Xantrex IP1012 AL User manual

IP1012 AL
Inverter/Charger
with Ignition
Protection
Owner’s Guide
IP1012 AL
IP1012_AL.book Page i Tuesday, May 1, 2007 12:18 PM

IP1012_AL.book Page ii Tuesday, May 1, 2007 12:18 PM

IP1012 AL Inverter/
Charger with Ignition
Protection
Owner’s Guide
IP1012_AL.book Page i Tuesday, May 1, 2007 12:18 PM

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products from 50 watt mobile units to 1 MW utility-scale systems for wind, solar, batteries, fuel cells,
microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and variable speed drives
that convert, supply, control, clean, and distribute electrical power.
Trademarks
IP1012 AL Inverter/Charger with Ignition Protection is a trademark of Xantrex International. Xantrex is
a registered trademark of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners
and are used herein for identification purposes only.
Notice of Copyright
©IP1012 AL Inverter/Charger with Ignition Protection Owner’s Guide April 2007 Xantrex
International. All rights reserved.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)
(A)MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR
OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(B)ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER
SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF
SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’SRISK; AND
(C)REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH
STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT
BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE
VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
April 2007 Revision A
Part Number
975-0337-01-01
Product Number
805-1011
Contact Information
Telephone: [phone] (toll free North America)
1 360 925 5097 (direct)
Fax: [phone] (toll free North America)
1 360 925 5143 (direct)
Email: [email protected]
Web: www.xantrex.com
IP1012_AL.book Page ii Tuesday, May 1, 2007 12:18 PM

iii
About This Guide
Purpose
The purpose of this Owner’s Guide is to provide explanations and
procedures for installing, operating, maintaining, and troubleshooting the
IP1012 AL Inverter/Charger with Ignition Protection.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, procedures for installing the inverter, as well as information
about operating and troubleshooting the unit. It does not provide details
about particular brands of batteries. You need to consult individual
battery manufacturers for this information.
Audience
The Guide is intended for anyone who needs to install and operate the
IP1012 AL Inverter/Charger with Ignition Protection. Installers should be
certified technicians or electricians.
Organization
This Guide is organized into four chapters and an appendix.
Chapter 1, “Introduction” describes the main performance and protection
features of the IP1012 AL Inverter/Charger with Ignition Protection.
Chapter 2, “Operation” explains how to calculate the size of the loads you
can run from the IP1012 AL. It also provides guidelines to help you run
loads safely and efficiently.
Chapter 3, “Maintenance” provides procedures for checking the terminal
connections on the inverter/charger, disconnecting the IP1012 AL from
the batteries, changing the overcurrent protection fuse and removing or
connecting the AC input and output cables.
IP1012_AL.book Page iii Tuesday, May 1, 2007 12:18 PM

Safety
iv 975-0337-01-01
Chapter 4, “Troubleshooting” provides information to help you identify
common problems which may occur. Read this chapter before calling
your authorized Xantrex dealer. If you cannot solve the problem, record
the details as suggested on “Information About Your System” on
page WA–4, then call your dealer.
Appendix A contains the inverter, charger, and transfer specifications for
the IP1012 AL. The specifications show rating curves for output surge,
current versus temperature, and pass-through current. Appendix A also
illustrates the three-stage charging profile used by the unit.
Conventions Used
The following conventions are used in this guide.
Related Information
You can find more information about Xantrex Technology Inc. as well as
its products and services at www.xantrex.com
WARNING
Warnings identify conditions or practices that could result in personal injury or
loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or
other equipment.
Important: These notes describe things which are important for you to know,
but not as serious as a caution or warning.
IP1012_AL.book Page iv Tuesday, May 1, 2007 12:18 PM

