Cooper Bussmann 1000W Installation Manual

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Cooper Bussmann Inverter

1000W / 1800W

INSTALLATION GUIDE

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Summary of Contents for Cooper Bussmann 1000W

Page 1: Installation Guide
Cooper Bussmann Inverter 1000W / 1800W INSTALLATION GUIDE...
Page 2 About Cooper Bussmann In a worldwide transportation marketplace Cooper Bussmann is your leading source for safe and reliable electrical power and machine control solutions. We’re experts on the effects of temperature, vibration, high moisture, harsh chemicals and transient power fluctuations. We know vehicle power and control systems from the smallest to the largest platforms, and will partner with you to develop reliable products and systems.
Page 3: Important Safety Instructions
Do not cover/obstruct ventilation systems.  Use wire in good condition and of appropriate ratings.  Attachments not recommended by Cooper Bussmann may be damaging to inverter.  Do not use inverter after being dropped, hit, or damaged.  Do not disassemble the inverter. Risk of shock, fire, and void of warranty may result.
Page 4 DC CONNECTION PRECAUTION(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 CONTENTS Installation ................pg 6 Configuration ................ pg 24 Specifications ............... pg 28 ...
Page 6 1. INSTALLATION Chapter 1 offers information as a guide to installing a Cooper Bussmann Inverter/Battery Charger. It will cover the following:  Materials list  Safety instructions  Sample installation tools and materials ...
Page 7: Materials List
Materials List Cooper Bussmann Inverter package includes the items listed below:  1 Cooper Bussmann Inverter unit  Owner’s / Installation Guide  25 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 ...
Page 8: Safety Instructions
Safety Instructions  WARNING: Shock hazard – All wiring of connectors or otherwise should be done by a technician, electrician, or person with electrical experience.  At the beginning of this guide there is a section of warnings and cautions, take note of any precautions concerning the installation.
Page 9: Installation Tools And Materials
Installation Tools and Materials To install the Cooper Bussmann Inverter, the following tools/materials are recommended:  Wire strippers  Mounting screws or bolts  #2 Phillips screwdriver  Wrench or socket for DC terminals (1/2 inch or 13mm) ...
Page 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.
Page 11 AC Shore Power – [“shore power” refers to AC input power from a utility grid, generator, or other AC source.] To charge batteries and pass power on to an AC load, a source of nominal 115Vac, 60Hz is needed. This source is predominantly the utility grid (wall power, power company) or an AC generator.
Page 12 AC Cabling – AC cabling includes but is not limited to all wires/cables between the AC source and the inverter, and all the cabling between the inverter and AC outputs (panels, circuit breakers, and loads). Wiring type and size varies with installation and load. Installation codes will recommend solid or stranded wires, overall size of conductors, and type/temperature ratings of insulation around the wire.
Page 13 STEP 2: Choose a Location for Inverter Mounting WARNING: Fire and Explosion hazard – 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 connecting to a fuel supply).
Page 14 Figure 1-3 Approved Mounting Orientation Connecting the Equipment Ground: WARNING: Fire hazard – Improper grounding may result in a fire hazard. It is crucial to never operate the inverter without ensuring the equipment is properly connected to ground. ...
Page 15: General Ac Wiring Considerations
Wire Routing guidelines Suggested cable size for DC input connections is 00 AWG. See Table 1-1 for the fuse rating required at the battery end of the positive DC input cable. Build the cables before rough fitting them to the vehicle. Note any points that will require special attention to avoid chafing or exposure to heat sources.
Page 16: Ac Input Connections
necessary, examine applicable codes for specific AC and DC wiring proximities. Figure 1-4 is an illustration of the AC wiring compartment. Figure 1-4 AC Wiring Compartment AC Wiring and GFCIs – AC input must be hardwired to the inverter. AC loads can either be plugged into the GFCI mounted to the front panel of the inverter, or hardwired directly to the panel.
