Studer Innotec C 1600-12, C 4000-48, C 2600-24 User Manual
STUDER INNOTEC
User and installer Manual
Sine wave Inverter, Battery charger, Transfersystem
COMPACT C 1600-12
COMPACT C 2600-24
COMPACT C 4000-48
Temperature sensor CT-35
Remote control RCC-01
Solar charge controller Cxxxx-S
Remote power sharing RPS-01
AC cable cover CFC-01
IP-23 top cover C-IP23
COMPACT
User manual COMPACT V4.0 E
STUDER INNOTEC
Summary
COMPACT
1 G
ENERAL INFORMATION ............................................................................................................... 4
1.1 OPERATING INSTRUCTIONS........................................................................................................................4
1.2 QUALITY AND WARRANTY ..........................................................................................................................4
1.3 W
ARRANTY DISCLAIMER............................................................................................................................4
1.4 LIABILITY DISCLAIMER ...............................................................................................................................4
1.5 PRECAUTIONS….......................................................................................................................................4
1.6 S
PECIAL PRECAUTIONS .............................................................................................................................5
2 INTRODUCTION ............................................................................................................................ 6
2.1 PRINCIPLE SCHEMATIC ..............................................................................................................................6
2.2 D
ESCRIPTION OF MAIN FUNCTIONS .............................................................................................................6
2.2.1 THE INVERTER ..................................................................................................................................6
2.2.2 THE TRANSFER SYSTEM ....................................................................................................................6
2.2.3 T
HE BATTERY CHARGER....................................................................................................................6
2.2.4 THE SOLAR CHARGE CONTROLLER (OPTIONAL) ...................................................................................7
2.2.5 REMOTE CONTROL ............................................................................................................................7
2.3 B
ATTERY CONNECTIONS............................................................................................................................7
2.3.1 PARALLEL CONNECTION .......................................................................................................................7
2.3.2 SERIES CONNECTION ...........................................................................................................................7
2.3.3
PARALLEL- SERIES CONNECTION ..........................................................................................................8
3 ASSEMBLY ................................................................................................................................... 8
3.1 PLACE OF ASSEMBLY.................................................................................................................................8
3.2 F
IXING………….. .....................................................................................................................................8
3.2.1 COMPACT .........................................................................................................................................8
3.2.2 PROTECTION COVER IP23 .................................................................................................................8
3.3 C
ONNECTION .…………………………………………………………………………………………………….8
3.3.1 GENERAL INSTRUCTIONS ON CONNECTING .........................................................................................8
3.3.2 PROTECTION COVER FOR THE TERMINALS CONNECTIONS ....................................................................9
3.4 C
ONNECTING PLAN / FRONT SIDE ..............................................................................................................9
3.5 CABLING/WIRING.....................................................................................................................................10
3.5.1 PRE-INSTALLATION SETTINGS ..........................................................................................................10
3.5.2 C
3.5.3 CONNECTION THE 230VAC-CONSUMER DEVICE (AC OUTPUT) .......................................................10
3.5.4 C
3.5.5 C
3.5.6 C
3.5.7 C
3.5.8 C
ONNECTION TO BATTERY ...............................................................................................................10
ONNECTION THE 230VAC INPUT (AC INPUT) ................................................................................11
ONNECT THE SOLARMODULES: SOLAR +/- (ONLY FOR SOLAR OPTION)...........................................11
ONNECTION TO AUXILIARY CONTACT .............................................................................................11
ONNECTION TO REMOTE CONTROL ................................................................................................11
ONNECTION TO TEMPERATURE SENSOR (TEMP.)............................................................................11
4 OPERATING ...............................................................................................................................12
4.1 DISPLAY AND OPERATING CONTROL ELEMENTS .......…………………………………….…………………….12
4.2 LIGHT EMITTING DIODES ...........................................................................................................................12
USH BUTTONS… ...................................................................................................................................13
4.3 P
4.4 T
URNING KNOBS.....................................................................................................................................13
4.5 THE INVERTER…. ...................................................................................................................................14
4.5.1 C
4.5.2 O
4.5.3 OVERHEATING (OVER TEMP)...........................................................................................................14
4.5.4 BATTERY CONDITION ......................................................................................................................14
4.6 T
4.6.1 CYCLE OF CHARGE..........................................................................................................................15
4.6.2 E
4.6.3 I
4.6.4 CHARGING CURRENT.......................................................................................................................16
4.6.5
4.7 T
4.7.1 SET THE TRANSFER VOLTAGE THRESHOLD........................................................................................17
4.7.2
User manual COMPACT V4.0 E 2
