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Xantrex IP1012 AL Owner'S Manual Download Page 32

Maintenance

3–6

975-0337-01-01

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. Turn the connector housing clockwise 1/2 

turn until you feel resistance, then another 

1/8

 turn until it locks into 

place. 

Figure 3-3

AC input and output cables

AC output connector

AC input connector

Inverter/charger
control cable

IP1012_AL.book  Page 6  Tuesday, May 1, 2007  12:18 PM

Summary of Contents for IP1012 AL

Page 1: ...IP1012 AL Inverter Charger with Ignition Protection Owner s Guide IP1012 AL ...

Page 2: ......

Page 3: ...IP1012 AL Inverter Charger with Ignition Protection Owner s Guide ...

Page 4: ...rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX A MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION B ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDE...

Page 5: ...nyone 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 IP1012 AL Inverter Charger with Ignition Protection Chapter 2 Operation explains how to c...

Page 6: ...ge current versus temperature and pass through current Appendix A also illustrates the three stage charging profile used by the unit Conventions Used The following conventions are used in this guide Related Information You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com WARNING Warnings identify conditions or practices that could resul...

Page 7: ...ing 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 char...

Page 8: ...king the final connection to a battery be sure the polarity is correct negative to negative and positive to positive 8 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 Most battery operated equipment uses a separate charger or transformer that is plugged into an AC recept...

Page 9: ...ng 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 or 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 Batt...

Page 10: ...eshooting 4 2 Common Problems 4 2 Blinking Lights on the Remote Switch 4 3 A Specifications Physical Specifications A 2 Inverter Specifications A 3 Charger Specifications A 4 Transfer and General Specifications A 5 Rating Curves and Charging Profiles A 6 ...

Page 11: ...1 Introduction Chapter 1 Introduction describes the main performance and protection features of the IP1012 AL Inverter Charger with Ignition Protection ...

Page 12: ...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 Figure 1 1 Features of the inverter charger 7 1 6 4 5 2 3 ...

Page 13: ... as a charger The unit can only operate in charge mode when external AC power referred to as shorepower is connected Inverter features 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 watt...

Page 14: ... a load Charger features 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 inverte...

Page 15: ...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 ...

Page 16: ...y it can be powered from the inverter charger Resistive loads 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 i...

Page 17: ...arger because they may be damaged or may not operate properly dimmer switches some small rechargeable hand power tools small battery operated appliances such as flashlights razors night lights variable speed motors Ambient Temperature Ambient temperature The ambient temperature that is the air temperature around the inverter charger will affect its output power Ambient temperature can rise when th...

Page 18: ...ay vary with the actual operating conditions Calculating Size of an AC Load Operating time To determine how long you can run your loads 1 List all the AC 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 ...

Page 19: ...Group 4D batteries the batteries have not been damaged by deep discharge and are relatively new Factors affecting load Consider these factors when you are calculating loads 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 ca...

Page 20: ...Table 2 1 Typical operating time with fully charged 400 Ah deep cycle batteries Appliance Watts Minutes Hours 10 20 2 3 5 10 15 20 30 45 70 85 100 Electric shaver not rechargeable 15 Table fan 15 Video game 25 Reading Lamp 40 Notebook computer 75 Computer printer 100 Hand held vacuum cleaner 100 19 in TV VCR combo 100 3 cu ft refrigerator 180 Electric blanket 200 Electric buffer 400 Electric drill...

Page 21: ...lt battery shows what happens if the alternator is overloaded 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 dischar...

Page 22: ...ge will climb again as the alternator now has enough power to charge the battery Solutions 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 Comment Small alternator overloads may not be immediately noticeable and can take several hours to discharge the batteries Large overloads will discharge the ba...

Page 23: ...d 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 Figure 2 3 Remote switch with indicator lights On Off Switch Indicator lights...

Page 24: ...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 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 3 Inverter On When yellow LED is solid ON it indicates the unit is currently inve...

