Studer HP-COMPACT HPC 2512, HP-COMPACT HPC 4024, HP-COMPACT HPC 5048, HP-COMPACT HPC 7048, RCC-01 User And Installation Manual

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E

User and installer Manual

Sine wave Inverter, Battery charger, Transfersystem

HP-COMPACT - HPC 2512
HP-COMPACT - HPC 4024
HP-COMPACT - HPC 5048
HP-COMPACT - HPC 7048

Remote control RCC-01

Remote power sharing RPS-01

Temperature sensor CT-35

STUDER INNOTEC TEL: ++41 (0)27 205 60 80
Rue des Casernes 57 FAX: ++41 (0)27 205 60 88

C

H -1

950 SIO

N E-MAIL:inf

o@studer

-inno.com

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 2

Summary

1 GENERAL INFORMATION...................................................................................................................................3

1.1 OPERATING INSTRUCTIONS ....................................................................................................................................3

1.2 Q

UALITY AND WARRANTY ....................................................................................................................................3

1.3 WARRANTY DISCLAIMER ......................................................................................................................................3

1.4 L

IABILITY DISCLAIMER .........................................................................................................................................3

1.5 PRECAUTIONS ........................................................................................................................................................4

1.6 SPECIAL PRECAUTIONS ..........................................................................................................................................4

2 INTRODUCTION...................................................................................................................................................5

2.1 PRINCIPLE SCHEMATIC...........................................................................................................................................5

2.2 DESCRIPTION OF THE MAIN FUNCTIONS .................................................................................................................5

2.3 B

ATTERY CONNECTING..........................................................................................................................................6

3 MOUNTING AND INSTALLING............................................................................................................................7

3.1 INSTALLATION PLACE ............................................................................................................................................7

3.2 F

IXING ...................................................................................................................................................................8

3.3 C

ONNECTIONS .......................................................................................................................................................8

3.4 C

ONNECTION PLAN................................................................................................................................................9

3.5 CABLING................................................................................................................................................................9

3.6 PRE-INSTALLATION SETTINGS ..............................................................................................................................10

4 CONTROL...........................................................................................................................................................12

4.1 DISPLAY AND CONTROL PARAMETERS .................................................................................................................12

4.2 L

IGHT EMITTING DIODES (LED)..........................................................................................................................12

4.3 PUSH BUTTONS ....................................................................................................................................................13

4.4 TURNING KNOBS .................................................................................................................................................13

4.5 T

HE INVERTER .....................................................................................................................................................13

4.6 THE BATTERY CHARGER ......................................................................................................................................15

4.7 THE TRANSFER SYSTEM.......................................................................................................................................17

4.8 T

HE MULTIFUNCTIONAL CONTACT......................................................................................................................18

4.9 THE REMOTE CONTROL.......................................................................................................................................19

4.10 THE TEMPERATURE SENSOR ................................................................................................................................19

4.11

REMOTE CONTROL FOR POWER SHARING..............................................................................................................20

5 PROGRAMMING ................................................................................................................................................20

5.1 STANDARD SETTING.............................................................................................................................................20

5.2 RESET VALUE.......................................................................................................................................................20

5.3 B

ATTERY VOLTAGES AND ABSORPTION TIME .......................................................................................................20

5.4 A

UXILIARY CONTACT ..........................................................................................................................................21

5.5 D

ISABLING SOME OF THE HP-COMPACT FUNCTIONS ........................................................................................23

6 INSTALLATION MAINTENANCE.......................................................................................................................24

7 EC COMPLIANCE ..............................................................................................................................................24

8 TECHNICAL DATA.............................................................................................................................................25

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 3

1 General Information

1.1 Operating instructions

This manual is part of the delivery package of every HP-COMPACT inverter-charger. It
serves as guidelines for safe and efficient operation of HP-COMPACT. The instructions
are only valid for use with the following devices and options:

HP-COMPACT : HPC2512 – HPC4024 – HPC5048– HPC7048
Temperature sensor : CT-35
Remote Control : RCC 01
Remote power sharing : RPS-01

Every person who installs a HP-COMPACT and/or works with it must be fully familiar with
the content of this manual and must follow exactly all the warning and safety instructions.
Installation of or any work on the HP-COMPACT must be carried out by a skilled and
trained personnel. Installation and application must comply with the respective local instal­lations codes and safety regulations.

1.2 Quality and Warranty

During production and assembling, all HP-COMPACT appliances go through many con­trols and tests. Production, controls and tests are carried out in accordance with firm and
established procedures. Every HP-COMPACT has its own serial number, which helps to
refer back to its original data in the event of controls or repairs. That is why you should
never remove the identification plate showing the serial number. The production assembly
and tests on all HP-COMPACT appliances are totally carried out in our company in Sion,
Switzerland. The warranty for these appliances is valid for uses and operating possibilities
mentioned in this manual.
The warranty period for the HP-COMPACT is 2 years.

