Thank you for purchasing a Vanner TruSine inverter system. We are confident that you will be satisfied with its
performance and its many features. W ith pr oper ins tallation and c are, you can look forward to years of s ervic e
from this high performance product.
This document will desc ribe the operation, technical s pecific ations and installation pr ocedures for the Tr uSine
Inverter/Charger System. If you require additional information please contact your dealer, or contact us
directly at the location shown on the cover of this manual.
1 System Features and Specifications
1.1 General Description
The TruSine system consists of a 4500 watt DC to AC true sine wave inverter, a 100 amp 24 volt battery
charger, an automatic AC trans fer switch, and a microproces sor based controller with data c ommunications
capability. A key feature of this system is the optional TSR-2 TruSine Remote Control Panel operator’s
interface which utilizes a high speed “data highway” to connect one or more TSR-2 units to the inverter.
TRUSINE INVERTER /CHARGER SYSTEM
AC Output To
AC Loads
AC In put Utility
Power G en era tor
BATTERY
INV E RT E R
CHARGER
MICROPROCESSO R
TSR-2 Remote
Control Panel
AUTOMATIC
AC
TRANSFER
SWITCH
CONTROLLER
V-NET Data Bus
TSR-2TSR-2
Figure 1 - System Diagram
1.2 System Features
•
Inverter
The inverter consists of two sine wave inverters built into one unit. A “ low power“ high efficiency 70 watt
inverter supplies power for the small loads. The “high power” 4,500 watt main inverter supplies power
when AC loads over 70 watts are applied. Designed for maximum efficiency this system conserves battery
power when only small loads are present. T o further conserve battery power the Load Demand feature
allows the inverter to ‘go to sleep’ if AC loads fall below a selected value. Load Demand may be disabled if
very small AC loads must be operated.
The inverter develops up to 4,500 watts of continuous power. Using TruSine
quality pure sine wave is produced. Total harmonic distortion (THD) is less than 2.0 percent.
®
technology, a very high
TruSine 4.5 kW InverterPage 4Owners Manual
System Features and Specificatiions
•
Battery Charger with Automatic Power Management
A high efficiency 100 amp multi-stage battery charger allows fully automatic charging of f looded and gel
lead acid battery banks. The efficient 0.85PF , compared to typical 0.59PF on triac type chargers, allows
full charger output from a 30 amp aux AC source. The system ’s Bulk - Absorption - Float charge cycle
quickly charges and maintains the charge on the battery bank. An Equalization charge cycle is provided
for flooded lead acid battery maintenance.
Automatic Power Management (APM) monitors the Aux AC Input amps and will reduce the battery
charger output as needed to keep the Aux AC Input amps below the preset APM Limit.
•
Automatic AC Power Transfer Switch with Solar Mode
An automatic AC transfer switch pr ovides system output power s ourced f rom the Aux AC Input (generator
or utility) or sourced from the battery, via the inverter. Solar Mode allows the inverter to oper ate on battery
power while shore power is present.
•
Gen Start
The Gen Start feature provides a s tart/stop s ignal to control a generator used f or r echarging the batter ies.
The start/stop signal consis ts of a c ontac t c losure to s tar t the generator bas ed on battery voltage and s top
the generator based on battery charging amps.
•
System Control
The TruSine contains a System ON/OFF Switch to turn the system ON and OFF. A control
microprocessor provides a variety of protection interlocks, system fault detection/reporting/recovery,
storage of system data param eters, and high speed data comm unications to the optional T SR-2 Remote
Control Panel. System protection functions include over load, over temperature, and high and low battery
voltage. Use the ON/OFF Switch to reset the system after shutdown for a s ystem fault. T he optional T SR2 Remote Control Panel provides a system status display and allows detailed control of individual system
functions.
•
TSR-2 TruSine Remote Control Panel (Optional)
The optional TSR-2 Remote Control Panel / Programming Panel is an
operator interface which connects to the TruSine Inverter/Charger via a 6conductor data bus and allows system operation near the inverter or from
remote areas. Multiple TSR-2 Remotes may be connected for optimum
flexibility. The TSR-2 contains an alphanumeric LCD display and functional
keypad making it easy to use. System status m essages are displayed, faults
are reported, system functions m ay be enabled/disabled or turned ON/OFF,
system setpoints may be examined and changed.
Figure 2: TSR-1 and TSR-2 Control Panels
Earlier production TSR Remotes, the TSR-1, are identical to the TSR-2 exc ept contain early software used
with TruSine inverter/charger model TSC24-4000D. The TSR-1 will work with TruSine 4500 models but cannot
access the GenStart and other new features of the TruSine 4500. The TSR-1 m ay be upgraded to TSR-2
status by changing software to part number A88769-A or newer. TSR-2 software is displayed upon startup and
also is identified in the General Inform ation Menu step 52. TSR-1 software is identified in the System Info
menu.
TruSine 4.5 kW InverterPage 5Owner’s Manual
System Features and Specifications
1.3 Specifications
Model TSC24-4500Model TSC24-4500D
AC OUTPUT
Voltage (RMS)120 VAC ± 3% adjustable120/240 VAC ± 3% adjustable
Frequency60 Hz ± 0.5%60 Hz ± 0.5%
AC WaveformSine WaveSine Wave
Total Harmonic Distortion (THD)Less than 2.0%Less than 2.0%
Power Factor Allowed-1 to 1-1 to 1
Continuous Output Rating @ 25ºC
L1 to Neutral4500 watts (37.5 amps)2,250 watts (18.8 amps)
L2 to NeutralN/A2,250 watts (18.8 amps)
L1 to L2N/A4,500 watts (18.8 amps)
Surge Capacity @ 25ºC (3 sec.)10,000 watts10,000 watts
DC INPUT:
Operating Range (24 Volt Nominal)21 to 34 Volts21 to 34 Volts
No Load, Inverter ON1.8 amps1.8 amps
No Load, Search Mode0.46 amps0.46 amps
Full power210 amps210 amps
Voltage (adjustable)120 Volts nominal ± 10%120/240 Volts ± 10%, 3wire 1Ø
Frequency60 Hz ± 12.5% (52.5 to 67.5)60 Hz ± 12.5% (52.5 to 67.5)
AC TRANSFER SWITCH
Power Rating30 amps @ 120 VAC30 amps @ 240 VAC
Transfer TimeLess than 40 millisecondsLess than 40 milliseconds
BATTERY CHARGER
Charger Output Current maximum100 amps100 amps
AC Input Current maximum30 amps
SYSTEM
Ambient Operating Temperature
Cooling Exhaust FanThermostatically controlledThermostatically controlled
MountingWall or ShelfWall or Shelf
Dimensions (wall mtd position)17.5”H x 19”W x 8.5”D17.5”H x 19”W x 8.5”D
Weight83 pounds83 pounds
TSR-2 Remote DC power draw0.11 amps0.11 amps
The System ON/OFF Switch, located on the f ront panel, allows the us er to turn the s ystem ON and OF F and to
reset the system after a fault. The inverter will always begin operation in the large inverter “high power” mode. If
the AC load is less than 70 watts the inverter will automatically switch to the “low power” high efficiency small
inverter after 5 seconds. T he optional TSR-2 Remote Control Panel allows the inverter to be dis abled (turned
OFF) while allowing the other system functions (charger, transfer switch) to continue to operate.
The Inverter AC Output Circuit Break er is a 2 pole, 20 amp breaker marked “O/I” located below the System
ON/OFF Switch. The breaker protects the Inverter AC output and Battery Charger AC input against a severe
overload. This breaker does not protect AC Passthrough Power. If the break er trips during inverter operation,
the system must be reset. Do this by turning the System ON/OFF Switch OFF and bac k ON. Do not use the
AC Output Circuit Breaker as an ON/OFF switch.
Protective Interlocks
Auto-restartAfter shutting down for any of the following fault conditions the inverter will try to restart
itself every 5 minutes. The inverter will restart if the fault condition is no longer present.
Manual restartManually restart the system by resetting the inverter after the fault conditions is removed.
Reset the inverter by turning the System ON/OFF Switch OFF and then ON.
Low BatteryThe inverter continually monitors battery voltage. If battery voltage falls below the Low
Battery Shutdown setpoint the inverter will shut OFF. Auto-restart will restart the inverter
after battery voltage rises above the Low Battery Warning setpoint.
High Battery The inverter will shut OFF if battery voltage rises above the High Battery setpoint.
Over Temperature The inverter will shut OFF if internal temperature sensors detect a high temperature
condition that would damage the inverter.
While operating in Solar Mode a high temp shutdown will transfer back to shore power until
the over-temperature condition clears.
Over Load - If a short circuit or an overload is applied to the inverter’s output the inverter will shut down.
Additional details regarding protective interlocks are found in the Alarm Menu in section 3.