v
Important Safety Information
General Precautions
1. Before using the inverter/charger, read all appropriate sections of this
guide and any cautionary markings on the inverter and the batteries.
2. Use the grounded AC cord supplied when connecting to AC input
power (qualified external AC which is when the external AC power is
100–130 Vac/54–66 Hz). Do not remove or attempt to defeat the
ground connection to the qualified external AC source in any way. If
an extension cord is necessary, ensure that it is at least 12 AWG and
no longer than 12 feet in length.
3. If possible, plug the inverter/charger into an AC source outlet that is
protected by a Ground Fault Circuit Interrupting (GFCI) device;
either a breaker or outlet.
4. Do not operate the inverter/charger if it has received a sharp blow,
been dropped, or otherwise damaged. If the unit is damaged, return it
to your authorized Xantrex dealer.
5. Do not dismantle the inverter/charger; it contains no user- serviceable
parts. Attempting to service the unit yourself could cause electrical
shock or fire. Internal capacitors remain charged after all power
is disconnected.
6. To reduce the risk of electrical shock, turn off the inverter/charger
from the remote switch, then disconnect both AC (shorepower) and
DC (battery) power from the unit before working on any circuits
connected to it. Turning off the remote On/Off switch alone does not
reduce this risk.
Important:: Save these instructions. This guide contains important
safety and operating instructions for the IP1012 AL Inverter/Charger with
Ignition Protection.
IP1012_AL.book Page v Tuesday, May 1, 2007 12:18 PM

Safety
vi 975-0337-01-01
Precautions When Working With Batteries
1. Follow all instructions published by the battery manufacturer and the
manufacturer of the equipment in which the battery is installed.
2. Make sure the area around the battery is well ventilated.
3. Never smoke or allow a spark or flame near the vehicle engine or a
battery.
4. Use caution to reduce the risk of dropping a metal tool on a battery. It
could spark or short circuit the battery or other electrical parts and
cause an explosion.
5. Remove metal items like rings, bracelets, and watches when working
with lead-acid batteries. These batteries produce a short-circuit
current high enough to weld a ring, other metal jewellery or tools,
thus causing severe burns.
6. If you need to disconnect a battery, always remove the negative
terminal from the battery first. Make sure all accessories are off so
you don’t cause an arc.
7. Before making the final connection to a battery, be sure the polarity is
correct; negative-to-negative, and positive-to-positive.
8. When you are making the final connection to a battery, you will see a
spark and hear a loud pop. This spark and popping sound is normal.
Precautions for Using Rechargeable Devices
Most battery-operated equipment uses a separate charger or transformer
that is plugged into an AC receptacle and produces a low voltage output.
If the label on the AC adapter or charger states that the adapter or charger
produces a low voltage AC or DC output (less than 30 volts), the inverter/
charger can power this charger or adapter safely.
Some chargers for small nickel-cadmium batteries can be damaged if
connected to the inverter/charger. Do not use the following loads and
appliances:
• Small battery-operated appliances like flashlights, razors, and night
lights that can be plugged directly into an AC receptacle to recharge.
• Some chargers for battery packs used in hand power tools. These
types of chargers display a warning label stating that dangerous
voltages are present at the battery terminals.
IP1012_AL.book Page vi Tuesday, May 1, 2007 12:18 PM

975-0337-01-01 vii
Important Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1 Introduction
Inverter/charger Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Operating Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
2 Operation
Planning for AC Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Type of Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
AC loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
DC loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Problem loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Calculating Size of an AC Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Running the Alternator While Operating AC and DC Loads - - - - - - - - - - - - - - 2–7
Using the Remote Switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Operating the Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Turning the Inverter On and Running Loads - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Running in Extremes Of Hot or Cold Temperatures - - - - - - - - - - - - - - - - - - - 2–11
Restarting After a Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Using Shorepower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Miscellaneous Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
3 Maintenance
Maintaining the Inverter/charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Checking Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Disconnecting and Connecting the Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Disconnecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Connecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Replacing the Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Removing and Reconnecting AC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Contents
IP1012_AL.book Page vii Tuesday, May 1, 2007 12:18 PM

Contents
viii 975-0337-01-01
4 Troubleshooting
Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Blinking Lights on the Remote Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
A Specifications
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Inverter Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Charger Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Transfer and General Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Rating Curves and Charging Profiles- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
IP1012_AL.book Page viii Tuesday, May 1, 2007 12:18 PM

1Introduction
Chapter 1, “Introduction” describes the main
performance and protection features of the IP1012 AL
Inverter/Charger with Ignition Protection.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM

Introduction
1–2 975-0337-01-01
Inverter/charger Features
Features The IP1012 AL is an ignition-protected, modified sine wave inverter/
charger weighing about 40 pounds (18 kg). It is sealed, dust and water
resistant, and can be mounted where it may be exposed to the elements.
Figure 1-1 shows its main features.
Consult Appendix A, “Specifications” for more detailed information
about the unit.
Figure 1-1 Features of the inverter/charger
7
1
6
4
5
2
3
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM

Operating Features
975-0337-01-01 1–3
Location Ignition protection for safe operation in applications that require ignition
protected equipment such as gasoline engine rooms or in a battery box.
Ingress protected (IP66) for wet applications where the inverter will be
cleaned with low pressure jets of water.
Operating Features
Inverter/charger The inverter/charger functions as an inverter or as a charger depending
upon the operational conditions. When the unit is inverting, it is said to be
in invert mode and is referred to as an inverter. When the unit is charging,
it is in charge mode and is referred to as a charger.
The unit can only operate in charge mode when external AC power
referred to as “shorepower” is connected.
Inverter
features The IP1012 AL offers the following inverter features:
• Ability to run many of the same appliances that you use at home
You can operate TVs, VCRs, satellite receivers, computers, hair
dryers, and small power tools for example. You can also run multiple
loads up to 1000 watts in total.
• Surge capability
The IP1012 AL will manage loads up to 3000 watts for short periods
of time as long as the peak current is less than 36 amps.
Feature Description
1Positive terminal with terminal cap on
2External DC fuse with fuse cover on
3Ambient Air Temperature sensor
4AC output connector
5AC input connector
6Inverter/charger control connector
7Negative terminal with terminal cap on
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM

Introduction
1–4 975-0337-01-01
• Low voltage shutdown
The inverter shuts off when your batteries reach a predetermined
voltage set in the microprocessor to protect batteries from permanent
damage. Low voltage shutdown also monitors frequency and voltage,
and protects against overload, short circuits and over-temperature.
• Automatic shutdown after 8 hours for loads less than 15 ±5 watts
This feature prevents the inverter from draining the batteries if it is
left on without a load.
Charger
features The IP1012 AL offers the following charger features:
• 3-stage charging with 50 amps maximum charging current for 12V
battery type when shorepower is connected, to ensure your batteries
are always charged
• Automatic transfer to invert mode
When the AC shorepower cord is disconnected, the unit automatically
switches to invert mode. When AC shorepower is available again, the
inverter automatically switches to charging/pass-through mode.
• Load management capability which temporarily reduces charging
current to the batteries when a large AC load is applied to the inverter
output. This capability helps reduce the chance of tripping the
shorepower breaker.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM

2Operation
Chapter 2, “Operation” explains how to calculate the
size of the loads you can run from the IP1012 AL.It
also provides guidelines to help you run loads safely
and efficiently.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM

Operation
2–2 975-0337-01-01
Planning for AC Loads
AC load AC load refers to an AC appliance you want to operate from the inverter/
charger. Loads include most appliances that you can plug into a standard
120 volt household electrical outlet.
Variables
affecting AC
loads
The IP1012 AL inverter/charger can power a wide range of loads. The
size of the load and the length of time you can operate it depends on
variables such as:
• type of load,
• ambient temperature,
• size, state of charge, temperature, and condition of batteries.
The larger your battery capacity and the higher the state of charge, the
longer the inverter/charger can run your AC loads. Battery capacity is
reduced as battery temperature lowers.
Type of Loads
AC loads
The way in which an AC load draws power may determine how
effectively it can be powered from the inverter/charger.
Resistive loads Toasters, coffee pots, and incandescent lights are examples of resistive
loads which do not need a high start-up current to start running. They use
a resistive heater element to generate heat or light. They are the simplest
and easiest loads for an inverter/charger to run. Large resistive loads, such
as electric stoves and water heaters, are impractical since their high power
requirements quickly drain the batteries.
Inductive loads TVs, VCRs, stereos, computers, and electric motors (power tools,
vacuum cleaners, for example) are examples of inductive loads which
surge on start up. They require a high startup current compared to a
resistive load such as a toaster or coffee pot. Depending upon its size, the
motor can take as much as six times of its operating current to start than it
does to keep it running once it has started. This surge can sometimes
exceed the inverter/charger’s maximum output rating and the inverter will
shut down.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM

Planning for AC Loads
975-0337-01-01 2–3
DC loads
DC loads are those that run off a 12 volt electrical system. A few
examples of DC loads are:
• marker lights, headlights, vehicle lighting, other lights using DC
power
• DC refrigerators
• VHF radios
• factory-installed radios or sound systems
• pumps, lights, fans, power vents, LPG leak detector, toilet, and some
water heaters.
DC loads and the inverter/charger both rely on the batteries for power.
Many DC loads running at one time will shorten the operating times of
AC loads.
Problem loads
Problem loads are loads you should not operate from the inverter/charger
because they may be damaged or may not operate properly:
• dimmer switches
• some small rechargeable hand-power tools
• small battery-operated appliances such as flashlights, razors, night
lights
• variable speed motors
Ambient Temperature
Ambient
temperature The ambient temperature, that is, the air temperature around the inverter/
charger, will affect its output power.
Ambient temperature can rise when the vehicle is exposed to hot weather
conditions or cabin heat from heaters.
Temperature
and power Generally, the output power decreases as the temperature increases. For example, at 77 °F (25 °C) the unit delivers 1000 watts for as long as you
have sufficient battery power. At 104 °F (40 °C) it delivers 1000 watts for
up to 30 minutes before shutting down, 2000 watts for 2 minutes, or 750
watts continuous.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM

Operation
2–4 975-0337-01-01
Figure 2-1 shows the relationship between ambient temperatures and the
length of time the unit will supply an output power level. Choose the
curve with the temperature range most closely approximating that of the
inverter/charger location, then look for the time in minutes. The
intersection of the time and temperature will indicate approximately the
output power of the unit. For example, between – 40 °F and 77 °F
(-40 °C to 25 °C), you will get 3000 watts for approximately one minute
or 2500 watts for 3 minutes. Times shown in this graph may vary with the
actual operating conditions.
Calculating Size of an AC Load
Operating time To determine how long you can run your loads:
1. List all the AC loads you think you will use and determine their
power requirement. You can usually find this information on a label
near the power cord on the appliance.
2. Look in Table 2-1 on page 2–6 to find the load’s operating time or the
operating time of a similarly sized appliance. The operating times
shown in the table indicate approximately how long a load will run
before the inverter/charger shuts down to prevent battery damage.
Figure 2-1 Output power versus time and temperature
0
500
1000
1500
2000
2500
3000
1 10 100
Time (minutes)
Output Power (VA)
-40 to 25C 40C 55C 70C 85C
– 40 to 77 F 104 F 131 F 158 F 185 F
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM

Planning for AC Loads
975-0337-01-01 2–5
3. To find the running time for several loads running simultaneously,
add their total wattage and look for an appliance with similar power
requirement in Table 2-1.
Battery
condition The information in Table 2-1 assumes:
• there is a properly maintained 12 volt 400 amp-hour battery bank, for
example, 4 Group 31 (100Ah) deep-cycle truck batteries or 2 Group
4D batteries
• the batteries have not been damaged by deep discharge and are
relatively new
Factors
affecting load Consider these factors when you are calculating loads:
• Loads that exceed 1000 watts may be run for a short time (about one
minute).
• Loads which run continuously such as a reading light, TV or
computer should not exceed more than 1000 watts in total.
• Poor battery condition, low battery capacity, low battery temperature,
and high ambient temperature will shorten the operating times listed
in the table.
• The presence of DC loads will reduce the operating times of the AC
loads.
IP1012_AL.book Page 5 Tuesday, May 1, 2007 12:18 PM

Operation
2–6 975-0337-01-01
* Average ‡ The inverter/charger shuts down after eight (8) hours if it does not detect a load (or loads less than 20 W.) †Based on four minute operation timeout and shutdown at 10.6 V for loads more than 150 W and
10.8 V timeout and shutdown for loads less than 150 W at 77 °F (25 °C).*
Table 2-1
Typical operating time with fully-charged 400 Ah deep-cycle batteries
†
Appliance Watts Minutes Hours
10 20 2 3 5 10 15 20 30 45 70 85 100
Electric shaver (not rechargeable) 15 ‡ Table fan 15 ‡ Video game 25 Reading Lamp 40 Notebook computer 75 Computer printer 100 Hand-held vacuum cleaner 100 19 in TV/VCR combo 100 3 cu. ft. refrigerator *180 Electric blanket 200 Electric buffer 400 Electric drill 1/2” 500 Halogen work light 750 Small Coffee maker 800 Toaster 1000 Microwave oven 1200 Hair dryer 1500
IP1012_AL.book Page 6 Tuesday, May 1, 2007 12:18 PM