Unipower INVC4850H, INVC9650H Operating Manual

UNIPOWER Corporation

NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: [phone] • Fax: [phone] • [e-mail]

EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: [phone] • Fax: [phone] • [e-mail]

OPERATING MANUAL

INVO Series

5KVA INVERTER / CHARGER

INVC4850H – 48V Battery
INVC9650H – 96V Battery

WWW.UNIPOWERCORP.COM

Manual No. INVO-1 © 2011 UNIPOWER Corp.

08/11 invo-.man All Rights Reserved

INVO SERIES INVERTER/CHARGER

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Manual No. INVO-1 Page 2 08/11 invo-man

INVO SERIES INVERTER/CHARGER

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Contents

ABOUT THIS MANUAL ............................................................................................................... 4

Purpose .................................................................................................................................................. 4

Scope ...................................................................................................................................................... 4

IMPORTANT SAFETY INSTRUCTIONS ................................................................................... 4

General Precautions ............................................................................................................................ 4

Personal Precautions .......................................................................................................................... 5

INSTALLATION ............................................................................................................................ 6

Unpacking and Inspection ................................................................................................................. 6

Basic Configuration ............................................................................................................................. 6

Batteries ................................................................................................................................................. 7

Battery Cable Size ................................................................................................................................ 7

DC Disconnect and Over-Current Protection ............................................................................... 8

Battery Cable Connection .................................................................................................................. 8

AC Cable Size ........................................................................................................................................ 9

AC Connections ................................................................................................................................... 9

OPERATION ................................................................................................................................ 11

Front Panel Controls and LCD Indicators ................................................................................... 11

Power ON/OFF .................................................................................................................................... 11

Configuration Switch ........................................................................................................................ 11

LCD Indicator ...................................................................................................................................... 12

Battery Charger .................................................................................................................................. 13

Circuit Breaker .................................................................................................................................... 13

SPECIFICATIONS ...................................................................................................................... 14

TROUBLESHOOTING ....................................................................................................................... 18

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ABOUT THIS MANUAL

Purpose

The purpose of this manual is to provide explanations and procedures for installation, operation and
troubleshooting. This manual should be read carefully before installation and operation.

Please retain this manual for future reference.

Scope

This document defines the functional requirements of the inverter/charger, which is intended for
worldwide use in electronic data processing applications. All manuals are applicable under all operating
conditions when installed in the End Use system, unless otherwise stated.

IMPORTANT SAFETY INSTRUCTIONS

WARNING: This chapter contains important safety and operating instructions. Read and
keep this User Guide for future reference.

General Precautions

1. Before using the inverter/charger, read all instructions and cautionary markings on:

The inverter/charger.
The batteries.
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 expose the inverter/charger to rain, snow or liquids of any type. The inverter/charger is

designed for indoor use only. Protect the inverter/charger from splashing if used in vehicle
applications.

4. Do not disassemble the inverter/charger. 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.

5. To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or

cleaning. Turning off the inverter/charger will not reduce this risk.

6. WARNING: WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS

DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL
OPERATION.

Provide ventilation to outdoors from the battery compartment. The battery enclosure should be
designed to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the
compartment. Vent the battery compartment from the highest point. A sloped lid can also be used
to direct the flow to the vent opening location.

7. NEVER charge a frozen battery.

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8. No terminals or lugs are required for hook-up of the AC wiring. AC wiring must be no less than

10 AWG gauge copper wire and rated for 75

o

C or higher. Battery cables must be rated for 75oC or
higher and should be no less than as stated in table 1. Crimped and sealed copper ring terminal
lugs with a 5/16 hole should be used to connect the battery cables to the DC terminals of the
inverter/charger. Soldered cable lugs are also acceptable.

9. Be extra cautious when working with metal tools on, or around batteries. The potential exists to

drop a tool and short-circuit the batteries or other electrical parts resulting in sparks that could
cause an explosion.

10. No AC or DC disconnects are provided as an integral part of this inverter/charger. Both AC and

DC disconnects must be provided as part of the system installation. See INSTALLATION section
of this manual.

11. No over current protection for the battery supply is provided as an integral part of this

inverter/charger. Over current protection of the battery cables must be provided as part of the
system installation. See INSTALLATION section of this manual.

12. GROUNDING INSTRUCTIONS - This inverter/charger should be connected to a grounded

permanent wiring system. For most installations, the Ground Lug should be bonded to the
grounding system at ONLY one in the system. All installations should comply with all national
and local codes and ordinances.

Personal Precautions

1. Someone should be within range of your voice to come to your aid when you work near batteries.

2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near

batteries. Wash your hands when done.