Load Demand
The TruSine Inverter’s Load Demand Mode is an energy-saving feature. Load Demand allows the inverter to go
to sleep when the AC load is below the ‘Enter Load Demand’ (watts) setpoint f or 5 seconds. While in Load
Demand (asleep) the inverter produc es only pulses of AC which are used to searc h for an AC load. When the
inverter senses an AC load greater than the ‘Exit Load Dem and’ (watts) s etpoint, the inverter will turn fully ON.
The Load Demand feature significantly reduces the DC amps drawn from the battery while the AC load is below
the Load Demand enter and exit setpoints.
The inverter will not enter Load Demand from the High Power mode. T he inverter will only enter Load Demand
from the 70 watt small inverter Low Power mode.
The ‘Enter Load Demand’ and ‘Exit Load Demand’ setpoint values may be adjusted to suit the AC loads by
using the optional TSR-2 Remote Control. T he Load Demand feature may be turned OFF by selecting Load
Demand enabled/DISABLED. This is recomm ended if very small AC loads under 5 watts, such as clocks or
LCD displays, must be operated.
2.2 Battery Charger
The battery charger’s advanced design incorporates an automatic, multi-stage charger. This design enables
TruSine 4.5 kW InverterPage 7Owner’s Manual
Descriptions of Operation
the unit to automatically charge batteries which maintains the battery’s integrity and reduces the likelihood of
premature battery failure. The battery charger is des igned to be used with lead-acid type batteries inc luding
sealed and gel types, but not for nickel-cadmium (Ni-Cad) or nickel-iron types.
Battery Charging Sequence
Stage 1: Bulk Charge Stage
The charger always starts in the Bulk Charge
Stage each time shore power becomes present
and/or each time the charger is turned ON. In
Bulk Charge the system charges at the ‘Bulk
Charge Amps’ setpoint until battery voltage rises
to the ‘Bulk Charge Voltage’ setpoint. Then the
voltage is held at that setpoint until charging
amps have fallen to 5 amps above the ‘Battery
Absorption Amps’ setpoint. This ends the Bulk
Charge Stage and begins the Absorption
Charge Stage. The charger will not enter the
Bulk Stage again until shore power is reapplied,
or until the charger or the system is turned ON again.
Stage 2: Absorption Charge Stage
The Absorption Charge Stage provides a contr olled “overcharging” of the battery which is necess ary to bring
the battery up to full charge. The batter y is charged at the ‘Absor ption Charge Amps’ until one of following three
conditions occur which signals the end of the Absorption Stage;
VOLTAGE
CURRENT
TIME
BULKABSORPTION
TRIGGER POINT
OPTIONAL
EQUALIZE
FLOAT
Time: The Absorption Maximum Time setpoint is reached
Time: The Absorption Charge Stage has reached ½ of the duration of the Bulk Charge Stage.
Voltage: Battery voltage reaches the ‘Absorption Voltage’ setpoint
Stage 2A Equalize Charge Cycle
When Equalize Mode is ENABLED, one Equalize Charge Cycle will follow the Absor ption Charge Stage. The
Equalize Cycle will last for the ‘Equalize Time’ setpoint. Equalize Mode will automatically switch to DISABLED at
the end of the Equalize Charge Cycle. During the Equalize Cycle the battery is charged at the ‘Absorption
Charge Amps’ setpoint and the Equalize Voltage setpoint.
The Equalize Charge Cycle provides a deliberate overcharging of the battery to remove sulfate which
accumulates on the battery plates through norm al use. Equalizing returns battery cells to equal perform ance
levels which improves battery performance and extends battery life. Consult the battery manufactur er for their
recommendation regarding equalize voltages how often the Equalize Cycle should be performed.
CAUTION
Do not equalize sealed (valve regulated lead acid or gel) batteries!
Consult battery manufacturer for
equalizing guidelines. Do not equalize more often than approximately once a month. Check battery fluids after
equalizing is complete, as gassing will occur. Use Equalize Mode only while batteries are well ventilated!
Stage 3: Float Charge Stage - Maintenance Mode
In the Float Stage the charging voltage is reduced to the ‘Float Charge Voltage’ setpoint and char ging cur r ent is
limited to the ‘Absorption Charge Amps’ setpoint. The charger will remain in the Float Stage until shore power is
reapplied, or until the charger or system is turned OFF and then ON again.
Charging Setpoints
The TruSine’s battery charger fac tory setpoints are for wet batteries. Do not use the f actory setpoints for gel
batteries. If gel batteries are used, consult the batter y manufacturer for charging recomm endations. Setpoints
for typical gel batteries are listed and may be used if specif ic recomm endations are not available from the gel
battery manufacturer.
Caution: Do not operate DC loads, such as DC lights, pum ps, etc., during battery charging. The loads may
cause overcharging by preventing the charging stages from reaching their ‘trigger points’ or may cause the
battery to run down even though the charger is ON.
TruSine 4.5 kW InverterPage 8Owners Manual
Description of Operation
Battery Charger Factory Setpoints (Factory Setpoints are for wet batteries, 4 size 8-D minimum.)
All Charging Setpoints are
Password Protected in the
TSR-2 Remote Control
Bulk Charge Volts26.0 - 32.028.4 VDC28.1 VDC
Bulk Charge Amps20% C Rate0 - 100100 Amps20% C Rate
Absorption Charge Volts28.0 - 34.030.0 VDC28.2 VDC
Absorption Charge Amps5% C Rate
Absorption Maximum Time10 - 25510 Minutes10 minutes
Float Charge Volts26.0 - 30.026.4 VDC27.2 VDC
Equalize VoltsWet only26.0 - 34.031.0 VDCNot used
Equalize Maximum TimeWet only5 - 3015 MinutesNot used
Battery ‘C Rate’ is equal to battery Amp Hour capacity.
GuidelineSetpoint
Range
10 - 5050 Amps5% C Rate
minimum
Factory Setpoint
(for Wet Battery)
Typical setpoint
for
Gel Battery
minimum
Automatic Power Management (APM)
A key feature of the battery charger operation is Automatic Power Management (APM). T his feature m onitors
the Aux AC input amps and will reduce the battery charger output as necessary to keep the Aux AC input amps
under the APM setpoint. The APM circuit will not limit power to the passthrough AC loads. If the passthrough
AC loads exceed the APM setpoint the battery charger output will be reduced to zero.
Adjust the “APM Limit” setpoint to match the circuit breaker at the Aux AC source. This will reduce the chance
of tripping the source’s circuit breaker due to battery charging.
On model TSC24-4500D (240VAC) the APM feature m onitors L1 and L2. APM decisions are based on the
heavier loaded line.
Example: With the APM Limit on a TSR24-4500D set at 15 amps, L1 loaded to 15 amps and L2 has no
load, then the APM will allow no power to go to charging. If the load on L1 is reduced to 10 am ps then
the charger will be allowed to use 5 amps.
2.3 Automatic Transfer Switch with Solar Mode
The Automatic T ransfer Switch consists of electro-mechanical relays contr olled by circuits which m onitor Aux
AC input voltage, Aux AC Input frequency and battery voltage.
In the normal mode of operation, Solar Mode OFF , the Automatic Tr ansfer Switch will autom atically accept ‘intolerance’ Aux AC input power whenever it is available within tolerance for the ‘AC Line Stabilization’ time delay.
The Aux AC input power will be used to operate the battery charger and to passthrough to operate AC loads.
Upon loss of ‘in-tolerance’ Aux AC input power, the transf er s witch will autom atic ally transfer the AC loads bac k
to inverter power. Transfer tim e is approxim ately 40 milliseconds (0.040 seconds). T he 0.040 second transfer
time allows all but the most sensitive loads to transfer from inverter power to shore power and back without
interruption.
The Transfer Switch will function properly as long as the System O N/OFF s witch is ON even while the Inverter
is disabled, while the Battery Charger is disabled or while the batteries are disconnected from the system.
The Transfer Switch switches both hot and neutral. For safety purposes the inverter output neutral is c onnec ted
to the inverter chassis ground only when the system is in inverter mode. This is a requirement of the National
Electric Code for all systems of this type that neutral should be connected to gr ound only at the source of ACpower, which is the inverter when in inverter mode. When Aux AC input (shore power, or generator) is
available, the Transfer Switch system breaks the connection between neutral and inverter chas sis ground. T he
neutral-to-ground connection for passthrough power is then expected to be provided by the Aux AC input
source. This transfer schem e presents no problems for a proper ly installed system. The installer should verify
that all AC circuits connected to the inverter AC output are an ins ulated neutr al type as r equired by the National
Electrical Code (NEC) article 551.
Solar Mode
Turn Solar Mode ON in applications where it is preferred to oper ate on battery power while ‘in tolerance’ Aux
AC input (shore power) is avaliable. With Solar Mode ON, the inverter will operate on battery power while Aux
AC input is available until battery voltage falls below the Low Battery Warning setpoint. Then the s ystem will
TruSine 4.5 kW InverterPage 9Owner’s Manual
Descriptions of Operation
accept Aux AC input, the batteries will be Bulk charged and the system will switch to inverter again.
