PURE SINE WAVE BI-DIRECTIONAL INVERTER MANUAL
10Kw / 15KwPURE SINE WAVEBI-DIRECTIONALINVERTER MANUAL0
Contents1. INTRODUCTION . 22. SAFETY INSTRUCTION . 33. SYSTEM DESCRIPTION . 64. INVERTER OPERATION . 104. INVERTER PROGRAMMING. 156. SPECIFICATIONS OF INVERTERS . 271
1. INTRODUCTION1.1GENERAL DESCRIPTIONThe Microcare Pure Sine Wave Inverters deliver true clean sine wave output power.The Power is applicable for any kind of load, such as air-conditioners, homeappliances, consumer electronics and office equipment. This series features a durableand continuous 24 hour operation. The compact and modular design makes utilityinteractive installations easier and more cost effective. It is a high quality product thatoffers the best price/performance ratio in the industry.1.2KEY 2.91.3Multiple microprocessor design base.Compatible with both linear and non-linear loads.24 hour operation of the inverter.DC start and automatic self-diagnostic function.THD less than 3%.Internal high power 3 stage charger.High efficiency design to save electricity.Low heat dissipation for long time operation.Designed to operate in a harsh environment.IMPORTANT NOTICES Read instructions carefully before operating Inverter.Inverter connection instructions must be followed.The unit should only be opened by skilled personal.Retain the load within in the rating of Inverter to prevent faults.Keep the Inverter clean and dry.If a 220vac supply is connected to the inverter and it is to be used as a UPS, thenthe inverter can only supply its rated power.2
2. SAFETY 2.1.62.1.72.1.82.2Do not put the Inverter on a rugged or inclined surface.Do not install the Inverter near water or in damp environments.Do not install the Inverter where it would be exposed to direct sunlight.Keep the Inverter far away from heat emitting sources.Do not block ventilation openings in the inverter housing.Do not leave objects on top of the Inverter.Do not expose the Inverter to corrosive gasses.Ambient temperature: 0 C – 40 C.INSTALLATION2.2.1 Connect the Inverter AC OUTPUT only to an earthed DB Panel.2.2.2 If a 220vAC supply or a generator is available, connect into the Live and Neutral INConnection.2.2.3 Make sure the BATTERY INPUT CIRCUIT BREAKER is OFF.2.2.4 Place cables in such a way that no one can step on or trip over them.2.2.5 Battery cables must be a minimum of 50mm² and as short as possible.2.2.6 Refer to the diagrams below for each inverter as to the cable placement andconnections.2.2.7 Minimum battery bank of 500A/Hours is suggested.2.3EARTHING OF EQUIPMENTEquipment surge protection products are an effective way of controlling dangerous surges thatcan enter a facility. When strategically placed and correctly installed, the Surge Protectors willeffectively reduce harmful over voltage conditions that can damage electrical and electronicequipment.It is important that the protection system includes both structural and surge protection equipment.When lightning current passes into the ground through any conductor (Example: Tree Trunk) apowerful electromagnetic force is set up due to the fast rise times of the strike. Thiselectromagnetic force then couples into any inductive loops that may be available in nearbybuildings. When these currents equalize, damage usually occurs to the equipment.3
2.3.12.3.22.3.32.3.4LIVE IN and N INLIVE OUT and N OUTEARTH 1EARTH 2––––Connect to GridConnect to AC Load.Connect to Earth Bar.Connect to Chassis Earth.The Microcare inverter is designed primarily for Grid / Mains connection to include charging.When Mains is connected to the inverter the Neutral connection is Earthed via the Mains.If the Inverter is connected as a stand-alone inverter with no Mains Connection, The Neutralis required to be earthed using an earth spike.If the Inverter is not earthed; warranty will be null and void.4
