Studer HP-COMPACT HPC 2512 Manual de funcionamiento

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E

User and installer Manual

Sine wave Inverter, Battery charger, Transfersystem

HP-COMPACT - HPC 2512

HP-COMPACT - HPC 4024

HP-COMPACT - HPC 5048

HP-COMPACT - HPC 7048

Remote control RCC-01

Remote power sharing RPS-01

Temperature sensor CT-35

STUDER INNOTEC TEL: ++41 (0)27 205 60 80

Rue des Casernes 57 FAX: ++41 (0)27 205 60 88

H -1

950

N E-MAIL:inf

o@s

uder

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STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 2

Summary

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

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

1.2 QUALITY AND WARRANTY ....................................................................................................................................3

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

1.4 LIABILITY DISCLAIMER .........................................................................................................................................3

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

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

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

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

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

2.3 BATTERY CONNECTING..........................................................................................................................................6

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

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

3.2 FIXING ...................................................................................................................................................................8

3.3 CONNECTIONS .......................................................................................................................................................8

3.4 CONNECTION PLAN................................................................................................................................................9

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

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

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

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

4.2 LIGHT EMITTING DIODES (LED)..........................................................................................................................12

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

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

4.5 THE INVERTER .....................................................................................................................................................13

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

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

4.8 THE MULTIFUNCTIONAL CONTACT......................................................................................................................18

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

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

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

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

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

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

5.3 BATTERY VOLTAGES AND ABSORPTION TIME.......................................................................................................20

5.4 AUXILIARY CONTACT ..........................................................................................................................................21

5.5 DISABLING SOME OF THE HP-COMPACT FUNCTIONS ........................................................................................23

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

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

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

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 3

1 General Information

1.1 Operating instructions

This manual is part of the delivery package of every HP-COMPACT inverter-charger. It

serves as guidelines for safe and efficient operation of HP-COMPACT. The instructions

are only valid for use with the following devices and options:

HP-COMPACT : HPC2512 – HPC4024 – HPC5048– HPC7048

Temperature sensor : CT-35

Remote Control : RCC 01

Remote power sharing : RPS-01

Every person who installs a HP-COMPACT and/or works with it must be fully familiar with

the content of this manual and must follow exactly all the warning and safety instructions.

Installation of or any work on the HP-COMPACT must be carried out by a skilled and

trained personnel. Installation and application must comply with the respective local instal-

lations codes and safety regulations.

1.2 Quality and Warranty

During production and assembling, all HP-COMPACT appliances go through many con-

trols and tests. Production, controls and tests are carried out in accordance with firm and

established procedures. Every HP-COMPACT has its own serial number, which helps to

refer back to its original data in the event of controls or repairs. That is why you should

never remove the identification plate showing the serial number. The production assembly

and tests on all HP-COMPACT appliances are totally carried out in our company in Sion,

Switzerland. The warranty for these appliances is valid for uses and operating possibilities

mentioned in this manual.

The warranty period for the HP-COMPACT is 2 years.

1.3 Warranty Disclaimer

We do not accept any liability for any damages occurring through use, manipulation, wor-

king situation and handling, which are not explicitly mentioned in these operating instruc-

tions.

Following cases are not covered by the warranty:

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

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

- Running liquid or oxidation through condensation in the appliance

- Defects caused by force, physical or mechanical means

- Changes not explicitly authorized by STUDER INNOTEC

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

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

- Damage from atmospheric overvoltages (lightning)

1.4 Liability Disclaimer

Respecting this manual, servicing and method of installation, functioning, application and

maintenance of the appliance can not be controlled or supervised by STUDER INNOTEC.

Hence we do not accept any liability and responsibility for damages, losses and costs

which result through the use of this appliance or which result through incorrect installation,

incorrect operation or wrong application and maintenance, or which by some other means

maybe connected to each other.

The use of STUDER INNOTEC’s inverters does exclusively involve the user’s liability.

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 4

This device is not designed for applications involving health care and medical treatments

where the patient life is concerned and where any mishap may be lethal.