Page 17 The inverter is not meant to operate loads that consume more than 1000 Watts or 1800 Watts (depending on the inverter model being used). The GFCI AC receptacle has been approved by Cooper Bussmann and cannot be removed from the inverter. The AC receptacle must be utilized, unless the AC output is hardwired. ...
Page 18 To make a hardwire connection with the AC OUTPUT of the inverter follow this procedure: 1. Ensure AC and DC power are OFF 2. Install required circuit breaker to the AC load wiring system. 3. Remove the knockout from the sidewall. Do not run the AC input and output wirings through the same knockout.
Page 19 AC wiring WITHOUT an Inverter Subpanel – This wiring configuration has the AC input to the inverter coming from an AC source directly. The AC must then be protected by a branch AC breaker or fuse, see Table 1-1 for fuse recommendations. The AC output is routed to the main AC panel which is protected by AC circuit breakers.
Page 20 To make connections to DC terminals: 1. Ensure the inverter is OFF and no connections are being made to DC or AC circuits. 2. Remove nuts and washers from the DC terminals of the inverter. 3. Depending on the size of the connectors chosen, strip about ¾ inches of insulation from the cables.
Page 21 The image below displays how the terminals should look after installation. Figure 1-6 DC Cable Connections Grounding: The grounding lug located on the sidewall of the inverter at the DC terminal end is used to connect the inverter chassis to the battery system’s negative connection or grounding bus, as required by electrical regulations.
Page 22 7. Route the cable to the inverter and insert the connection into the jack located near the battery select dip switch. IMPORTANT: The communications cable should not be in parallel or in the same conduit as the AC and/or DC wires. If required, only cross the wires at 90° angles of each other. ...
Page 23 Note: If the INVERTER button on the inverter is ON, the inverter will automatically supply the appliance(s) with 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 ≈...
Page 24 2. CONFIGURATION This chapter will address optimal inverter function for specific, electrical system requirements. Covering the following:  Loading battery types on to the main unit  Customizing the display, alarm, and current settings Setting Battery Types on Main Unit ...
Page 25 Customizing Display, Alarm, and Charging Current Settings The display panel is capable of adjusting the following:  What is presently displayed on the screen  Enable/Disable the audible alarm  Modifying the charging current ...
Page 26 To adjust alarm settings: By default, the alarm is ON. Press and hold the Select button for two seconds. The screen will display one of two things: “AL0” – this indicates the alarm is OFF “AL1” – this indicates the alarm is ON ...
Page 27 Charging Current Guidelines AC Input Circuit Branch Breaker Maximum By-pass AC Current Charger DC Current Setting (Amps) or fuse size Available (Amps) (Amps) 12-110-1800-B4, 12-110-1800-B4, 12-110-1000-B2 12-110-1000-B2 12-110-1000-B4 12-110-1000-B4 13.5 13.5 12.5 18.5 18.5 17.5 13.5 13.5 28.5...
Page 28: Specifications
SPECIFICATIONS Appendix A is the location for product performance information and electrical specifications for the 1000W and 1800W Cooper Bussmann Inverter. Important: Specs are subject to changes without notice. Technical Specifications: ...
Page 29 Utility to Inverter AC input recovery from 100 VAC Inverter to Utility Utility to Inverter and Inverter to Utility 5 VAC minimum hysteresis Maximum AC output by‐ 20 Arms pass current AC transfer time – 20 Seconds nominal Inverter to Utility AC transfer time –Utility < 50 ms to Inverter Time delay on transfer 20 s +/‐ 2s from Inverter to Utility  Voltages +/‐ 5V Battery Charger AC input operating range 95 – 135VAC AC input range with full 105V – 135VAC power AC input current with no < 0.50 Arms load Input current full load < 6 Arms (12‐110‐1000‐B2)
Page 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 ...
Page 31 Mechanical Specifications MIL-STD-202G, Method 214A, Test Condition A Vibration Must operate per specification during and after the test. 5.35 Grms, 4hr / axis MIL-STD-202G, Method 213B, Test Condition J ...
Page 32 Per SAE J1455 The inverter shall present no safety hazard. Internal fuses will Reverse Polarity Sec. 4.11.1 open in the inverter system, requiring factory service for Test –24 Vdc replacement. Applied to DC Terminals Regulatory Requirements Comply with the UL 458 requirements of the...