2.4 Gen Start
The Gen Start feature is designed for use in installations having a generator to provide Aux AC input power for
battery charging. The Gen Start feature provides a contac t closure to signal the generator to start when battery
voltage falls below the ‘Gen Start Volts’ setpoint. The Gen Star t contacts open when bulk charging am ps fall
below the ‘Gen Stop Amps’ setpoint. Bulk charging amps are sampled every 4 minutes, therefore the minumum
generator ON time is 4 minutes. The contacts are NEC Class 2, rated 2 amps at 12 or 24 VDC.
Gen Stop Amps should be set higher than the Absorption Charge Amps setpoint.
Caution: The battery charging process will be affected if 24VDC loads are being powered during battery
charging. The increased char ger output, required to power those loads, may keep the charger from reaching
the ‘Gen Stop Amps’ setpoint.
3 TSR-2 Remote Control Panel (optional)
3.1 General Description
The TSR-2 TruSine Remote Control Panel is an optional
display/keypad module that allows the installer to adjust the
system operation factory setpoints and allows the user to
monitor and control in detail the TruSine Inverter/Charger
operation. The TSR-2 connects to the inverter at the V-NET
Port. One or more contr ol panels may be installed to provide
the necessary level of system control and flexibility. The
TruSine Inverter/Charger System setpoints will not change
after removal of the TSR-2 Remote.
TSR-2 Control Panel
The TSR-2 TruSine Remote Control Panel contains a 32 character (two 16 character lines) liquid crystal display
(LCD), a red Alarm LED indicator, and a f unctional keypad. A menu schem e is used to allow the operator to
select and control system functions, and to display information. In the event of a system fault the Alarm LED will
illuminate and a fault mes sage will be displayed. The T SR- 2 Remote connects to the invert er’s V- Net Port via a
6 conductor modular data communic ation cable. The unit is supplied with a 25’ long cable with a 6-pin RJ-11
connector at each end.
Early production TSR-1 Remotes, used with earlier model Vanner inverter/chargers, are identical to the TSR-2
but will need the software upgraded to A88769-A to access the GenStar t and other new features in the TruSine
4500 Inverter/Charger. TSR-2 software is identified in the General Information Menu step 52. TSR-1 software is
identified in System Information step 53 for theTSC24-4000D.
TruSine 4.5 kW InverterPage 10Owners Manual
TSR-1 Remote Control
3.2 Adjustable Factory Setpoints for the TruSine 4500
The following chart lists the Factory Setpoints for all System functions which may be adjusted,
Enabled/Disabled, or turned ON/OFF using the optional TSR-2 Remote Control. (Software
Remote AddressSameSame1 – 101
*Note - Inverter Address, Step 92, applies only to systems having multiple inverters and multiple TSR-2
Remotes. Do not change Inverter Address from 1 in a single inverter s ystem. The TSR-2 will im mediately stop
responding if Inverter Address is changed. Use Demo Mode to change Step 92 ‘Inverter Address’ back to 1.
3.3 Operation
The TSR-2 Remote Contr ol Panel contains: a Menu button; an Escape button; a two-line display; four control
buttons located at the corners of the two-line display; and an Alarm indicator light. The two-line display will
contain information that will instruc t the operator to take action based on display characters at each “ corner” of
the display. For example, if the display has an ‘up arrow’ in the left position of the upper display line, press the
upper left control button to step up in the m enu sequenc e. Likewise, a ‘down arrow’ would instruct you to press
the corresponding control button to move down in the menu sequence. For data values, press the control
button corresponding a displayed +(plus sign) or – (m inus s ign) to inc reas e or decr eas e the data value. System
functions are turned ON or OFF by selecting ‘ENABLED’ or ‘DISABLED’ from the display. Capital letters
indicate the selected status.
TruSine 4.5 kW InverterPage 11Owner’s Manual
TSR-2 Remote Control
The TSR-2 Remote uses a menu approach to select desired system functions. When menu command
messages are shown on the display, the operator may select the desired function by pressing the
corresponding control button. Press the ESC (Escape) button at any time to step back one level. Pres s the
MENU button at any time to return to the Main Menu.
The MAIN MENU and all submenus are structured as follows:
MAIN MENU
BASIC CONTROL
MONITOR
AUTOSCAN(display)
MANUAL SCAN(display)
GENERAL INFO(display)
ADVANCED CONTROL
ADVANCED CONTROL
COMMUNICATIONS
The MAIN MENU is made up of the following two displays. Select the arrows to scroll up or down.
BSCONTROLALARMS
MONITOR↓
GENERAL INFO↑
ADV CONTROL
Select the BSCONTROL (BASIC CONT ROL) subm enu fr om the f irst display by pressing the upper left Control
Button. The TSR-2 will then display the BASIC CONTROL submenu which is Step 10. The following figure
shows Step 10 and describes how the buttons on the TSR-2 work while Step 10 is displayed.
Step 10 from the Control Menu
PUSH TO SCROLL UP
PUSH TO SCROLL DOWN
INVERTER
PUSH TO ENABLE
(SHOWN ENABLED)
PUSH TO GO BACK
ONE MENU LEVEL
ENABLED disabled
MENUESC
Adjustable Contrast Control
The TSR-2 Display has an adjustable contrast control. To increase intensity: hold down the lower left control
button and press the upper right control button repeatedly until the desired level is obtained. To decrease
intensity: hold down the lower left control button and press the lower right control button r epeatedly until the
desired contrast level is obtained.
Demo Mode
Use Demo Mode to become f amiliar with the TSR-2 m enu sequences. T he TSR-2 is placed in Dem o Mode by
connecting the Data Cable while both the Escape button and the Menu button are held down. Discontinue
Demo Mode by disconnecting the data cable.
If someone accidentally changes the Inverter Address, Step 92, the TSR-2 im mediately will stop responding.
Use Demo Mode to reset Step 92 ‘Inverter Addres s’ to 1. The Comm unication Addresses are the only settings
selected in Demo Mode which carry back to normal operation.
PUSH TO DISABLE
PUSH TO RETURN
TO MAIN MENU
Placing changes into effect
The only changes which go into effect without resetting the system are ‘enabling or disabling’ the inverter and
TruSine 4.5 kW InverterPage 12Owners Manual
TSR-1 Remote Control
the charger. Changes to other system func tions or setpoints will not go into effect until the system is reset.
Reset the system by turning the System ON/OFF Switch, located on the front of the inverter, OFF for 5 seconds
and then back ON. When changing setpoint values you must leave that screen before resetting the system.
The system also can be reset via the T SR-2. W hen changing inverter func tions, disable/enable the inver ter to
reset the inverter. When changing char ger functions, disable/enable the charger to reset the charger. Reset
both if in doubt.
Password
Acceptance of factory setpoints or adustments to setpoints should be made only by qualified personnel. If
certain setpoints are incorrect then system performance degradation or external equipment damage could
occur; i.e. battery damage due to improper charging, etc. The most sensitive system adjustments are located in
the Advanced Control Menu which is password protected. The password for gaining acc ess to the Advanced
Control Menu consists of pres sing the four Control Buttons in the following sequence: upper left, lower right,
lower left, upper right.
3.4 Menu Map
Initial Display(Push any button to enter main menu.)
TSR-2
A88769-A
MAIN MENU:
Ref.
StepDisplayFunctionAction
1BSCONTROLSelects the BASIC CONTROL submenuGo to Step 10
2MONITORSelects the MONITOR display submenuGo to Step 20
3ALARMSSelects the ALARMS display submenuGo to Step 100
4↓ Down ArrowScrolls down in the menuGo to Step 5
5GENERAL INFOSelects the GENERAL INFO display submenuGo to Step 50
6ADV CONTROLSelects the ADVANCED CONTROL submenus Go to Step 60
7↑ Up ArrowScrolls up in the menuGo to Step 1
BASIC CONTROL Menu:
10↑Inverter↓Allows inverter to operate automaticallyControls inverter
ENABLED disabled(ENABLED) or turns inverter OFF (DISABLED).
11↑ Load Demand ↓Allows Load Demand to operate automaticallyControls inverter
ENABLED disabledor turns Load Demand OFF (DISABLED).
