Xantrex Technology IP1012 AL manual

IP1012 AL Inverter/Char g er with Ignition Pr otection Owner’ s Guide IP1012 AL IP1012_AL.book Page i Tues day, 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 Tues day, May 1, 2007 12:18 PM[...]

About Xantrex Xantrex T echnology Inc. is a worl d-leadin g supplier of advanced power electroni cs and controls with products from 50 watt mobile units to 1 MW utility -scale system s for wind, solar , batteries, fuel cells, microturbines, and backup power applicati ons in bo th grid-connected and st and-alone systems. Xantrex products include inv[...]

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/Char ger with Ignition Protection. Scope The Guide provides safety guidelin es, detai led planning and setup information, procedures for installing the invert[...]

Safety iv 975-0337-01-01 Chapter 4, “T roubleshooting” provides information to help you identify common problems wh ich may occur . Read this chapter before calling your authorized Xantrex dealer . If you cannot solve the pro blem, record the details as suggested on “In formation About Y our System” on page W A–4, then call yo ur dealer .[...]

v Important Safety Information General Pr ecautions 1. Before using the inverter/char ger , re ad 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 in put power (qualified external AC which is when the external AC power is 100–130 V ac/5[...]

Safety vi 975-0337-01-01 Precautions W hen W orking With Batteries 1. Follow all instructions publi shed 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. [...]

975-0337-01-01 vii Important Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v 1 Introduction Inverter/charger Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Operating Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - [...]

Contents viii 975-0337-01-01 4 Troubleshooting Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Blinking Lights on the Remote Switc h - - - - - - - - - - - - - - - - - - - - - -[...]

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

Introduction 1–2 975-0337-01-01 Inverter/charg er F eatur es Features The IP1012 AL is an i gnition-protected, modified sine wave inverter/ charger weighing about 40 poun ds (18 kg). It is sealed, dust and water resistant, and can be mounted wher e it may be exposed to the elements. Figure 1-1 shows its main features. Consult Appendix A, “Speci[...]

Operating F eatures 975-0337-01-01 1–3 Location Ignition protection for safe operatio n in applications that require ignition protected equipment such as gasoline engine rooms or in a battery box. Ingress protected (IP66 ) fo r wet applications where the inverter will be cleaned with low pressure je ts of water . Operating F eatures Inverter/char[...]

Introduction 1–4 975-0337-01-01 • Low voltage shutdo wn 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 vo ltage, and protects against overload, sh ort circuits and over -temperatu re. • Automatic shu[...]

2 Oper ation 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 Tues day, May 1, 2007 12:18 PM[...]

Operation 2–2 975-0337-01-01 Planning for A C 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. V ariables affecting AC loads The IP1012 AL in verter / charger can power a wide range of loads. The s[...]

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 , vehicl e lighting, other lights using DC power • DC refrigerators • VHF radios • factory-installed radios or soun d systems • pumps, lights, fans, po wer vents, LP G[...]

Operation 2–4 975-0337-01-01 Figure 2-1 shows the relationship b e tween 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 fo r the time in minutes. The intersection of the time and temper[...]

Planning for AC Loads 975-0337-01-01 2–5 3. T o find the running time for sever al loads running simultaneously , add their total wattage and look fo r an appliance with similar power requirement in T able 2-1. Battery condition The information in T able 2-1 assumes: • there is a properly m aintained 12 volt 400 amp-hour batte ry bank, for exam[...]

Operation 2–6 975-0337-01-01 * A verage ‡ The inverter / char ger 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 shutd own for lo ads less than 150 W at 77 °F (25 °C).* Ta b l e 2 - 1 T[...]

Planning for AC Loads 975-0337-01-01 2–7 Running the Alternator W hile Operating A C and DC Loads Recharging Running the alternator does not gu arantee that the battery is being fully recharged by the alternator if you ar e running a combination of lar ge AC and DC loads. The alternato r must provide m ore po wer than the draw of the combined DC [...]

Operation 2–8 975-0337-01-01 Indication If the alternat or is overloa ded the: • battery voltage gauge on the instrument panel begins dropping from approximately 14 volts towards 12 volts, • battery power on the remote swit ch indicator signals a low battery with a slow blink, • inverter shuts down at 10.4 volts and AC loads will stop opera[...]

Using the Remote Switch 975-0337-01-01 2–9 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 shorep owe r 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 an[...]

