Vanner ITC-Series User manual

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Owner’s Manual
ITC-Series Inverter Page 1 Owner’s Manual 8/07/03
ITC-Series
Inverter/Charger System
Model ITC12-2100 and 3200
Vanner Incorporated
4282 Reynolds Drive
Hilliard, Ohio 43026
[phone]
1-800-ACPOWER
www.vanner.com
Owner’s Manual D911149
August 18,2003
File D911149-A.doc

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ITC-Series
ITC-Series Inverter Page 27/18/03
Notes

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Table of Contents
ITC-Series Inverter Page 3 Owner’s Manual 8/07/03
Table of Contents
1 SYSTEM FEATURES AND SPECIFICATIONS
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1.1 GENERAL DESCRIPTION
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1.2 SYSTEM FEATURES
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1.3 SPECIFICATIONS
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1.4 COMPONENT IDENTIFICATION/LOCATION
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2 DESCRIPTION OF OPERATION
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2.1 INVERTER
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2.2 BATTERY CHARGER
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2.3 GEN START/AUTO-THROTTLE
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2.4 CHARGER AND APM PROGRAMMING
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3CUSTOMER WIRING IDENTIFICATION
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3.1 AC INPUT & OUTPUT WIRING
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3.2 DC (BATTERY) WIRING
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3.3 FRONT PANEL CONTROL/DISPLAY OUTLET
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3.4 SYSTEM ON/OFF SWITCH
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3.5 REMOTE SIGNAL CONTACTS
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4 INSTALLATION
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4.1 BASIC GUIDELINES
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4.2 DC WIRING
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4.3 AC WIRING
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4.4 SYSTEM START-UP AND TESTING
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5 GENERAL INFORMATION SECTION
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5.1 GENERIC INVERTER DESCRIPTION
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5.2 INVERTER SIZING
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5.3 DC POWER CONSUMPTION
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5.4 BATTERY TERMINOLOGY AND RATINGS
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5.5 SIZING THE INVERTER BATTERY
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5.6 BATTERY AND CHARGING SYSTEM CONSIDERATIONS
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5.7 BATTERY CHARGING GUIDELINES
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6 MAINTENANCE & TROUBLESHOOTING
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6.1 PREVENTATIVE MAINTENANCE
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29

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ITC-Series
ITC-Series Inverter Page 47/18/03
Figures
F 1 Figure 1.1-1 System Diagram
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F 2 Figure 1.4-1 Component Location
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F 3 Figure 1.4-2 ITC Control/Display Unit
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F 4 Figure 1.4-3 ITC Control/Display Unit Component Identification
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F 5 Figure 1.4-4 Suspended Mounting Configuration
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F 6 Figure 1.4-5 Bench Mount Configuration
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F 7 Figure 1.4-6 Suspended Dimensions in Inches
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F 8 Figure 1.4-7 Bottom Mount Dimensions in Inches
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F 9 Figure 1.4-4 Customer Terminations
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F 10 Figure 2.2-1 Charging/Voltage Curves
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F 11 Figure 2.4-1 APM/Charger/Config DIP Switch Settings
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F 12 Figure 3-1 Customer Terminations
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F 13 Figure 4.1-1 Shelf Mount Configuration
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F 14 Figure 6.1-1 Options Terminal Strip
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Tables
T 1 Figure 2.2-2 Battery Charger Factory Setpoints
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T 2 Table 4-1 DC Cable and Fuse Sizing Chart
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Front Panel Wiring Identification
ITC-Series Inverter Page 5 Owner’s Manual 8/07/03
Introduction
Thank you for purchasing the Vanner ITC-Series inverter/charger system. We are confident that you will be
satisfied with its performance and its many features. With proper installation and care, you can look forward to
years of service from this high performance product.
This document will describe the operation, technical specifications and installation procedures for the ITC-Series
inverter/charger system. If you require additional information please contact your dealer, or contact Vanner
directly at the location shown on the cover of this manual.
1System Features and Specifications
1.1 General Description
The ITC-Series system consists of a DC to AC true sine wave inverter, a 12-volt battery charger, an automatic
AC transfer switch, and a microprocessor based controller. An important feature of this system is the ITC-Series
Control/Display Unit user interface.
Control/Relay
Board
Power
Stage
Transformer
ITC-Series Inverter System
AC Out 120 Vrms
Relay Contol Output for AutoThrottle
120 Vrms Input for Charger
Control Display Panel
+12 VDC
Low Battery Indicator Contact
Overload
Overload
Low
Battery
Bulk
Fault
Fault
I N C O R P O R A T E D
Inverter
On/Off
Charger
On/Off
Fuse
12 Volt
Battery
CB In
CB Out
Dead
Battery
Supply
Sig
nal
Rel
ay
s
Microprocessor
Control System
for Inverter/
Charger
On/Off Switch
Optional Remote Switch
GFCI
F 1Figure 1.1-1 System Diagram

