DC to AC Power Inverter Model #: 430-1200-0 (12 … to AC Power Inverter Model #: 430-1200-0 (12-1200IC-EV ... Damage to the Power Inverter will occur if an external AC power source

170 Cherry AvenueWest SayvilleNew York 11796

Phone: 800-346-0857 Fax: 631-567-5826

E-Mail: [email protected]

Topic

Safety Instructions.................................................Specifications.........................................................Nomenclature........................................................Optional Features..................................................System Components..............................................Physical Description..............................................Inverter Mounting.................................................DC Wire Gauge & Fusing......................................Remote “On/Off” Switch........................................AC Input & Output connections...........................Wiring Diagram....................................................Theory of Operation..............................................Trouble Shooting...................................................Appendix..............................................................

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Manual: 430-1200-0As of October 5, 2012

DC to AC Power InverterModel #: 430-1200-0 (12-1200IC-EV)


Phone: 800-346-0857 Fax: 631-567-5826


1. SAFETY INSTRUCTIONS

IMPORTANT: Read this manual before installation, it contains important safety, installation, and operating instructions. Save this manual and keep it in a safe place.

1.1 Inverter Safety Instructions:

•Warning:PowerInvertersproducehazardousvoltages.Toavoidriskofharmorfire,theunitmustbeproperlyinstalled. •Warning:Therearenouserserviceablepartsinside,donotremovethecover. •Warning:PowerInvertersshouldnotbemountedinalocationthatmaybeexposedtorainorspray. •Warning:PowerInvertersshouldnotbeinstalledinazeroclearanceenclosure. •Warning:DamagetothePowerInverterwilloccurifcorrectpolarityisnotobservedwheninstallingtheinverter’sDC input cables. •Warning:DamagetothePowerInverterwilloccurifanexternalACpowersourceisappliedtotheinverter’sAChard wireoutput. •Warning:PowerInverterscontainacircuitbreakerandcapacitorthatmayproduceaspark.Donotmountinaconfined battery or gas compartment. •Warning:BesurethePowerInverteristurnedOFFduringinstallation.

1.2 Battery Safety Information:

•Warning:Workinginthevicinityoflead-acidbatteriesisdangerous.Thereisariskofacidexposure. •Warning:Batteriesgenerateexplosivegasesduringoperation. •Warning:Thereisriskofhighcurrentdischargefromshortingabatterythatcancausefireandexplosion.Useinsulated tools during installation. •Warning:Removeallrings,watches,jewelryorotherconductiveitemsbeforeworkingnearthebatteries. •Warning:Inspectthebatteriesonceayearforcracks,leaksorswelling. •Warning:Disposeofthebatteriesaccordingtolocalregulations.Donotincineratebatteries;riskofexplosionexists.

2. TECHNICAL SPECIFICATIONS2.1 Other Design Features: Patented constru-tion,andcoolingmethodswiththermallycontrolledcoolingfan,hospitalgradeGFCIoutletprotection,AChardwireoutputconnectionsandRemote“On/Off”switchhookup.ACfieldwiringcompartmentboxincludedwith“H”option.

2.2 Unit Protection: Automatic electronic short cir-cuit/overloadprotection,Automaticovertemperatureshutdownandoutputcircuitbreakers.

2.3 Battery Protection:Automaticlowbatteryshut-downat10.5VDCwithin-rushdelay.

2.4 Usage:Any120VAC,60Hzsinglephaseprod-uctwithintheinverter’spowerrating.

2.5 Certifications:ULCertified

*Chargeoutputislimitedwhentemperaturecompen-sation cable is not connected

INVERTERBASEMODEL 12-1200IC-EVDimensions-LxWxH(Inches): 12”x11.5”x6.9”

Efficiency: Upto88%InputCurrent(AmpsDC): Upto120

InputVoltage(VoltsDC): 11 to 17Operating Temperature: -20°Cto40°C(0°Fto104°F)OutputCurrent(AmpsAC): Upto10OutputFrequency(Hz): 60+/-.05%OutputPower(Watts): 1200OutputVoltage(VoltsAC): 120+/-5%OutputWaveform: PureSinewith<5%THDPeakOutput(AmpsAC): 30Weight(lbs.): 32BATTERYCHARGER:InputCurrent(AmpsAC): Upto12OutputCurrent(AmpsDC): Upto55TRANSFERRELAY:

CurrentRating(AmpsAC): 12TransferTime(Milliseconds): Lessthan16-typicalREMOTEPANELREADY: Built-InConnections020-4290-0ChargerStatusPanel OptionalLEDPanel020-4289-0InverterStatusPanel OptionalLEDPanel