Page 33: Mechanical Specifications
MECHANICAL SPECIFICATIONS: Dimensions: Finish: Anodized Aluminum, Terminals: 1045 steel, Bright Tin Plate per ASTM-B545, Class A over, Nickel Plate per ASTM-B689, Type 1 Connectors: DC Input: M8 x 1.25 Stud Chassis Ground: M6 x 1.00 Stud ...
Page 34 DC Input AC Input AC Output Minimum Required UL Minimum Recommended Minimum Wire Size Listed Fuse Wire Size Branch Circuit Wire Size Recommended (AWG) (Amp) (AWG) (Amp) (AWG) Model Fuse (Amp) 12‐110‐1000 3 125 ...
Page 35 Fault Codes and Trouble Shooting: Inverter Section  DC Input Warning and Shutdown Unit start up voltage (Lo setting): > 10.5 +/‐ 0.3 VDC and < 16.0 +/‐ 0.3 VDC Unit start up voltage (Mid setting): > 11.8 +/‐ 0.3 VDC and < 16.0+/‐ 0.3 VDC Unit start up voltage (Hi Setting): > 12.2 +/‐ 0.1 VDC and < 16.0 +/‐ 0.3 VDC Condition UVSD Setting (+/‐ Display Audible Alarm Comment setting 0.3V) Over Voltage Shutdown Lo or HI 16.0 VDC Beep @ 1 Hz Note 1 Over Voltage Recovery Lo or HI 15.5 VDC N/A Note 2 Under Voltage Warning...
Page 36 AC Output Overload Protection and Warning and Shutdown Model Condition Power (W) Dis‐ Audible alarm play V<11.4 11.4<V<11.8 V>11.8 Warning (+/‐100W) 1000 1100 E06 Beep @ 0.33Hz 12‐110‐1000‐xx Shutdown (+/‐100W) 1050 1100 1200 E03 Beep @ 1 Hz Warning (+/‐200W) 1750 1850 2000 E06 Beep @ 0.33Hz 12‐110‐1800‐xx Shutdown (+/‐200W) 1850 1950 2100 E03 Beep @ 1 Hz AC Output Short Circuit Protection ...
Page 37 Model DC Output Fuse 12‐110‐1000‐B2 2x25A (Auto Blade) 12‐110‐1000‐B4 3x25A (Auto Blade) 12‐110‐1800‐B4 Over Temperature Protection Location Condition > 95°C Max. Charge current reduced to half of full load Charger Transformer > 100°C Max. Charge current reduced to 0A AC Transfer Relay > 70°C System shutdown (no auto‐reset) Note: Max. charge current resumes normal level when Charger Transformer sensor temperature drops below 90°C Warning (°C) Error code / Audio Shutdown (°C) Error Code / Audio Location alarm alarm Off Rectifier Diode >90 <88 E07 / >95 <80 E04 /...
Page 38 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 Charger and AC Transfer Section AC Input Surge Protection ‐ 175 J MOV is connected across the Line and Neutral of AC Input Charger DC Output Over Voltage Shutdown ‐ Battery Over voltage protection: 16.0 +/‐ 0.5Vdc (Error code: E10) ‐ Audio Alarm: Beep @ 1 Hz and AC charger is latched off ‐ Bypass mode is available ‐ To reset error code, remove AC Input and turn unit off and on Dead Battery Charging Battery voltage must meet the following conditions or Error code E11 will display: ‐ Initial battery voltage must be 10V or higher for charge to commence ‐ In event battery voltage drops below 10V after charge is initiated (Added Load) Maximum time for battery voltage to rise above 10V in Bulk charge: 15 minutes ‐ Audio Alarm: 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 ...
Page 40 To select what is being displayed on the screen during by‐pass mode, press ‘Select’ button to toggle the display to show following: ‐ DC Input Voltage in Vdc with ‘Input Voltage’ LED On ‐ Inverter function setting ‘In0/1’ with Input Voltage/Current and Output Power LED Off ‐ Charger current setting in Adc with Input Voltage and Output Power LED Off ‐ Alarm function setting ‘AL0/1’ with Input Voltage and Output Power LED Off ‐ Under voltage shutdown setting ‘sdL/n/h’ with Input Voltage and Output Power LED Off ‐ Battery Type [FI]=Fixed, ‘FLo’=Flooded, ‘gEL’=Gel, ‘Ag’=AGM To enter feature select mode: ‐ Press and hold the ‘Power’ button for five seconds to enter into the feature select mode. ‐ Press ‘Power’ button to select feature 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 disable/enable) ‘Sd’: Shut down low SdL, Shut down mid [Sdn], Shut down high SdH ‘bAt’: Battery type select: [FI]=Fixed, ‘FLo’=Flooded, ‘gEL’=Gel, ‘Ag’=AGM (under voltage shutdown Lo/ Hi)
Page 41 Fan On/Off setting Parameter Fan on Fan off Load >500W <200W Extrusion temp >60C <55C Rectifier Diode >70C <60C Display Panel Indicators / Switches ‐ ‘Main’ On/Off momentary switch ‐ ‘Select’ momentary switch ‐ 3 x 7‐segment LED display ‐ ‘STATUS’ LED (tri color) ‐ ‘Battery Voltage’ LED (Green) ‐ ‘Battery Current’ LED (Green) ‐ ‘Output Power’ LED (Green) ‐ Remote communication cable, 6‐wire, 25ft long (P/N 31‐5267‐00) User Messages / Diagnostics ...
Page 42 FCC Part 15, Class B Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.

This manual is also suitable for:

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