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