Xantrex IP1012 AL User's Manual
Contents
1. 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 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 Disconne2. Altitude limit 15 000 feet 5000 metres AC neutral to ground bonding Invert mode AC output neutral is connected to AC ground chassis Charge mode AC output neutral is connected to AC input neutral AC input neutral is always isolated from AC ground 975 0337 01 01 Specifications Rating Curves and Charging Profiles 3000 2500 2000 1500 1000 4 500 Output Power VA 1 10 100 Time minutes e 40 to 25C g 40C 4 55C 70C 85C 40 10 77 F 104 131 F 158F 185 F Figure A 1 Output surge rating Maximum charger current vs Temperature Charger current Amps 40 20 0 20 40 60 Ambient temperature C Figure A 2 Charging current versus temperature derating curve A 6 975 0337 01 01 Rating Curves and Charging Profiles Bulk Absorption Charge Float Charge Charging Bulk Volts Setting Float Volts Setting DC Voltage Constant current maximum charge rate Reduced voltage Constant voltage Load current on demand DC Current Time Figure A 3 Three stage charging profile 975 0337 01 01 A 7 A 8 Index A AC cables removing or connecting 3 6 AC load calculating size 2 4 definition 2 2 factors affecting 2 2 types of 2 2 AC power connect delay 2 12 alternator effects of overloading 2 7 ambient
3. 1 2 second Blink Level 3 Very slow blink Light is on for one second and off for one second 975 0337 01 01 4 3 Troubleshooting 4 4 Table 4 2 explains the blinking pattern of the Charger indicator when the unit is in charge mode Table 4 2 Charger indicator blink patterns Condition Blink Level High Battery voltage 1 Inverter too hot 2 Charge cycle not complete after 20 hours 3 Table 4 3 explains the Inverter indicator flashing pattern when the unit is in invert mode Table 4 3 Inverter indicator blink patterns Condition Blink Level High Battery voltage 1 Inverter too hot Low Battery Over current NIN Auto shutdown inverter 975 0337 01 01 Specifications 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 All specifications are subject to change without notice Specifications Physical Specifications Physical specifications Enclosure Sealed dust and water resistant ignition protected Dimensions Approximately 8 5 21 8 cm H x 7 17 7 cm W x 13 0 33 0 cm D excluding DC ground connector similar to Group 31 battery dimensions Net weight 40 Ibs 18 kg maximum without mountin
4. INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT WA 2 975 0337 01 01 Warranty and Return Exclusions If this product is a consumer product federal law does not allow an exclusion of implied warranties To the extent you are entitled to implied warranties under federal law to the extent permitted by applicable law they are limited to the duration of this Limited Warranty Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages so the above limitation s or exclusion s may not apply to you This Limited Warranty gives you specific legal rights You may have other rights which may vary from state to state or province to province Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization RMA number and the correct factory Ship address Products must also be shipped prepaid Product shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared to supply e serial number of your product Information abou
5. Possible Problem Troubleshooting Remedy Loads stop operating without warning after they have been running Shorepower is not connected Too many appliances have reduced the battery voltage to shutdown level Ambient temperature is too high Reduce the number of loads Allow the inverter to cool and restart Recharge the batteries Disconnect appliances and let the unit cool down The inverter will not work even after toggling the switch charging the batteries and letting the unit cool down Remote switch may be disconnected at the unit Fuse on the unit shown in Figure 1 1 may have blown Check that the remote switch is firmly connected Replace the fuse or return the unit to an authorized Xantrex dealer AC voltage at receptacles reads low Wrong type of voltmeter being used Use a true RMS meter In inverter mode times to shutdown are getting shorter for the same kind of AC load Bad battery cable or corroded battery terminals Batteries too old or damaged Blinking Lights on the Remote Switch Check the cables and connectors Replace the batteries You may encounter different sequences of blinking lights when the inverter is enabled i e switch is on or the unit is charging Light sequences are described as follows Blink Level 1 Fast blink Light is on for 1 4 second and off for 1 4 second Blink Level 2 Slow blink Light is on for 1 2 second and off for
