Orbit BEHLMAN INV 1210 Use and care manual

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USER'S GUIDE AND
TECHNICAL REFERENCE
DC TO AC INVERTER
BEHLMAN MODEL INV 1210
FOR SERVICE ASSISTANCE
CONTACT BEHLMAN
CUSTOMER SERVICE DEPARTMENT
PHONE TOLL FREE 1-800-874-6727
OR WRITE
BEHLMAN
CUSTOMER SERVICE DEPARTMENT
80 CABOT COURT
HAUPPAUGE, NY 11788
PHONE: [phone]
FAX : [phone]
FOR SALES INFORMATION:
PHONE: [phone]
USA : [phone]
FAX : [phone]
DATE: 8/00 REV: -

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SAFETY SUMMARY
Thefollowingsafetyprecautionsmustbeobservedduringallphasesofoperation,service,and
maintenance of this equipment. Failure to comply with these precautions or with specific
warnings elsewhere in the manual violates safety standards associated with the design and
intendeduse of this equipment. This manual formsanintegralpart of the equipment and must
be available to operating personnel.
GROUND THE EQUIPMENT
This equipment may have high leakage current to chassis due to EMI filtering requirements. To
minimize shock hazard, the equipment chassis(s) must be connected to an electrical safety ground.
This equipment is supplied with a three conductor line connection for single phase applications
and/or a five wire connection for three phase applications. Both types include an earth terminal
intended for safety ground connections. In addition, isolated installation sites may require neutral to
earth connections as per NEC section 250 (National Electrical Code). Refer installation to licensed
electrician or other qualified personnel.
DO NOT OPERATE IN EXPLOSIVE ATMOSPHERE
Do not operate the equipment in the presence of flammable gases or fumes. Operation of any
electrical instrument in such an environment constitutes a definite safety hazard.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel must not remove equipment covers. Component replacement and internal
adjustments must be made by qualified maintenance personnel. Do not replace components with
power applied. Under certain conditions, dangerous voltage may exist even with the power removed.
To avoid injuries, always disconnect power and discharge circuits before touching them. During
normal operation the operator does not have access to internal hazardous voltages. However,
depending on the user’s application configuration, HIGH VOLTAGES HAZARDOUS TO
HUMAN SAFETY may be normally generated at the output terminals. The customer/user must
insure that the output power lines are labeled properly as to the safety hazard and that any
inadvertent contact is eliminated.
DO NOT SERVICE OR ADJUST ALONE
Do not attempt internal service or adjustment unless another person, capable of rendering first
aid and resuscitation is present.
DO NOT SUBSTITUTE PARTS OR MODIFY INSTRUMENT
Because of the danger of introducing additional hazards, do not install substitute parts or perform
any unauthorized modification to this equipment. Contact Behlman Electronics for proper
replacement parts and specific service information.

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DANGEROUS PROCEDURE WARNINGS !
Warnings will precede potentially dangerous procedures in this manual. Instructions contained in
the warning must be followed. Warnings will be preceded by the caution symbol (above).
RISK OF ELECTRIC SHOCK
This symbol warns personnel of hazardous conditions due to the exposure of hazardous voltage
that can be lethal if contacted.
Neither Behlman Electronics, Hauppauge, NY, USA, nor any of the subsidiary sales
organizations can accept any responsibility for personnel, material or inconsequential injury, loss
or damage that may result from improper use of the equipment and/or accessories provided.
For additional safety related technical information, contact the Behlman Electronics sales
department or local sales representative.
[email protected]