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Front Panel Wiring Identification
ITC-Series Inverter Page 67/18/03
1.2 System Features
H
Inverter
The inverter consists of a sine wave inverter that supplies power when AC loads are applied. Depended on
your model, the inverter develops 2100 or 3200 watts of continuous power. Using TruSine®technology, a
very high quality sine wave is produced. Total harmonic distortion (THD) is less than 4.0 percent. The
inverter also has a three second surge rating of 6400 Watts.
H
Battery Charger with Automatic Power Management
A high efficiency, multi-stage battery charger, allows fully automatic charging of flooded 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 AC source. The system’s Bulk, Absorption, and Float charge cycle quickly charges
and maintains the battery bank. An Equalization charge cycle is provided for flooded lead acid battery
maintenance.
Automatic Power Management (APM) monitors the AC Input current and will reduce the battery charger
output as needed to keep the AC input current below the preset APM Limit.
I
GenStart/Auto-Throttle
The GenStart/Auto-Throttle feature provides a start/stop signal to control an automatic throttle module. The
start/stop signal consists of a contact closure to start the Auto-Throttle based on battery voltage of 12.3 VDC.
The GenStart/Auto-Throttle turns off when the battery charging current falling below 10 amps. Call Vanner
at 1-800-ACPOWER for technical assistance in selecting the proper auto-throttle kit to use for this
application.
I
Low Battery Contact
This contact allows remote monitoring of the Inverters battery status. The contact will closes when battery
voltage falls below 11 volts. This will alert the user to take appropriate measures to avoid shutdown of the
Inverter at 10.5VDC.
I
Remote Power Switch
This loop between Options Terminal 7 and 8 (left side of Options Terminal) allow remote control of the
system On/Off. Tying these two terminals together or optionally, tying the terminal 7 (Remote Switch) to
battery ground applies power to the unit.
Note: The Front Panel switch will always overrule the remote switch in terms of disabling the unit.
J
System Control
The ITC contains a System ON/OFF Switch located in the front of the ITC. This switch is used to turn the
control power ON and OFF. This power switch also has a break out loop for a series switch that can be
placed in a remote location from the unit (See Remote Power Switch above). A control microprocessor
provides a variety of protection interlocks, system fault detection/reporting/recovery, storage of system data
parameters, and high-speed data communications to the ITC Control/Display Unit. This Control/Display Unit
also has individual on/off switches for independent Inverter and Charger control. The ITC will protect itself in
the event of any overload, over temperature, high or low battery voltage condition.
J
ITC Control/Display Unit
The ITC Control/Display Unit is a user interface that is connected to the ITC Control Board via a 6-wire
communication bus. This Control/Display unit can be an integral part of the Inverter or can be removed and
mounted in a remote area to allowing remote system operation. Two of these units can talk to the System
Control Board one Unit would be configured as a Master, and the other as Slave. The configuration switches
on top of the Master allow programming of the Charger current, Automatic Power Management and battery
type settings.
NOTE: It should be noted that if the Control Display unit is taken out of the front of the unit, the cover plate

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Front Panel Wiring Identification
ITC-Series Inverter Page 7 Owner’s Manual 8/07/03
must be installed in it’s place to insure that debris does not enter the unit through the opening and to
maintain proper airflow through the unit.
1.3 Specifications
Model ITC12-2100 Model ITC12-3200
AC OUTPUT
Voltage (RMS) 120 VAC
Frequency 60 Hz ± 0.5%
AC Waveform Sine Wave
Total Harmonic Distortion (THD) Less than 4.0% @ full power
Power Factor Allowed -1 to 1
Continuous Output Rating @ 25ºC
Phase to Neutral 2100 watts (17.5 amps) 3200 watts (26.7 amps)
Surge Capacity @ 25ºC (3 sec.) 6400 watts
DC INPUT:
Operating Range (12 Volt Nominal) 10.5 to 17 Volts
No Load, Inverter ON 4 amps
No Load, Inverter OFF 0.30 amps
Full power 208 amps 350 amps
INVERTER EFFICIENCY @ 12VDC
200 watts 77%
500 watts 88%
700 watts 88%
1000 watts 88%
1500 watts 86%
2000 watts 84%
2500 watts NA 81%
3000 watts NA 78%
3200 watts NA 77%
AC INPUT
Voltage 120 Volts nominal
Frequency 60 Hz ± 12.5% (52.5 to 67.5)
AC TRANSFER SWITCH
Power Rating 30 amps @ 120 VAC
Transfer Time Less than 40 milliseconds
BATTERY CHARGER
Charger Output Current maximum 80 amps
AC Input Current maximum 30 amps (0.88PF @ rated output)
SYSTEM
Ambient Operating Temperature -40 to+40
V
C (-40 to+104
V
F)
Cooling Exhaust Fan Thermostatically controlled
Mounting Shelf or suspended
Dimensions (Bottom mount position) 8 1/4”H x 18 7/16”W x 13 5/8”D
Weight 66 pounds