Operation 2–10 975-0337-01-01 Switch indicators lights The switch indicator lights (i.e., LED) provide information about the operating s tate of th e inverter/char g er . Under normal operating conditions the lights will behave like this: 1 Float When green LED is solid ON, the charge cycle is completed. It also mean s that the Charger On yellow [...]

Operating the Inverter/Charger 975-0337-01-01 2–11 Operating the Inverter/Char ger This section provides guidelines for operating the IP1012 AL. T urning the Inverter On and Running Loads To r u n l o a d s : 1. T urn the remote switch on by pressing to the right. 2. Check that the Inverter indicator is illuminated and Charge indicator is off if [...]

Operation 2–12 975-0337-01-01 Battery Charging Connection cord When you are connected to shorep ower , the Charge indicator is illuminated and the unit is both passing power through t o the appliances and charging the batteries. T o avoi d low voltage problems, make sure your connection cord to sho repower i s not to o lon g or too lig ht to supp[...]

3 Maintenance 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 • removing or connecting the AC input and output cables. IP1012_AL.book Page 1 Tues day, May 1, 2007 12:18 PM[...]

Maintenance 3–2 975-0337-01-01 Maintaining the Inverter/charg er Before doing any maintenance on the IP101 2 AL, review all safety instructions in “Important Safety Information” on page v. Checking T erminals T o check that the battery cables ar e firmly connected, you will need to remove the terminal caps. T o remove the terminal cap: 1. Usi[...]

Disconnecting and Connecting the Bat teries 975-0337-01-01 3–3 Disconnecting and Connecting the Batteries Disconnecting T o disconnect from the battery: 1. Disconnect the shorepower cable and turn the inverter/charger of f from the remote switch. 2. Remove the inverter/char g er ca bles from the battery by first disconnecting the nega tive cable [...]

Maintenance 3–4 975-0337-01-01 3. T o reconnect the cab les: a) Connect one end of the positive battery cable to the IP1012 AL. b) Connect one end of the negative battery cable to the IP1012 AL. c) Connect the other end of the pos itive battery cable to the positive terminal of the battery . d) Connect the other end of the negative ba ttery cable[...]

Replacing the Fuse 975-0337-01-01 3–5 T o replace the fus e: 1. Lift the fuse cover off as sh own in Figure 3-2. 2. Remove the blown fuse and install the new fuse. Be sure to use a lock washer when replacing the nuts. T ighten to a torque of 4 to 5.5 ft-lb (5.5 to 7.5 Nm). . 3. Replace the fuse cover by placing it over the fuse and pressing down [...]

Maintenance 3–6 975-0337-01-01 Removing and Reconnecting A C Cables T o remove the AC cables: ➣ Grasp the knurled surface of the connector housing as shown in Figure 3-3 and turn counter clockwise approximately o ne-half turn. Gently pull the cable out by grasping the connector . To r e c o n n e c t : 1. Align the key of the co nnector with th[...]

4 T r oubleshooting Chapter 4, “T roubleshooting” provides information to help you identify common pr oblems 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 Y our System” on page W A–4, then call your dealer . IP1012_[...]

T roubleshooting 4–2 975-0337-01-01 T r oubleshooting Common Problems The unit shuts down during operat ion for four main reason s: • low battery—when the battery reac hes approximately 10.6 Vdc for more than four minutes with lo ads greater than 150 watts , or 10.8 Vdc for loads less than 150 watts. Low battery shutdown also occurs when batt[...]

T roubleshooting 975-0337-01-01 4–3 Blinking Lights on the Remote Switch Y ou may encounter different sequen ces of blinking lights when the inverter is enabled (i.e., switch is on ) or the unit is charg ing. Light sequences are described as follows: Loads stop operating without warning after they have been running. Shorepower is not connected. T[...]

T roubleshooting 4–4 975-0337-01-01 T able 4-2 explains the blin king pattern of the Char ger indicator when the unit is in charge mode. T able 4-3 explains the Inv erter indicator flashing pattern wh en the unit is in invert mode. T able 4-2 Charger indicator blink patterns Condition Blink Level High Battery vol tag e 1 Inverter too ho t 2 Charg[...]

A Specifications Appendix A contains the invert er , charger , and transfer specifications for the IP1012 AL. The specifications show rating curves for output surg e, current versus temperature, and pass-through current. Appendix A also illustrates the three-st age char ging pr ofile used by the unit. All specifications are subject to change withou[...]