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CLAIM FOR DAMAGE IN SHIPMENT
Under the FOB factory terms of sale, ownership and responsibility are transferred to the customer
whentheequipmentleavesthefactory.EachBehlmanproductis shipped from the factory in proper
operating condition.
Immediately upon receiving equipment, unpack and inspect it for evidence of damage incurred in
shipment. File a claim with the freight carrier if the equipment has been damaged in any way or it
fails to operate properly. Forward a copy of the damageclaim report toBehlman. Include the model
number, serial number and date the shipment was received. Behlman will advise the disposition of
the equipment and will arrange for necessary repair or replacement.
RETURNING EQUIPMENT TO FACTORY
Do not return equipment to the factory without prior authorization from Behlman.
A RETURN MATERIAL AUTHORIZATION NUMBER (RMA) is required to return equipment.
This equipment, like all precision electronic equipment, is susceptible to shipping damage. It
contains heavy magnetic components as well as delicate electronic components.
If equipment is returned without prior authorization, the shipment will be refused, the customer
being liable for all shipping, handling and repair costs.
When packing for reshipment, use the original shock absorbent material and shippingcontainer to
preclude damage to the equipment.
Insure that the return authorization numbers (RMA) is available on the container for identification.
SHIPPING INSTRUCTIONS
RACK MOUNTED UNITS
1) Box(es) must be double wall with minimum 350 lbs. bursting test.
2) Box(es) must provide for a minimum of 3 to 4 inches of clearance around sides, top and
bottom of unit.
3) When packing unit, utilize either a foam-in-place system or high density foam. Clearance
provided for above must be completely filled with foam.
FAILURE TO COMPLETELY SECURE UNIT IN BOX WILL ALLOW
MOVEMENT DURING SHIPPING, RESULTING IN DAMAGE.
4) Secure box(es) to pallet(s). This is necessary to insure proper handling and protection
during shipping.
5) Place the following warning label on box(es)
DO NOT STACK
6) Ship unit(s) using a freight cargo carrier; air or ground.
CABINET MOUNTED UNITS
Cabinet mounted units require that a special crate be used. The crate should be manufactured of
plywood (3/8" or thicker) and reinforced (using 1 x 3 or larger pine) on all edges. The unit must be
firmly secured to the crate’s base. The crate must be shock mounted to avoid damage during
shipping. Detail drawings for Behlman's crates are available upon request.

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WARRANTY CERTIFICATE
Behlman Electronics, Inc. warrants to the original purchaser, for a period of one (1) year from the
shipment from Behlman, each item to be free from defects in material and workmanship. Behlman’s
obligation and the Purchaser’s sole remedy for any breach or violation of this agreement is limited to
adjustments, repair or replacements for parts which have been promptly reported by the Purchaser as
having been in its opinion, defective and so found by Behlman upon inspection. All replacement parts
will become the property of Behlman on an exchange basis. This warranty will not apply if such
adjustment repair or parts replacement is required because accident, neglect, misuse, failure of
environmental controls, transportation damage or causes other than normal use.
If during the warranty period a defect should impair the performance of the unit, Behlman agrees, at its
option, to repair or replace the unit or its defective components F.O.B. Behlman at 80 Cabot Court,
Hauppauge NY 11788 or at another Behlman service facility at Behlman’s option. To obtain service
under this warranty, the original Purchase shall notify Behlman at the above address or by telephone at
631-435-0410 and provide information about the defect or impairment of performance. Behlman with
then supply the Purchaser a Return Material Authorization (RMA) number. This number must be
attached to the equipment sent back for warranty repair. Equipment must be shipped back to Behlman
prepaid. No collect shipments will be accepted.
Behlman shall be excused from supplying warranty service if the unit’s case has been opened or if the
unit has been subject to unauthorized repair. All service outside the scope of this warranty shall be
paid for by the Purchaser at Behlman’s rates in effect at the time of this repair. Behlman will not
perform any repairs outside of the warranty without written authorization by the Purchaser. If the repair
is a warranty repair, Behlman will ship the unit back to the Purchaser, by a method determined solely
by Behlman, prepaid. If the Purchaser requests, any other means of transportation it shall be at the
Purchaser’s expense.
The use of the equipment shall be under the Purchaser’s exclusive management and control. The
Purchaser will be responsible for assuring the proper installation, use, management and supervision of
the equipment. Behlman will not be liable for personal injury or property damage.
The forgoing warranties are in lieu of all other warranties, expressed or implied including without
limitation warranties of merchantability and fitness for purpose.
In no event shall Behlman be liable for loss of profits, loss of use, or any indirect, consequential or
incidental damages. Purchaser agrees that Behlman will not be liable for any damages caused by the
Purchaser’s failure to fulfill any of the Purchaser’s responsibilities set forth herein.