HARGE DETECTION SYSTEM „STANDBY“ .........................................................................................14
VERLOAD .....................................................................................................................................14
HE BATTERY CHARGER..........................................................................................................................15
QUALIZATION CHARGING................................................................................................................15
NPUT CURRENT REPARTITION (POWER SHARING) .............................................................................15
BATTERY CONDITION ......................................................................................................................16
HE TRANSFER SYSTEM ..........................................................................................................................16
FAST (UPS)- MODE FOR THE TRANSFER SWITCH.................................................................................17
STUDER INNOTEC
COMPACT
4.7.3 DELAYED MODE OF THE TRANSFER SYSTEM .....................................................................................17
HE SOLAR CHARGE CONTROLLER (OPTION) ............................................................................................17
4.8 T
4.9 T
HE MULTIFUNCTIONAL CONTACT............................................................................................................18
4.10
THE REMOTE CONTROL..........................................................................................................................18
4.11 THE TEMPERATURE SENSOR ...................................................................................................................19
5 PROGRAMMING.......................................................................................................................... 19
5.1 STANDARD SETTING ................................................................................................................................19
5.1.1 WORKING MODE..............................................................................................................................19
5.1.2 BATTERY VOLTAGE..........................................................................................................................19
5.1.3 A
5.2 RESET VALUE…......................................................................................................................................19
5.3 BATTERY VOLTAGES AND ABSORPTION TIME .............................................................................................19
5.3.1 T
5.3.2 SET THE VOLTAGE AND TIMING THRESHOLD ......................................................................................20
5.4 PROGRAMMING THE AUXILIARY CONTACT..................................................................................................20
5.4.1 P
5.4.2 T
5.4.3 EXAMPLES......................................................................................................................................21
5.4.4 M
5.5 D
5.5.1 DIAGRAM OF THE DIFFERENT MODES ...............................................................................................22
UXILIARY CONTACT .......................................................................................................................19
ABLE OF VOLTAGE AND TIMING THRESHOLD ....................................................................................19
RINCIPLE ......................................................................................................................................20
HE PROGRAMMING OF THE AUXILIARY CONTACT IS CARRIED OUT IN THE FOLLOWING STEPS .............20
ANUAL OPERATING OF AUXILIARY CONTACT...................................................................................21
ISABLING SOME OF THE COMPACT FUNCTIONS ........................................................................................21
6 MAINTENANCE ...........................................................................................................................22
7 EC
8 T
COMPLIANCE ....................................................................................................................... 22
ECHNICAL DATA ....................................................................................................................... 23
User manual COMPACT V4.0 E 3
STUDER INNOTEC
COMPACT
1 General Information
1.1 Operating instructions
This manual is a part of the delivery package of every COMPACT inverter-charger. It serves as
guidelines for safe and efficient operation of COMPACT. The instructions are only valid for use with
the following devices and options:
COMPACT C 1600-12
COMPACT C 2600-24
COMPACT C 4000-48
Temperature sensor CT-35 AC cable cover CFC-01
Remote Control RCC-01 IP23 cover C-IP23
Power sharing remote control RPS-01 Solar charge controller CxxxxS
Every person who installs a COMPACT and/or works with it must be fully familiar with the contents
of this manual and must follow exactly all the warnings and safety instructions. Installation of or any
work on the COMPACT must be carried out by a qualified and trained staff. Installation and
application must comply with the respective local installations codes and safety regulations.
1.2 Quality and Warranty
During production and assembling, all COMPACT appliances go through many controls and tests.
Fabrication, controls and tests are carried out in accordance with firm and established procedures.
Every 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 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 COMPACT is 2 Years.
1.3 Warranty Disclaimer
We do not accept any responsibility 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 COMPACT 1600-12)
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 connecting cables
Connecting other sources of energy such as PV-Modules on the INPUT „SOLAR +/-„
Transport damage, i.e. through bad handling and /or packing.
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 Firma Studer INNOTEC.
Hence we do not accept any liability and responsibility for damages, loses 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 together
to these. Similarly, we do not accept any responsibility 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 issuing any prior notice.
1.5 Precautions
This manual must be readily available for the user at all times. The user must be familiar with the
precautions and safety aspects.
User manual COMPACT V4.0 E 4
STUDER INNOTEC
During operation of COMPACT, high tensions are generated at the connections and inside of the
appliance which could be deadly fatal. Work on the appliance and on the installation should only
be carried out by qualified and trained personnel.
The whole installation connected with the COMPACT must comply with the respective valid codes
and ordinances.
Persons without the written authorization from Studer INNOTEC are strictly forbidden to carry out
any changes or repairs on the appliances. For authorized changes only original parts are to be
used.
The COMPACT may only be used when it has been installed in accordance with these instructions
and all parts have been correctly assembled and installed.