2.3.5Inverter Neutral ConnectionThe inverter has a floating neutral so the neutral voltage will be close to 110v. In this casethe live voltage with respect to the earth will also be around 110v.If you use your inverter for a standalone application you need to bridge the neutral inputwith the earth terminal on the inverter (these two are next to each other for this purpose).You can now fit an earth leakage after the inverter.But if you are going to supply your inverter with AC from the grid then you need to put theinverter before the earth leakage and you need to keep the inverter neutral input connectedto the GRID neutral at all times.So if you what to switch the GRID input to the inverter off then one must only switch live.You can then put the earth leakage directly after the inverter. The grid will pull the inverterneutral to 0v.2.3.5 Inverter Earth Connection to Grid.2.3.6 Inverter Earth Connection Off-Grid.5
2.4MAINTENANCE AND SERVICE1. Caution – Risk of Electric Shock.2. Batteries may cause electric shock and have a high short-circuit current. Pleasetake the precautionary measures specified below and any other measuresnecessary when working with batteries. Remove wristwatches, rings and other metal objects. Use only tools with insulated grips and handles.3. SYSTEM DESCRIPTION3.1SYSTEM DESCRIPTION. (10Kw and 15Kw Inverters.)3.1.1 System Front View. (10Kw Inverter.)6
3.1.2 System Right View. (10Kw Inverter.)3.1.3 System Left View. (10Kw Inverter.)7
3.1.4 System Front View. (15Kw Inverter.)3.1.5 System Right View. (15Kw Inverter.)8
3.23.2.13.2.23.2.33.2.43.2.53.2.63.2.73.2.8FRONT PANEL DESCRIPTIONLCD Display: This indicates the UPS’s operational information, including outputvoltage, battery voltage, output load and inside temperature.UP–Key: Use to move the display up.DOWN–Key: Use to move the display down.ENTER–Key: It is pressed with the UP–Key to turn on the UPS. Push the ENTERbutton to confirm or store DATA.Push the UP and DOWN keys together to turn off the inverter.Fault LED (Red): To indicate the INVERTER is in a fault condition because ofinverter shutdown or over temperature.Warning LED (Yellow): To indicate the INVERTER is in the status of overload orbattery LOW.Normal LED (Green): To indicate the INVERTER is operating normally.9
4. INVERTER OPERATION4.1 Check Prior to Start Up4.1.14.1.2Check Input and Output cables are secured.Check if Battery voltage meets the INVERTER rating.4.2 Operation ProcedurePlease follow the instructions below for the UPS operation.Push and hold the RED PRECHARGE BUTTON until the Display shows writing then turnon the BATTERY CIRCUIT BREAKER while holding the RED PRECHARGE BUTTON in.Once the BATTERY CIRCUIT BREAKER has been turned on then the REDPRECHARGE BUTTON can be released.MICROCAREMICROCARE PLEASEOKInverterENTERMenu UpUPSWAIT ErrorONMenu DownOFFThe display then changes to:MICROCAREUPS TURNED OFF CALIBRATING OKInverterErrorENTERMenu UpONMenu DownOFF10
The display then changes to:MICROCAREUPS TURNED OFFOKInverterENTERMenu UpONErrorMenu DownOFFThen Push the ENTER Button and the display will change RMenu UpONErrorMenu DownOFFBy pressing the Enter-key and the UP-key simultaneously for 3 seconds, the UPS willstart up and the OK LED will light up to indicate the power is being supplied from theinverter to the load and the MAINS / FAIL LED comes ON. The display will ERMenu UpONErrorMenu DownOFF11
By turning on a load the OUTPUT % will change to indicate the amount of LOAD as a %of the unit being used in KW. Above 5% of load is displayed.MICROCAREMICROCAREINVERTER15KW27% OKInverterENTERMenu UpErrorMenu DownONOFFWhen the Up-key and the Down-key are pressed simultaneously for 3 seconds, the UPSwill be turned OFF after two beeps.LCD DISPLAY MENUWith the inverter ON or OFF use the Up/Down keys to select menu-displays of the LCDdescribed below.The screen will show the following:Using the UP/Down Buttons the following screens can be seen.This shows the power rating of the UPS and its % output.MICROCAREMICROCAREINVERTER OKInverterENTERMenu UpON15KW47%ErrorMenu DownOFF12
Using the UP arrows the following details can be checked:This shows the battery voltage and the amps that the UPS is drawing from the battery.MICROCAREBATT VOLTBATT AMPS::OKInverterENTERMenu Up54.27.0ErrorMenu DownONOFFIf the battery Amps changes to CHR AMPSMICROCAREBATT VOLTCHR AMPS::OKInverterENTERMenu Up54.710.0ErrorMenuONOFFThis shows the Charge Amps that are being put back into the battery bank from thecharging source.This shows the output voltage and amps that the load is drawing from the Invertersupplied Power.MICROCAREUPS VOLTSUPS AMPS::OKInverterENTERMenu Up2207.0ErrorONMenu DownOFF13
