Airpax Dimensions ADI-64/500 User manual

OWNERS MANUAL JANUARY 2007
Airpax Dimensions, Inc.
DC to AC Power Inverters
OWNERS MANUAL for Model:
121335B
ADI-64/500
Form 121335
A
irpax Dimensions, Inc.
4467 White Bear Parkway [phone]
St. Paul, MN 55110-7626 Fax [phone]

OWNERS MANUAL
FOR AIRPAX DIMENSIONS
INVERTERS
Model ADI-64/500
Table of Contents
Page
1. General . . . . . . . . . . . 2
2. Description . . . . . . . . 2
3. Installation . . . . . . . . 2
4. Start Up/Operation. . . 4
5. Troubleshooting. . . . . 4
6. Installation Figure 1 . . 5
7. Limited Warranty. . . . .6
Page 2
1. GENERAL
1.01 Dimensions inverters have been
designed and manufactured for many user
applications and long life. They utilize
patented construction methods and high
technology electronic parts and circuitry.
1.02
CAUTION: Inverters produce haz-
ardousvoltages,toavoid riskofharmorfire
the unit must be properly installed. There
are no user serviceable parts inside, do not
remove the cover.
CAUTION: The inverter should not be
mounted in a location that may be exposed
to rain or spray.
CAUTION: The inverter should not be
installed in a zero clearance enclosure.
CAUTION: Damagetotheinverterwilloccur
if correct polarity is not observed when
installing the DC input cables.
CAUTION: Damagetotheinverterwilloccur
if an external AC power source is applied to
the inverter’s AC output or its hardwire
output.
CAUTION: The inverter contains a circuit
breaker and capacitor that may produce a
spark. Do not mount in a confined battery or
gas compartment.
CAUTION: Working in the vicinity of lead-
acid batteries is dangerous. Batteries gener-
ate explosive gases during operation. There
is a risk of acid exposure. There is also a risk
of high current discharge from shorting the
battery that can cause fire and explosion.
CAUTION: Be sure both the inverter and, if
used, the external AC input circuit breaker or
fuse, are turned "OFF" during installation.
2. DESCRIPTION
2.01The inverter converts64 VDCto regu-
lated 120 VAC, 60 HZ, having a quasi-sine
wave form.
2.02 The inverter has a controlled output
frequency of 60 HZ + 0.6Hz.
2.03
The inverter has internal protection
against output short circuit, output overload
andhightemperatureconditions. Also,there
is a thermally controlled cooling fan.
2.04 The inverter is designed to operate
al
most any 120 VAC, 60 HZ, single phase
equipment within its power ratings, unless
theequipmentisspeciallydesignedforapure
sine waveform.
3. INSTALLATION
3.01The following instructions should be
thoroughly read and understood before instal-
lation.
3.02 CAUTION: Inverters produce hazard-
ousvoltages. To avoidrisk of harmor fire the
unit must be properly installed.
CAUTION: Damagetotheinverterwilloccur