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OPERATING MANUAL FOR MODEL SERIES INV 1210
TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 Specifications
2.0 THEORY OF OPERATION
3.0 OPERATING INSTRUCTIONS
3.1 Installation
3.2 Wiring
3.3 Controls and Indicators
3.4 Optional alarm contacts
4.0 OPERATIONAL CONSIDERATIONS
4.1 Load Limitations
4.2 Powering Reactive Loads
4.3 Powering Lamps
4.4 Powering Motors
4.5 Powering Non-Linear Loads
5.0 TROUBLESHOOTING
5.1 Maintenance
6.0 MECHANICAL OUTLINE
REVISION HISTORY

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1.0 INTRODUCTION
The Behlman INV 1210 series of power inverters incorporate the latest in switched
mode power technology to provide regulated AC power from a user supplied DC source.
These devices produce a” modified sinewave” output, which represents the RMS value
of what is available from typical utility power.
Each model provides electronic protection along with a high short term overload
capacity making them ideal for many loads requiring large “in - rush” currents. All units
are housed in a rugged steel enclosure making them well suited to operation in industrial
applications.
Available options include an AC input bypass and signaling contacts. The AC bypass
option is available in two configurations. The “DI” option favors the DC input and will
switch to AC when the DC input is lost. The second option , A1, will favor the AC line
input and will switch to the inverter if the line is lost. These features allow the unit
to be incorporated into a user defined back-up power system.
1.1 SPECIFICATIONS
INPUTS:
MODEL DC INPUT DC BURDEN
1210-250 250 VDC +/- 20% 7.5 AMPS @ 210 VDC
1210 - 125 125 DC +/- 20 % 15 AMPS @ 100 VDC
1210 - 48 48 VDC +/- 20 % 40 AMPS DC @ 38 VDC
AC INPUT (optional bypass mode only) 130 Vac max @ 15 amps (internal fuse)
OUTPUT
Power: 1200 VA
Voltage: 120 VAC +/-2% 60 Hertz (available @ 50 and 400 Hertz)
Current: 10 amps continuous (60 amps peaks)
Waveform: Modified sinewave
Efficiency: Better than 85% at nominal input.
PROTECTION
Input: DC circuit breakers (AC 15 amps fuse. optional )
Output: Electronic over current protected.
Thermal: Thermal cut-out monitors temperature. Shuts down during
Over-temp conditions. Automatic Reset.
MECHANICAL 3.5"H x 17" W x 17"D (rack mountable)
ENVIRONMENTAL Operating temperature 0 to +55C, 95% RH non - condensing

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2.0 THEORY OF OPERATION
The INV 1210 series utilizes high frequency switched mode power conversion to
convert the incoming DC to an AC output. The first stage is a DC to DC converter which
“steps - up” the input voltage to a regulated +/- 160 Vdc. This voltage is applied to a
second high frequency “house keeping” supply and the output inverter. The house-
keeping supply provides operating voltage for the output inverter and alarm circuits.
The output section consists of a crystal controlled oscillator and power switching
devices. The crystal derived clock frequency is divided down and applied to optically
isolated IGBT drivers. The result is a 320V p/p pulse train at the output Frequency. The
peak value of this pulse train is equivalent to the peak value of a 120Vac rms. This type
of waveform is known as Modified sinewave.
The control circuitry on the output inverter assembly also provides protective functions.
Output current is measured and used to provide foldback type limiting in the event of an
overload. Output short circuits will terminate output pulses, when peak current exceeds
approximately 60 Amperes. If the overload is left unattended the unit will enter a “burst
mode” as it repeatedly attempts to drive the overload.
The alarm and bypass circuits ( if provided ) allow for external monitoring of input
and output status. The AC input/ bypass feature allows the AC power line to be applied
to the model INV 1210 and sent directly to the output terminals. In the event the AC
is interrupted, a relay will switch the output to the inverter. Units supplied with the D1
option will switch the line through when the DC is not available or the inverter has
a fault .The AC input is fused at 15 amps.