12↑ Enter Load Dmd ↓Selects the size of the AC load at which the Controls inverter
+XX Watts - inverter goes into Load Demand (asleep)
13↑ Exit Load Dmd ↓Selects the size of the AC load at which the Controls inverter
+XX Watts - inverter turns fully ON (wakes up)
14↑Charger↓Allows charger to operate automaticallyControls Charger
ENABLED disabled or turns the charger OFF (DISABLED)
15↑ Equalize Cycle ↓Allows Equalize Cycle to operate automaticallyControls Charger
ENABLED disabledor turns the Equalize Cycle OFF (DISABLED)
16↑APM Limit↓Sets Automatic Power Management AmpsControls Charger
+ XX Amps AC -
TruSine 4.5 kW InverterPage 13Owner’s Manual
TSR-2 Remote Control
MONITOR Menu:
20AUTOSCAN System status displayGo to Step 30
21MANUAL SCANSystem status displayGo to Step 40
AUTOSCAN Menu:
30Press ESC to quit.Go to 31
31Inverter/Charger/System Displays inverter status messageGo to 32
SYSTEM STATUS
32APM LimitDisplays APM setpointGo to 33
XX Amps AC
33Aux AC InputDisplays if Aux AC Input is within voltageGo to 34
ERRORand frequency tolerance
34System AC VoltsDisplays Aux AC input volts or Go to 35
XXX VACinverter AC output volts
35System AC AmpsDisplays Aux AC input amps orGo to 36
XXX Amps ACinverter AC output amps
36Battery VoltsDisplays battery voltageGo to 37
XX.XX VDC
37Battery StatusDisplays if battery is within operating rangeGo to 38
GOOD(within high and low battery setpoints)
38Batt TemperatureDisplays battery temperature if optional Go to 31
XXX º Cbattery temperature sensor is installed
MANUAL SCAN Menu:
40Inverter/Charger/System Displays inverter status messageGo to 41
SYSTEM OFF↓
41APM LimitDisplays APM setpointGo to 42
↑XX Amps AC ↓
42Aux AC InputDisplays if Aux AC Input is within voltageGo to 43
↑ERROR↓and frequency tolerance
43System AC VoltsDisplays Aux AC input volts orGo to 44
↑ XXX VAC↓inverter AC output volts
44System AC AmpsDisplays Aux AC input amps orGo to 45
↑ XXX Amps AC ↓inverter AC output amps
45Battery VoltsDisplays battery voltageGo to 46
↑ XX.XX VDC↓
46Battery StatusDisplays if battery is within operating rangeGo to 47
↑ GOOD↓(between high and low battery setpoints)
47Batt TemperatureDisplays battery temperature if optionalGo to 40
TruSine 4.5 kW InverterPage 14Owners Manual
TSR-1 Remote Control
↑ XXX º C↓battery temperature sensor is installed
GENERAL INFORMATION Menu:
Press right control buttons to scroll up. Press left control buttons to scroll down.
50↑ INVERTER SW (↓)
(↑) REV. 1.13↓
51(↑)Model:(↓)
(↑) TSC24-4500(D) (↓)
52(↑) TSR-2(↓)
(↑) A88769-A(↓)
53(↑)VANNER POWER GRP(↓)
(↑)4282 REYNOLDS DR (↓)
54(↑)HILLIARD, OHIO(↓)
(↑)43026-1297, USA(↓)
55(↑)PH: 614-771-2718(↓)
(↑)FAX: 614-771-4904(↓)
56(↑)http://(↓)
(↑)www.vanner.com(↓)
57(↑)mail to:pwrsales(↓)
(↑)@vanner.com(↓)
ADVANCED CONTROL Menus:
60PasswordUse control buttons to enter password:If correct go to
XXXXupper left, lower right, lower left, upper right.Step 61 if not
Go to Step 6
61ADVANCED CONTROL Selects ADVANCED CONTROL submenuGo to Step 70
62COMMUNICATIONSSelects the COMMUNICATIONS submenuGo to Step 90
ADVANCED CONTROL Menu:
70↑ InverterOutput ↓Adjusts inverter AC output voltage setpointGo to Step 71
+ XXX VAC- and the ±10% range for Aux AC input voltage
73↑ HighBat ShutDn ↓Adjusts inverter High Battery ShutdownGo to Step 74
+ XX.XX VDC - DC Volts setpoint
74↑ BulkChrg Volts ↓Adjusts Bulk Charge DC Volts setpointGo to Step 75
+ XX.XX VDC -
75↑ Bulk Chrg Amps ↓Adjusts Bulk Charge DC Amps setpointGo to Step 76
TruSine 4.5 kW InverterPage 15Owner’s Manual
TSR-2 Remote Control
+ XX ADC -
76↑ AbsorpChrgVolt ↓Adjusts Absorption Charge DC Volts setpointGo to Step 77
+ XX.XX VDC-
77↑AbsorpChrgAmps↓Adjusts Absorption Charge DC Amps setpointGo to Step 78
+ XX ADC-
78↑Absorp MaxTime ↓Adjusts Absorption Charge maximum timeGo to Step 79
+ XXX minutes - duration setpoint
79↑ FloatChrgVolts ↓Adjusts Float Charge DC Volts setpointGo to Step 80
+ XX.XX VDC -
80↑ Equalize Volts ↓Adjusts Equalize Cycle DC Volts setpointGo to Step 81
+ XX.XX VDC -
81↑ EqualizMaxTime ↓Adjusts Equalize Cycle maximum timeGo to Step 82
+ XX minutes- duration setpoint
82↑Batt Temp Comp ↓Turns ON/OFF Battery Temperature Go to Step 83
ONoffCompensation for Battery Charger
83↑ Batt Temp Coef ↓Adjusts Battery Temperature CompensationGo to Step 84
+ XX.XmV/ºC/Cell - Coeficient
84↑BattTempShutDn ↓Adjusts battery charger High Battery Temperature Go to Step 85
+ XXºC- shutdown setpoint
85↑ Gen Start Mode ↓Allows Gen Start to operate automatically (ON) Go to Step 86
onOFFor turns Gen Start OFF.
86↑ GenStart Volts ↓Adjusts battery voltage setpoint at which the Go to Step 87
+ XX.XX VDC- Gen Start contacts close
87↑ Gen Stop Amps ↓Adjusts Bulk Charging amps setpoint at whichGo to Step 88
+ XX ADC- the Gen Start contacts open
88↑ Aux AC Delay ↓Sets time delay after Aux AC input powerGo to Step 89
+ XXX Seconds - is present until AC transfer occurs
89↑Solar Mode↓Allows inverter to operate in Solar Mode or Go to Step 70
onOFFturns Solar Mode OFF (DISABLED)
COMMMUNICATIONS Menu Used only for multiple inverter and/or multiple TSR-2 applications.
90Look for Inverters?Starts automatic Remote configuration.If yes, go to
yes NOThe default setting is NO.Step 91, If no
go to Step 92
91 Remote Addr: 1Displays the addresses of the Remote(s) and
Inverter Addr: 1the Inverter(s)
92↑ Inverter Addr:↓The Address of the system’s first inverter is 1.Go to Step 93
+ 1- Do not change. See Demo Mode if changed.
93↑ Remote Addr: ↓Sets the Remote address number.Go to Step 90
+ 1- The remote address will match the inverter(s).
TruSine 4.5 kW InverterPage 16Owners Manual
TSR-1 Remote Control
ALARM Menu:
100ALARMIf system faults exist the ALARM LED will beGo to next step
(message)↓ON and Alarm message(s) will be displayed.
101Getting Alarms(↓)
from Inverter...Press lower right control button to scroll through Alarm Messages.
Alarm Message DisplayedDescription of Problem
1. AC Input ERRORThere is no Aux AC input voltage or the Aux AC input is out of voltage or
frequency tolerance limits.
2. Battery HighBattery voltage is above High Battery Shutdown setpoint (will shut down
system).
3. Battery LowBattery voltage is below Low Battery Warning setpoint and soon will reach
Low Battery Shutdown setpoint.
4. Current LimitInverter AC output amps are at the Maximum Current allowed. The AC
voltage will be fall if load increases. Overload Shutdown will occur if
voltage falls below tolerance for 3 seconds.
5. OverloadInverter has shut down due to overload. High AC load caused inverter
output voltage to fall below tolerance for three seconds.
6. Hardware FaultInternal circuit failure or power brick high temperature (will shut down
system.
7. Overheat1) High internal temperature (transformer, triac plate or power brick).
System shutdown will occur. 2) AC output circuit breaker tripped.
TruSine 4.5 kW InverterPage 17Owner’s Manual
Front Panel Wiring Identification
4 Front Panel Wiring Identification
AC IN
AC OUT
CHASSIS
GROUND
POWER ON
POWER
OFF / ON
BATTERY
TEMP
SENSOR
V-NET
PORT
SERIAL
PORT
AC OUTPUT
CIRCUIT BREAKER
INV . O N
LOW BA TT.
GEN START
FOR CONNECTION TO
CLASS 2 CIRCUITS ONLY
BATT.BATT.
4.5 kW Power Inverter
Front Panel
All field wiring enters the TruSine housing through the front panel. This is the bottom surface when the unit is
oriented in the wall mounted position.