6. Common Problems The unit shuts down during operation for four main reasons low battery when the battery reaches approximately 10 6 Vdc for more than four minutes with loads greater than 150 watts or 10 8 Vde for loads less than 150 watts Low battery shutdown also occurs when battery voltage reaches 10 4 Vdc for three seconds e high battery when the battery voltage exceeds 16 Vdc overload when the AC load connected to the inverter exceeds the rated load e over temperature when the internal temperature thresholds are reached Table 4 1 lists problems you may encounter and offers suggestions to fix them Table 4 1 Symptom Troubleshooting reference Possible Problem Remedy Loads will not start when there is no shorepower Inverter is not turned on Batteries are at low voltage Inverter is too hot Turn the inverter on Recharge the batteries by running the engine or connecting to shorepower Wait until the inverter has cooled down Loads stop running almost as soon as they start 4 2 Load is too heavy Batteries are at low voltage level Bad battery cable or corroded battery terminals Batteries are in poor condition Reduce the load Recharge the batteries by running the engine or connecting to shorepower Check the cable and connectors Test and replace if necessary 975 0337 01 01 Table 4 1 Symptom Troubleshooting reference Continued
7. RV truck Length of time inverter has been installed Battery battery bank size Battery type e g flooded sealed gel cell AGM DC wiring size and length Alarm sounding Description of indicators on front panel Appliances operating when problem occurred OOO oO oO OF Description of problem WA 4 975 0337 01 01 Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 975 0337 01 01 Printed in China
8. although AC shore power is present that it may or may not be within the operating voltage range Refer to Table 4 2 Charger indicator blink patterns on page 4 4 for more information Inverter indicator light NOI __ Inverter On When yellow LED is solid ON it indicates the unit is currently inverting Therefore the AC output is active Unit Error When yellow LED is flashing it indicates that a faulty condition has occurred Refer to Table 4 3 Inverter indicator blink patterns on page 4 4 for more information 2 10 975 0337 01 01 Operating the Inverter Charger Operating the Inverter Charger This section provides guidelines for operating the IP1012 AL Turning the Inverter On and Running Loads To run loads 1 Turn the remote switch on by pressing to the right 2 Check that the Inverter indicator is illuminated and Charge indicator is off if you are not connected to shorepower 3 Connect appliances one at a time to the inverter charger Don t connect too many high surge appliances at once Some appliances may halt or dim momentarily while another is starting up Running in Extremes Of Hot or Cold Temperatures Hot Cold In extremely hot conditions the inverter may shut down sooner than it would in normal or cold temperatures When the ambient temperature is high reduce the number of loads In extreme cold temperatures your batteries may have less stored energy At 0 F 18 C you
9. 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 975 0337 01 01 DC loads Problem loads Planning for AC Loads DC loads are those that run off a 12 volt electrical system A few examples of DC loads are e marker lights headlights vehicle lighting other lights using DC power e DC refrigerators VHF radios e factory installed radios or sound systems e 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 are loads you should not operate from the inverter charger because they may be damaged or may not operate properly e dimmer switches e some small rechargeable hand power tools small battery operated appliances such as flashlights razors night lights variable speed motors Ambient Temperature Ambient The ambient temperature that is the air temperature around the inverter temperature charger will affect its output power Ambient temperature can rise
10. fuse Be sure to use a lock washer when replacing the nuts Tighten to a torque of 4 to 5 5 ft lb 5 5 to 7 5 Nm N CAUTION Do not overtighten fuse nuts 3 Replace the fuse cover by placing it over the fuse and pressing down until it snaps into place If the fuse blows a second time without being able to operate the unit do not change the fuse again Call your authorized Xantrex dealer 975 0337 01 01 3 5 Maintenance Removing and Reconnecting AC Cables To remove the AC cables gt Grasp the knurled surface of the connector housing as shown in Figure 3 3 and turn counter clockwise approximately one half turn Gently pull the cable out by grasping the connector To reconnect 1 Align the key of the connector with the slot on the terminal of the IP1012 AL 2 Insert the connector firmly Turn the connector housing clockwise 1 2 turn until you feel resistance then another 1 8 turn until it locks into place Inverter charger control cable AC output connector AC input connector Figure 3 3 AC input and output cables 3 6 975 0337 01 01 Troubleshooting 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 Troubleshooting Troubleshooting
11. information about the unit Figure 1 1 Features of the inverter charger 1 2 975 0337 01 01 Location Operating Features Feature Description Positive terminal with terminal cap on External DC fuse with fuse cover on Ambient Air Temperature sensor AC output connector AC input connector Inverter charger control connector WN 7 Negative terminal with terminal on 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 Inverter features 975 0337 01 01 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 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 e Surge capabil