Page 25: ...ature is high reduce the number of loads Cold In extreme cold temperatures your batteries may have less stored energy At 0 F 18 C your battery has only half the standby power than it has at 77 F 25 C Restarting After a Shutdown 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 turni...

Page 26: ...s are connected This feature helps to prevent nuisance tripping of the shorepower breaker Miscellaneous Hints Automatic shutdown 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 Output power The total output of the in...

Page 27: ...enance 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 ...

Page 28: ... 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 To replace the cap place it over the terminal and push down until it snaps into place WARNING The metal base of the IP1012 AL may be hot when operating in high ambient temperatures Do not touch the metal en...

Page 29: ...nnect the ground wire if the unit must be removed from its mounting bracket Connecting 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 WARNING Explosion or Fire Make sure the battery compartment is well ventilated Flammable fumes are often present when working with batteries Note If you have a DC...

Page 30: ... when connecting the unit to the battery If the fuse blows for any reason replace it with only the fuse types listed below Littelfuse Mega Fast Blow 250 A 32 V part number 298250 Bussmann 250 A 48 V part number AMG 250 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 n...

Page 31: ...when replacing the nuts Tighten 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 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 Figure 3 2 Removing the fuse cover 1 2 3 CAUTION Do not overtighten fuse nuts ...

Page 32: ...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 Figure 3 3 AC input and output cables AC output connector AC input connector Inverter charger c...

Page 33: ...ormation 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 ...

Page 34: ...hresholds are reached Table 4 1 lists problems you may encounter and offers suggestions to fix them Table 4 1 Troubleshooting reference Symptom 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...

Page 35: ...nd 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 ...

Page 36: ...dicator flashing pattern when the unit is in invert 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 Inverter indicator blink patterns Condition Blink Level High Battery voltage 1 Inverter too hot 1 Low Battery 2 Over current 2 Auto shutdown inverter 3 ...

Page 37: ...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 ...

Page 38: ...hout mounting brackets or external cables External finish Base Clear anodized aluminum Top cover black anodized or black powder coated aluminum Mounting Orientation All allowed Mounting method 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 fee...

Page 39: ...ing 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 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 a...

Page 40: ...15 Vdc DC high voltage shutdown 16 0 0 2 Vdc DC high voltage restart Less than 16 0 Vdc same as DC high voltage shutdown There is no hysteresis Inverter specifications Continued Charger specifications Charging method Three stage charging with battery temperature compensation See Figure A 3 Algorithm for generic flooded batteries only No equalization mode AC input voltage 100 130 Vac AC input frequ...

Page 41: ...ous 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 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 C Altitude limit 15 0...

Page 42: ...e A 2 Charging current versus temperature derating curve 0 500 1000 1500 2000 2500 3000 1 10 100 Time minutes Output Power VA 40 to 25C 40C 55C 70C 85C 104 F 131 F 158 F 185 F 40 to 77 F Maximum charger current vs Temperature Charger current Amps Ambient temperature C 40 20 0 20 40 60 80 0 10 20 30 40 50 60 ...

Page 43: ... 7 Figure A 3 Three stage charging profile Bulk DC Voltage DC Current Charging Started Constant current maximum charge rate Constant voltage Reduced voltage Load current on demand Float Volts Setting Bulk Volts Setting Time Absorption Charge Float Charge ...

Page 44: ...A 8 ...

Page 45: ...er 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 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 l...

Page 46: ...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 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 ambien...

Page 47: ...ed design in the repair or replacement If Xantrex 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 ...

Page 48: ...g strikes c the product if repairs have been done to it other than by Xantrex or its authorized service centers 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 SOL...

Page 49: ... to supply The serial number of your product Information about the installation and use of the unit Information about the failure and or reason for the return A copy of your dated proof of purchase Record these details in Information About Your System on page WA 4 Return Procedure 1 Package the unit safely preferably using the original box and packing materials Please ensure that your product is s...

Page 50: ...ved 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 If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service Serial Number ___________________________ P...

Page 51: ......

Page 52: ...x 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 ...

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