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1.Plug-inACcord:Connectstoa120VACoutlet(notavailablewith“H”option)2.QuickDCinputdisconnect:Connectstothebatterybank.3.Temp.Comp.ConnectorPort:Connectstothetemp.comp.cable4.CoolingFan:Temperaturecontrolledtriggerswhennecessary.5.BondingLug:Connectstothegroundsystem.6.BatterySelectorSwitch(“A”,“B”,“C”):“A”-AGM,“B”-Gel,“C”-WetLeadAcid7.Remotepanelterminalboardconnections:Usedtoconnecttheremotepanels(chargerandinverter)andtheremote“On/Off”switch.8.LEDStatusControlPanel:Providesinverterstatus(Seefigure2onpage7)9.Local“On/Off”Switch:SwitchestheinverterONorOFF.10.InputBreaker:Tripstoprotecttheinverterfromspikes11.OutputBreaker:Tripstoprotecttheinverter’sinternalcircuitryfromshortedACloadsoroverloadsituations.12.GFCIOutlets:Hospitalgradestyleprovides120VACOutput.

3. PHYSICAL DESCRIPTION

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3 5

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(1)Externalpower:GreenLEDon-ExternalACpowerline pass thru.(2)Inverterpower:GreenLEDon-Inverterisoperating from batteries (3)Lowbattery:RedLEDon-Lowbatteryvoltagecondition(4)Overload:RedLEDon–Overloadcondition(5)Hightemp:RedLEDon–Hightemperaturecondition(6)Bulkmode:Batterychargerisonbulkmode.(7)Acceptancemode:Batterychargerisonacceptance mode(8)Floatmode:Batterychargerisonfloatmode(9)Conditionmode:Batterychargerisonconditionmode

(10)CheckBattery:Errormessagecheckbatteriesorbattery cable(11)ChargerStatusPanel:BrownWire-Terminal9 WhiteWire-Terminal10 BlackWire-terminal11 (12)InverterStatusPanel:GreyWire-Terminal6 GreenWire-Terminal7 RedWire-Terminal8(13)RemoteOn/OffSwitch:Connectstoterminals5,4,3and1 accordingly.(14)Interlock:Connectstoterminal1

(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)

(11) (12) (13) (14)

4. INVERTER MOUNTING

Note:Beforemountingtheinvertersystem,readthesafetyinstructionsectiononpage3.

4.1 Tools for Installation:Thefollowingtoolsareneededforinverterinstallation:Crimper,Cableties,Cutter,Drill,#2Phillips Screwdriver,Tapemeasure,Wirecutters,WireStrippers.

4.2 Mounting Recommendations:

Note:Theinvertermountinglocationshouldprovideadequateventilationandclear-ancetomaintainroomtemperatureduringoperation.Atleast1/2inchofclearanceisrequiredonallsides.

(1)Locateasuitable,secureverticalorhorizontalmountingsurfaceasclosetothebatteriesaspossiblewithoutbeinginthesameairtightcompartment.

(2)Ifmountingtheinverteronaverticalsurface,itisrecommendedthatthefrontcontrolpanelbepointingdownwheneverpossible.

(3)Locatethemountingholesonthechassisflangesandfastenthemusing¼inchdiameterscrewstosecuretheinverter.

(4)Wirethepanelusinginsulatedbuttspliceorequivalent.Theterminalblockontheinverterusesastrippedwireconnection.

3 2.5

12

11.5

10.5Case UE

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5. DC WIRE GAUGE, & FUSING

5.1 Inverter Cable:An“invertercable”kit(positivecable,negativecableandproperfuse)isneededtoconnecttheinvertertoa batterybank.An8-gaugesinglestrandcableisalsorecommendedtoconnecttheinverter’sbondinglugto ground.

Theinvertercablelengthandthesizeoftheinverterwilldeterminethecablegaugeandthefusesizetouse. Themaximuminvertercablerecommendedis20-ft;itmustbefusedwithin18-infromthepositive(+)terminal of the battery.

Crossreferencetheinvertermodel,andtheestimatedcablelengthinTableItodeterminepropercablegauge, andfusesize.Theinvertercablekitcanbepurchaseddirectlyfromfactory.Seetheaccessoriessectionon this manual.

5.2 Cable Recommendations:Tofurnishan“invertercable”kit,followbelowrecommendations:

1.Usestrandedcoppercablesinallcases. 2.UseSGXcross-linkedpolyurethaneinsulationtypethatcomplieswiththehightemperatureinsulationrequirements (125°C.)ofSAEJ-1127andvehiclemanufacturerrequirements. 3.Cablegaugerecommendationsareminimum.Forhigherthannormaltemperatureapplicationsorlargemotorloads andotherapplicationswithhighsurgecurrentsusecablegauge1to2sizeslargerthanrecommendedontableI above. 4.Keepthecablelengthsbetweenbatteryandinverterasshortaspossible. 5.UseBussmannfusetypeANNorANLandfuseblock#3576.Seetheaccessoriessectiononthismanual.