4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters

eyes, immediately flood eyes with running cool water for at least 15 minutes and get medical
attention immediately.

5. Baking soda neutralises lead acid battery electrolyte. Keep a supply on hand in the area of the

batteries.

6. NEVER smoke or allow a spark or flame in the vicinity of a battery or generator.

7. Be extra cautious when working with metal tools on and around batteries. The potential exists to

short-circuit the batteries or other electrical parts which may result in a spark that could in turn
cause an explosion.

Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
battery. A battery can produce short-circuit currents high enough to weld a ring or the like to metal,
causing severe burns.

If a remote or automatic generator start system is used, disable the automatic starting circuit and/or
disconnect the generator from its starting battery while servicing to prevent accidental starting during
servicing.

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INSTALLATION

Unpacking and Inspection

Carefully unpack the inverter/charger from its shipping carton.

Verify all of the items listed below are present. Please call customer service if any items are missing:

 The Inverter/Charger
 1 DC red cable
 1 DC black cable
 1 User’s manual (this document)

Basic Configuration

The following illustration shows the basic utility backup application for the Invo Series 5KVa
inverter/charger.

Figure 1 - Utility Backup

For other application configurations such as renewable energy systems using solar or wind power please
contact sales.

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The Invo Series 5KVA Inverter/Charger can feed almost any kind of appliance including those with
motor characteristic, e.g. fluorescent lights, fans, refrigerators and air conditioners.

Note: Appliances such as air conditioners often require at least 3 minutes to restart after a short-term
power outage (time is required to balance the refrigerant gas in inside circuit). In order to protect your air
conditioner, please consult the manufacturer whether they have already provided a time delay function
before installing the INVO Series inverter; otherwise, the inverter will trigger an overload fault and shut
off its output to protect your appliance. Even so there is some risk of damage to the air conditioner for
which UNIPOWER cannot be held responsible.

Batteries

The INVO inverter/charger supports either a 48 volt or a 96 volt battery bank depending on the model.
Please refer to figure 2 for wiring the battery correctly. Before proceeding, ensure you have appropriate
size batteries for your application. The INVO inverter/charger can be used with flooded lead-acid, or
sealed GEL/AGM lead-acid batteries so ensure that your batteries are in one of these categories.

The battery must be wired to match the inverter/chargers DC input voltage specifications. We recommend that the
battery capacity not smaller than 100AH (INVC4850H) / 50AH (INVC9650H).

Figure 2.1 - INVC5048H battery string wiring

Figure 2.2 - INVC5096H battery string wiring

Battery Cable Size

The following table shows minimum recommended battery cable size. Be sure the cable you select is no

smaller than this.

Model

Number

Typical

DC Current

Cable length

1~3m per pole

Battery Terminal

Torque value

INVC5048H 100A 4 AWG 10~15 Nm

INVC5096H 50A 6 AWG 10~15 Nm

Table 1 - Minimum recommended battery cable size

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DC Disconnect and Over-Current Protection

For safety and to comply with regulations, battery over-current protection and disconnect devices are
required. Fuses and disconnects must be sized to protect the DC cable size used, and must be rated for DC
operation. Do not use devices rated only for AC service – they will not function properly.

Note that some installation requirements may not require a disconnect device, although over-current
protection is still required.

Battery Cable Connection

Observe Battery Polarity! Place the ring terminal of the DC cable over the bolt and directly against the

inverter/charger’s battery terminal. Tighten the M8 screw to 5-8 Nm. Do not place anything between

the flat part of the Backup terminal and the battery cable ring terminal or overheating may occur.
DO NOT APPLY ANY TYPE OF ANTI-OXIDANT PASTE TO TERMINALS UNTIL AFTER
THE BATTERY CABLE WIRING IS TORQUED!!

Figure 3 below illustrates the proper method to connect the battery cables to the inverter/charger
terminals.

WARNING: Shock Hazard. Installation must be performed with care for the high battery

voltage in series.

Caution!! Do NOT place anything between battery cable ring terminals and terminals on

the inverter. The terminal screw is not designed to carry current.

Apply Anti-oxidant paste AFTER terminals have been tightened.

Verify that the cable lugs are flush with the battery terminals.
Tighten battery cables to terminals (10~15 Nm).

Figure 3 - Battery Cable Connections to inverter/charger

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AC Cable Size

Before wiring the input and output of the inverter, refer to table 2 for minimum recommended cable sizes
and torque values.

Model Number AC Input AC Output Torque value

INVC5048H 10AWG 10AWG 1.2~1.8 Nm

INVC5096H 10AWG 10AWG 1.2~1.8 Nm

Table 2 - Min recommended cable size, torque value for AC wiring

AC Connections

Installation should be done only by a qualified electrician. Consult the local codes for the proper wire
sizes, connectors and conduit requirements.