4.1 AC Input & Output Wiring
The AC wiring compartment is located on the left side of the unit. The compartment contains a removable
access cover and two cable clamps for the AC input and AC output wiring. Inside the compartment is a terminal
strip for making AC input and AC output connections.
NOTE
The AC output voltage and the required Aux AC input voltage of Model
TSC24-4500
is 120 VAC, 60Hz.
The AC output voltage and the required Aux AC input voltage of Model
TSC24-4500D
is 120/240 VAC,
60Hz, single phase, 3 wire. L1 and L2 are 180 degrees out of phase and cannot be tied together . T he unit
may be damaged if the AC input power is not 180 degrees out of phase. Exam ples of unacceptable power
are two phases from a three phase generator or power from two separate 120 volt generators.
4.2 DC (Battery) Wiring
A DC wiring compartment is located behind the wiring panel on the right side of the unit. T he compartment
contains a removable access cover and two cable c lamps for the battery positive and battery negative cables.
The inverter’s battery cable terminal lugs can accommodate cable sizes up to 250 MCM.
4.3 System ON Indicator
The light emitting diode (LED) indicates that the System ON/OFF Switch is ON.
4.4 Battery Temperature Sensor Port
This is an RJ-11 (4-wire) jack for optional Battery Temperature Sensor.
4.5 V-NET Port / TSR-2 Remote Control Port
This is an RJ-11 (6-Wire) jack for communications with the optional TSR-2 Remote Control / Operator Interface
Panel.
4.6 Serial Interface Port
This is an RJ-11 (6-Wire) jack for RS-232 serial communications.
4.7 Inverter Output Circuit Breaker
This 20-Amp cir cuit br eaker provides over current pr otection f or Inver ter AC output and the Battery Charger AC
input. This breaker does not protect the Aux AC passthrough power.
TruSine 4.5 kW InverterPage 18Owners Manual
Front Panel Wiring Identification
4.8 System ON/OFF Switch
Use this rocker switch to tur n the system ON and OFF and to reset the system. The System ON/OFF Switch
does not interrupt Aux AC input power or DC input power to the system.
4.9 Remote Signal Contacts
Three sets of contacts provide signals (continuity) for Remote Inver ter ON/O FF indication, Rem ote Low Battery
Warning indic ation and Gen Start control. Contacts are rated 2 amps for 12 or 24 volt, Class 2 c ircuits. W ir ing
connections are made through a 6 c onduc tor plug- in terminal block. Screw pres sur e- clamp terminals ac cept up
to 14 gauge wire.
5 INSTALLATION
Unpacking the Inverter
Inspect the shipping container and equipment for loose or damaged parts. If any damage is found, im m ediately
notify the freight carrier.
5.1 Basic Guidelines
The wiring of your inverter installation should conform to the National Electric Code ( NEC) and any other state
or local codes in effect at the time of ins tallation. These codes have been written f or your protection and their
requirements should be followed.
Mounting
Locate a secure, dry, flat horizontal or vertical surfac e large enough to m ount the invert er. T he location should
be as close to the battery as possible without being in the same com partment and should provide adequate
ventilation to maintain room tem perature while the inverter is operating. The location must allow unobstructed
cooling air flow at sides and bottom of the unit, and the loc ation must be free from road spray, dripping water or
other moisture contamination. A recommended minimum clearance of 4 inches (102 mm) should be
maintained on all sides of the unit.
WARNING:
compartments, or other areas hazardous locations requiring ignition protection.
NOTE
The wiring of your inverter installation should conform to the National Electric Code ( NEC) and any other state
or local codes in effect at the time of installation. Article 551 of the NEC requires any DC cable from a batter y,
which measures longer than 18 inches along its length, be protec ted by a fuse. Other codes m ay require each
ungrounded output conductor from a storage battery, other than to the engine cranking motor, to have a
manually reset trip-free circuit breaker or fuse within 72 inches of the battery as measured along the conductor.
Risk of fire or explosion. The inverter must not be mounted in fuel storage areas, battery
5.2 DC Wiring
Preliminary Considerations
1.
BE AWARE
THERE WILL BE A LARGE SPARK
occur every time the batteries are connected.
2. The DC cables should be as short as possible. It is electrically mor e efficient to run the lower current AC
wiring longer distances than the DC cables. (See DC Cable Sizing Chart for proper size.)
3. Route the DC positive and negative cables as c lose together as possible, and use cable ties to keep them
together. This reduces some electromagnetic radiation that could interfere with some sensitive electronics.
3. On vehicle installations do not use the vehicle chassis as the DC negative conductor. Use a cable the same
size as the DC positive to go directly from the inverter to the battery negative.
4. Route the AC and DC power wiring separately, and with as much physical separation as poss ible, from low
voltage wiring such as audio and video signal wires.
that, as a large number of capacitors become charged upon completion of the DC circuit,
when the last battery connection is made. The spark is norm al and will
TruSine 4.5 kW InverterPage 19Owner’s Manual
Installation
5. DC power input cables which pass through steel or other ferrous metal walls need to pass through the same
hole. If two holes are required, cut a slot connecting the two holes to prevent a transformer effect.
6. Do not allow wire fragments or metal shavings to fall into the DC wiring c ompartment or to enter the inverter
in any way. Severe inverter damage will result which is not covered by the warranty.
7. Do not connect the inverter to the battery at this time. Final battery connections will be made after all
installation issues have been inspected.
8. WARNING:
9. WARNING:
inverter and is not covered under warranty. Risk of f ire or ex plosion of batteries m ay occur due to very high
currents.
10.A DC fuse is required to properly protect the inverter.
11.T he table below shows the recommended m inimum cable size which should be used. W ire sizing charts
published in the NEC may allow a greater amp capacity than we recommend. We have sized the cable for a
maximum voltage drop to maintain better performance of your inverter installation. The inverter’s DC cable
terminal lugs can accommodate cable sizes up to 250 MCM.
Fuse
Fuse Holder
A poorly made high current connection may result in risk of fire and personal injury.
Be sure of the polarity of the DC input wiring. Reverse polarity may severely damage your
TruSine 4500 DC Cable and Fuse Sizing Chart
Model Number
Cable Size
4/016
250MCM19
Bussmann ANL500 Vanner 03646
Bussmann 4164 Vanner 03637
TSC24-4500 and TSC24-4500D
Distance from battery to inverter in feet
(Length of cable is 2 times the distance.)
DC Wiring Installation
The DC input terminals are located in the f ield wiring com partm ent located at the f ront right side of the unit and
accessed from the top. The connections are compression terminals which require a stripped cable and are
tightened by an Allen wrench. The positive and negative cables enter the com partm ent through separ ate strain
reliefs located at the right front of the unit.
WARNING
Never make electric al connections "live". Mak e the connections to the inverter fir st and the battery last. Mak e
certain the ON/OFF control switch on front of inverter is in the OFF position before connecting to the battery.
NOTE
Severe damage to the inverter will result, which is not covered under warranty, if wire fragments or other m etal
particles enter the inverter through the DC wiring compartment.
Procedure
Step 1:T urn the inverter OFF and disconnect all AC and DC power to the wiring harness. Mak e sure power
to the inverter wiring is disconnected. Verify that the inverter is turned OFF (the Inverter ON-OFF
switch is in the OFF position).
Step 2: Select a location for the unit. An ideal installation location has the following characteristics:
• Close to the battery (usually within six feet).
• Protected from the weather.
• Well ventilated.
Step 3: Route DC input cables. Route the negative and positive DC input cables from the inverter to the
battery. If required, protect cables where they contact hard, sharp edges.
Step 4: Install the in-line fuse. Install the in-line fuse in the r ed, positive DC input cable between the battery
and inverter, within 18 in. of the battery or DC wiring bus system.
Step 6: Connect the inverter to the battery.
A)Remove the cover plate on the DC cable compar tment exposing the positive and negative Allen head
terminal lugs.
B)Remove the two Allen screws from the terminal lugs.
C)Strip the positive and negative DC cable ends 3/4 in.
TruSine 4.5 kW InverterPage 20Owners Manual
Installation
D)Insert the black, negative ( -) cable end through the s train relief and into the negative term inal lug. Be
sure that all cable strands are completely in the lug.
E)Insert the Allen screw into the negative terminal block and tighten to 275 inch-pound.
F)Insert the red, positive ( +) cable end through the strain relief and into the positive ter minal lug. Be
sure that all cable strands are completely in the lug.
G)Insert the Allen screw into the positive terminal block and tighten to 275 inch-pounds.
H)Tighten the two cable clamps.
I)Inspect the DC cable compartment to ensure that no foreign particles are present.
J)Replace the cover plate over the DC cable compartment.
K)Repeat steps E and G every 30 days.
Step 7:Verify Installation. Verify all connections are tight and bright and the cables are secure.
5.3 AC Wiring
Preliminary Considerations
1. Output and Input Voltages
The AC output voltage and required Aux AC input voltage of Model
TSC24-4500
is 120 VAC, 60Hz.