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3.0 OPERATING INSTRUCTIONS
3.1 INSTALLATION
The INV 1210 series inverters have been designed to be installed in a standard 19" relay
rack or EIA type enclosure. A set of accessory rack “ears” are provided for this feature.
These rackmount adapter brackets may be mounted at the front panel or in the middle of
the chassis. In both cases, the adapters are held in place using #10/32 hardware.
CAUTION! WHEN INSTALLING RACK MOUNT ADAPTERS,
HARDWARE USED (MACHINE SCREWS) MUST NOT EXCEED
3/8" IN LENGTH. LONGER SCREWS MAY DAMAGE INTERNAL
COMPONENTS AND CREATE A SHOCK HAZARD
Mount the unit in a suitable location as not to block the flow of cooling air at the front,
rear and sides of the inverter chassis. This device will pull in cool air from the front and
sides and exhaust warm air from the rear. It is recommended that a minimum clearance
of 3 inches be provided at the front and rear and 1 to 2 inches on the sides.
When rack mounting, it is permissible to mount the inverter by the mounting ears only.
If the unit is intended for use in a mobile or other high vibration application the use of
additional support for the rear of the chassis is highly recommended.
3.2 WIRING
Wiring to the inverter will vary depending on voltage and options ordered. In addition
local electrical codes must be considered for permanent installations. The NEC
(National Electrical Code) requires that separately derived AC sources (back-up
generators, inverters, ect.) must have one conductor bonded to earth ground. This
may be accomplished with the 1200 series by following the recommended hook -up
diagrams that follow. These examples require the terminal strip output option.
WARNING!
ALL INSTALLATIONS AND VERSIONS OF THIS DEVICE REQUIRE THE USE OF
THE SAFETY EARTH CONNECTION TO THE CHASSIS. FAILURE TO DO SO MAY
CREATE A FIRE OR SAFETY HAZARD. THE VOLTAGE AND CURRENT
PRODUCED BY THIS UNIT CAN BE LETHAL. REFER INSTALLATION TO
QUALIFIED PERSONNEL.
FAILURE TO OBSERVE DC POLARITY ON THE INPUT TO THIS DEVICE MAY
CAUSE DAMAGE TO THE INTERNAL CIRCUITRY. THIS WILL VOID EQUIPMENT
WARRANTY

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3.2 WIRING (continued)
Units supplied with the AC input bypass option should be wired slightly differently so
that neutral is “carried through” to the output but is not shorted to the GND terminal.
This
will place one side of the inverter output at the neutral potential. It should be noted that
this is only recommended to satisfy the NEC requirements. The output of the inverter is
isolated from the DC input and the line.
For units supplied with NEMA 15R type receptacles, simply connect the DC input to
the inverter and plug the load into the receptacles. Connect the chassis of the inverter to
an external earth ground.