On the left of rear chassis is the AC hardwire cover. A six-way terminal block is provided to make the AC
connections. The terminal block is used to hardwire the AC input, AC output, and ground. The National
Electrical Code requires that an external disconnect switch be used in the AC input wiring circuit. The
AC breakers in a sub panel will meet this requirement.

1. Disconnect the inverter/charger from the battery either by turning off the battery switch or

removing the battery cables from the battery. Turning off the inverter/charger does not constitute
disconnecting from the battery.

2. Feed the wires through the cable clamp and AC cover. See Figure 4.

Figure 4 - AC Cable Connections to inverter/charger

3.

Following the wiring guide located in the AC wiring compartment as Figure 4, connect the GND
(green/yellow), Line (brown), and neutral (blue) wires from the AC input (utility, generator, etc.)
to the terminal

block.

Caution!! Be sure that AC source is disconnected before attempting to hardwire it to the

inverter/charger.

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4. Connect the AC Line output wiring to the terminal marked AC Line (output) following the wiring

guide inside the compartment. Connect the AC neutral out to the AC neutral out terminal. Torque
the wires into the terminal block.

5. Use the two M3 screws to lock the AC cover.

6. Tighten the clamps on the AC cable jackets (not the individual wires) to provide strain relief for

the connections.

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OPERATION

Front Panel Controls and LCD Indicators

Figure 5 shows the controls and indicator lights on the front of the INVO Series inverter/charger. They
control and provide information in both inverter and battery charging modes of operation.

Figure 5 - Front Panel

Power ON/OFF

Located on the left of the panel is the ON/OFF Switch. Once the inverter/charger has been properly

installed and the batteries connected, press this switch to the ON position to switch on the
inverter/charger.

Important Note: INVO Series has a fail-safe system that will not allow it to switch on unless batteries

are connected and the charge voltage of the batteries is above 42V for the INV5048H and 82V for the

INV5096H.

Configuration Switch

On the right of panel are the 4 configuration switches which setup the inverter/charger operation
parameters. See table 3 for details.

Switch Function Description

up Move up to pre-select

down Move down to pre-select

configuration Enter configuration mode, and turn page

enter Enter to confirm

Table 3 - configuration button function

After you press configuration button and enter configuration mode, there is a total of 4 configuration
pages. Change the page by pressing the configuration button again.

Page Description Selectable option

1 Input range Normal / Generator / Wide Range
2 Output range 220V / 230V / 240V
3 Battery type AGM / GEL / FLOODED
4 Charger current 35A/20A(INVC5048H), 20A/10A(INVC5096H)
5 Saver mode ON/OFF

Note: The 220v and 240v output function is reversed for further feature.

Table 4 - configuration button function

On/Off
switch

LCD indicator

Configuration switches

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LCD Indicator

The LCD display provides system status, and the user-friendly panel eases program settings. See Figure

6.

Figure 6 - LCD display interface

 AC Mode Indicator

The line mode symbol will show and the indicator will display the input voltage, output voltage and
load.

 Inverter Mode Indicator

The inverter mode symbol will show and the indicator will display the input voltage, output voltage,
load.
The battery capacity segment will indicate the battery capacity depending on the battery voltage
level.

 Charging Indicator

When line mode and input within range, the charging symbol will show up. And battery capacity
segment will roll flashing in turn basing on capacity.

 Charger mode battery indicator

Status

Battery

Capacity

5 4 3 2 1

CC/CV

75% ~ 100% ON Flash 1 Solid ON Solid ON Solid ON

50% - 75% ON Flash 2 Flash 1 Solid ON Solid ON

25% ~ 50% ON Flash 3 Flash 4 Flash 1 Solid ON

0% ~ 25% ON Flash 4 Flash 3 Flash 2 Flash 1

Low Battery Flash Flash 4 Flash 3 Flash 2 Flash 1

Floating Full ON Solid ON Solid ON Solid ON Solid ON

 Inverter mode battery indicator

Battery

Capacity

5 4 3 2 1 ALARM

Full ON ON ON ON ON -­75% ON OFF ON ON ON -­50% ON OFF OFF ON ON -­25% ON OFF OFF OFF ON --

0% ON OFF OFF OFF OFF --

Low Alarm Flash OFF OFF OFF OFF 1 beep / 2s

Off Flash OFF OFF OFF OFF --

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 Load indicator

The load indicator shows the load percentage in VA or W, whichever is bigger, the overload indicator will
flash when an overload is present.