12. is required In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex Proof of purchase may be in any one of the following forms e The dated purchase receipt from the original purchase of the product at point of sale to the end user or e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or e The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes c the product if repairs have been done to it other than by Xantrex or its authorized service c
13. the inverter charger cables from the battery by first disconnecting the negative cable at the inverter charger Then disconnect the positive and negative cables at the battery If you are replacing batteries make sure they are flooded lead acid or AGM batteries and that they are all the same capacity and age as the others in the bank Disconnect the ground wire if the unit must be removed from its mounting bracket To connect to the batteries 1 Ensure shorepower is disconnected and the inverter charger is off 2 Connect the ground wire if it was previously removed AN CAUTION Reverse Polarity Do not connect cables in reverse polarity If you do the fuse will blow and the unit could be damaged AN WARNING Explosion or Fire Do not proceed to the next step if flammable fumes are present Explosion or fire may result Thoroughly ventilate the battery compartment before making this connection 975 0337 01 01 3 3 Maintenance 3 To reconnect the cables a Connect one end of the positive battery cable to the IP1012 AL b Connect one end of the negative battery cable to the P1012 AL N WARNING Possible popping sound and sparks Follow steps c and d in sequence If you switch the steps you may hear a popping sound and see sparks when you make that connection to the negative terminal If flammable fumes are present explosion or fire may result c Connect the other end of the posit
14. unit Conventions Used The following conventions are used in this guide 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 Related Information You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com iv 975 0337 01 01 Important Safety Information Important Save these instructions This guide contains important safety and operating instructions for the IP1012 AL Inverter Charger with Ignition Protection 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 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
15. when the vehicle is exposed to hot weather conditions or cabin heat from heaters Temperature Generally the output power decreases as the temperature increases For and power example at 77 F 25 C the unit delivers 1000 watts for as long as you 975 0337 01 01 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 2 3 Operation 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 3000 2000 1500 1000 4 Output Power VA a e Time minutes 40 to 25C g 40C 4 55C 70 85 40 to 77 F 104 131 158 185 Figure 2 1 Output power versus time temperature Calculating Size of an AC Load Operating time To determine how long you can run your loads 1 List all the A
16. 0 1 Hz from 40 F to 185 F 40 C to 85 C ambient temperature Power factor allowed All 0 to 1 leading or lagging Peak efficiency Greater than 93 at 12 6 Vdc input at 77 F 25 C Idle power consumption Less than 15 W inverting with 120 Vac output and no load Auto shutdown mode Inverter output is less than 15 5 W and battery is less than 13 Vdc for 8 hours Off mode power consumption Less than 120 mW when inverter switch is off or in auto off mode A 3 Specifications Inverter specifications Continued Shutdowns and Restarts DC low voltage shutdown 1 Battery voltage drops below 10 6 0 15 Vdc at heavy loads more than 150 W or 10 8 Vdc at light loads less than 150 W for more than 4 min and 10 sec 30 5 2 Battery voltage is below 10 4 0 2 for 3 seconds DC low voltage restart 13 0 0 15 DC high voltage shutdown 16 0 x 0 2 Vdc DC high voltage restart Less than 16 0 Vdc same as DC high voltage shutdown There is no hysteresis Charger Specifications All charging specifications are at nominal conditions 77 F 25 C 14 0 at 50 A charging 120 Vac 60 Hz unless otherwise specified Charger specifications Charging method e Three stage charging with battery temperature compensation See Figure A 3 e Algorithm for generic flooded batteries only No equalization mode
17. AC input voltage 100 130 Vac AC input frequency 54 66 Hz Minimum battery voltage 7 Vdc The charger does not operate below this level Maximum charger input current 13 0 ins Maximum charge rate 50 5 ADC See Figure A 2 Charging current versus temperature derating curve on page A 6 Charger efficiency Greater than 80 975 0337 01 01 Transfer and General Specifications Charger specifications Continued Absorption charge voltage 14 3 0 3 Vdc at 77 F 25 C Float charge voltage 13 3 0 3 at 77 F 25 C Temperature compensation 0 023 Vdc from 2 C to 85 C 28 4 F to 185 F Below 2 C the charger voltage defaults to the 2 C voltage Overvoltage shutdown Greater than or equal to 15 3 0 3 Vdc Transfer and General Specifications Transfer and general specifications AC input bypass current 15 AAC maximum continuous at 122 F 50 C Derates to 5 AAC at 185 F 85 C Transfer speed 10 40 ms typical AC low voltage transfer 90 5 Vac AC low voltage restart 95 5 Vac 30 second delay AC high voltage transfer None Standby off consumption lt 0 7 watts at 12 5 Vdc with charger and inverter both off Operating temperature range 40 F to 185 F 40 C to 85 C Storage temperature range 40 F to 185 F 40 C to 85