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3.2 WIRING (continued)
The recommended wire size for each model is listed below. These sizes are based on a
maximum wire length of 10 to 15 feet. Longer wires should be increased in diameter.
MODEL #
DC INPUT WIRING AC INPUT \ OUTPUT WIRING
1200-48-XX # 8 AWG ( 45 A) # 14 AWG ( 15 A max.)
1200-125-XX # 12 AWG (15 A typ.) # 14 AWG ( 15 A max )
1200-250-XX #14 AWG ( 7.5 A typ.) # 14 AWG ( 15 A max )
3.3 CONTROLS AND INDICATORS
Refer to figure on the next page for locations.
1. DC POWER CIRCUIT BREAKER Switch inverter on/off, protects DC source.
2. AIR INTAKE Pull in cooling air, min 3" clearance.
3. STATUS LEDs Indicate presence of AC IN, DC IN, and
INVERTER status. (optional)
4. LINE BYPASS FUSE Protects input line when used as stand-by
Supply (optional).
5. OUTPUT CONNECTOR 2 NEMA 15R shown. Connects inverter to
load. Also available as terminal block or
special (consult factory).
6. AC LINE INPUT For applying AC line input for feed through
During stand-by type operation. #6/32
hardware.
7. FAN EXHAUST Min 3" clearance.
8. DC INPUT For connecting DC input to inverter. Uses
#8/32 hardware.
9. ALARM CONTACTS 3 “C” form, “dry” contacts for monitoring
AC IN, DC IN, and INVERTER. (optional)
NOTE: An additional #10/32 grounding stud is provided on the rear panel of the unit to be used
as a convenient safety earth connection.

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CONTROLS AND INDICATORS MODEL INV 1210 SERIES
INVERTERS ALL MODELS

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3.4 OPTIONAL ALARM CONTACTS
The alarm contact option provides the user with a convenient means of monitoring
the DC input, AC input, and AC output of the inverter. Each function provides one
set of “dry” C form contacts which accommodate any logic required. The contact rating
of the alarm functions are 0.3 amp @ 125 Vac maximum. These alarms will indicate the
availability or loss of each voltage. The figure below illustrates the alarm wiring.
3.5 OPERATION
1. Connect the load to the inverter. If multiple loads are used it is good practice to
switch all loads off before switching on the inverter. This will prevent multiple
in - rush currents from tripping protective circuits in the inverter.
2. Switch on the inverter. At this point, the sound of the cooling fans should be evident.
3. If the inverter contains the alarm / bypass option, the appropriate front panel LEDs
should be illuminated.
4. To test the inverter, use a True RMS type meter to confirm the output voltage is as
specified.
5. To test bypass functions on units equipped as such, remove the AC input and confirm
that the INVERTER lamp stays illuminated and the inverter output voltage is still
present. For units with the DI option, switching the DC off will place the unit in the
bypass mode and the AC line input will be routed to the output connector.

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4.0 OPERATIONAL CONSIDERATIONS
4.1 LOADING LIMITATIONS:
The INV series are designed to produce a power level of 1200 Watts ( real power) under
continuous operating conditions. In addition, they can supply bursts of over 1500 watts
for several seconds. Peak repetitive currents on the order of 60 amps may also be
supplied continuously as long as they do not exceed the RMS value of 10 amps.
This high peak current capability allows the INV 1210 series to start most high in - rush
loads. It must be understood that the DC power source suppling the inverter must also
have this capability in order to derive these benefits. A poorly regulated or high internal
resistance DC power source will affect operation of the inverter.
4.2 POWERING REACTIVE LOADS
Capacitors and inductors are reactive in nature. If the load is applied during the peak of
the AC cycle there may be a considerable in rush of current several magnitudes larger
than the steady state current. This current is only limited by any series resistance that may
be present in the load circuit. Under the right conditions, this could trip the overload
protection circuits in the inverter.
Several methods can be used to prevent tripping the protection circuits in the power
source . One common method is to insert a limiting impedance in series with the load.
This could be in the form of a fixed resistor or NTC (negative temperature coefficient)
thermistor. Also, zero crossing switching can be employed.
Loads with a large parallel capacitance will draw large current spikes during the edge
transitions of the output waveform. This may generate EMI (electro-magnetic
interference). Also, loads that are pure inductors will produce “ringing” on the edges of
the output waveform which will also cause EMI. If the loadto be supplied are purely
capacitive or inductive, the Behlman model INV1200 should be considered. The model
1200 produces a sinewave output.
4.3 POWERING LAMPS
Tungsten filaments lamps, when cold, present a very low resistance. Once they are
energized, their resistance quickly climbs to it’s steady state value. This characteristic
must be accounted for when driving tungsten filament lamps. The same methods for
driving reactive loads can be applied to tungsten.
4.4 POWERING MOTORS
Driving an AC motor presents a special problem. Most motors require a starting current
that is several times higher than the running current. This current may last for a few
cycles to several seconds depending on the construction and mechanical load on the
motor. This current is sometimes referred to as the motor’s “locked rotor” current. This
current is not to be confused with the in- rush current that usually occurs over the course
of one or two cycles of the AC waveform.