The AC output voltage and required Aux AC input voltage of Model
single phase, 3 wire. L1 and L2 are 180 degrees out of phase and cannot be tied together. T he unit may
be damaged if the AC input power is not 180 degrees out of phase. Exam ples of unacceptable power ar e
two phases from a three phase generator or power from two separate 120 volt generators.
2. AC Wire Size
To properly size the AC input and output wiring the installer must consider the inver ter output c apability, the
inverter passthrough capability and the battery charger input requirement. The AC input/output terminal
strip is a compression lug style which will accept up to #6 AWG wire.
Model TSC24-4500 – The 37.5 am p at 120 volt (4500 watt) inver ter output c apability requires #8 AWG wire
minimum be used for the AC output. The AC transfer switch is rated 30 amps at 120 volts.
Use input wire up to #6 AWG sized to suit the AC input source. The AC output wire should be the same
size as the AC input wire but not less than #8 AWG.
Model TSC24-4500D – The 18.75 am p at 240 volt (4500 watt) inverter output c apability requires #12 AWG
wire minimum be used for the AC output. The AC transfer switch is rated 30 amps at 240 volts.
Use input wire up to #10 AWG sized to suit the AC input source. The AC output wire should be the same
size as the AC input wire but not less than #12 AWG.
3. The AC Input and Output wiring compartment is access ed from the top left s ide of the unit. F ield wires are
brought in through two cable clamps to the terminal strip identifying the “AC Input” and “AC Output”
terminals.
Model TSC24-4500 – The 120VAC Input and AC output terminals are labeled L1, N, and G.
Model TSC24-4500D – The 240VAC input and AC output terminals are labeled L1, L2, N and G.
4. AC feedback will cause damage to the inverter! The power dis tribution c irc uits must be designed to prevent
AC power from an external sour ce (shore power or a generator) from feeding back into the inver ter's AC
output.
TSC24-4500D
is 120/240 VAC, 60Hz,
5. The inverter AC output must be wired to a Ground Fault Circuit Interrupter (GFCI) to ensure a safe
installation. Always maintain an isolated neutral downstream from the GFCI to prevent nuisance tripping.
6. NEC ‘Branch Circuit Rated’ circuit breakers must be installed in all installations having Aux AC input.
The CHASSIS BONDING LUG located on the front of the unit has been provided for safety to prevent
7.
possible shock hazards. Connect a #8 AW G m inimum size wire to this terminal and then to chas sis of the
vehicle, the installation's grounding system, or to earth ground.
Failure to connect the chassis bonding lug to the chas s is of the vehicle, the installation's grounding system,
or to earth ground may result in a lethal shock hazard.
AC Wiring Procedure
Step 1: Connect the AC output. Remove the cover of the AC wiring compartment to expose the AC
TruSine 4.5 kW InverterPage 21Owner’s Manual
Installation
input/output terminal strip. Identify the lower terminals labeled “AC Output”. Insert the field wires
through the lower strain relief into the AC wiring compar tment. Tighten the strain relief. Connect the
field wires to the proper AC output terminals.
Step 2: Connect AC Input. Identify the terminal strip’s upper terminals labeled “AC Input”. Insert the field
wires through the upper strain relief into the AC wiring compartment. Tighten the strain relief.
Connect the field wires to the proper AC input terminals. Replace the AC wiring compartment cover.
Step 3: Connect Bonding Lug. Use a #8 AWG or larger copper c onductor to c onnect the chas sis bonding lug
to the chassis of the vehicle, the installation’s grounding system, or to earth ground.
Step 4: Verify Installation. Verify all connections are tight and secure for maximum performance.
5.4 TSR-2 TruSine Remote Control Panel Installation
Unpacking the Optional TSR-2 TruSine Remote Control Panel
Inspect the shipping container and equipment for loose, damaged, or missing parts. If any damage is found,
immediately notify the freight carrier.
Installing the TSR-2 TruSine Remote Control Panel
The TSR-2 TruSine Remote Control Panel may be located near the inverter or at a c onvenient remote location.
The unit is supplied with a 25’ long twisted data cable with a 6-pin RJ-11 connector at each end.
Step 1:Locate a suitable clean dry location for installation. T he TSR-2 f ront panel is 6½ wide x 5¼ high. The
back housing is 5¾ wide x 4½ high x 1¾” deep with cable entry on the right side.
Step 2: Route the data cable from the remote panel mounting area to the inverter.
Step 3: Plug the data cable into the RJ-11 modular jack labeled “V-NET” on the front of the inverter.
Step 4: Plug the data cable into the RJ-11 modular jack on right side of the TSR-2.
Step 5: Mount the TSR-2 Remote Panel using four #8 screws (not included).
5.5 System Start-up and Testing
Step 1:Completely install the TruSine 4500 Inverter/Charger following the system design considerations and
instructions provided previously in this manual.
Step 2:Place the System On/Off switch located on the front of the inverter in the OFF position.
Step 3:Verify that the external GFCI breaker is reset and connect an AC load, such as a 100-Wattlight.
Step 4:Turn ON the battery DC power to the inverter.
Step 5:Turn ON the AC shore power (or generator) to supply the AC input power to the system.
Step 6:Place the System On/Off switch located on the front of the inverter to the ON position.
Step 7:The green Power On LED on the front of the inverter should come ON.
Step 8:The TSR-2 TruSine Remote Control Panel (optional), if used, should display the main menu.
Step 9:The AC output test light should be ON, indicating the presenc e of shore power and corr ect operation
of the AC transfer switch.
Step 10: Disconnect the AC shor e power input. T he AC output tes t light s hould immediately quickly blink onc e,
indicating the transfer switch transferred the test light from shore power to inverter power.
Step 11: At this point, apply AC loads up to 4,500 watts to verify full-power operation.
Step 12: Apply shore power. After a delay the AC output test light should blink indicating the transfer of the
load from inverter power to shore power.
Step 13: Test the battery charger operation:
TruSine 4.5 kW InverterPage 22Owners Manual
Installation
A) Discharge the battery by placing the AC load on the system and operating the inverter, (rem ove shore
power input).
B) When the battery charge level is low, the inverter will turn off.
C) Apply shore power and observe the battery charger operation. Connect an am meter to the DC cables
between the inverter and the battery to monitor the current (DC amps ), and a volt meter to the battery to
monitor the battery voltage. The battery charger will step through its sequence and stop in the float
mode.
Step 14: The system is now ready for operation.
6 GENERAL INFORMATION SECTION
6.1 Generic Inverter Description
In general, an inverter converts DC electrical power into AC power. T h is power c an be us ed to operate var ious
AC-driven appliances. Typical DC power sources include batteries that store electrical energy, power
generated from a vehicle alternator or renewable energy sources such as photovoltaic (solar) panels.
The most com mon battery systems are 12 or 24 volt. Some systems, however, operate on higher voltages
such as 32, 36, 48, or 120 volts. The most comm on inver ter AC output power is 120 volts at a fr equency of 60
Hz. Some inverters, however, are designed to produce 240 volts, or both 120 and 240 volts at 60 Hz. Because
some countries use power of dif ferent voltage and frequency (e.g., 230 volts at 50 Hz), inverters ar e available
to conform to these requirements.
The three available inverter types are distinguished by the type of AC output wave form they produce. This
wave form affects the AC loads they operate. This section provides an overview of these inverter types,
including the advantages and disadvantages associated with using each type.
Sine Wave Inverter
Sine wave inverters produce an AC output wave form like power pr oduced by the electric utility com panies and
rotating generators. The sine wave inverter’s wave form is characterized by the highest peak voltage and
smooth voltage transitions (no square wave components). Such inverters are the most costly of the three
inverter types because they contain additional electronics to produce the required wave form. A measure of the
sine wave quality is Total Harmonic Distortion (THD), and is expressed in a perc entage. The lower the THD
the higher the quality of the sine wave power.
Modified Sine Wave Inverter
Modified sine wave inverters are sometimes called “quasi sine wave inverters” or “modified square wave
inverters.” Modified sine wave inverters gener ally cost more than square wave inverter s because they contain
additional electronic circuitry to produce true RMS regulated AC output. Modified sine wave inverters have
higher AC peak voltages than square wave inverters, and automatic ally control the width of the AC output wave
form to regulate the output voltage (pulse- width modulation). The shape of the modified sine wave invert er’s
wave form includes a square wave com ponent. It is stepped in such a way, however, to c losely approximate
the true sine wave produced by the electric utility companies. Although this wave form has a higher peak
voltage than do square wave inverters, its peak voltage is not as high as a pure sine wave. Therefore, AC
loads containing power supplies might not always operate properly on the modified sine wave inverter.