On the IN- and OUTPUT points of the COMPACT only the already selected energy sources and
consumer devices should be connected.
In order to carry out any maintenance or repair work on the COMPACT without danger, all
connections must be disconnected beforehand.
COMPACT
Caution: Even when a COMPACT has been disconnected from the all connections, at the
OUTPUT point there could still be deadly fatal tensions present. To remove these tensions
you must switch on the COMPACT ON with the ON/OFF switch. After one minute the
electronics are discharged and any work can now be safely carried out.
The 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 COMPACT must be protected from water-spray and any
other wet conditions.
The COMPACT may only be connected to lead –acid or lead-gel batteries.
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 area, they should be placed in such a way that there is no danger of short
circuiting through carelessness. Never charge frozen batteries.
The COMPACT is not to be used or sold for life support equipment or applications.
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 the eyes 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.
Under certain conditions 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.
User manual COMPACT V4.0 E 5
STUDER INNOTEC
A
T
R
A
A
A
Ω
A
A
COMPACT
2 Introduction
The COMPACT is a sine wave inverter with integrated battery charger and solar charger controller
with many additional functions, it has been developed to be used as stand-alone (independent of a
grid-system) AC provider, or as continuous / break-free current supply provider.
2.1 Principle schematic
C IN
Input
230Vac
L
PE
N
100nF
1uF
10nF
10nF
L
PE
N
C OUT
Output
230Vac
4x2,7M
Filter
UX. CONT
.
Battery
BATTERY
CT35
150A
1uF
1uF
Inverter
Charger
Temp. Sensor
Microprocessor,
SOLAR
Solarmodule
Max. 6m
Temp.
6p 8p
Control, Adjustment
RJ11
Remote control
Display
Max. 40m
Remote control
Remote control
INVERTER - CHARGE
RCC-01
COMPAC
TRANSFER
AC IN
SOLAR CHARGE
EQUALIZE
Program
Contact active
Contact manual
AUXILIARY CONTACT ON/OFF
(Program) (Change sta tus)
%
C OUT
160
130
INVERTERCHARGER
100
70
RESET
80
60
LARM
(Select)
60
50
40
40
20
30
Over Temp.
10
20
Overload
Battery
5
10
Ch
Low/High
Inv
arg
ert
er
er
OFF
2.2 Description of main functions
2.2.1 The Inverter
The sine wave inverter built in the COMPACT generates a sinusoidal AC voltage with an
exceptionally precise voltage and stabilized frequency. In order to start large electric motors, the
user has the possibility to employ a short-start-power which is 3-times the nominal power of the
COMPACT.
The inverter is protected against overload and short circuit. A power-stage with the latest MOSFET power transistors, a toroidal transformer, and a fast regulating system make-up a robust and
reliable inverter with highest efficiency. A 1-20 Watt adjustable charge detection system serves to
provide the smallest energy consumption and ensures a long life for the battery.
2.2.2 The Transfer system
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 alternating voltage at the
output for use by the connected consumer devices. On the other side the batteries are charged.
The distribution of energy between the consumer devices and battery charger is automatic.
2.2.3 The Battery charger
The built-in battery charger is so arranged that it can charge the batteries quick very completely. A
microprocessor controlled, 3 to 4 Step charging process ensures the optimum charging of the
batteries. The desired charging current can be set continuously from 0 – 55A (C 4000-48: 0 - 50A).
The battery charger is meant for the lead-acid and lead-gel batteries. Thanks to the floating charge
system the batteries can remain continuously connected.
User manual COMPACT V4.0 E 6
STUDER INNOTEC
2.2.4 The solar charge controller (optional)
With the built-in solar charge controller, the COMPACT is a complete solar-power-center. In a solar
installation this controller ensures that the batteries are charged correctly. With the COMPACT,
batteries can be charged with a generator and with the solar modules at the same time. The
charging of batteries with both energy sources is carried out fully automatically.
2.2.5 Remote control
As an option, a remote control can be connected to COMPACT. All operating elements and
displays with the exception of the level adjustment are available on the remote control. The remote
control is furnished with a 20m long cable. This cable can go to 40m long. On the remote control
output power and charging current are also shown.
COMPACT
2.3 Battery connections
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 COMPACT many
batteries have to be connected together in parallel and or in series. Following three examples are
shown:
2.3.1 Parallel Connection
12V 12V 12V
2.3.2 Series Connection
2V 2V 2V 2V 2V 2V
2V 2V 2V 2V 2V 2V
2V 2V 2V 2V 2V 2V
C 1600-12
C 1600-12
C 2600-24
12V 12V 12V 12V
C 4000-48
User manual COMPACT V4.0 E 7
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