Cooper Bussmann 1000W Installation Manual Download Page 10 | Manualshive

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10

STEP 1: Determine an installation type

Installation of the inverter will involve many common components, some

which are shown below.

Figure 1-2

shows some of those components and their

relevance with each other in a standard heavy truck or recreational vehicle
installation.

Figure 1-2

Typical Recreational Vehicle and Fleet Vehicle Installation

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Summary of Contents for 1000W

Page 1: ...Transportation Products Cooper Bussmann Inverter 1000W 1800W INSTALLATION GUIDE ...

Page 2: ...xt generation systems that will create efficiencies not yet realized The Cooper Bussmann mission is to respond completely and uniquely to OEM requirements for vehicle electronic products and control solutions providing cost reduction and customization We are committed to continuous new product development and offer you a competitive advantage through R D expertise and a technology portfolio that m...

Page 3: ...y while servicing the unit It is possible for the inverter to produce arcs and or sparks do not install or use inverter near flammable materials i e gas powered machines fuel tanks or any components connected to a fuel supply Follow any instructions from the battery manufacturer being used Personal Precautions When Working with Batteries WARNING risk of electrical shock burn from high short circui...

Page 4: ...s Make only DC output connections or disconnections after setting all unit switches to OFF position and opening AC disconnect s It is recommended to review TMC RP 160 and RP 163 which include wiring and selection recommendations ...

Page 5: ...5 CONTENTS Installation pg 6 Configuration pg 24 Specifications pg 28 ...

Page 6: ...ling a Cooper Bussmann Inverter Battery Charger It will cover the following Materials list Safety instructions Sample installation tools and materials Installation procedures for mounting and connecting the product ground AC cabling DC cabling and grounding techniques ...

Page 7: ...her and Flat Washer for Battery Positive and Battery Negative 1ea M6x1 00 Nuts with Lock Washer and Flat Washer for Chassis Ground Connection One Red and one Black Insulating Boot for covering up to 00 AWG Battery Positive and Battery Negative Connections 2ea cable clamps for retention of hardwired AC Input and AC Output 2ea ground lugs for chassis ground connection of hardwired AC input and AC ou...

Page 8: ...precautions concerning the installation Prior to engaging in any service all AC and DC power sources need to be disconnected and all AC and DC devices and generators need to be disabled Follow proper cable routing and strain relief guidelines Installation Codes Installation codes vary depending on specific industry location and application of inverter It is the installer s responsibility to ensure...

Page 9: ...tandard wall cable sized appropriately for load application Wire nuts or crimp connectors for AC wire and appropriate tools DC cable sized appropriately for load application Lugs for DC cables to mount on size M8 x 1 25 studs DC stud terminals and appropriate tools i e crimping tool Lug for Chassis Ground cable to mount on size M6 x 1 00 stud DC stud terminal and appropriate tools i e crimping too...

Page 10: ...ill involve many common components some which are shown below Figure 1 2 shows some of those components and their relevance with each other in a standard heavy truck or recreational vehicle installation Figure 1 2 Typical Recreational Vehicle and Fleet Vehicle Installation ...

Page 11: ...r hard wired used on the source of the inverter must be rated to a max 30A and must also be approved for use on 115Vac systems The wire used between the breaker and the inverter needs to be sized accordingly to pass the same amount of current rated for the fuse AC Output The fuse or circuit breaker on the output should not be rated any higher than that of the input The wire between the inverter an...

Page 12: ...s and the inverter Heavy truck or RV installations normally require multi strand insulated cables for flexibility and durability they also usually require over current protection devices DC cables must be copper and must be rated to at least 75 C The cables should also terminate with lugs that fit the DC stud terminals on the inverter m8 x 1 25 Choosing small cables may result in variable device f...

Page 13: ...Also give at least 1inches 2 5cm on each side and 2 inches 5cm at the AC end Do not allow ventilation to be obstructed Safe Do not install the inverter in the same compartment as flammable liquids batteries or any unsafe materials Close in Avoid excessive cable lengths especially between inverter and battery banks Batteries Never allow battery acid to come in contact with the inverter or the wirin...

Page 14: ...ally the vehicle s chassis or DC negative bus ground using a properly insulated copper wire There are no restrictions on length for the equipment ground cable General practice is to not have a ground cable within one 1 AWG of the supply cable STEP 4 Connect the AC input wires optional for AC Input WARNING Fire Shock and Energy hazard Ensure all other wiring is disconnected from all sources before ...

Page 15: ...tective conduit or wrap Torque DC input cable fasteners to 12 2 13 6 Nm Torque Chassis Ground cable fastener to 6 6 7 3 Nm Model DC Input AC Input AC Output Minimum Wire Size AWG Required Fuse Amp Minimum Wire Size AWG Branch Circuit Protection Required Recommended Fuse Amp Minimum Wire Size AWG Recommended Fuse Amp 12 110 1000 3 125 12 15 14 N A See Note 12 110 1800 1 200 12 20 12 N A See Note 12...