6. REMOTE “ON/OFF” SWITCH

Acustomersuppliedremote“On/Offswitch”canbewiredtotheterminalboardlocatedonfrontlabeled“RemoteOn/OffSwitch”using18-gaugewiresbytwodifferentmethods:

•PositiveStart:Useajumperbetweenterminal4and5,connectthe“On/OffSwitch”betweenterminals2and3. •NegativeStart:Useajumperbetweenterminal2and3,connectthe“On/OffSwitch”betweenterminal4andground, leave terminal 5 open.

Note:Terminal1(Interlock)mustbefusedat1-Ampandconnectedto+12VDCormasterdisconnectswitch.

7. TEMPERATURE COMPENSATION CABLE CONNECTION

Connecttheringterminatedendtothenegativesideofabatterybankandthe2-pinconnectorendtotheappropriateportlocatedatthebackoftheinverterlabeled“temp.sense”.Thetemp.comp.cablecollectscriticalinformationfromthebatteriesforpropervoltage and charge current at that moment.

PLEASE NOTE:IftheTemp.Comp.Cableisnotconnected;thebatterychargeroutputcurrentwillbelimitedto25AmpDC.

Table I:CableandFusingGuideat5%VoltageDropatFullOutput

Warning:PropercablegaugemustbeusedtopreventexcessivevoltagedropattheinverterDCinput.

Inverter Model

FullLoad(AmpsDC)

InvertertoBatteryEstimatedCableLengthInFeet1’to10’ 11’to15’ 16’to20’

12-1200 120 4AWG,200AFuse 2AWG,250AFuse 1AWG,300AFuse

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8. OPTIONAL INVERTER & CHARGER STATUS PANELS

8.1 CHARGER STATUS PANEL WIRING: BrownWire-Terminal9 WhiteWire-Terminal10 BlackWire-terminal11

8.2 INVERTER STATUS PANEL WIRING: GreyWire-Terminal6 GreenWire-Terminal7 RedWire-Terminal8


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9. AC INPUT & OUTPUT CONNECTIONS

Warning:DonotconnectanothersourceofACpowerdirectlytotheoutputoftheinverter.Thiswillresultindamagenotcovered underwarranty.

9.1 Local 120VAC, 60Hz AC Output:Theinverter’slocalACoutputpowerisprovidedattheGFCIprotectedoutletlocatedon front.

9.2 120VAC, 60Hz AC Input:Connecttheplug-incableextendingfromthebackoftheinvertertoanon-GFCIACoutlet.

Note:Connectingtheplug-incordtoGFCIprotectedoutletsmaycausesomeinterferencewiththeinverter’sGFCIfrontoutput outlets.

10. WIRING DIAGRAM

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11. THEORY OF OPERATION

Thelocal“On/OffSwitch”locatedonfront,orthe“RemoteOn/OffSwitch”ifusedcontrolstheinverter.BoththeLocaland“RemoteOn/Off”switchesareconfiguredinparallel.Tocontroltheinverterremotelysetthe“LocalOn/Offswitch”toOFF.

Note:+12VDCmustbeappliedtoterminal1fortheinvertertooperate.ThemoduledisconnectswitchifavailablemustbesetON.

Operational modes:“ExternalPower”modeand“InverterPower”mode.

11.1 External Power Mode:ThegreenLED“ExternalPower”willcomeonindicatingthatthereisavalidexternalACpowerline appliedtotheinverterACinput.Iftheinverterpanel171413-1isincludedandtheinverterissetON, thegreenLED“Inverter”willblinktoindicatethattheinverterisinstandbymode(shorepoweravail- able.)

•TransferRelaySwitch:TheloadsattachedtotheinverteroutputwilloperatedirectlyfromtheexternalACpowerline independentlyoftheinverterON/OFFstatus.IftheinverterisleftON(standbymode),thebuilt- intransferrelaywillautomaticallycyclebackandforthbetween“InverterPower”modeand “externalpower”modedependingontheavailabilityoftheexternalACpowerline.

•BatteryCharger:Thebatterychargercannotbedefeated,andwillengageautomaticallyindependentlyoftheinverter ON/OFFstatus.Thechargingprocessgoesthrougha3-stepchargingmodes:Bulk,acceptanceand floatmode.Aconditioningmodeautomaticallytriggersevery10thcompletechargingcycle.

TheproperLEDlightlocatedonfrontoftheinverterwillcomeontoindicatethechargingstatusmode.Ifthechargerpanel171412-1isincluded,thegreenLED“Charger”willblinktoindicate“bulk”or“acceptance”mode.IfthegreenLEDkeepssteady,thechargerisin“float”mode.

Note:Thebatterychargerwillengageonly,iftheindividualbatteryvoltageisabove9-volt.

