t 1 408 987 6359 www.xantrex.com/support 975-0347-01-01 REV.
Duracell1000.
Duracell1000.book Page ii Friday, September 7, 2007 1:47 PM About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products ranging from small mobile units to utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems.
Duracell1000.book Page iii Friday, September 7, 2007 1:47 PM About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the Duracell® Inverter 1000. 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.
Duracell1000.book Page iv Friday, September 7, 2007 1:47 PM About This Guide Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions 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.
Duracell1000.book Page v Friday, September 7, 2007 1:47 PM Important Safety Instructions WARNING This chapter contains important safety and operating instructions. Read and keep this Owner’s Guide for future reference. 1. Before installing and using the Duracell® Inverter 1000, read all instructions and cautionary markings on the Duracell® Inverter 1000, the batteries, and all appropriate sections of this guide. 2. Do not expose the Duracell® Inverter 1000 to rain, snow, spray, or bilge water.
Duracell1000.book Page vi Friday, September 7, 2007 1:47 PM Safety Explosive gas precautions WARNING: Explosion hazard 1. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your Duracell® Inverter 1000. 2. This equipment contains components which tend to produce arcs or sparks.
Duracell1000.book Page vii Friday, September 7, 2007 1:47 PM Safety Precautions When Working With Batteries WARNING: Explosion or fire hazard 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 engine or batteries. 4. Use caution to reduce the risk or dropping a metal tool on the battery.
Duracell1000.book Page viii Friday, September 7, 2007 1:47 PM Safety Precautions for Using Rechargeable Appliances CAUTION: Equipment damage The output of the inverter is non-sinusoidal. Most rechargeable battery-operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage charging output. Some chargers for small rechargeable batteries can be damaged if connected to the Duracell® Inverter 1000.
Duracell1000.
Duracell1000.
Duracell1000.
Duracell1000.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 1 Introduction Congratulations on your purchase of the Duracell® Inverter 1000! The Duracell® Inverter 1000 has been designed to give you quality power, ease of use, and reliability. Please take a few moments to read this chapter to familiarize yourself with the main performance features and protection features of the Duracell. Quality Power The Duracell is a quality inverter designed for recreational vehicle (RV) and truck applications.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Ease of Use Superior features and rugged durability have been combined with ease of use: • • The Duracell is compact, light weight, and easy to install. Loads can be powered directly from the AC outlets. Comprehensive Protection The Duracell is equipped with numerous protection features to guarantee safe and trouble-free operation: Low battery alarm 11.0 V or lower.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 2 Features Chapter 2 describes the main features of the Duracell. We recommend that you familiarize yourself with them before installing and operating the inverter.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM AC Panel 3 2 4 5 1 6 Figure 2-1 AC Panel Feature Description 1 On/Off Switch turns the inverter’s control circuit on and off. This switch is not a power disconnect switch. Disconnect AC and DC power before working on any circuits connected to the inverter. 2 Power light is a green light indicating the On/Off Switch is on and AC voltage is present at the inverter’s AC outlets.
Duracell1000.book Page 3 Friday, September 7, 2007 1:47 PM DC Panel DC Panel 3 4 2 5 1 6 Figure 2-2 DC Panel l Feature 975-0347-01-01 Description 1 Chassis Ground Screw connects to vehicle chassis, DC grounding bus or to engine’s negative bus. 2 Positive DC Cabling Terminal always connects to the cable connected to the positive terminal of the battery. 3 Negative DC Cabling Terminal always connects to the cable connected to the negative terminal of the battery.
Duracell1000.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 3 Installation Chapter 3 provides information on cables and fuses to help you plan for your installation and provide procedures for installing the Duracell. We highly recommend that you read the entire chapter before beginning the installation procedures so that you can plan an installation that is suited to your power needs.
Duracell1000.
Duracell1000.
Duracell1000.book Page 4 Friday, September 7, 2007 1:47 PM Installation Codes Governing installation codes vary depending on the location and type of installation. Electrical installations must meet local and national wiring codes and should be performed by a qualified electrician. In residential applications, electrical codes do not allow permanent connection of AC distribution wiring to the inverter’s AC output receptacles.
Duracell1000.book Page 5 Friday, September 7, 2007 1:47 PM Designing Your Installation Choosing an Appropriate Location WARNING: Explosion or fire hazard The Duracell contains components that tend to produce arcs or sparks. To prevent fire or explosion, do not install the inverter in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment. WARNING: Fire hazard To reduce the risk of fire, do not cover or obstruct the ventilation openings.