Page 16: ... output hardwiring are located on the front sidewalls Make sure to read the labels on the inverter for proper input and output wiring AC Input Connections 1 Ensure AC and DC power are OFF 2 Install required circuit breaker to the AC input wiring system 3 Remove mounting screws holding the GFCI AC receptacle and take off the front panel 4 Leave the GFCI inside the inverter but remove the knockout f...

Page 17: ...ARNING Shock fire and energy hazard Ensure all sources have been disconnected from power before continuing Wiring of the inverter should be in accordance with wiring codes WARNING Shock hazard and equipment damage DO NOT connect any AC input source to the output terminals of the inverter Connecting an AC voltage source to the output of the inverter will cause serious damage and possibly hazardous ...

Page 18: ...reak down and possibly cause permanent damage 10 It is very important to not confuse the connections i e putting the line conductor into the neutral termination From the AC cable typical wire color schemes are as follows BARE COPPER or GREEN or GREEN YELLOW insulation is GROUND wire BLACK or BROWN insulation is the LINE wire WHITE or BLUE insulation is the NEUTRAL wire Confirm proper wires are in ...

Page 19: ...ed to negative Perform this observation at the inverter and the battery Reversing this connection will damage the inverter and will invariably be detected by the manufacturer WARNING Fire hazard Proper wire must be used in all connections The temperature rating of the wire must be at least 75 C All connections must be snug loose connections may overheat The procedure below will illustrate how to c...

Page 20: ...on to the inverter Tighten the nut to 12 2 13 6 Nm The connection should be tight enough that the ring terminal does not move on the DC terminal CAUTION A loose connection at any terminal may cause the wires to overheat and melt insulation they will also cause an excessive voltage drop CAUTION Over tightening any of the lugs and nuts may cause damage to the DC input terminals CAUTION Reverse polar...

Page 21: ...igned grounding bus Tighten to 6 6 7 3 Nm STEP 7 OPTIONAL Mount removable display in remote location 25ft max The communications cable for optional mounting of the display should be at maximum 25 feet Mounting the display flush into a wall or panel requires an opening about 3 25in x 1 25in and 1 5in deep 8 25cm x 3 18cm and 3 81cm deep Mounting the display panel 1 The location for the panel should...

Page 22: ...DC fuse and disconnect or the DC circuit breaker to start supplying the inverter with DC power Testing in INVERT MODE 1 If hardwired ensure utility grid power is not present 2 Press the Inverter button ISEC to turn the inverter on The status LED on the panel will glow yellow and the display screen will illuminate 3 Using an appliance within the inverter s range plug it into the GFCI on the front o...

Page 23: ...th inverted power from the battery upon the utility grid power source failing or becoming disconnected The same will happen if the utility grid voltage falls too low less than 90Vac WARNING Shock hazard Utility grid power will always pass through the inverter to the AC output even if the inverter is turned OFF ...

Page 24: ...erter can operate from several different types of lead acid batteries It is important to make sure the battery type is configured on the unit for optimum charging process before installing batteries WARNING Fire hazard Programming the incorrect battery type may result in battery damage and a fire risk Battery Type Setting O P Voltage VDC Tolerance 0 2Vdc Bulk Absorption Float Fixed 13 5 13 5 13 5 ...

Page 25: ...ltage in Volts and the Input Voltage V LED indicator will be illuminated 1 Press the Select button once Screen display the DC input current in Amperes and the Input Current A LED indicator will illuminate 2 Press the Select button once more Screen display the AC output power in kilowatts and the Output power KW LED indicator will illuminate 3 Press the Select button once more third time Screen dis...

Page 26: ...ust the charging current By default the charging current is as follows 20A for the 12 110 1000 B2 40A for the 12 110 1800 B4 12 110 1000 B4 1 Press and hold the Inverter button for five seconds This brings the inverter into Charge Current Setting Mode 2 Press the Select button to switch between the different current ratings in Amps 2 5 10 20 for the 12 110 1000 B2 2 10 20 40 for the 12 110 1800 B4...

Page 27: ... AC Current Available Amps 12 110 1000 B2 12 110 1800 B4 12 110 1000 B4 12 110 1000 B2 12 110 1800 B4 12 110 1000 B4 15 2 2 13 5 13 5 5 10 12 5 11 10 20 11 8 5 20 40 8 5 3 5 20 2 2 18 5 18 5 5 10 17 5 16 10 20 16 13 5 20 40 13 5 8 5 30 2 2 28 5 28 5 5 10 27 5 26 10 20 26 23 5 20 40 23 5 18 5 Table 3 1 Charging Current Guidelines ...

Page 28: ...put current inverter on Input voltage 11 5VDC and greater 0 9a DC Input voltage less than 11 5VDC 1 5a DC No load input current inverter off 1 0mA Inverter button off and no utility power connection All DC Voltage tolerances 0 3VDC AC Outputs 1000W 1800W Continuous output power 1000W 8 3a 1800W 15a Surge output power 5 seconds 1200W 2000W Surge output power 2000W 200ms 3600W 300ms Operating Temper...

