 37
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Base Unit Specifications
Assembled Dimensions: 30.5”H x 47.5”O.A.L x 19.5”W
Assembled Weight: 430 lbs.
Inverter: Samlex America 3000 watt true sine-wave
Battery Bank: 4 AGM Deep-Cycle Batteries, 110 amp/hrs each.
Battery Bank Capacity: 440 Amp/hours, 5,280 Watt/hours
AC Charger: 20 Amp Smart Battery Charger
Solar Charger/Controller: Instapark 60 Amp MPPT Solar Power Charge
Controller.
Solar Panel Assembly Specifications
(300 Watt Model)
Assembled and folded Dimensions: 50.75”H x 8”D x 25.5”W
Unfolded Dimensions: 47.75”H x 60”W
Assembled Weight: 68.2 lbs.
Rated Output (Nominal) Optimum Operating Voltage (Vmp): 18.9V
Optimum Operating Current (Imp): 15.87 A
Open - Circuit Voltage (Voc): 22.5 V
Short- Circuit Current (Isc): 17.25 A
Maximum Power at STC: 300 W
Operating Module Temperature: -40°C to + 90°C
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In this manual, the following symbols are used to
highlight important facts:
Denotes circumstances where failure to follow the procedures
outlined in the manual may result in property damage.
Denotes circumstances where failure to follow the procedures
outlined in the manual may result in personal injury or death.
Always remember that electricity is utterly devoid of mercy and
never grants second chances!
Note on Batteries
This Quantum Harvest power station is designed to use AGM batteries
that measure 12.91” Long, by 6.77” Wide by 9.29” High. The particular
battery model we use is the UB121100 110AH model. Other models of
similar dimensions and specifications will also work.
*Caution* Although the low voltage at the battery terminals
means that electrical shock or electrocution is impossible,
nonetheless, batteries store an enormous amount of potential energy,
that if accidentally released by a short-circuit, can melt metal tools, start
fires and cause personal injury. Eye protection MUST BE WORN
whenever working with batteries of this size, and extreme care must be
exercised at all times. Anything electrical is unforgiving of mistakes.
!Warning! Note that although the voltage at the battery
terminals is insufficient to shock a person, the current coming
from the inverter receptacles is 120 volt house current, and that
is indeed capable of inflicting a severe, potentially fatal shock.
Always be sure that extension cords are not frayed or worn, and that all
equipment plugged into the inverter is in a safe condition.
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Section 1: Capacities and recommended usages
This 3,000 watt model is the next-to-largest true sine-wave unit we currently produce,
and with it's premium, industrial-grade Samlex inverter with proven soft-start technology, will
reliably start and power anything within it's capability, even fussy items that will not run with
cheaper, modified sine-wave inverters. It will run full-size refrigerators and freezers, table saws
and chop saws, as well as any hand-held tools, such as drills, grinders and circular saws, etc. It
will also, of course, power smaller items such as TVs, cell phones,laptops, tablets, etc.
This Model is available with an optional transformer and proprietary soft-start
mechanism to augment the built-in system in the inverter, which allows it to reliably start and
power up to to a 1 hp submersible well pump. It is NOT recommended to power large resistive
loads like central air-conditioners,water heaters and electric space heaters, as well as large
electric motors, such as industrial air compressors, etc.
Used within it's limits, this unit will provide many years of trouble-free service, and be a
joy to own and use. But like most things, if you push it beyond it's limits, you will be plagued
by expensive repairs and poor performance.
This machine contains a battery bank of four, 110 amp/hour batteries, for a total capacity
of 440 amp/hrs. How much real power is that? If we multiply the 440 amp/hours by the
nominal voltage (12 volts), we get a capacity of 5,280 watt/hours (watts = volts times amps).
This machine will run a full-sized refrigerator or freezer for several days, even without the
solar panels hooked up.
On the next page is a partial list of common electrical appliances and their approximate
loads, provided in part by the good folks at: http://www.energy.gov
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Section 2: Controls/Circuit Protection Devices
There is one main fuse, a 400 ampere ANL type fuse,
shown to the right, located beside the inverter. There is
one spare fuse included in the spare parts kit. To
replace the fuse, first, be sure the main switch is turned
off, then, using a 9/16” wrench, remove the two nuts.
Lift the fuse out and place the new one over the studs;
reapply the nuts, being careful to not over-tighten.
Detail of Main Control Panel
Anderson connector for Voltage/Charging amps meter 220 volt AC
breaker
booster cables 220 volt system on/off switch
Polarity indicator LEDs for use
with the booster cables
(see section 5)
12 Volt DC cigarette
lighter-style outlets
USB charger ports (2) 120 volt AC outlets
Inverter start button 220 volt AC outlet
Main Switch; 4 positions available.
Off position isolates the inverter and control panel from the batteries.
Position #1 is the normal use position in which the unit draws from the internal battery bank.
Position #1&2 is the position used when using the booster cables, and allows the unit to run
from both the internal battery bank and the vehicle's charging system.
Position #2 is not normally used, and allows the load to be run directly from an automobile's
charging system, bypassing the internal battery bank.
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Detail of Main Panel Circuit Breakers
40 amp for AC charger
30 amp for right-most
120volt outlets
30 amp for left-most 120volt
outlets
20 amp for 12 volt DC outlets
5 amp for USB charger, 20 amp, 220 volt AC breaker
and soft-start module
control system
Detail of AC Charger
Battery voltage selector
Battery type selector
Max. charge current
selector
Initiate charging sequence button Display toggle between % charge and
battery voltage button
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Detail of Solar Charger/Controller
and related circuit-breakers
The solar charge controller is completely automatic, and requires no user intervention or
maintenance.
Steady red light indicates batteries
are being charged, blinking red light
indicates full charge.
Yellow light indicates connection to
battery bank.
Green light in the middle may be
ignored in this application.
Right; The solar charge controller is
protected by 2, 70-amp circuit-breakers.
It is recommended that they be kept in
the disconnected position (shown) until
the solar panels are plugged in; then
push the red levers down to latch,
turning the breakers on. To shut off,
depress the red button to the left of the
levers. These breakers both must be
engaged to charge the batteries from the
solar panels.
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