ifcorrectpolarityisnotobservedwheninstall-
ing the DC input cables.
CAUTION: Damage to the inverter will occur
ifanexternalACpowersourceisappliedtothe
inverter’s AC outlet or its hardwire output.
CAUTION: Be sure both the inverter and the
external AC input circuit breaker or fuse (if
needed) are turned "OFF" during installation.
NOTE: All wiring must follow the National
Electric Code, Provincial, or other codes in
effectat the timeof installation, regardlessof
suggestions in this manual. All wires should
be copper conductors.
3.03 Mounting
3.03.1 Locate a suitable, secure flat
mounting surface as close to the battery as
possible without being in the same air tight
compartment.
3.03.2 The location should have ad-
equate ventilation and clearance to maintain
roomtemperaturewhiletheunitisoperating.
Atleast1/2inchofclearanceisrequiredonall
sides.
3.03.3 Secure the unit with #8 or
largerscrewsorboltsinthemountingslotson
the flanges of the chassis.
3.04 Chassis Bonding Lug - FIG. 1
3.04.1 Connect a #8 gauge or greater
copper wire between the bonding lug on the
inverter and the earth grounding system or
the vehicle chassis.
3.05 Battery Wiring - FIG. 1
3.05.1
CAUTION: Make sure that hy-
drogen gas does not accumulate near the
battery by keeping the area well ventilated. A
sparkmayresultwhenconnectingthebattery
wiringduetoaninitialchargingoftheinternal
input capacitor.
3.05.2 Use stranded copper wire be-
tween the battery and inverter as indicated.
Aline fuse must be installed between the
battery and the inverter, within 18 inches of
the battery.
DC Input Wire Lengths (maximum)
and Fusing Guide
Distance(feet)
Model 1-19 20-40 Fuse
64/500 12 ga 10 ga 15
3.05.3 NOTE: Using smaller input
cable or longer length will greatly degrade
the inverter surge performance.
IMPORTANT NOTE FOR VEHICLE
INSTALLATION:
Do not use the vehicle
chassis as the negative return in place of a
return cable. Use the same size cable as
the positive connection and run directly to
the battery.
3.05.4 Install the wires at the battery,
inverterandthenfuseholder. Makesurethat
clean,tightconnectionsaremade. Usecare
nottotouchthepositiveandnegativewires
together. Thiswillresultinaviolentsparkand
couldresultinexplodingbatteriesandfire.
3.05.5 The battery input terminals are
locatedintheinverterwiringcompartment. A
sparkmayresultwhenconnectingthebattery
wire, due to an initial charging of the internal
input capacitor.
3.05.6
CAUTION: Damage to the
inverter will occur if correct polarity is not
observed. This damage is
NOT covered by
warranty.
3.06 120 VAC Output
3.06.1
CAUTION: Do not connect an-
Page 3

5.02 If the inverter fails to operate, use the
following troubleshooting procedure.
5.02.1 Connecta100wattlightbulbto
the inverter output.
5.02.2 Makesuretheinverteristurned
"On", the output circuit breaker is reset and
that the voltage is at least 64 VDC at the DC
input terminals. If not, check DC wiring con-
nections and the line fuse.
5.02.3Observethefaultindicatinglights
on the front of the inverter.
a) The Low battery light indicates a low
DC condition. Switch the inverter “Off” for 5
seconds, then “On” again. The light coming
on again indicates a fault in the DC wiring, DC
voltage, or the line fuse.
b)TheOverloadlightindicatesanoutput
wiring short circuit or a load that is too large
forthepowerratingoftheinverter. Switchthe
inverter “Off”, remove the short circuit or
excessive load from the output, then switch
the inverter back “On”.
c) The High temperature light indicates
the inverter has overheated. The unit will
automaticallyturnbackonwhenithascooled
to 400C. Verify that the inverter is not in a
closed compartment and that the fan is not
blocked.
5.02.4 If the above steps are
completed and
the inverter still will not oper-
ate satisfactorily, call Airpax Dimensions, Inc.
for a return authorization number.
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other source of AC power directly to the
output of the inverter. This will result in
damage to the inverter that is not covered
under warranty!
3.06.2 The 120 VAC output of the
inverterisprovidedatthereceptacleoutleton
the inverter.
3.06.3 The 120 VAC output is also pre-
sented behind the wiring compartment panel
fordirecthardwirewireleads.Theblackishot,
thewhite wireis neutral and the greenwire is
ground. The cable clamp strain relief should
be used to secure the field wires.
3.06.4 Remote AC outlets should be
mounted at a convenient location in a listed
outlet box with approved strain relief. The
GFCIoutletsshouldbeHubbell,ModelGFR5352XX
(20A) or GFR5252XX (15A).
4. START UP/OPERATION
4.01To operate the inverter turn the switch
to “On”. Make sure that the output breaker is
reset.
Turn the switch to “Off” when the
inverter is not in use.
5. TROUBLESHOOTING
5.01 Dimensions offers free phone consul-
tationconcerninginstallationortroubleshoot-
ing.
Call the Customer Service Department at:
1-651-653-7000 or 1-800-553-6418
fax: [phone]
e-mail: [email protected]
NOTE: Becausethe inverterhasaquasi-sine
waveform, a TRUE RMS voltmeter (such as a
Fluke 87) is required for an accurate reading.
Other voltmeters that use averaging circuitry
will give incorrect readings.