Specifications A–2 975-0337-01-01 Physical Specifications Physical spe c ifications 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 lbs. (18 kg) maximum [...]

Inverter Specifications 975-0337-01-01 A–3 Inverter Specifications All inverter specifications are at nominal conditions; 1000 W resistive load, 12 Vdc inverting on the IP1012 AL, 120 V ac, unless otherwise specified. Inverter specifications Output wave form Modified sine wave Output power continuous 1000 V ac continuous Surge rating 3000 V A for[...]

Specifications A–4 975-0337-01-01 Charg er Specifications All charging specificati ons are at nominal conditions: 77 °F (25 °C), 14.0 Vdc at 50 A charging, 120 V ac, 60 Hz unless otherwise specified. Shutdowns an d 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 li[...]

T ransfer and General Specifications 975-0337-01-01 A–5 T r ansfer and General Specifications Absorption charge voltage 14.3 ± 0. 3 Vdc at 77 ° F (25 °C) Float char ge vol tage 13.3 ± 0. 3 Vdc at 77 ° F (25 °C) T emperature compen sation – 0.023 Vdc from -2 °C to 85 °C (28.4 °F to 185 °F). Below -2 °C, the charger voltage defaults to[...]

Specifications A–6 975-0337-01-01 Rating Curves and Charging Pr ofiles Figure A-1 Output surge rating Figure A-2 Charging current versus te mperature derating curve 0 500 1000 1500 2000 2500 3000 1 10 100 Tim e (mi nut e s ) Out put Powe r ( V A ) - 4 0 to 2 5 C 40C 55C 70C 85 C 104 F 131 F 158 F 185 F – 40 to 77 F Maximum charger current vs. T[...]

Rating Curves and Charging Profiles 975-0337-01-01 A–7 Figure A-3 T hree-stage charging profile Bulk DC V oltage DC Current Charging Started Constant current @ maximum charge rate Constant voltage Reduced voltage Load current on demand Float V olts Setting Bulk V olts Setting T ime Absorption Char ge Float Char ge IP1012_AL.book Page 7 Tues day, [...]

A–8 IP1012_AL.book Page 8 Tues day, May 1, 2007 12:18 PM[...]

975-0337-01-01 IX-1 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 temperature effect on operation 2–2, 2–11 effect on output power 2–3 appliances see AC load battery-operated vi a[...]

Index IX–2 975-0337-01-01 loads, effect of lar ge loads on alternator 2–7 low battery sh utdown 4–2 low volt a ge sh utdown 1– 4 M maintenance checking terminal connections 3–2 replacing the fuse 3–4 N nickel-cadmium batteries vi O operating time of AC loads (table) 2–6 output power of IP 1012 2–12 over temperature shutdown 4–2 ov[...]

975-0337-01-01 WA–1 W arranty and Return Information Wa r r a n t y What does this warranty cover? This Limited W arranty is provided by Xantrex T echnology Inc. ("Xantrex") and covers defects in workmanshi p and ma terials in your IP1012 AL Inverter/Ch arger with Ignition Protection. This warranty perio d lasts for one (1) year from th[...]

W arranty and Return WA–2 975-0337-01-01 What proof of pur chase is requir ed? In any warranty claim, da ted proof of purchase must accompany the product and th e product must not have been disass embled or modifi ed without prior written authorization by Xantrex. Proof of purchase may be in any one of the following form s: • The dated purchase[...]

W arranty and Return 975-0337-01-01 WA–3 Exclusions If this product is a consumer product, federal law does not allow an exclusion of implied warrant ies. T o the extent you are entitled to i mplied warranties under federal law , to the extent permit ted by applicable law they are limited to the duration of this Limited W arranty . Some states a [...]

W arranty and Return WA–4 975-0337-01-01 Out of W arr anty Service If the warranty period for y our IP1012 A L Inverter / Charger with Ignition Protect ion has expired, if the unit was damaged by misuse or incorrect installation, if ot her conditions of the warranty have not been met, or if no dated proof of purchase is available, your unit may b[...]

IP1012_AL.book Page 5 Tues day, May 1, 2007 12:18 PM[...]

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.c om www.xantrex.com 975-0337-01-01 Printed in China IP1012_AL.book Page 6 Tues day, May 1, 2007 12:18 PM[...]