Shows the Grid Volts and power draw from the grid power supply:MICROCAREGRID VOLTSGRID AMPS::OKInverterENTERMenu Up22710.0ErrorMenu DownONOFFThis shows the internal temperature of the UPS.MICROCARETEMPERATURE26.3 deg/celOKInverterErrorENTERMenu UpONMenu DownOFFThis shows that the control cards in the UPS have a 100% communication.MICROCARESIGNAL STRENGTHDISPLAY-UPSOKInverterENTERMenu Up100%ErrorMenu DownONOFF14
This indicates the serial number of the Inverter.MICROCARESERIAL NUMBER:MCxx7777OKInverterENTERMenu UpErrorMenu DownONOFFThe Serial number of the inverter needs to be noted and supplied when requestingany fault support information.4. INVERTER PROGRAMMINGThere are two MENUS’ which allow the user to change either the SET UP or theBATTERY settings.Push the UP / DOWN keys to select which menu is to be changed.MICROCAREENTERSETUPMENUOKInverterENTERMenu UpON?ErrorMenu DownOFFPush ENTER if you want to enter the SETUP menu.15
By pushing ENTER button you can change whether the inverter runs in NORMAL SENSEmode; or SOLAR CONTROL u UpErrorMenu DownONOFFNORMAL SENSE is to be selected when connecting a Generator to the Inverter or for anyoff-grid inverter installation.Push the ENTER button. The menu changes to:MICROCAREUPSSOLARMODECONTROLOKInverterENTERMenu UpONErrorMenu DownOFFSOLAR CONTROL MODE is to be selected when a Grid Connection is available. TheInverter will switch over to the Grid Power to supply the load when the batteries reach theset level and will revert back to battery power once the battery bank has been rechargedto the set level.In order to run correctly in Solar Control Mode, the BATTERY OFF AT setup needsto be changed in the BATTERY SETUP MENU to: (2V – 48V; 1.5V – 36V; 1V – 24V;0.5V – 12V) Less than the BATTERY RUN TO Value setup in the SETUP MENU.When the inverter is running in solar control mode and the Charge level is set to LEVEL 1,the inverter will run the load using mains power and the solar regulator will charge thebattery bank. The inverter will switch back over to battery power when the AC RUN TOValue is reached.16
Push the UP button in SOLAR CONTROL mode you can then access the battery run tomenu: (This allows the user to set the level the battery will go down to before switching tomains power.)MICROCARESOLARBAT RUN TOCONTROL46.0vOKInverterENTERMenu UpONErrorMenu DownOFFBattery Run To:48v System – 46v (Default) (Can be changed in 2v Increments)36v System – 34.5v (Default) (Can be changed in 1.5v Increments)24v System – 23v (Default) (Can be changed in 1v Increments)12v System – 11.5v (Default) (Can be changed in 0.5v Increments)Push the ENTERbutton. The Menu settings can be changed.Push the UP button. The menu changes to AC RUN TO menu:(Allows the user to set the level the mains/solar regulator will charge the battery to beforethe inverter switches back to battery power.)MICROCARESOLARACRUN TOCONTROL54.0vOKInverterENTERMenu UpONErrorMenu DownOFFAC Run To:48v System – 54.4v (Default) (Can be changed in 2v Increments)36v System – 40.5v (Default) (Can be changed in 1.5v Increments)24v System – 24v (Default) (Can be changed in 1v Increments)12v System – 12v (Default) (Can be changed in 0.5v Increments)Push the ENTER button. The Menu settings can be changed.17
To change the menu, push the UP button.The menu will then change to:MICROCARETRANSFER8mS SWITCHSOFTSTARTOKInverterENTERMenu UpONErrorMenu DownOFFThe Settings available for this are as follows:3mS NOSOFTSTART5mS NOSOFTSTART8mS SOFTSTARTGEN SOFTSTARTGEN SLOWRAMP3 milli second transfer time and will restart load instantly with mains fail prediction.5 milli second transfer time and will restart load instantly with mains fail prediction.(Default) 8 milli second transfer time and will ramp theRMS voltage up in less than 1 second - with mains failprediction.8 milli second transfer time and will ramp the RMS voltageup in less than 1 second - with no mains fail prediction.8 milli second transfer time and will ramp the RMS voltageup in 3 seconds - with no mains fail prediction.18