Page 5
Low battery
High Temperature
Charge voltage
adjustment
External power
Output
breaker
POS
NEG
BondingLug
Fuse
Fuseholder and Fuse
AC Hardwire
Output
On
Off
Inverter power
Inverter
Overload
FRONT VIEW
64 VDC
Source

Limited Warranty
SHIPPING TERMS: F.O.B. St. Paul Minnesota. Freight prepaid and billed, subject to prior credit approval.
MINIMUM ORDER: $50.00 Net Price
LOSS OR DAMAGE: Loss or damage in transit is the responsibility of the carrier. Any claim should be filed with the delivering
transport company. Invoice, Bill of Lading and Delivery receipt with damage noted therein must accompany any claims for
freight damage. Claims for shortage and lost shipments must be made in writing to Airpax Dimensions, St. Paul, MN within 10
days of date of shipment. Claims not reported within this time frame will not be honored.
PRICES: Prices are subject to change without notice. All orders are subject to acceptance at the factory. We reserve
the right to invoice prices in effect at time of shipment.
TERMS: Net 30 days with approved credit, credit card or C.O.D.
RETURNGOODSPOLICY
No returned materials will be accepted without an accompanying Returned Materials Authorization Number (RMA) from
factory.
Credit will be issued for returned goods to the original purchaser within 60 days of purchase, provided the inverter is returned
to Dimensions unused and not mounted. The amount of credit will be issued at Dimensions discretion based on the
condition of the product.
Customer must be in good standing with Dimensions.
Inverters that are discontinued, high-voltage (over 24vdc), special-order or used are excluded and will not be eligible for
credit. Non-inverter items such as cable assemblies, fuses and fuse holders, will not be eligible for credit
Support components supplied by Dimensions vendors will be covered under that manufacturer’s credit return policy.
Customer pays return freight.
PLEASE SHIP FREIGHT PREPAID AUTHORIZED RETURNS TO:
Airpax Dimensions, Inc. / 4467 White Bear Parkway / St. Paul, MN 55110
LIMITED WARRANTY: Dimensions warrants to the original purchaser for use that the goods or any component thereof
manufacturedbyDimensionswillbefreefromdefectsinworkmanshipforaperiodof1yearfromthedateofpurchase,provided
suchgoodsareinstalled,maintainedandusedinaccordancewithDimensionsandtheoriginalmanufacturer’swritteninstructions.
ComponentsnotmanufacturedbyDimensions,butusedwithintheassemblyprovidedbyDimensions,aresubjecttothewarranty
period as specified by the individual manufacturer of said component, provided such goods are installed, maintained and used
inaccordance withDimensionsand themanufacturer’swritten instructions.
DimensionssoleliabilityandthePurchaser’ssoleremedyforafailureofgoodsunderthislimitedwarrantyandforanyandallclaims
arising out of the purchase and use of the goods, shall be limited to the repair or replacement of the goods that do not conform
to this warranty. The return of the purchase price in cash is at the sole discretion of Dimensions.
To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return
Material Authorization (RMA). Once obtained, send the Return Material Authorization Number along with the defective
part or goods to: Airpax Dimensions, Inc., 4467 White Bear Parkway, St. Paul, MN 55110, freight prepaid.
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE
YEAR FROM DATE OF PURCHASE.
DIMENSIONS ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THE PRODUCT, EXCEPT AS
STATED IN THIS LIMITED WARRANTY. DIMENSIONS WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
WARNING: LIMITATIONS ON USE: Dimensions products are not intended for use in connection with Life Support Systems
and for Avionic use. Dimensions makes no warranty or representation in connection with their products for such uses.
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