Similarly, we do not accept any liability for any violation of the patents rights or violation of

any third party’s rights resulting from the use of this appliance

STUDER INNOTEC reserves the right to modify the technical data or these operating ins-

tructions without any prior notice.

1.5 Precautions

This manual must be readily available for the user at any time. The user must be familiar

with the precautions and safety aspects in the country of installation.

During operation of HP-COMPACT, high voltages are generated at the connections and

inside of the appliance which could be lethal. Work on the appliance and on the installation

should only be carried out by skilled and trained people.

The whole installation connected with the HP-COMPACT must comply with the rules and

codes in force.

People without the written authorization from STUDER INNOTEC are strictly forbidden to

carry out any change or repair on the appliances. For authorized changes only original

parts are to be used.

The HP-COMPACT may only be used when it has been installed in accordance with these

instructions and all parts have been correctly assembled and installed.

The HP-COMPACT may only be connected to lead-acid or lead-gel batteries.

Caution: Even when a HP-COMPACT has been disconnected from all connections,

at the OUTPUT point there could still be deadly voltages present. To remove these

voltages you must switch on the HP-COMPACT ON with the ON/OFF switch. After

one minute the electronics are discharged and any work can now be safely carried

out.

The HP-COMPACT is only suitable for internal use and under no circumstances should it

be subjected to snow, rain, or any other wet conditions.

By installations in motorized vehicles the HP-COMPACT must be protected from water-

spray and any other wet conditions.

Caution: In normal use lead-acid and lead-gel batteries give out explosive gases. Never

smoke or allow a spark or flame in the vicinity of batteries. The batteries must always be

stored or placed in a well ventilated room, they should be placed in such a way that there

is no danger of short-circuit through carelessness. Never charge frozen batteries.

1.6 Special precautions

While working on batteries there should always be a second person close to you or within

your voice range, in case help is needed.

Plenty of fresh water and soap must be ready at hand so that in case of acid coming in

contact with skin, eyes and clothes, the areas in question can be thoroughly washed.

If acid enters the eyes, you must thoroughly wash them with cold running water for at least

15 minutes. It is recommended that you immediately consult a medical doctor.

Baking powder neutralizes battery acid electrolyte. Always keep some at hand.

Special care must be taken when working with metal tools near or on the batteries. With

tools such as screwdrivers, spanners etc. short-circuits can result. Sparks produced by the

short-circuit can cause an explosion.

When working on batteries all personal metal items such as rings, necklaces and bracelets

must be removed. Batteries are so powerful that short-circuit with these items can melt

them and thus cause severe burns. Always follow the battery manufacturer instructions.

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 5

Under certain conditions HP-COMPACT or a connected generator can start automatically.

While working on an electrical installation you must ensure that these appliances are dis-

connected beforehand from the installation.

2 Introduction

The HP-COMPACT is a sine wave inverter with integrated battery charger with many addi-

tional functions, it has been developed to be used as stand-alone (no grid-feeding) AC

provider, or as continuous / break-free current supply provider (UPS).

2.1 Principle schematic

2.2 Description of the main functions

2.2.1 The inverter

The sine wave inverter HP-COMPACT generates a sinusoidal AC voltage with an excep-

tionnlaly precise voltage and stabilized frequency. In order to start large electric motors,

the user has the possibility to use a short surge power which is 3 times the nominal power

of the HP-COMPACT.

The inverter is protected against overload and short-circuit. A power stage with the latest

MOS-FET power transistors, a toroidal transformer, and a fast regulating system makes a

robust and reliable inverter with the highest efficiency. A 1-20 Watt adjustable charge de-

tection system allows the smallest energy consumption and ensures a long life for the bat-

tery.

2.2.2 The transfer system

HP-COMPACT can be connected to an AC source. For example a stand-by emergency

generator or the AC network. With the transfer system, on one side you have an alternati-

ing voltage at the output for the use of consumer appliances. On the other side the battery

6p 8p

AC IN

AUX.

CONTACT

OFF

ACOUT

OverTe mp.