To change the menu, push the UP button.The menu will then change to:MICROCARELOADHIGHMONITORINGNO RESETOKInverterENTERMenu UpONErrorMenu DownOFFThe sensitivity of the SHORT CIRCUIT TRIP may be changed through 5 LEVELS. PushENTER to select the mode:HIGH NO RESETMED NO RESETHIGH 3x RESETMED 3x RESETLOW EMERGENCYHigh sensitivity to short circuits - will trip the inverter after a shortdelay time period.Medium sensitivity to short circuits - will trip the inverter after amedium delay time period.High sensitivity to short circuits - will trip the inverter after a shortdelay time period, with soft start to prevent in rush current.Medium sensitivity to short circuits - will trip the inverter after a shortdelay time period, with soft start to prevent in rush current.Low sensitivity to short circuits - will trip the inverter after a longdelay time period. Only to Used in Emergency Situations.19
To change the menu, push the UP button.The menu will then change to:MICROCAREIF AC INPUTAC OUTPUT OKInverterENTERMenu UpONONNORErrorMenu DownOFFThe settings available are as follows:AC OUTPUT NORThis will allow the inverter to supply rated power.A 15Kw Inverter will supply 15kw of Power.AC OUTPUT 200%-This will allow the inverter to supply 200% rated power.A 15Kw Inverter will supply 30kw of Power.If the grid fails and the load is exceeding 100% ofthe inverter power, the inverter will shut down dueto overload.To change the menu, push the UP button, The menu will then change to:MICROCARELOADTRANSFERNO DELAYOKInverterENTERMenu UpONErrorMenu DownOFFThe settings available are as follows:As soon as Grid power is available the Inverter will synchronise andNO DELAYswitch from battery to Grid.30 seconds after Grid power is available the Inverter willDELAY 30Secsynchronise and switch from battery to Grid.5 minutes after Grid power is available the Inverter will synchroniseDELAY 5 Minand switch from battery to Grid.20
Pushing the UP button will give you 3 options to SAVE the changed data. The display willshow:MICROCAREEXIT AND SAVESETUPMENU ?OKInverterENTERMenu UpONErrorMenu DownOFFMICROCARERESTORE FACTORYSETUPOKInverterENTERMenu UpONMENU ?ErrorMenu DownOFFMICROCAREEXIT, DO NOT SAVESETUPMENU ?OKInverterENTERMenu UpONErrorMenu DownOFF21
If the changes to the settings need to be saved push ENTER if the enter button is pushedthen the inverter may show:MICROCARESAVING DATAPLEASE WAITOKInverterENTERMenu UpONErrorMenu DownOFFIf no entry is made for 1 minute the display will return to the main menu and the back light willturn off.Use the UP/DOWN button to select BATTERY menu:MICROCAREENTERBATTERYMENUOKInverterENTERMenu UpON?ErrorMenu DownOFFPush ENTER to access the Battery Setup Menu:22
To change the BATTERY CHARGE menu push ENTER button:MICROCAREBATTERYLEVEL (X)CHARGESELECTEDOKInverterENTERMenu UpONErrorMenu DownOFFThe Settings available for this function are as follows:50% OF RATED CHR(Default). 50% of charge rate as per list supplied below.75% OF RATED CHR75% of charge rate as per the list supplied below.MAX CHARGE RATE100% of charge rate as per the list supplied below.TURNED OFF0% of charge rate as per the list supplied below.SLOW CHARGE5% of charge rate as per the list supplied below.25% OF RATED CHR25% of charge rate as per the list supplied below.INVERTER10Kw36V10Kw48V15Kw48VCHARGE AMPS100A100A150AAbove is the list of charge amps for the inverters.In regards to the battery charge level – The Level selected will allow the battery charge tothe batteries.LEVEL 3 – 25% – On a 10Kw48V Inverter will allow a charge of 25A to the battery.LEVEL 5 – 75% – On a 10Kw48V Inverter will allow a charge of 75A to the battery.23
To change the menu, push the UP button.The menu will then change to:MICROCAREACINPUTLEVEL (X)POWERSELECTEDOKInverterENTERMenu UpONErrorMenu DownOFFThis allows the UPS to extract the maximum amount of power from a generator. The UPSconstantly monitors the voltage from the generator and then applies maximum charge.LEVEL 1 is the highest load to the generator while LEVEL 6 is the minimum. The factorydefault LEVEL is 1. This only needs to be adjusted if there is a generator connected.When a generator is running the generator will supply the AC Load first and theinverter will charge batteries with any excess power created from the generator.24
