IP1012_AL.
IP1012_AL.
IP1012_AL.
IP1012_AL.book Page ii Tuesday, May 1, 2007 12:18 PM About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems.
IP1012_AL.book Page iii Tuesday, May 1, 2007 12:18 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 IP1012 AL Inverter/Charger with Ignition Protection. Scope The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the unit.
IP1012_AL.book Page iv Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page v Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page vi Tuesday, May 1, 2007 12:18 PM Safety Precautions When Working With Batteries 1. Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed. 2. Make sure the area around the battery is well ventilated. 3. Never smoke or allow a spark or flame near the vehicle engine or a battery. 4. Use caution to reduce the risk of dropping a metal tool on a battery.
IP1012_AL.
IP1012_AL.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM 1 Introduction Chapter 1, “Introduction” describes the main performance and protection features of the IP1012 AL Inverter/Charger with Ignition Protection.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM 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 information about the unit.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM Operating Features Location Feature Description 1 2 3 4 5 6 7 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 Negative terminal with terminal cap on Ignition protection for safe operation in applications that require ignition protected equipment such as gasoline engine rooms or in a battery box.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM Introduction • Charger features 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.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM 2 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 help you run loads safely and efficiently.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM Operation Planning for AC Loads AC load AC load refers to an AC appliance you want to operate from the inverter/ charger. Loads include most appliances that you can plug into a standard 120 volt household electrical outlet. Variables affecting AC loads The IP1012 AL inverter/charger can power a wide range of loads.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM Planning for AC Loads DC loads DC loads are those that run off a 12 volt electrical system. A few examples of DC loads are: • • • • • marker lights, headlights, vehicle lighting, other lights using DC power DC refrigerators VHF radios factory-installed radios or sound systems pumps, lights, fans, power vents, LPG leak detector, toilet, and some water heaters. DC loads and the inverter/charger both rely on the batteries for power.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page 5 Tuesday, May 1, 2007 12:18 PM Planning for AC Loads 3. To find the running time for several loads running simultaneously, add their total wattage and look for an appliance with similar power requirement in Table 2-1.
2–6 10 20 2 3 Minutes Hours 5 ‡ ‡ 10 15 20 30 45 70 85 100 Based on four minute operation timeout and shutdown at 10.6 V for loads more than 150 W and 10.8 V timeout and shutdown for loads less than 150 W at 77 °F (25 °C).* † ‡ The inverter/charger shuts down after eight (8) hours if it does not detect a load (or loads less than 20 W.) * Average Hair dryer Microwave oven Toaster Small Coffee maker Halogen work light Electric drill 1/2” Electric buffer 3 cu. ft.
IP1012_AL.book Page 7 Tuesday, May 1, 2007 12:18 PM Planning for AC Loads Running the Alternator While Operating AC and DC Loads Recharging 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 combined DC and AC loads for your battery to fully recharge.
IP1012_AL.book Page 8 Tuesday, May 1, 2007 12:18 PM Operation Indication If the alternator is overloaded the: • Solutions Comment battery voltage gauge on the instrument panel begins dropping from approximately 14 volts towards 12 volts, • 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.
IP1012_AL.book Page 9 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page 10 Tuesday, May 1, 2007 12:18 PM Operation Switch indicators lights The switch indicator lights (i.e., LED) provide information about the operating state of the inverter/charger. 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 means that the Charger On yellow LED turns off.
IP1012_AL.book Page 11 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page 12 Tuesday, May 1, 2007 12:18 PM Operation Battery Charging Connection cord When you are connected to shorepower, the Charge indicator is 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.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM 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 2 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM Disconnecting and Connecting the Batteries Disconnecting and Connecting the Batteries Disconnecting WARNING: Explosion or Fire Make sure the battery compartment is well ventilated. Flammable fumes are often present when working with batteries. To disconnect from the battery: 1. Disconnect the shorepower cable and turn the inverter/charger off from the remote switch.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM 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 IP1012 AL. 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.
IP1012_AL.book Page 5 Tuesday, May 1, 2007 12:18 PM Replacing the Fuse To replace the fuse: 1. Lift the fuse cover off as shown in Figure 3-2. 3 1 2 Figure 3-2 Removing the fuse cover 2. Remove the blown fuse and install the new 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). . 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.
IP1012_AL.book Page 6 Tuesday, May 1, 2007 12:18 PM Maintenance Removing and Reconnecting AC Cables To remove the AC cables: ➣ 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.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM 4 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.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM Troubleshooting Troubleshooting 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 Vdc for loads less than 150 watts. Low battery shutdown also occurs when battery voltage reaches 10.4 Vdc for three seconds.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM Troubleshooting Table 4-1 Troubleshooting reference (Continued) Symptom Possible Problem 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. Reduce the number of loads. Allow the inverter to cool and restart. Recharge the batteries. Ambient temperature is too high. Disconnect appliances and let the unit cool down.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM Troubleshooting 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.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 PM A 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.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 PM Specifications Physical Specifications Physical specifications A–2 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 without mounting brackets or external cables External finish Base - Clear anodized aluminum.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM Inverter Specifications Inverter Specifications All inverter specifications are at nominal conditions; 1000 W resistive load, 12 Vdc inverting on the IP1012 AL, 120 Vac, unless otherwise specified. 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 A-1 for output at different temperatures.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM Specifications Inverter specifications (Continued) Shutdowns and Restarts DC low voltage shutdown 1. 2. 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 s) Battery voltage is below 10.4 ± 0.2 Vdc for 3 seconds DC low voltage restart 13.0 ± 0.15 Vdc DC high voltage shutdown 16.0 ± 0.2 Vdc DC high voltage restart Less than 16.
IP1012_AL.book Page 5 Tuesday, May 1, 2007 12:18 PM 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 Vdc 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.
IP1012_AL.book Page 6 Tuesday, May 1, 2007 12:18 PM Specifications Rating Curves and Charging Profiles Output Power (VA) 3000 2500 2000 1500 1000 500 0 1 10 100 Time (minutes) -40 to 25C 40C 55C 70C – 40 to 77 F 104 F 131 F 158 F 85C 185 F Figure A-1 Output surge rating Maximum charger current vs.
IP1012_AL.
IP1012_AL.
IP1012_AL.
IP1012_AL.
IP1012_AL.book Page 1 Tuesday, May 1, 2007 12:18 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 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.
IP1012_AL.book Page 2 Tuesday, May 1, 2007 12:18 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.
IP1012_AL.book Page 3 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.book Page 4 Tuesday, May 1, 2007 12:18 PM 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.
IP1012_AL.
IP1012_AL.book Page 6 Tuesday, 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.com www.xantrex.