18. C 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 2 4 975 0337 01 01 Planning for AC Loads 3 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 The information in Table 2 1 assumes condition 2 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 Consider these factors when you are calculating loads affecting load 975 0337 01 01 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 load
19. CUMENTATION 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 S RISK 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 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Web www xantrex com About This Guide Purpose Scope Audience 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 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
20. 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 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 Safety Precautions When Working With Batteries Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed Make sure the area around the battery is well ventilated Never smoke or allow a spark or flame near the vehicle engine or a battery 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 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 If yo
21. P1012 AL from the batteries changing the overcurrent protection fuse removing or connecting the AC input and output cables Maintenance Maintaining the Inverter charger Before doing any maintenance on the IP1012 AL review all safety instructions in Important Safety Information on page v WARNING The metal base of the IP1012 AL may be hot when operating in high ambient temperatures Do not touch the metal enclosure until the unit has cooled down Checking Terminals To check that the battery cables are firmly connected you will need to remove the terminal caps To remove the terminal cap 1 Using a flathead screwdriver as shown in Figure 3 1 place the blade in the lip of the cap and push it gently against the cap until it lifts off 2 replace the cap place it over the terminal and push down until it snaps into place Figure 3 1 Removing the terminal cap 3 2 975 0337 01 01 Disconnecting and Connecting the Batteries Disconnecting and Connecting the Batteries Disconnecting AN WARNING Explosion or Fire Make sure the battery compartment is well ventilated Flammable fumes are often present when working with batteries Connecting To disconnect from the battery 1 Disconnect the shorepower cable and turn the inverter charger off from the remote switch Note If you have a DC Disconnect installed you should open it before proceeding to the next step Remove
22. Smart choice for power ntrex IP1012 AL Owner s Guide IP1012 AL Inverter Charger with Ignition Protection www xantrex com xantrex IP1012 AL Inverter Charger with Ignition Protection Owner s Guide 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 A MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DO
23. cting 3 3 Connecting 3 3 Replacing the Fuse 3 4 Removing and Reconnecting AC Cables 3 6 975 0337 01 01 vii Contents 4 viii Troubleshooting Troubleshooting 42 Common Problems 42 Blinking Lights on the Remote Switch 4 3 Specifications Physical Specifications A 2 Inverter Specifications A 3 Charger Specifications 4 Transfer and General Specifications A 5 Rating Curves and Charging Profiles 6 975 0337 01 01 Introduction Chapter 1 Introduction describes the main performance and protection features of the IP1012 AL Inverter Charger with Ignition Protection Introduction 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
24. enters hereafter ASCs d the product if it is used as a component part of a product expressly warranted by another manufac turer e the product if its original identification trade mark serial number markings have been defaced altered or removed Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE
25. ex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and Hawaii are excluded Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada How do you get service If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual For some products Xantrex maintains a network of regional Authorized Service Centers Call Xantrex or check our website to see if your product can be repaired at one of these facilities 975 0337 01 01 WA 1 Warranty and Return What proof of purchase