Overload

ACIN

SOLA RC HA RGE

Contactmanual

Contactactive

Program

COMPA CT

AUXILIARYCONTACT ON/OFF

INVERTER - C HARGER

(Select)

RCC-01

INVER TERCHARGER

(Program) (Changestatus)

Batt ery

Low/High

RESET

ALARM

TRAN SFER

Charger

Inv er ter

100

130

160

A %

EQUALIZE

RCC-01

BATTERY

CT35

100nF

2,2nF

1uF 1uF

4x2,7MΩ

Remote control

Temp. / remote

power sharing

Max. 6m Max. 40m

AC OUT

Equalize

Transfer delay

RPS-01

RCC-01CT35

2,2nF

AC Input AC Output

Temp. sensor

Fuse

Filter

Inverter/

charger

Microprocessor

controlled

Display

Circuit breaker (thermal)

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 6

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

battery charger is automatic.

2.2.3 The battery charger

The built-in battery charger is so designed that it can charge the battery quickly and fully. A

microprocessor controlled, Step charging process, ensures the optimal charging of the

battery. The desired charging current can be set continuously from 0 to 70/90/100/110 A,

as per the model. The setting is made accordingly to the battery capacity and power avai-

lable.

The battery charger is designed for lead-acid and lead-gel batteries. Thanks to the floating

charge system the batteries can remain continuously connected.

2.2.4 Remote control

As an option, a remote control RCC-01 can be connected to HP-COMPACT. All operating

features and displays, save the adjustment levels (22/23/24/26), are available on the re-

mote control. It is supplied with a 20m long cable. This cable can be up to 40m long. On

the remote control, output power and charging current are also displaid.

2.2.5 Remote control for Power Sharing

This remote control RPS-01 can be connected to the HP-COMPACT in the gland for the

temperature sensor. The maximum current available from the energy source can be ad-

justed by the turning button.

2.3 Battery connecting

Lead-acid batteries are normally available in blocks of 2V, 6V or 12V. In most cases, to

generate the necessary operating voltage and the capacity of the batteries for the HP-

COMPACT many batteries have to be connected together in parallel and or in series. Here

are 3 examples of connection:

2.3.1 Connection in parallel

12V 12V 12V

HPC-2512

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 7

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

12V 12V 12V 12V

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

HPC-4024

HPC-5048

HPC-2512

12V 12V 12V 12V

HPC-4024

2.3.2 Connection in serie

2.3.3 Connection in parallel and in serie

3 Mounting and installing

3.1 Installation place

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

- Protection from unauthorized handling

- Dry dust free room, no condensation

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

- Keep ventilation holes free

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

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 8

3.2 Fixing

3.2.1 HP-COMPACT

Basically the HP-COMPACT can be installed in any desired location but only vertically.

First of all the plate supplied along with the HP-COMPACT must be screwed firmly (due to

the weight of the device) on the wall. Then the HP-COMPACT is hooked on the plate and

screwed underneath.

Cautious: the fixing must be fully made otherwise the HP-COMPACT may fall and cause

important damages.

In motor vehicles HP-COMPACT must be fixed on vibrations reducing elements. The HP-

COMPACT must not be fixed on a combustible base, as the back of the casing can get hot

and reach up to 60 degrees Celsius.

3.3 Connections

3.3.1 General instructions on connecting

The cable connection on the terminals AC INPUT and AC OUTPUT must be carried out

with a screwdriver Nr.3 and the connection of the AUX RELAY terminal with a screwdriver

Nr.2.

The conductor cross section on the terminals AC INPUT / AC OUTPUT / must comply with

the local rules.

All connecting cables and also the battery cables must be fixed with strain relief clamps.

The fuses supplied with the HPC4024, 5048 and 7048 have to be installed (see descrip-

tion in 3.4). The cable cross section for the HP 2512, 4024, 5048 and 7048 is resp. 95, 70,

50 and 70 mm2and their length must be as short as possible (max. 2m).

The fuse supplied with the product (save for HPC 2512) does not protect the battery ca-

bles.

To protect the battery cables, a fuse corresponding to the conductor cross section must be

fixed directly on to the battery.