Battery Charger

 Inverter to Charger Transition

The internal battery charger and automatic transfer relay allow the inverter/charger to operate as
either a battery charger or an inverter (but not both at the same time). The inverter/charger
automatically becomes a battery charger whenever AC power is supplied to its AC input. The AC
input is internally connected to the AC output while in battery charger mode.

 Charger Terminology

1. Constant Current Stage - During this cycle, the batteries are charged at a constant current.

2. Constant Voltage Stage - During this cycle, the batteries are held at a constant voltage (14.1V

per 12V block for AGM & GEL, 14.6V per 12V block for FLOODED) and accept whatever
current (less than the current in CC stage) is required to maintain this voltage. This ensures full
charging.

3. Float Stage - During this cycle, the batteries are held at the float voltage (13.5V per 12V block).

4. Whenever the AC is reconnected, the charger will reset the above cycle.

5. If the charger maintains the float state for 21 consecutive days, the charger will reset the cycle.

Circuit Breaker

The inverter/charger contains one input circuit breaker located on the rear panel of the chassis, next to the

AC input terminal block. This circuit breaker protects the charger and bypass circuits. The circuit breaker
will trigger if the input is over-current. The circuit breaker is push to reset.

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SPECIFICATIONS

Table 5 - Line Mode Specifications

MODEL INVC5048H INVC5096H

Input Voltage Waveform Sinusoidal (Utility or Generator)

Nominal Input Voltage 230Vac

Low Line Disconnect

170Vac (Normal)

90Vac (Generator / Wide Range)

Low Line Reconnect

180Vac (Normal)

100Vac (Generator / Wide Range)

High Line Disconnect 280Vac

High Line Re-connect 270Vac

Max AC Input Voltage 300Vac rms

Nominal Input Frequency 50Hz / 60Hz (Auto-detect)

Low Line Frequency Disconnect 40±1Hz

Low Line Frequency Reconnect 42±1Hz

High Line Frequency Disconnect 65±1Hz

High Line Frequency Reconnect 63±1Hz

Output Voltage Waveform Same as Input Waveform

Output Short Circuit Protection Circuit Breaker 40A

Efficiency (Line Mode) >95%

Transfer Switch Rating 40A

Transfer Time
(AC to DC)

10ms (typical)

20ms (typical)
Transfer Time
(DC to AC)

10ms (typical)

20ms (typical)

Power Limiting

Input Voltage

Max Output power

5KVA/4.2KW

2.5KVA/2.1KW

90V 180V

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Table 6 - Inverter Mode Specifications

MODEL INVC5048H INVC5096H

Output Voltage Waveform Pure Sine Wave

Rated Output Power 5,000VA

Power Factor 0.84

Nominal Output Voltage 230Vac

Output Frequency 50Hz / 60Hz ± 1Hz

Output Voltage Regulation ±10% rms

Nominal Efficiency >90%

Over-Load Protection

fault after 5s@≥150% load

fault after 10s@110%~150% load

Surge rating 10,000VA

Capable of starting electric motor 2.5HP

Output Short Circuit Protection Current limit (Fault after 4 cycles max.)

Bypass Breaker Size 40A

Nominal DC Input Voltage 48V 96V

Min DC start voltage 40V 80V

Low DC Alarm 42.0 ± 1.2Vdc 84.0 ± 2.4Vdc

Low DC Alarm Recovery 43.2 ± 1.2Vdc 86.4 ± 2.4Vdc

Low DC Shut-down 40.0 ± 1.2Vdc 80.0 ± 2.4Vdc

Low DC Shut-down Recovery 44.0 ± 1.2Vdc 88.0 ± 2.4Vdc

High DC Shut-down 60.0 ± 1.2Vdc 120.0 ± 2.4Vdc

High DC Shut-down Recovery 1 58.0 ± 1.2Vdc 116.0 ± 2.4Vdc

Power saver setting

0W (Set “OFF” at LCD)

10W ±5W enter 5+/-2W leave (Set “ON” at LCD)

Tare loss(nominal)

Saver OFF:<50W

Saver ON:<10W

DC component of AC output <100mV

Half wave load detection Yes(when unbalance current>35A)

Power Limitation

Note 1: Line voltage must be available for charging.