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4.4 POWERING MOTORS (continued)
The model 1210s current limiting can be an advantage when starting motors.
During the starting period, the motor will attempt to draw excessive power from the
inverter. The current limit circuit will “pulse” the output current with high peaks in
an attempt to start the motor. During this time the current supplied to the motor will
be a series of 60 amps “bursts”, this allows the motor to start rotating. Once the motor
reaches it’s normal operating speed, it generates the required “back EMF” and the supply
current drops off to the nominal “run” current for the motor.
Note that certain types of motors will not run well using the modified sinewave produced
by this device. If in doubt, consult the motor manufacturer.
4.6 POWERING NON-LINEAR LOADS
Loads utilizing rectifiers and SCRs interact with the AC power source and have a
profound effect on the output waveform. Consider the use of a bridge rectifier followed
by a capacitive filter, the current waveform associated with this circuit is illustrated
below. The input current to this type of circuit is drawn in large “gulps” whenever the
voltage across the capacitor falls below the peak of the input waveform. This current is
limited only by the series impedance present in the wiring and capacitor. The impedance
of large electrolytic capacitors is very small. This action causes a current waveform with
a peak value that may be several times the RMS value. This ratio of peak current to RMS
current is known as “Crest Factor”. High values of crest factor cause distortion of the AC
voltage waveform. The model 1210 handles this type of load well.

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4.6 POWERING NON-LINEAR LOADS (continued)
Other non-linear loads such as phase controlled SCR bridges or some types of power
factor corrected “front ends” will be adversely affected by the modified sinewave
produced by this equipment. These devices require a sinusoidal voltage for proper
operation and timing.
It should be noted that this unit produces a waveform with square edges. These
waveform produce harmonics at frequencies much higher than the fundamental
(50/60Hz). Some loads may be affected by these harmonics. If there is any doubt as to
the suitability of this equipment for a particular application, consult the Behlman
engineering department for assistance.

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5.0 TROUBLESHOOTING
In the event problems are encountered during the installation and operation of the
inverter
refer to the chart below before assuming the inverter is at fault. If It is determined the
fault is with the inverter, contact Behlman Electronics for service information.
SYMPTOM POSSIBLE CAUSE ACTION
Low or no output Output overloaded Check load current .
Disconnect load and recheck
output voltage using TRMS
meter. Recycle power.
Erratic operation Input voltage fluctuating Monitor voltage at DC input
terminals of inverter. Make
sure it is with in
specifications
No AC input alarm
( optional)
AC - Bypass fuse blown Check fuse. Measure AC
input at rear panel.
Output distorted high peak load current Reduce loading if distortion
is objectional.
DC breaker repeatedly trips DC polarity reversed or
internal fault in inverter Check polarity, if ok, the unit may have an internal fault.
Return for service
NOTE: Service of this device requires specialized equipment and trained personnel. There are
no internal user serviceable parts. Removing the cover will expose individuals to
hazardous voltages. Refer service to qualified persons only !
5.1 MAINTENANCE
The INV 1210series requires very little in the way of routine maintenance. If the unit
is operated in a dirty or dusty environment it should be removed from service
periodically
and cleaned. The use of forced air is perfect for cleaning dust and debris from fan intakes
and heatsink assemblies. Light brushing and vacuuming is also effective

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6.0 MECHANICAL OUTLINE

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REVISION HISTORY
Rev. ECO DESCRIPTION DATE
- N/A INITIAL RELEASE 5/9/2016