1.3 Warranty Disclaimer

We do not accept any liability for any damages occurring through use, manipulation, wor­king situation and handling, which are not explicitly mentioned in these operating instruc­tions.
Following cases are not covered by the warranty:

- High voltage at INPUT (i.e. 48V at the Battery INPUT of HP-COMPACT 2512)

- Reverse polarity on Battery connections (+/- reversed)

- Running liquid or oxidation through condensation in the appliance

- Defects caused by force, physical or mechanical means

- Changes not explicitly authorized by STUDER INNOTEC

- Not or only partly tightened screws and nuts after change of fuses or cables connecting

- Transport damage, i.e. through bad handling and /or packing

- Damage from atmospheric overvoltages (lightning)

1.4 Liability Disclaimer

Respecting this manual, servicing and method of installation, functioning, application and
maintenance of the appliance can not be controlled or supervised by STUDER INNOTEC.
Hence we do not accept any liability and responsibility for damages, losses and costs
which result through the use of this appliance or which result through incorrect installation,
incorrect operation or wrong application and maintenance, or which by some other means
maybe connected to each other.
The use of STUDER INNOTEC’s inverters does exclusively involve the user’s liability.

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 4

This device is not designed for applications involving health care and medical treatments
where the patient life is concerned and where any mishap may be lethal.
Similarly, we do not accept any liability for any violation of the patents rights or violation of
any third party’s rights resulting from the use of this appliance
STUDER INNOTEC reserves the right to modify the technical data or these operating ins­tructions without any prior notice.

1.5 Precautions

This manual must be readily available for the user at any time. The user must be familiar
with the precautions and safety aspects in the country of installation.
During operation of HP-COMPACT, high voltages are generated at the connections and
inside of the appliance which could be lethal. Work on the appliance and on the installation
should only be carried out by skilled and trained people.
The whole installation connected with the HP-COMPACT must comply with the rules and
codes in force.
People without the written authorization from STUDER INNOTEC are strictly forbidden to
carry out any change or repair on the appliances. For authorized changes only original
parts are to be used.
The HP-COMPACT may only be used when it has been installed in accordance with these
instructions and all parts have been correctly assembled and installed.
The HP-COMPACT may only be connected to lead-acid or lead-gel batteries.

Caution: Even when a HP-COMPACT has been disconnected from all connections,
at the OUTPUT point there could still be deadly voltages present. To remove these
voltages you must switch on the HP-COMPACT ON with the ON/OFF switch. After
one minute the electronics are discharged and any work can now be safely carried
out.

The HP-COMPACT is only suitable for internal use and under no circumstances should it
be subjected to snow, rain, or any other wet conditions.
By installations in motorized vehicles the HP-COMPACT must be protected from water­spray and any other wet conditions.
Caution: In normal use lead-acid and lead-gel batteries give out explosive gases. Never
smoke or allow a spark or flame in the vicinity of batteries. The batteries must always be
stored or placed in a well ventilated room, they should be placed in such a way that there
is no danger of short-circuit through carelessness. Never charge frozen batteries.

1.6 Special precautions

While working on batteries there should always be a second person close to you or within
your voice range, in case help is needed.
Plenty of fresh water and soap must be ready at hand so that in case of acid coming in
contact with skin, eyes and clothes, the areas in question can be thoroughly washed.
If acid enters the eyes, you must thoroughly wash them with cold running water for at least
15 minutes. It is recommended that you immediately consult a medical doctor.
Baking powder neutralizes battery acid electrolyte. Always keep some at hand.
Special care must be taken when working with metal tools near or on the batteries. With
tools such as screwdrivers, spanners etc. short-circuits can result. Sparks produced by the
short-circuit can cause an explosion.
When working on batteries all personal metal items such as rings, necklaces and bracelets
must be removed. Batteries are so powerful that short-circuit with these items can melt
them and thus cause severe burns. Always follow the battery manufacturer instructions.

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 5

Under certain conditions HP-COMPACT or a connected generator can start automatically.
While working on an electrical installation you must ensure that these appliances are dis­connected beforehand from the installation.

2 Introduction

The HP-COMPACT is a sine wave inverter with integrated battery charger with many addi­tional functions, it has been developed to be used as stand-alone (no grid-feeding) AC
provider, or as continuous / break-free current supply provider (UPS).

2.1 Principle schematic

2.2 Description of the main functions

2.2.1 The inverter

The sine wave inverter HP-COMPACT generates a sinusoidal AC voltage with an excep­tionnlaly precise voltage and stabilized frequency. In order to start large electric motors,
the user has the possibility to use a short surge power which is 3 times the nominal power
of the HP-COMPACT.
The inverter is protected against overload and short-circuit. A power stage with the latest
MOS-FET power transistors, a toroidal transformer, and a fast regulating system makes a
robust and reliable inverter with the highest efficiency. A 1-20 Watt adjustable charge de­tection system allows the smallest energy consumption and ensures a long life for the bat­tery.

2.2.2 The transfer system

HP-COMPACT can be connected to an AC source. For example a stand-by emergency
generator or the AC network. With the transfer system, on one side you have an alternati­ing voltage at the output for the use of consumer appliances. On the other side the battery

6p

8p

AC IN

AUX.
CONTACT

L

PE

N

L

PE

N

OFF

AC OUT

Over Temp.