11.2 Inverter Power Mode:ThegreenLED“Inverter”willcomeon.Iftheinverterpanel171413-1isincludedthegreenLEDwill turnONsteady.TheACpowerproducedbytheinvertercomesfromtheenergystoredinthebattery bankthroughasophisticatedelectronicinversionprocess.Atransformer,aMetalOxideSiliconField EffectTransistors(MOSFET),afiltercapacitoranda16-bit,16MHzmicroprocessorcontrolareused togeneratecleanusefulACpower.

Note:Thesignaloutputwaveformproducedbytheinverterwhenin“invertermode”ispuresinusoidal.Ithasatotalharmonicdistortionoflessthan5%.

12. TROUBLESHOOTING

1)NoACoutputpower:

1.1)NoLEDson: •Makesure+12VDCisappliedtoterminal1“Interlock”. •Checkin-linefusewhichislocatedwithin18”fromthebattery’spositivepost. •DCconnectionstobetightandclean. •Batteryvoltagetobeabove9VDC •BypassordisconnectremoteOn/Offswitchifused.

1.2)GreenLED“InverterPower”on: •Disconnectallloadsandconnectatestlighttothehardwireoutputleads(Black:Hot,White:Neutral, Green:Ground.) •Iftestlightison:BadGFCI. •Iftestlightisoff:Possiblebadinverter.

1.3)GreenLED“ExternalPower”on:Repeat1.2stepsabove.

2)LowBattery: •Theuseofbatteryisolatorisnotrecommendedduetoexcessivevoltagedropacrossterminals •Batteryvoltagetobeabove10.5whenvehicle’sengineisOFF,andabove13VDCwhenitisON. •CheckforproperDCwiregage(seewiregauge&fusingsection)

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Note:Theuseofdeep-cyclebatteriesisstronglyrecommendedoninverterapplication;deepdischargecyclestypicalwithinverterapplications can shorten the life of other type of batteries.

3)Overload: •Unplugallloads,disconnecttheACoutputhardwireleadsifusedandresettheinverterOn/Off: •Iftheoverloadconditionpersist,possiblebadinverter •Overloadconditionsclears,checkforshortcircuitsorcheckloadsizeversusinverteroutputwattagesize.

4)HighTemperature: •Lettheinvertertocooldownto40°C(104°F)

5)CheckBattery: •Resettheinverter(plug/unplugcordfromshorepower)anddisconnectDCcables(Pos.andNeg.)and connectthembackafterafewminutes. •ShortcellbatteryorcorrodedLooseDCwires •Batteryvoltagetobeabove9voltsforthechargertoengage •Checkvoltageandcurrentreadingsagainstbelowchart

13. APPENDIXBattery Specifications Chart:

14. WARRANTY POLICY

AllproductsmanufacturedbyKussmaulElectronicsCompanyInc.arewarrantedtobefreeofdefectsofmaterialorworkmanship.Liabilityislimitedtorepairingorreplacingatourfactory,withoutcharge,anymaterialordefectswhichbecomeapparentinnormalusewithinthespecifiedwarrantyperiod.AllElectronicitemsarewarrantedfor3years,AutoandAirEjectsarewarrantedfor2yearsandAutoPumpsarewarrantedfor1yearfromthedatetheequipmentwasshipped.Equipmentistobereturned,shippingchargesprepaidandwillbereturned,afterrepair,shippingchargespaid.

KussmaulElectronicsCompany,Inc.shallhavenoliabilityfordamagesofanykindtoassociatedequipmentarisingfromthein-stallationand/oruseoftheKussmaulElectronicsCompany,Inc.products.Thepurchaser,bytheacceptanceoftheequipment,assumesallliabilityforanydamageswhichmayresultfromitsinstallation,useormisuse,bythepurchaser,hisoritsemployeesor others.

BatteryType BatteryChargerVoltages@25°C(78°F)andChargeTimeBulk Accept Float Conditioning

WetCell 14.6Vdc 13.2Vdc 15VdcMax.Sealed 14.3Vdc 13.4Vdc NeverWetCell Upto8Hrs. Upto8Hrs. N/A Upto3Hrs.Sealed Upto8Hrs. Upto6Hrs. N/A Never

Group Number

VoltageVoltsDC

CapacityAmp-Hour

DimensionsInInches WeightLbs.L W H

GC2 6 220 103/8 73/16 105/8 70L16 6 350 113/4 71/8 163/4 12527/31 12 95 13 613/16 97/16 704D 12 180 203/4 83/4 97/8 1408D 12 225 203/4 111/8 97/8 170

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Documents

DC to AC Power Inverter Model #: 430-1200-0 (12 … to AC Power Inverter Model #: 430-1200-0 (12-1200IC-EV ... Damage to the Power Inverter will occur if an external AC power source