To change the menu, push the UP button.The menu will then change to:MICROCAREBATTERYBSTBOOST58.4 volts OKInverterENTERMenu UpONErrorMenu DownOFFBy pushing ENTER this allows the user to adjust the BATTERY BOOST voltage.To change the menu, push the UP button.The menu will then change to:MICROCAREBATTERYBSTBSTTIMEFOR2 HOURSOKInverterENTERMenu UpONErrorMenu DownOFFThis allows the user to select the TIME that the BOOST VOLTAGE will be held at beforechanging to FLOAT. By pushing ENTER you can select 1, 2 or 3 hours.25
To change the menu, push the UP button.The menu will then change to:MICROCAREBATTERYOFF ATLOW44.0 VOLTSOKInverterENTERMenu UpONErrorMenu DownOFFThis selects at what BATTERY LOW VOLTAGE the UPS will shut down. By pushingENTER you can select to change the voltage.Push the UP button.It is possible to FORCE the charger to go into another charge mode on a temporary basis.If the charger is in FLOAT but you require it to go back into BOOST then the next menuwill allow rENTERMenu UpONMenu DownOFFPushing the ENTER button allows the charge to be changed from AUTO to BOOST orFLOAT.Push the UP button:This will give you the options of saving the changes that have been made. Push ENTER atthe correct SAVE menu.26
6.CapacityInputOutputSPECIFICATIONS OF INVERTERSMODEL 36/100001000036 Vdc30 - 45 Vdc333 amps100 watts220 Vac45 amps 3 % RMS for entire battery voltage range50Hz 0.1Hz1Pure Sine Wave90%Circuit BreakerProgrammable Overload Levels and AutoRetry41.4V42.9V .46.5VSelectable 1, 2, 3 hours.120 ampsDepending on the generator power available.WattNominal VoltageAcceptable Voltage RangeMaxi Input AmpsManual Mode PowerVoltageAmpsVoltage RegulationFrequencyFrequency RegulationPower FactorWave FormEfficiencyOverload ProtectionChargerFloat VoltageBoost VoltageBoost TimeMaximum CurrentGeneration Mode27
CapacityInputOutputWattNominal VoltageAcceptable Voltage RangeMaxi Input AmpsManual Mode PowerVoltageAmpsVoltage RegulationFrequencyFrequency RegulationPower FactorWave FormEfficiencyOverload ProtectionChargerFloat VoltageBoost VoltageBoost TimeMaximum CurrentGeneration ModeMODEL 48/100001000048 Vdc40-60 Vdc250100 watts220 Vac45 amps 3 % RMS for entire battery voltage range50Hz 0.1Hz1Pure Sine Wave92%Circuit BreakerProgrammable Overload Levels and AutoRetry55.2V57.2V to 62.0VSelectable 1, 2, 3 hours100 ampsDepending on the generator poweravailable.28MODEL 48/150001500048 Vdc40-60 Vdc375150 watts220 Vac68 amps 3 % RMS for entire battery voltage range50Hz 0.1Hz1Pure Sine Wave85%Circuit BreakerProgrammable Overload Levels and AutoRetry55.2V57.2V to 62.0VSelectable 1, 2, 3 hours.
The Microcare Pure Sine Wave Inverters deliver true clean sine wave output power. . continuous 24 hour operation. The compact and modular design makes utility interactive installations easier and more cost effective. It is a high quality product that . 1.2.8
output generated: modified sine wave, and pure sine wave1. A modified sine wave can be seen as more of a square wave than a sine wave; it passes the high DC voltage for specified amounts of time so that the average power and rms voltage are the same as if it were a sine wave.
4. Advantages of a Pure Sine Wave Inverter Today s inverters come in two basic output waveforms: modified sine (which is actually a modified square wave) and pure sine wave. Modified sine wave inverters approxi
encodes a sine wave. The duty cycle of the output is changed such that the power transmitted is exactly that of a sine-wave. This output can be used as-is or, alternatively, can be filtered easily into a pure sine wave. This report documents the design of a true sine wave inverter, focusing on the inversion of a DC high-voltage source.
Again modified sine wave inverters are named after their output waveform. The output of the modified sine wave inverter cycles through positive, ground and negative voltage as shown in the diagram above, to give a similar output waveform to pure sine wave. Modified sine wave inverters are a much cheaper alternative to pure sine wave inverters .
800VA Pure Sine Wave Inverter’s Reference Design Sanjay Dixit, Ambreesh Tripathi, Vikas Chola, and Ankur Verma ABSTRACT This application note describes the design principles and the circuit operation of the 800VA pure Sine Wave Inverter. The pure Sine Wave inverter has various applications because of its key advantages such as operation
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