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Table 7 - Charge Mode Specifications

MODEL INVC5048H INVC5096H

Nominal Input Voltage 230Vac

Input Voltage Range

180V~ 270Vac (Normal range)

100V~ 270Vac (Generator / Wide Range)

Nominal Output Voltage Determined by battery type

Nominal Charge Current

20A(95-175V, gen/wide only)
35A(175-275V) @ 35A setting
20A(175-275V) @ 20A setting

10A(95-175V, gen/wide only)

20A(175-275V) @ 20A setting

10A(175-275v) @ 10A setting

Battery initial voltage(sps setup) >35Vdc >70Vdc

Charger Short Circuit Protection Inverter/charger shuts down automatically

Over Charge Protection

Batt.V≥60Vdc, Fault,

Buzzer alarm

Batt.V≥120Vdc, Fault,

Buzzer alarm

Charge Algorithm

Three stage:

Boost CC (constant current stage) → Boost CV (constant voltage stage)

→ Float (constant voltage stage)

Battery Type Setting(±0.3V/batt.)

Battery Type

Boost CC/CV Float

Voltage(V) Voltage(V)

48 96 48 96

Flooded 58.4 116.8 53.6 108

AGM/Gel 56.4 112.8 54 108

Charger current (+/-10%)

INVC5096H (INVC5048H)

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Table 8 - General Specifications

Safety Certification CE(EN60950)

EMI Classification EN62040-2, CLASS A

Operating Temperature Range 0°C to 45°C

Storage temperature -15°C ~ 60°C

Altitude, operational Elevation: 0 ~ 1500 Meters

Relative humidity 5% to 95% non-condensing

Audible Noise 60dB max.

Cooling Forced air, variable speed fan

Dimension 350mm (w) x 110mm (h) x 407mm (d)

Net Weight 9Kg

Table 9 Fault code/ Audible alarm

Fault
Code

Protect
Function

Active
Mode

Condition

Warning
(O/P=ON)

Fault
(O/P=OFF)

Restart

Operate Condition

--

Low DC
Voltage
Alarm

Inverter

DC Voltage
<Low
DC Alarm

1beep/2s -- -- --

0

Low DC
Voltage
Protection

Inverter

DC Voltage
<Low
DC Shut-down

--

Beep
continuous

Auto Mains is normal

1

Over Charge
Protection

Line

DC Voltage
>High DC input
Shut-down

Beep continuous -- Manual --

1

Over Voltage
Protection

Standby

DC Voltage
>High DC input
Shut-down

--

Beep
continuous

Auto

DC
Voltage<High
DC input Shut­down Recovery

2

Over Load
Protection

Line/
Inverter

110%~150% load

1beep/0.5s,and
continuous 10s

Beep
continuous

Manual --

>150% load

1beep/0.5s,and
continuous 5s

Beep
continuous

Manual --

3

Output Short
Circuit
Protection

Inverter

Output
Voltage<20Vrms

--

Beep
continuous

Manual --

4

Fan Fault
Protection

Line/
Inverter

Fan Locked
Fan Defected

2beep/2s,and
continuous 1min

Beep
continuous

Manual --

5

Over Temp
Protection

Line/
Inverter

HEAT SINK
Temp≥100℃

--

Beep
continuous

Auto

HEAT SINK
Temp≤ 55℃

6

Back-EMF
Protection

Standby

Reverse input and
output

--

Beep
continuous

Manual --

9

Output
Abnormal

Inverter

(Output Voltage
<170Vrms and
output current
under 32Arms) or
Output Voltage
>280Vrms

--

Beep
continuous

Manual --

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TROUBLESHOOTING

Problem Possible Causes Remedy

No LCD display

1. Battery Weak
<35V for 5048H
<70V for 5096H

1. Re-charge battery

2. Battery defective
(can't be charged)

2. Replace Battery

3. Power switch is not pressed 3. Press and hold power switch

4. Battery polarity reversed
Can’t start up the
inverter/charger

4. Return to UNIPOWER for repair

Mains normal but
operates in inverter mode

1. AC input missing 1. Check AC input connections

2. Input breaker triggered 2. Reset the input breaker

Alarm buzzer beeps
continuously

1. Overload

1. Verify that the load matches the capability
specified

2. Output short circuit 2. Check wiring or remove abnormal load

3. Over temp 3. Remove any obstruction in front of airflow inlet

4. Over charger 4. Restart the inverter/charger

5. Over voltage

5. lower the DC input voltage under the high DC
Input shut-down recovery:

58.0±1.2Vdc for 5048H

116.0±2.4Vdc for 5096H

6. Fan fault

6. Check for any fan obstruction, if not fan should
be replaced

7. Back-EMF 7. Check the AC Input and output wire connection

8. DC voltage under the low
DC shut-down

8. Make sure mains is normal to recharge the
battery if not switch the power off until mains is
normal

Back up time is
shortened

1. Overload 1. Remove some non-critical load

2. Battery voltage is too low 2. Charge battery for 8 hours or more

3. Battery bank is too small 3. Increase battery bank capacity