26. ffect of large loads on alternator 2 7 low battery shutdown 4 2 low voltage shutdown 1 4 M maintenance checking terminal connections 3 2 replacing the fuse 3 4 nickel cadmium batteries vi operating time of loads table 2 6 output power of IP 1012 2 12 over temperature shutdown 4 2 overload shutdown 4 2 P physical specifications A 2 problem loads 2 3 problems causing shutdown 4 2 proof of purchase WA 4 purchase date WA 4 R rating curves output surge rating A 5 razors see problem loads rechargeable tools see problem loads remote switch blinking lights on the 4 3 remote switch to disable inverter 2 9 resistive load see AC load type of resistive loads examples of 2 2 restarting after shutdown 2 11 S safety information v safety monitoring feature 1 4 serial number WA 4 IX 2 servicing no user serviceable parts v shorepower definition 1 3 shutdown automatic 2 12 restarting after 2 11 shutdown reasons for 4 2 size of AC load calculating 2 4 surge capability 1 3 surge loads examples of 2 2 T temperature see ambient temperature temperature and power relationship of 2 4 temperature and time derating curve figure 2 4 terminals caps removing 3 2 three stage charging profile A 6 time running time of AC loads 2 4 transfer specifications A 5 troubleshooting reference 4 2 turning on unit with the remote switch 2 11 U us
27. for this information 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 P1012 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 Safety 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
28. g brackets or external cables External finish Base Clear anodized aluminum Top cover black anodized or black powder coated aluminum Mounting Orientation Mounting method All allowed Four M8x1 25 threaded holes accessible from bottom only one in each corner and or battery hold down bar over center top of cover Recommended torque 5 6 ft lb 7 8 Nm Battery cable 2 AWG Minimum maximum 10 feet long each way Battery size 12 volt 225 Ah minimum to prevent overstress of battery in charge mode 400 Ah recommended 975 0337 01 01 Inverter Specifications All inverter specifications are at nominal conditions 1000 W resistive load 12 Vdc inverting on the IP1012 AL 120 Vac unless otherwise 975 0337 01 01 specified Inverter Specifications Inverter specifications Output wave form Modified sine wave Output power continuous 1000 Vac continuous Surge rating 3000 VA for 30 seconds at 40 F to 77 F 40 C to 25 C See Figure 1 for output at different temperatures Operating voltage range 10 4 Vdc to 16 0 Input DC voltage rating 12 Vdc Output voltage 120 Vac RMS Output voltage regulation 108 to 125 Vac under steady state 0 to 1000 W load with 10 6 to 14 5 Vdc input at 25 C 77 F 108 to 132 Vac up to 1000 W 10 6 to 16 Vdc input at 40 F to 185 F 40 C to 85 C Output frequency 60 0
29. help you run loads safely and efficiently Operation Planning for AC Loads AC load Variables affecting AC loads Type of Loads AC loads Resistive loads Inductive loads 2 2 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 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 e type of load e 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 The way in which an AC load draws power may determine how effectively it can be powered from the inverter charger 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 TVs VCRs stereos computers and electric motors power tools vacuum cleaners for example are
30. ing guidelines for 2 11 V variable speed motor see problem loads warranty out of warranty service WA 4 terms and conditions WA 1 X Xantrex web site 1V 975 0337 01 01 Warranty and Return Information Warranty What does this warranty cover This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your IP1012 AL Inverter Charger with Ignition Protection This warranty period lasts for one 1 year from the date of purchase at the point of sale to you the original end user customer You will be required to demonstrate proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require original proof of purchase as described What proof of purchase is required What will Xantrex do Xantrex will at its option repair or replace the defective product free of charge provided that you notify Xantrex of the product defect within the Warranty Period and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty Xantrex will at its option use new and or reconditioned parts in performing warranty repair and building replacement products Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantr
31. ity 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 1 3 Introduction Charger features 1 4 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 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 975 0337 01 01 Operation Chapter 2 Operation explains how to calculate the size of the loads you can run from the IP1012 AL It also provides guidelines to
32. ive battery cable to the positive terminal of the battery d Connect the other end of the negative battery cable to the nega tive terminal of the battery 4 Tighten to a torque of 12 to 15 ft lbs 10 Note If you have a DC Disconnect installed you should close it before proceeding to the next step 5 Check that the inverter is operating by enabling it from the remote switch as explained in Using the Remote Switch on page 2 9 Replacing the Fuse AN WARNING Correct Fuse Type To reduce the risk of fire and electrical hazards replace the fuse only with a fuse of the same type and rating Using the wrong fuse type can damage the unit and void your warranty The inverter charger external DC fuse shown in Figure 1 1 protects the unit from causing wiring and battery damage due to over current and from reverse polarity when connecting the unit to the battery If the fuse blows for any reason replace it with only the fuse types listed below e Littelfuse Mega Fast Blow 250 A 32 V part number 298250 Bussmann 250 A 48 V part number AMG 250 Note Additional fusing may be required seven 7 inches from the battery post if the inverter is located away from the batteries with long cable runs 3 4 975 0337 01 01 Replacing the Fuse To replace the fuse 1 Lift the fuse cover off as shown in Figure 3 2 Figure 3 2 Removing the fuse cover 2 Remove the blown fuse and install the new