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Front Panel Wiring Identification
ITC-Series Inverter Page 87/18/03
1.4 Component Identification/Location
The Figures below show the location of the various components of the ITC system.
INCORPORATED
Inverter
On/Off
Charger
On/Off
Overload
Low
Battery
Fault
Overload
Bulk
Fault
1
TOP VIEW
3
6
7
8
9
4
5
FRONT VIEW
13
2
14
15
16
10
LEFT SIDE VIEW
RIGHT SIDE VIEW
11
12
15
16
OPTIONS CABLE ENTRY
CHASSIS GROUND
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
BATTERY TERMINAL ACCESS
REMOTE CABLE INPUT
CONTROL/DISPLAY PANEL
INVERTER ON/OFF SWITCH
CHARGER ON/OFF SWITCH
SYSTEM ON/OFF SWITCH
AC INPUT BREAKER (CB-1)
AC OUTPUT BREAKER (CB-2)
GFCI BREAKER (CB-3)
AC INPUT CABLE ENTRY
BATTERY +
BATTERY -
GFCI OUTLET
AC OUTPUT CABLE ENTRY
OPTIONS CABLE ENTRY
CHASSIS GROUND
F2Figure 1.4-1 Component Location

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Front Panel Wiring Identification
ITC-Series Inverter Page 9 Owner’s Manual 8/07/03
Equalize button access
Through Access hole.
Overload
Overload
Low Battery
Bulk
Fault
Fault
INCORPORATED
Inverter
On/Off
Charger
On/Off
On/Off Switch for Inverter
On/Off Switch for Charger
Serial Communications
Connection
Configuration Switches
for Programming
Configuration Switches Access
Configuration Switches
Note: Power Must be
Cycled to read a new
DIP Switch value
F 3Figure 1.4-2 ITC Control/Display Unit
F 4Figure 1.4-3 ITC Control/Display Unit Component Identification
ITEM DESCRIPTION
1 Inverter Indicator
Light Solid when on, flashes when enabled but not on
2 Inverter On/Off
Button Enables/Disables Inverter Function
3 Charger Indicator
Light Solid when on, flashes when enabled but not on
4 Charger On/Off
Button Enables/Disables Charger Function
5 Overload Light Dual Purpose – Indicates if Inverter or Charger is Overloaded
6Low Battery/Bulk
Light Dual Purpose – Indicates Low Battery in Inverter Mode – In charger mode, if on indicates that Charger is in Bulk Mode and if in Equalize, this light flashes.
7 Fault Light Dual Purpose – Indicates that a fault has occurred in the inverter or Charger – Could be a Over
Temperature shutdown, Low/High Battery Shutdown, Power Stage Fault, or Input AC fault
8 Equalize Button This is used to enable the equalization cycle on the battery during charging.
Overload
Overload
Low Battery
Bulk
Fault
Fault
INCORPORATED
Inverter
On/Off
Charger
On/Off
1
2
3
4
5
6
7
8

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Front Panel Wiring Identification
ITC-Series Inverter Page 10 7/18/03
x
Versatile Mounting System
The mechanical system used for mounting the ITC-Series allows both shelf and under-counter mounting,
while still allowing access to user AC and control terminals through a removable front cover.
ACCESS PANEL REMOVABLE FROM
FRONT WHEN UNDER TABLE
MOUNTED.
DOCKED DISPLAY/CONTROL PANEL
`
DC TERMINATIONS
POWER ON/OFF SWITCH
With Indicator
F 5Figure 1.4-4 Suspended Mounting Configuration
Mounting Feet shown in Benchtop
Mounting Configuration
Access Cover To DC
Terminations
F 6Figure 1.4-5 Bench Mount Configuration