Square Wave Inverter
The square wave inverter is a low cost device that produces a pure square wave AC power output. This AC
power can be an accurate 60 Hz frequency if it is crystal controlled. It does not have the necessary peak
voltage to properly operate many AC appliances that contain electronic power supplies (e.g., com puters, TVs ,
and VCRs). The square wave is appropriate when operating AC loads such as resistive heating devices.
6.2 Inverter Sizing
Output Power Rating - Power output is an important consideration when purchasing an inverter. Power is
defined as the rate that a device produces (or uses) electrical energy. This rate is measured in watts or
kilowatts (one kilowatt equals 1,000 watts), or sometimes in voltamps. Voltamps are roughly equal to watts and
TruSine 4.5 kW InverterPage 23Owner’s Manual
General Information
are obtained by multiplying volts times amps produced or used by a device
To properly determine an inverter size (in watts) for your application decide which AC loads you plan to operate.
Inverter size is the sum of the wattages of the AC loads that you wish to run at the s ame time, plus a safety
factor, say 10 to 20 percent.
Continuous Output Power - Continuous power is defined as the AC power in watts (or voltamps) an inverter can
produce on a continuous basis. The ambient temperature can affect the continuous rating of the inverter, and is
normally specified, e.g., 25° C. or 40°C.
Surge Output Power - Inverter power can also be rated in terms of surge power. Surge power is the shor t ter m
duration of AC power that the inverter can produce. It is often specified as the watts (or voltam ps) that can
operate a resistive load for two or three sec onds. Som etim es this is s pecif ied in AC am ps because the inver ter
may allow output voltage to drop (which would reduce is wattage). Like continuous power, the surge rating is
affected by ambient temperature.
Note - Regardless of an inverter’s power r atings, an inverter’s AC output capability is only as s trong as the DC
source. To achieve optim um perfor mance an inverter m ust be installed with properly sized cable and have an
ample DC supply. Recommended cable sizes are listed in the DC Cable and Fuse Chart. The following
sections in this manual will cover the basic information required to properly size the inverter battery and the
vehicle alternator. Keep in mind that if information in this manual directly conflicts with instructions from a
specific battery or other equipment manufacturer, Vanner recommends that those manufacturer's
recommendations be followed.
6.3 DC Power Consumption
An inverter takes in DC power, and produces AC power to operate AC loads . In general, we can see a direct
relationship between DC input power and AC output power. This allows us to establish the f ollowing rule of
thumb:
For 12 volt DC inverters: Output Watts ÷ 10 = DC Input Amps.
For 24 volt DC inverters: Output Watts ÷ 20 = DC Input Amps.
This rule of thum b can be used to estimate the minim um alternator size required for your application. It may
also be used in calculating the minimum size battery required when operating from an alternator and battery
combination; a photovoltaic panel and battery combination; or when operating f rom battery alone. The following
examples should help to clarify the use of this rule of thumb.
Example A
What is the DC current draw of a 12 volt DC input inverter when it is operating a vacuum cleaner with a
name plate rating of 6 amps at 120 volts AC?
The appliance rating is given in amperes , so we must f irst calculate the power it consum es. T hen the
rule of thumb can be used to find the DC input current of the inverter.
Output power = 120 volts x 6 amps = 720 watts, and
DC input current = 720 ÷ 10 = 72 amps DC.
Example B
What is the DC current draw of a 24 volt DC input inverter when it is operating a toaster with a name
plate rating of 1050 watts at 120 volts AC?
Since the appliance is rated in watts, the rule of thumb can be applied directly:
DC input current = 1050 ÷ 20 = 52.5 amps DC.
This information on estimating the DC input current requirement for an inverter will allow you to size an
alternator or charging system to supply an inverter for c ontinuous operation. This rule of thumb will be used
later in the discussions on battery sizing.
TruSine 4.5 kW InverterPage 24Owners Manual
General Information
6.4 Battery Terminology and Ratings
Batteries used for automotive applications generally are lead-acid storage batteries. They can be separated
into two categories according to their use: engine cranking batteries and deep cycle batteries. The engine
cranking battery is specifically designed to supply hundreds of amps for a short period of time to start an
engine. Cranking an engine usually uses a small portion of the battery's total capacity and once the engine is
running, the battery is quickly recharged by the engine's alternator. The deep cycle battery is specifically
designed to deliver current for extended periods of time and can be almost totally discharged before
recharging.
The "deep cycle" lead-acid battery is designed to withstand the deep discharge/recharge cycling that is typical
of most inverter installations. These batteries are available in the "maintenance free" style where the electrolyte
does not need to be checked or replenished and they also are available in the gelled electr olyte style or "Gel
Cells". Deep cycle batteries are generally advertised for use in recreational vehicles or boats and are
sometimes referred to as RV or marine batteries.
Battery Council International (BCI) is a voluntary industry organization which has helped to standar dize battery
ratings. Ratings in use at this date are:
CCA (Cold Cranking Amperes): Rating in am ps a battery cold soaked at 0°F or –20°F will carry for 30
seconds and maintain a minimum terminal voltage of 7.2.
MCA (Marine Cranking Amperes): Rating in amps a battery cold soaked at 30°F will carry for 30 seconds
and maintain a minimum terminal voltage of 7.2.
RC (Reserve Capacity): Rating in minutes a battery will carry a 25 amp load at 80°F and maintain a
minimum terminal voltage of 10.5.
AH (Amp Hour): At the “20 Hour Rate”, also called the C Rate, a battery having a 100 AH rating mus t
carry a 5 amp load for 20 hours (100AH ÷ 20 hours = 5 amps) and maintain a term inal voltage of
10.5 at 80°F. (Two 100AH 12volt batteries connected in series provides 100AH at 24 volts . Two 100
AH 12volt batteries connected in parallel provides 200 AH at 12 volts.).
CCA and MCA are used for sizing an engine cranking battery and have no bearing on a batter y's cycling ability.
RC is a rating given to cranking batteries to pr ovide an idea of how long a vehic le c ould be driven if the vehicle
charging system were to fail.
The most important and probably least understood battery capacity rating is the ampere-hour. One simple
reason the AH rating is misunders tood is that a battery rated at 100 AH cannot always deliver 100 AH. The
underlying reason is the efficiency with which the battery converts its chemic al energy into electric energy. The
AH capacity of a battery is affected in the following ways:
Discharge rate: A battery becomes less efficient as the dischar ge current increases. For example, a typical
100 AH battery is specified to be able to deliver 5 amps for a period of 20 hours . If the dischar ge current were
increased to 25 amps, the capacity will be reduced to approximately 75 AH (25 amps x 3 hours = 75 AH).
Operating temperature: A battery becomes less efficient at lower tem peratures. Most battery manufacturers
specify the battery AH capacity at 80° F. At a temperature of 32° F, the same batter y will have only about 65%
of its rated capacity even though it may be fully charged. At a temperature of 0° F , a battery's capacity will be
reduced to about 40% of its rated capacity.
Battery age: As a battery is used, the active material on the battery plates will gradually deteriorate and become
useless. As the battery gets older, there will be less and less useful material left on the plates and the
operating time will become noticeably shorter. A batter y will age faster (loose active m aterial from its plates
faster) if it is deeply discharged regularly, if it is left in a discharged state for extended periods of time, or if it is
repeatedly overcharged.
Series and/or Parallel Connected Batteries: Up to this point we have spok en of the batter y as if it were a s ingle
battery. In some cases this may be true, but in general, the battery may be made up of several individual
batteries electrically connected together to form a "Bank" of batteries. Batteries can be connected in series,
parallel, or a combination of s eries and parallel as long as all of the batteries in the bank are of equal ratings,
are from the sam e manuf acturer, and are the sam e age. Old and new batteries should never be m ixed in the
same battery bank. Mixed batteries will result in accelerated battery failure due to the unequal discharge and
recharge rates.
A series connection is where two or mor e batteries are connec ted positive (+) to negative (- ). T he total voltage
TruSine 4.5 kW InverterPage 25Owner’s Manual
General Information
of the battery bank is the sum of the voltage of each battery in the bank. For exam ple, most large custom
coaches require a 24 volt battery to crank the large diesel engine. The 24 volts is usually provided by
connecting two 12 volt batteries in series, and sometim es by connecting four 6 volt batteries in s eries. The
ratings of the series connected batter y bank remain the same as the individual battery's rating. If the battery
bank is made up of two 8D size batteries in series , eac h with a CCA of 1050 amps, 425 m inutes RC, and amphour capacity of 200 AH, then these individual battery ratings are also the ratings of the entire 24 volt battery
bank.
Parallel connected batteries are batteries which are connected pos itive to positive and negative to negative.
They form a battery bank that has the same voltage as each individual battery. The ratings of a parallel
connected battery bank, in general, are the sum of the individual batteries. For instanc e, if two 8D batteries are
connected in parallel, and each battery has the ratings given in the paragraph above, then the ratings for the
battery bank become 2100 CCA, 900 minutes RC, and approximately 400 amp-hours. Parallel connected
batteries should be of the same voltage and rating to achieve optimum battery life and performance.