Duracell1000.book Page 6 Friday, September 7, 2007 1:47 PM Calculating Cable Sizes To operate safely and effectively, the Duracell needs proper cables and fuses. Because the Duracell has low-voltage and high-current input, it is essential that you use low-resistance wiring between the battery and the inverter to deliver the maximum amount of usable energy to your load.
Duracell1000.book Page 7 Friday, September 7, 2007 1:47 PM Designing Your Installation Calculating Size of Chassis Ground Cable Refer to Table 3-2 to plan the size of the chassis ground cable that runs from the grounding point to the chassis ground screw on the inverter’s DC panel. Table 3-2 Recommended Chassis Ground Cable sizes Application Chassis ground cable size (Stranded cable is recommended) Maximum Battery Fuse Size Recreational Vehiclea No.
Duracell1000.book Page 8 Friday, September 7, 2007 1:47 PM Calculating Fuse/Circuit Breaker Size Because your batteries can provide thousands of amps of short-circuit current, you need fuses or circuit breakers that can safely withstand the short-circuit current that the batteries can produce. To select the correct fuse type and size: 1. Determine the total short-circuit current rating for your batteries.
Duracell1000.book Page 9 Friday, September 7, 2007 1:47 PM Installing the Duracell Installing the Duracell Do not proceed with the installation of your Duracell until you have read the section, “Designing Your Installation” on page 3–1. The more thorough your planning, the better your power needs will be met to achieve maximum performance from your Duracell. Safety Instructions Before you start to install the Duracell: • • • Review the “Important Safety Instructions” on page v.
Duracell1000.book Page 10 Friday, September 7, 2007 1:47 PM Materials The following checklist is a general list of required materials.
Duracell1000.book Page 11 Friday, September 7, 2007 1:47 PM Installing the Duracell Overview of Installation Steps These are the three steps for installing your Duracell. Do not proceed with installation until you have read “Designing Your Installation” on page 3– 1. 1. Mount the inverter. 2. Connect the chassis ground. 3. Connect the DC cables. Mounting the Inverter Do not mount the inverter under the hood of your vehicle. See “Choosing an Appropriate Location” on page 3–5. To mount the Duracell: 1.
Duracell1000.book Page 12 Friday, September 7, 2007 1:47 PM Connecting the Chassis Ground WARNING: Shock hazard Never operate the Duracell without properly connecting the chassis ground. Electrical shock hazard could result from improper grounding. The Duracell has a screw terminal labelled CHASSIS GND on the rear panel as shown in Figure 3-3 on page 3–12. Follow the guidelines in “Grounding Locations” to connect the inverter’s chassis to the ground.
Duracell1000.book Page 13 Friday, September 7, 2007 1:47 PM Installing the Duracell To connect the chassis ground terminal to a grounding point: • Recreational Vehicle: Connect the CHASSIS GND screw to the vehicle’s chassis using a recommended 8AWG minimum copper wire (if insulated then green insulation with or without one or more yellow stripes) or larger. Chassis Ground Screw We recommend that you attach the cable to the chassis ground screw with a ring terminal.
Duracell1000.book Page 14 Friday, September 7, 2007 1:47 PM If you are using crimp connectors, use the tool recommended by the terminal manufacturer. Make sure no stray wires protrude from the terminal. (You may find it more convenient to have the crimp connectors attached by the company that sells you the cable and/or connectors.) 4. For each cable end that will be connected to the inverter, strip 1/2 inch (13 mm) to 3/4 inch (19 mm) of insulation from the cable.
Duracell1000.book Page 15 Friday, September 7, 2007 1:47 PM Installing the Duracell CAUTION Do not over tighten the nut on the DC input terminals. Damage to the DC input terminals may result. The maximum torque setting is 6–7 lbF-in (0.68–0.79 Nm). CAUTION: Reverse polarity DC power connections to the Duracell must be positive to positive and negative to negative. A reverse polarity connection (positive to negative) will blow a fuse in the inverter and may permanently damage the inverter.
Duracell1000.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 4 Operation Chapter 4 explains how to operate the Duracell efficiently and effectively.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Operating Several Loads at Once If you are going to operate several loads from the Duracell, turn them on one at a time after you have turned the inverter on. Turning loads on separately helps to ensure that the inverter does not have to deliver the starting current for all the loads at once, and will help prevent an overload shutdown.