Overload

AC IN

SOLAR CHARGE

Contact manual

Contact active

Program

COMPACT

AUXILIARY CONTACT ON/OFF

INVERTER - CHARGER

(Select)

RCC-01

INVERTERCHARGER

(Program) (Change status)

Battery
Low/High

RESET
ALARM

10

20

30

40

50

60

70

TRANSFER

Charger

Inverter

5

10

20

40

60

80

100

130

160

A %

EQUALIZE

RCC-01

BATTERY

CT35

100nF

2,2nF
2,2nF

1uF 1uF

4x2,7M

Ω

Remote control

Temp. / remote

power sharing

.

Max. 6m

Max. 40m

AC OUT

Equalize

Transfer delay

RPS-01

RCC-01CT35

2,2nF
2,2nF

AC Input

AC Output

Temp. sensor

Fuse

Filter

Inverter/
charger

Microprocessor
controlled

Display

Circuit breaker (thermal)

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 6

park is being charged. The distribution of energy between the consumer appliances and
battery charger is automatic.

2.2.3 The battery charger

The built-in battery charger is so designed that it can charge the battery quickly and fully. A
microprocessor controlled, Step charging process, ensures the optimal charging of the
battery. The desired charging current can be set continuously from 0 to 70/90/100/110 A,
as per the model. The setting is made accordingly to the battery capacity and power avai­lable.
The battery charger is designed for lead-acid and lead-gel batteries. Thanks to the floating
charge system the batteries can remain continuously connected.

2.2.4 Remote control

As an option, a remote control RCC-01 can be connected to HP-COMPACT. All operating
features and displays, save the adjustment levels (22/23/24/26), are available on the re­mote control. It is supplied with a 20m long cable. This cable can be up to 40m long. On
the remote control, output power and charging current are also displaid.

2.2.5 Remote control for Power Sharing

This remote control RPS-01 can be connected to the HP-COMPACT in the gland for the
temperature sensor. The maximum current available from the energy source can be ad­justed by the turning button.

2.3 Battery connecting

Lead-acid batteries are normally available in blocks of 2V, 6V or 12V. In most cases, to
generate the necessary operating voltage and the capacity of the batteries for the HP­COMPACT many batteries have to be connected together in parallel and or in series. Here
are 3 examples of connection:

2.3.1 Connection in parallel

12V 12V 12V

H

P

C

-

2

5

1

2

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 7

2V 2V 2V 2V 2V 2V

12V 12V 12V 12V

2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V

H

P

C

-

4

0

2

4

H

P

C

-

5

0

4

8

H

P

C

-

2

5

1

2

12V 12V 12V 12V

HP

C

-

4

02

4

2.3.2 Connection in serie

2.3.3 Connection in parallel and in serie

3 Mounting and installing

3.1 Installation place

The location of the HP-COMPACT must be driven by the following criteria:

- Protection from unauthorized handling

- Dry dust free room, no condensation

- Never install directly over the battery and never in a cabinet together with the batteries

- Keep ventilation holes free

- In mobile installations it is important to keep the vibrations down as low as possible

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 8

3.2 Fixing

3.2.1 HP-COMPACT

Basically the HP-COMPACT can be installed in any desired location but only vertically.
First of all the plate supplied along with the HP-COMPACT must be screwed firmly (due to
the weight of the device) on the wall. Then the HP-COMPACT is hooked on the plate and
screwed underneath.
Cautious: the fixing must be fully made otherwise the HP-COMPACT may fall and cause
important damages.
In motor vehicles HP-COMPACT must be fixed on vibrations reducing elements. The HP­COMPACT must not be fixed on a combustible base, as the back of the casing can get hot
and reach up to 60 degrees Celsius.

3.3 Connections

3.3.1 General instructions on connecting

The cable connection on the terminals AC INPUT and AC OUTPUT must be carried out
with a screwdriver Nr.3 and the connection of the AUX RELAY terminal with a screwdriver
Nr.2.
The conductor cross section on the terminals AC INPUT / AC OUTPUT / must comply with
the local rules.
All connecting cables and also the battery cables must be fixed with strain relief clamps.
The fuses supplied with the HPC4024, 5048 and 7048 have to be installed (see descrip­tion in 3.4). The cable cross section for the HP 2512, 4024, 5048 and 7048 is resp. 95, 70,
50 and 70 mm2 and their length must be as short as possible (max. 2m).
The fuse supplied with the product (save for HPC 2512) does not protect the battery ca­bles.
To protect the battery cables, a fuse corresponding to the conductor cross section must be
fixed directly on to the battery.
All cables must be tightly screwed in place. For safety, a yearly control is recommended. In
mobile installations controls must be carried out more often.
Connecting must be done by qualified people. Material such as cable, connectors and dis­tribution boxes, fuses etc. used in the installation must comply with the respective valid
low-voltage installation rules and regulations in force.

3.3.2 Protection cover of the terminals connections

The protection cover must to be closed after any service on the appliance.