Page 29: ... 2s Voltages 5V Battery Charger AC input operating range 95 135VAC AC input range with full power 105V 135VAC AC input current with no load 0 50 Arms Input current full load 6 Arms 12 110 1000 B2 11 5 Arms 12 110 1000 B4 12 110 1800 B4 AC input frequency 60 Hz 1 Hz Operating Temperature Range 0C to 50C Allow for 1 5 Adc charge current reduction above 40C DC Output Voltage Battery Type Setting O P ...

Page 30: ...30 DC Output Current Model Maximum DC Output current Adc Setting 1 Setting 2 Setting 3 Setting 4 12 110 1000 B2 2 0 5 5 0 5 10 1 20 2 12 110 1800 B4 12 110 1000 B4 2 0 5 10 1 20 2 40 4 Charge Algorithm ...

Page 31: ...006 Sec 4 2 Fig 4B Must operate per specification during and after the test Altitude Operating Per SAE J1455 Rev JUN2006 Sec 4 9 Table 2 Must operate per specification during and after the test Altitude Non operating Per SAE J1455 Rev JUN2006 Sec 4 9 Table 2 Must operate per specification after the test Electromagnetic Specifications Conducted Immunity Per SAE J1113 3 Severity Level L6 0 5W Manual...

Page 32: ...inverter shall present no safety hazard Internal fuses will open in the inverter system requiring factory service for replacement Regulatory Requirements UL 458 Comply with the requirements of the standard UL Mark CSA C22 2 No 107 1 Comply with the requirements of the standard CUL Mark ...

Page 33: ...5 foot RJ11 cable for remote mounting of control panel 2 ea M8x1 25 Nuts with Lock Washer and Flat Washer for Battery Positive and Battery Negative 1ea M6x1 Nuts with Lock Washer and Flat Washer for Chassis Ground Connection One Red and one Black Insulating Boot for covering up to 00 awg Battery Positive and Battery Negative Connections 2ea cable clamps for retention of hardwired AC Input and AC O...

Page 34: ...Minimum Wire Size AWG Recommended Fuse Amp 12 110 1000 3 125 12 15 14 N A See Note 12 110 1800 1 200 12 20 12 N A See Note 12 110 1000 B2 3 125 12 20 14 N A See Note 12 110 1000 B4 3 125 12 20 14 N A See Note 12 110 1800 B4 1 200 10 30 12 N A See Note Note AC output fuse is not required as all models feature a 15 or 20 Amp AC output breaker ...

Page 35: ...rning Mid 12 1 VDC E05 0 33 Hz Under Voltage Shutdown Mid 11 8 VDC E01 Beep 1Hz Note 1 Under Voltage Recovery Mid 12 6VDC N A N A Note 2 Under Voltage Warning HI 12 2VDC E05 0 33 Hz Note 3 Under Voltage Shutdown HI 12 2VDC E01 Beep 1Hz Note 1 Under Voltage Recovery HI 13 0VDC N A N A Note 2 Note 1 Unit will shut down instantly and initiate a 30 second auto reset period If the DC input voltage retu...

Page 36: ... with the buzzer beeping 1 Hz Note Manual reset is required to restart Inverter after AC Overload or Short Circuit shutdown System will automatically reset AC Overload or Short Circuit shutdown error when utility is available The supplemental protector or the branch protection specified in the Installation Guide should be open under bypass short circuit output condition Incorrect Connection Protec...

Page 37: ...Charger Transformer sensor temperature drops below 90 C Location Warning C Error code Audio alarm Shutdown C Error Code Audio alarm On Off On Off Rectifier Diode 90 88 E07 Beep 0 33Hz 95 80 E04 Beep 1 Hz Extrusion 63 60 60 56 Note Over temperature shutdown of these sensors is auto reset Sensor temperature tolerance is 5 C Reverse Battery Protection Model DC Input Fuse 12 110 1000 xx 4 x 30A Auto B...

Page 38: ...39 AC Output Protection There is no detection method for AC back feed to inverter output Inverter output bridge MOSFET and related circuitry component failure are an acceptable failure mode ...

Page 39: ... Beep 1 Hz and AC charger is latched off following 15 minute delay Bypass mode is available To reset error code remove AC Input and cycle unit off and on until reset Parametric Display The two buttons on the display panel can be used to select what is being displayed on the screen and to enter into feature select mode To select what is being displayed on the screen during inverter mode press Selec...

Page 40: ...e by toggle between Current setting Cur Inverter disable In Alarm setting AL Under Voltage shutdown setting Sd and Factory default dEF Once the feature is selected press the Select button to toggle between setting Cur 2A 5A 10A 20A select charger current for 12 110 1000 B2 2A 5A 20A 40A select charger current for 12 110 1000 B4 12 110 1800 B4 In In0 In1 inverter disable enable AL AL0 AL1 alarm dis...

Page 41: ...ft long P N 31 5267 00 User Messages Diagnostics The following Fault codes are provided on digital display when system Fault Warning occurs E01 DC Input Under VoltageShutdown E02 DC Input Over Voltage Shutdown E03 Inverter Output Overload or Short Circuit Shutdown E04 Inverter Over TemperatureShutdown E05 DC Input Under VoltageWarning E06 Inverter Output Overload Warning E07 Inverter Over Temperat...

Page 42: ...erference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Co...

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