33. loads you may either trip the AC system breaker if one is installed or the shorepower breaker Reduce the load and reset the affected breaker The charger will automatically reduce battery charging if other AC loads are connected This feature helps to prevent nuisance tripping of the shorepower breaker Miscellaneous Hints Automatic shutdown Output power Connect delay to AC power Load failure The inverter automatically turns off if it has not detected any AC loads for 8 hours when AC load is less than 15W or the loads are so small the inverter cannot detect them such as an alarm clock or a small television less than 15W The total output of the inverter charger is 1000 watts Note The IP1012 AL does not provide any warning before it shuts down If you need to operate a critical AC load be sure there are no heavy loads connected and that the batteries have been recently charged If you are connected to shorepower the Charge indicator should be on and the Inverter indicator off The Charge indicator may blink slowly when you first apply shorepower because of a connect delay about 30 seconds but then will illuminate steadily If any loads fail to operate or the inverter shuts down refer to Chapter 4 Troubleshooting for suggestions 975 0337 01 01 Maintenance Chapter 3 Maintenance provides procedures for e checking the terminal connections on the inverter charger e disconnecting the I
34. ombined DC and AC loads for your battery to fully recharge This example for a 12 volt battery shows what happens if the alternator is overloaded AC Loads 1000 W Owner Installed 38A Loads Factory Installed DC Loads Figure 2 2 AC and DC loads powered by the alternator The alternator is charging at 130 amps while the engine is running and there is a 1000 W AC load The efficiency of the inverter charger is approximately 90 which means it is drawing about 1100 W DC from the battery or 92 amps This leaves 38 amps for all DC loads If the DC loads require more than 38 amps the battery will actually discharge even though the alternator is running Operation Indication Solutions Comment 2 8 If the alternator is overloaded the battery voltage gauge on the instrument panel begins dropping from approximately 14 volts towards 12 volts e battery power on the remote switch indicator signals a low battery with a slow blink inverter shuts down at 10 4 volts and AC loads will stop operating The battery voltage gauge will climb again as the alternator now has enough power to charge the battery You can reduce the AC or DC load on the battery or for continuous operation of large AC and DC loads you can consider installing a larger alternator Small alternator overloads may not be immediately noticeable and can take several hours to discharge the batteries Large overloads will discharge the bat
35. r battery has only half the standby power than it has at 77 F 25 C Restarting After a Shutdown 975 0337 01 01 If the loads stop operating suddenly it usually means that the battery voltage is too low or you have drawn too much power for too long Try restarting the inverter by turning the switch off then on again If you are running several loads try disconnecting one or two of them before restarting If the load doesn t start right away let the inverter rest a few minutes then try again The sudden stoppage means your batteries should be recharged as soon as possible If the inverter still refuses to power your loads start the vehicle to charge the batteries Note Turning the switch off then on again to restart after a shutdown should only be considered a temporary measure The batteries likely need to be recharged Operation Battery Charging Connection When you are connected to shorepower the Charge indicator is cord illuminated and the unit is both passing power through to the appliances and charging the batteries To avoid low voltage problems make sure your connection cord to shorepower is not too long or too light to support the loads you are running A 12 gauge or larger extension cord is recommended AC voltage If the Charge indicator flashes slowly about twice per second this means the AC voltage is out of range and your batteries are not charging Using Shorepower If you are running too many