Duracell1000.book Page 3 Friday, September 7, 2007 1:47 PM Operating Limits Operating Limits Power Output The Duracell can deliver up to 1000 watts continuous. The wattage rating applies to resistive loads such as incandescent lights. Input Voltage The allowable Duracell input voltage ranges are shown in the following table: 975-0347-01-01 Operating Condition Voltage Range Normal 10.5 V–15.0 V Optimum Performance 12.0 V–13.0 V Low Voltage Alarm 11.0 V or less Low Voltage Shutdown less than 10.
Duracell1000.book Page 4 Friday, September 7, 2007 1:47 PM Inverter Loads The Duracell will operate most AC loads within its power rating of 1000 watts. However, some appliances and equipment may be difficult to operate, and other appliances may actually be damaged if you try to operate them with the Duracell. Please read “High Surge Loads” and “Trouble Loads” carefully. High Surge Loads Some induction motors used in freezers, pumps, and other motor-operated equipment require high surge currents to start.
Duracell1000.book Page 5 Friday, September 7, 2007 1:47 PM Routine Maintenance Routine Maintenance Duracell unit Minimal maintenance is required to keep your Duracell operating properly. Periodically you should: • • • Clean the exterior of the unit with a damp cloth to prevent the accumulation of dust and dirt. Ensure that the DC cables are secure and fasteners are tight. Make sure the ventilation openings on the DC panel and bottom of the inverter are not clogged.
Duracell1000.book Page 6 Friday, September 7, 2007 1:47 PM If one of your Xantrex battery-integrated products has reached the end of its useful life, we urge you to dispose of the product correctly and safely. Xantrex recommends taking the following steps to recycle your product depending on battery chemistry and size. Ni-MH, Li-ion or small Pb Batteries (up to 2 lbs. or 1 kg) If you are recycling a product that contains a Ni-MH, Li-ion or small Pb battery (up to 2 lbs.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 5 Troubleshooting Chapter 5 will help you identify the source of most problems that can occur with the Duracell. If you have a problem with the inverter, please review this chapter before contacting your dealer. If you are unable to solve a problem and need to contact your dealer, record the details on the form “Information About Your System” on page WA–6.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Common Problems Buzz in Audio Equipment Some inexpensive stereo systems may emit a buzzing noise from their loudspeakers when operated from the Duracell. This occurs because the power supply in the audio system does not adequately filter the modified sine wave produced by the inverter. The only solution is to use a sound system that has a higher quality power supply.
Duracell1000.book Page 3 Friday, September 7, 2007 1:47 PM Troubleshooting Reference Troubleshooting Reference WARNING: Electrical Shock and Burn Hazard Do not disassemble the Duracell. It does not contain any user-serviceable parts. Attempting to service the unit yourself could result in an electrical shock or burn. Table 5-1 Troubleshooting Reference Problem Possible Cause Low output voltage (96 VAC–104 VAC) You are using a voltmeter that Use a true RMS reading voltmeter such as the Fluke 87.
Duracell1000.book Page 4 Friday, September 7, 2007 1:47 PM Table 5-1 Troubleshooting Reference Problem Possible Cause Solution No output voltage. Fault Light is on. Low input voltage Recharge the battery; check the connections and cable. High input voltage Make sure the Duracell is connected to a 12 V battery. Check the voltage regulation of the charging system. Thermal shutdown Allow the unit to cool off. Reduce the load if continuous operation is required. Improve ventilation.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM A Specifications Appendix A contains electrical performance and physical specifications for the Duracell® Inverter 1000. Electrical Performance Electrical performance Duracell Output power at 77 º F (25 ºC) ambient temperature and 12 Vdc input: • Maximum continuous output power • Maximum surge power 1000 W 2000 W Output voltage 115 Vac RMS Output waveform Modified sine wave Output frequency 60 Hz Input voltage 10.5–15.
Duracell1000.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM B Battery Types The information in Chapter B will help you to select, connect, and maintain batteries that are most appropriate for your application. The batteries that you use strongly affect the performance of the Duracell. It is important to connect the inverter to the correct size and type of battery. Battery Types Automotive Starting Batteries The lead-acid battery you are most familiar with is probably the starting battery in your vehicle.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Deep-Cycle Batteries Deep-cycle batteries are designed for deep discharge service where they will be repeatedly discharged and recharged. They are marketed for use in recreational vehicles, boats, and electric golf carts—so you may see them referred to as RV batteries, marine batteries, or golf cart batteries.