6.5 Sizing the Inverter Battery
Sizing a battery system for an inverter application can be a very tedious task if all the dif ferent variables, suc h
as discharge rate, depth of discharge, and operating life time are included in the calculations . T o simplify these
calculations and get a reasonably correct battery size, we will assume: 1) A 50% depth of discharge for the
purpose of obtaining a reasonable life tim e for a reas onable battery system cost, 2) there is no charge cur rent
into the battery system, 3) the batteries are in a fully charged state at the beginning of the dis charge cycle, and
4) the DC current draw from the battery does not exceed 1/3 the C rate for any length of time.
Follow the steps listed below to find the AH capacity required for your application.
Step 1:Mak e a list of each appliance, its power require ment in watts, and the amount of time in hours it will
be operating between charging cycles. Note: If the appliance is rated in am peres (am ps) instead of
watts, multiply the amps by the voltage (120 or 240) to get watts.
Step 2:Calculate the watt-hours required for each appliance by multiplying the power requirement by the
operating time of that appliance.
Step 3:Calculate the total watt-hours needed by adding together the watt-hours of each appliance.
Step 4:Find the amp-hours consumed by dividing the total watt-hours found in step 3 by 10 for 12 volt DC
systems or by 20 for 24 volt DC systems.
Step 5:Multiply the amp-hours consumed by 2 (for 50% depth of discharge) to get the battery amp-hour
capacity desired.
Example 1:Follow Steps 1 through 3 (above)
AppliancePower Rating
TV, VCR, Stereo225 watts2.5 hours 563 watt-hours
Small Refrigerator3003.8 1,140
Microwave8000.3 240
TOTALS 1,943 watt-hours
Step 4:Amp-hours consumed = 1943 watt-hours ÷ 20 = 97.15 amp-hours for 24 a volt system.
Step 5:The minimum battery size for this application is 2 x 97.15 = 194.3 amp-hours.
Operating TimeWatt-Hours Consumed
6.6 Battery and Charging System Considerations
The Battery and DC Charging System is a very important part of your inverter installation respons ible to supply
all of the DC power required by the inverter. The system normally consists of the primary charger (engine
alternator or photovoltaic array), a secondary charger, if used, the battery, and other equipment which may be
used such as battery isolator diodes. The com plexity of the system depends on the way the inverter is us ed.
In some cases, such as utility or service vehicles, the system may be as simple as the engine alternator and
the cranking battery which also powers the inverter. In most cases, additional equipment is needed to provide
additional DC power and/or protection. These systems c an be grouped into two categories, the single battery
TruSine 4.5 kW InverterPage 26Owners Manual
General Information
and the dual battery systems.
In the single battery system, there is one battery which is shared for starting the engine and operating the
inverter. This is a common practice in a service vehicle where the engine runs all the time and allows the
alternator to provide continuous charging for the battery. In this case, the inverter can be connected dir ectly to
the engine cranking battery. The most important detail of this system is the alternator output rating. The
continuous output of the alternator needs to be at least as m uch as the total DC cur rent draw on the system.
The total DC current draw must include the inverter, warning lights, radios, engine controls, and any other
device connected to the DC system. Care should be used when operating this type of system while the engine
is shut off. The inverter will shut its elf OFF for low battery but most other DC loads will not. The vehicle battery
may be drained too low to restart the engine.
The dual battery system uses two separate batteries, one for starting the engine and operating the vehicle's
systems, and one for operating the inverter. T he two batteries are usually referr ed to as the "crank ing battery"
and the "house or auxiliary battery" respectively. The two separate batteries are usually charged from the
same source, the engine alternator , but are s epar ated by a device called a battery isolator. The battery isolator
allows DC current to flow from the alternator into each battery, but blocks curr ent from f lowing from one batter y
to the other. This is a must to protect the cranking battery in recreation vehicles, boats and other vehicles
where the inverter needs to be operated when the engine (therefore the alternator) is not running.
6.7 Battery Charging Guidelines
CAUTION
The following information on batter y charger setup adj ustments should be used as guidelines only. Vanner
strongly recommends that you contact the m anufacturer of your batteries to obtain the specif ic charging
setup values for the type and model of battery you are using. This is due to the fact that battery charging
parameters such as bulk, absorption, float and equalize voltages vary from one manufacturer to another,
and that gel cell batteries have different param eters than wet lead acid batteries. An im properly adjusted
battery charger may cause damage to your batteries!
The maximum charging current for a battery is usually equal to 20% of the battery's Amp hour capacity (“C”) for
lead acid batteries, and 50% of the battery's C for gel cell batteries. T he C rate is numerically equal to the
amp-hour capacity for the battery. For example, a 280 amp-hour battery has a C rate of 280 amps, and the
maximum charge rate would be 56 amps DC. (Note that this is not the same as the batter y's Cold Cranking
Amp rating.) You should also take into consideration that if two batteries ar e connected in parallel their amphours add but if batteries are connected in series their amp-hours remain the same.
7 MAINTENANCE & TROUBLESHOOTING
7.1 Preventative Maintenance
There are no user serviceable com ponents inside the TruSine Inverter/charger. For servic e refer to Vanner
Power Group or other qualified service personnel.
Maintenance Items:
For continued reliability and safety, a monthly maintenance program should be implemented to include the
following:
1. Check to insure that all AC and DC wiring is secure and connections are tight and corrosion free.
2. Check air ventilation openings for dust and other obstructions.
3. Examine receptacle, indicators and switches for cracks and breaks.
Trouble Shooting
Problem: The TSR-2 Remote Control Panel does not respond.
Check:Suspect Step 92 Inverter Address has been changed from 1. Change back to 1 using Demo
TruSine 4.5 kW InverterPage 27Owner’s Manual
General Information
Mode. See TSR-2 Remote Control Panel operation.
TruSine 4.5 kW InverterPage 28Owners Manual
Warranty
8 Warranty
NORTH AMERICAN LIMITED WARRANTY
Vanner Inc., doing business as The Vanner Power Group, referred to herein as Vanner, warrants that this
product is free from def ects in m aterials and work m anship f or a period of two (2) years from date of installation
or two and one half (2 1/2) years from date of manufacture, whichever is less if and only if the following
requirements are complied with:
1. The product is installed and checked out properly according to all guidelines, instructions, and
checkout procedures set forth in the product Installation and Operating Manual.
2. The installer records all checkout data required and completes, signs, and returns the warranty
registration card to Vanner within ten (10) days after installation.
3. The product was purchased after January 1, 2000.
Vanner does not warrant its products against any and all defects when: defect is a result of material or
workmanship not provided by Vanner; normal wear and tear , or defec ts caus ed by misuse or us e in c ontrary to
instructions supplied, neglect, accident, reversed polarity, unauthorized repairs and/or replacements.
All warranties of merchantability and fitness for a particular purpose: written or oral, ex pressed or implied, shall
extend only for a period of two (2) years from date of installation or two and one half (2 1/2) years fr om date of
manufacture, whichever is f irst. T her e are no other warranties that extend beyond those described on the face
of this warranty. Some states do not allow limitation on how long an implied warranty lasts, so the above
limitations may not apply to you.
Vanner does not undertake responsibility to any purchaser of its produc t f or any undertak ing, r epr esentation, or
warranty made by any dealers or distributors selling its products beyond those herein expressed unless
expressed in writing by an officer of Vanner.
Vanner does not assume res ponsibility for incidental or consequential damages, including, but not limited to,
responsibility for loss of use of this product, removal or replacement labor, loss of time, inconvenience,
expense for telephone calls, shipping expense, loss or damage to property, or loss of revenue. Some states do
not allow the exclusion or limitation of incidental or consequential damages , so these lim itations may not apply
to you.
Vanner reserves the right to repair, replace, or allow credit for any material returned under this warranty. Any
damage caused by the customer will be charged or deducted from the allowance.
All warranty work will be performed at Vanner’s fac tory, or authorized repair facility utilizing a valid W arranty
Authorization Number (WAN) prior to repair. Products shall be delivered to Vanner’s facility, freight prepaid and
fully insured. Products repaired under warranty, or replacement parts or products will be returned to North
American location prepaid via sam e transportation means and level of service as received, unless directed
otherwise. Prepaid freight policy does not apply to locations outside North America.
TruSine 4.5 kW InverterPage 29Owner’s Manual
TruSine
4.5 kW Inverter/Charger System
Vanner Power Group
4282 Reynolds Drive
Hilliard, Ohio 43026
1-800-AC POWER
(1-800-227-6937)
Tel: 614-771-2718
Fax: 614-771-4904
www.vanner.com
e-mail: pwrsales@vanner.com
Manual Number D98771 Rev B
March 1, 2000 Printed in USA
TruSine 4.5 kW InverterPage 30Owners Manual
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