36. s 2 5 Operation x ST LL 18 M OST Ue 5591 10 umopinus pue A 8 01 pu M OST speo A 9 01 UMOPINYs pue jnoeur uo CA Oc 591 SPROT 10 peor e 1 1 JOU soop JI snou 9 14819 Joye UMOP sinus ou OOST 008 000I Jo seO 008 OSL 39481 uoSo eH 00 C T OMA 007 Joyyng IPAH 00 jexue q 081 101819811 jj E 001 YOA AL Ut 6T 001 Ioueo o umnoeA 001 SL Jojnduioo 1004310 OV duweg Surpeos SC 8 t SI t SI o qeoS1eqo1 JOU INPA A 001 581 OL Sr O j 045101 Sj Oc 01 PVM eouercky 99uemeg ep o daep uv uim aup ugerdo dA T Z L 975 0337 01 01 2 6 Planning for AC Loads Running the Alternator While Operating AC and DC Loads Recharging Example 975 0337 01 01 Running the alternator does not guarantee that the battery is being fully recharged by the alternator if you are running a combination of large AC and DC loads The alternator must provide more power than the draw of the c
37. t the installation and use of the unit Information about the failure and or reason for the return e copy of your dated proof of purchase Record these details in Information About Your System on page WA 4 Return Procedure Package the unit safely preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging 2 Include the following The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box Areturn address where the unit can be shipped Post office boxes are not acceptable Acontact telephone number where you can be reached during work hours A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of the USA or Canada In addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility and that the ASC repairs this partic
38. temperature effect on operation 2 2 2 11 effect on output power 2 3 appliances see AC load battery operated vi auto shutdown feature 1 4 automatic shutdown 2 12 automatic transfer between AC and DC 1 4 batteries disconnecting from 3 3 nickel cadmium vi precautions for working with vi battery charging 2 12 battery condition effect on AC loads 2 5 battery operated appliances see problem loads battery packs vi breaker switch resetting 2 12 C charger features 1 3 charger specifications A 4 charging batteries 2 12 cold temperatures running in 2 11 connect delay to AC power 2 12 connection cord recommended size 2 12 current vs temperature derating curve A 6 975 0337 01 01 Customer Service preparing to call WA 4 D DC loads effect on alternator 2 7 effect on operating times of AC loads 2 3 derating curves current vs temperature A 6 dimmer switch see problem loads disconnecting from batteries 3 3 extension cord see connection cord F Features of inverterecharger 1 2 flashlights see problem loads fuse replacing 3 4 H high battery shutdown 4 2 hot temperatures running in 2 11 indicator lights blinking patterns 4 2 inductive load see AC loads Information about Your System form WA 4 inverter purchase date WA 4 serial number W A 4 inverter features 1 3 inverter specifications A 3 L load management capability 1 4 IX 1 Index loads e
39. tery in a shorter time At low engine RPMs the alternator current will drop significantly causing alternator overload to occur even with reduced AC and DC loads 975 0337 01 01 Using the Remote Switch Using the Remote Switch Switch settings The switch shown in Figure 2 3 is used to disable the inverter The charger is always on as long as shorepower is connected regardless of the switch position If the switch is The inverter is On Providing AC to the outlets when there is no shorepower and the battery voltage is acceptable Off Providing pass through AC to the outlets only if there is shorepower The inverter is disabled and will not provide AC power in the absence of shorepower 1 Indicator 2 lights 3 Off Figure 2 3 Remote switch with indicator lights 975 0337 01 01 2 9 Operation Switch The switch indicator lights 1 LED provide information about the indicators lights operating state of the inverter charger Under normal operating conditions the lights will behave like this i TN Float When green LED is solid ON the charge cycle is completed It also means that the Charger On Charger indicator yellow LED turns off lights Charger On When yellow LED is solid ON it indicates that AC shore power is within operating voltage range relay is connected from shore power to AC output and the charger is actively charging AC Low High When yellow LED is flashing it indicates that
40. u 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 Before making the final connection to a battery be sure the polarity is correct negative to negative and positive to positive 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 vi 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 975 0337 01 01 Contents Important Safety Information 1 Introduction Inverter charger Features
41. ular Xantrex product 975 0337 01 01 WA 3 Warranty and Return Out of Warranty Service If the warranty period for your IP1012 AL Inverter Charger with Ignition Protection has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your unit may be serviced or replaced for a flat fee To return your IP1012 AL Inverter Charger with Ignition Protection for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page WA 3 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received Information About Your System As soon as you open your IP1012 AL Inverter Charger with Ignition Protection package record the following information and be sure to keep your proof of purchase Serial Number Product Number 805 1011 Purchased From Purchase Date If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service Type of installation e g
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