Duracell1000.book Page 3 Friday, September 7, 2007 1:47 PM Battery Size Battery Reserve Capacity Battery reserve capacity is a measure of how long a battery can deliver a certain amount of current—usually 25 amps. For example, a battery with a reserve capacity of 180 minutes can deliver 25 amps for 180 minutes before it is completely discharged. Amp-hour (Ah) Capacity Amp-hour capacity is a measure of how many amps a battery can deliver for a specified length of time—usually 20 hours.
Duracell1000.book Page 4 Friday, September 7, 2007 1:47 PM Estimating Battery Requirements To determine how much battery capacity you need: 1. Determine how many watts are consumed by each appliance that you will operate from the Duracell. You can normally find the watt rating labelled on the product. If only the current draw is given, multiply it by 115 to get the power consumption in watts. 2. Estimate how many hours each appliance will be operating each day. 3.
Duracell1000.book Page 5 Friday, September 7, 2007 1:47 PM Estimating Battery Requirements This example illustrates how quickly your battery needs can escalate. To reduce the required battery size, you can conserve energy by eliminating or reducing the use of some loads or by re-charging more frequently. When sizing your battery, resist the temptation to skip the last step of this calculation (multiplying by 2).
Duracell1000.book Page 6 Friday, September 7, 2007 1:47 PM Using Multiple Batteries As your power requirements increase, you may need to use more than one battery to obtain sufficient capacity. Read “Two Batteries Connected In Parallel” and “Two Separate Battery Banks” to determine whether two batteries or two battery banks are more appropriate for your applications.
Duracell1000.book Page 7 Friday, September 7, 2007 1:47 PM Battery Tips Battery Tips WARNING Review “Precautions When Working With Batteries” on page vii before you work with the batteries in your system. Explosive/ Corrosive Gases Temperature Sensitivity Lead-acid batteries may emit hydrogen gases, oxygen, and sulfuric acid fumes when recharging. To reduce the risk of explosion: • • Vent the battery compartment to prevent the accumulation of gases.
Duracell1000.book Page 8 Friday, September 7, 2007 1:47 PM Battery State of Charge B–8 You can measure battery state of charge with a hydrometer or approximate state of charge with a voltmeter. Use a digital voltmeter that can display tenths or hundredths of a volt when measuring 10 to 30 volts. Make your measurements when the battery has not been charged or discharged for several hours. For a deep-cycle battery at 77º F (25º C), use the following table: Battery Voltage State of Charge 12.7–13.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM C Alternators and Charging Systems Appendix C provides guidelines for recharging batteries from an alternator, from AC power, and from alternate energy sources. A good charging system is important for the health of your batteries. Poor recharging methods can quickly damage batteries. Charging System Requirements Your charging system should be capable of delivering a charging current equal to 25% of the amp-hour capacity of your battery.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Charging With an Engine Alternator Read the following information to determine whether your vehicle’s standard alternator will be adequate by itself, whether you should install an alternator controller, or whether you need a high-output alternator. Using a Standard Vehicle Alternator A typical engine alternator (12 volts) may not be able to meet the requirements outlined above if your system uses large capacity batteries.
Duracell1000.book Page 3 Friday, September 7, 2007 1:47 PM Charging From AC Power Charging From AC Power When recharging from AC power, use a good quality marine battery charger or RV converter that meets the requirements outlined in “Charging System Requirements” on page C–1. For information about battery chargers, visit our web site at www.xantrex.com or call Customer Service on page ii. Do not use chargers intended for occasional recharging of automotive starting batteries.
Duracell1000.
Duracell1000.book Page 1 Friday, September 7, 2007 1:47 PM 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 Duracell® Inverter 1000. This warranty period lasts for 6 months from the date of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims.
Duracell1000.book Page 2 Friday, September 7, 2007 1:47 PM Warranty and Return What proof of purchase 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.
Duracell1000.
Duracell1000.book Page 4 Friday, September 7, 2007 1:47 PM Warranty and Return 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 To" address. Products must also be shipped prepaid.
Duracell1000.book Page 5 Friday, September 7, 2007 1:47 PM Warranty and Return Out of Warranty Service If the warranty period for your Duracell® Inverter 1000 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 inverter may be serviced or replaced for a flat fee.
Duracell1000.book Page 6 Friday, September 7, 2007 1:47 PM Warranty and Return Information About Your System As soon as you open your Duracell® Inverter 1000 package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number (on DC end) _________________________________ ❐ Purchased From _________________________________ ❐ Purchase Date _________________________________ If you need to contact Customer Service, please record the following details before calling.