All cables must be tightly screwed in place. For safety, a yearly control is recommended. In

mobile installations controls must be carried out more often.

Connecting must be done by qualified people. Material such as cable, connectors and dis-

tribution boxes, fuses etc. used in the installation must comply with the respective valid

low-voltage installation rules and regulations in force.

3.3.2 Protection cover of the terminals connections

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

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 9

3.4 Connection Plan

A Battery +/- Connection terminal (M8) for battery cable (HPC 4024/5048/

7048 with fuse)

B Reserved

C Remote contr. Connection terminal for Remote Control RCC-01

D Transfer delay Slide switch for Transfer Delay

E Equalize Slide switch for equalization of the Battery

F Temp. Connection terminal for Temperature sensor CT-35 and/or

Remote Power Sharing RPS-01

G Aux. Contact Connection terminal for Auxiliary Contact

H AC Input Connection terminal for AC-input

J ID Plate Identification plate with Technical data and Serial number

K AC Output Connection terminal for AC-output

L Reserved

M Hole Pass through hole for RCC-01, CT-35 and RPS-01

N Protection Thermal circuit breaker 30A (50A for HPC7048) for the

Transfer system

3.5 Cabling

Connecting the HP-COMPACT is a very important step of the installation. You must take

care that all connection work is carried out in a clean and correct way and that under no

circumstance a cable is connected to a wrong terminal.

Connecting of the HP-COMPACT must be carried out in the following order. In case of

dismantling this order must be reversed.

LN LN

Battery AC in AC out

Auxiliary

contact

Remote

control

RCT-01

temperature sensor CT35

H G K

remote power sharing RPS-01

STUDER INNOTEC HP-COMPACT

User manual HP-COMPACT V3.0 E 10

3.6 Pre-installation settings

Before you start with the cabling of the HP-COMPACT you must set the type of battery. In

case sealed-gel batteries are used then you must set the small slide-switch „Equalize“

which is on the front with the connection terminals, in OFF position. In case of „normal“

lead-acid – batteries, these can handle a higher equalizing charge, the same slide switch

can be set in ON position. In case of doubt leave the setting in OFF position.

This will allow an equalizing cycle (higher end of charge voltage) during the next charge

process. Since then equalizing will occur every 25 usual cycles.

3.6.1 Connection to battery

3.6.1.1 On the appliance side

Mount the supplied glands on the battery cable before the setting of the cable terminal. Set

the cable terminal and mount the glands on the appliance. Repeat the process for the sec-

ond battery cable.

Connect the red cable (+)

on the “+ Battery” appliance

connection point according

to the plan below.

Connect the black cable (-)

on the “- Battery” appli-

ance connection point

according to the plan

above.

The supplied fuse (except

with the HPC2512) must

be mounted according to

the plan below.

3.6.1.2 On the battery side

Caution: before connecting the battery, check carefully the voltage and the battery polarity

with a voltmeter. A polarity reverse will seriously damage the inverter (for example: con-

necting a HPC2512 to a 48V-Battery).

Get the batteries ready for connection: suitable terminals, fuse on one of the connection

points, cable in good shape with, if necessary, terminals rightly set. Mount the red cable on

the positive (+) pole, and the black cable on the negative (-) pole of the battery.

While connecting the second cable, a spark due to the charge of the capacities at the input

stage is normal. In the same time an acoustic signal tells that the control processor has

started. All LED’s of the synoptic light during a short time, then the synoptic shows that the

appliance has stopped. The LED “OFF” (13) must be turned on.

After the battery connection, the battery state-of-charge LED shows a 100% capacity dur-

ing 1 to 2 minutes, the necessary time for the processor to compute again the current

state-of-charge of the battery.

If the LED “Battery Low/High” (12) is lighting, the battery voltage is too low. If it is blinking,

the battery voltage is too high. Caution: a battery voltage too high or inappropriate can se-

Cable terminal M8

Bolt M8 x 16

Steel washer

Lugs M10

Screw M8x30 Torque 10Nm

Steel washer

Ceramic washer

Fuse CF8

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