Owners Manual SRC12-1500 Inverter/Charger © ¨¦ ¤ £ ¥ ¤ £ ¢ ¡ § Model SRC12-1500 Owner's Manual D013068 SRC12-1500 INVERTER/CHARGER 1 Owners Manual 2 ¨ Typical Inverter Installation OEM Alternator Fuse block within 18" of Battery 12 Volt Battery OEM Battery Common OEM ground at Starter or Engine Block Inverter/Charger SRC12-1500 INVERTER/CHARGER Owners Manual 1 2 3 4 5 6 7 8 Table of Contents Introduction ........................................................................................................................... 4 1.1 Specifications...........................................................................................................................5 1.2 Standard Features....................................................................................................................6 1.3 Definitions................................................................................................................................6 1.4 Parts and Accessories..............................................................................................................7 SAFETY INSTRUCTIONS ...................................................................................................... 7 2.1 General Precautions.................................................................................................................7 2.2 Explosive Gas Precautions.......................................................................................................8 2.3 Precautions When Working with Batteries................................................................................8 Component Identification ..................................................................................................... 9 (1) ON/OFF/Reset Push Button .....................................................................................................9 (2) INVERTER Indicator Light..................................................................................................... 10 (3) BATTERY LOW Indicator Light ............................................................................................. 10 (4) OVER TEMPERATURE Indicator Light ................................................................................. 10 (5) OVERLOAD Indicator Light ................................................................................................... 10 (6) BULK/ABSORPTION Indicator Light ..................................................................................... 10 (7) FLOAT Indicator Light ........................................................................................................... 10 (8) REMOTE PANEL OR IFM1 Jack........................................................................................... 11 (9) INVERTER CONTROL TERMINAL ........................................................................................ 11 (10 )LOAD DEMAND ON/OFF (Switch 1).................................................................................... 11 (11) BATTERY TYPE Wet/Gel (Switch 2)..................................................................................... 11 (12) CHARGING RATE High/Low (Switch 3) ................................................................................ 11 (13) REMOTE CONTROL Selector IFM1/Remote (Switch 4)......................................................... 11 (14) INVERTER CONTROL TERMINAL Enable/Disable (Switch 5) .............................................. 11 (15) 15 Amp INV/CHG Circuit Breaker........................................................................................... 11 (16) 15 Amp AC Output Circuit Breaker......................................................................................... 11 (17) 120V, 60Hz @ 15A Max. AC Output ...................................................................................... 11 (18) 120V, 60Hz @ 15A Max. AC Input ......................................................................................... 12 (19) Air Exhaust Vents................................................................................................................... 12 (20) Mounting Flanges with 5/16" diameter mounting holes ........................................................... 12 (21) Air Intake Vents (rear and left side) ........................................................................................ 12 (22) Chassis Ground Bonding Lug ................................................................................................. 12 (23) Positive DC Input Connection (Red) ....................................................................................... 12 (24) Negative DC input Connection (Black) ................................................................................... 12 INSTALLATION.................................................................................................................... 12 4.1 Unpacking the Inverter ........................................................................................................... 12 4.2 Inverter Installation Considerations......................................................................................... 12 4.3 DC Wiring Considerations ...................................................................................................... 13 4.4 DC Wiring Installation Procedure ........................................................................................... 14 4.5 AC Wiring Installation Procedure............................................................................................ 14 4.6 (Optional) SR10 Remote Monitor/Control Panel Installation ................................................... 14 SYSTEM START-UP AND TESTING PROCEDURES .......................................................... 16 5.1 Inverter Start-up and Testing.................................................................................................. 16 5.2 Procedure to Check Battery Charger Operation...................................................................... 17 THEORY OF OPERATION ................................................................................................... 18 PREVENTIVE MAINTENANCE............................................................................................. 20 7.1 Maintenance Items................................................................................................................. 20 7.2 Troubleshooting Procedures................................................................................................... 20 APPENDICES ....................................................................................................................... 22 8.1 Problem Loads....................................................................................................................... 22 8.2 DC Power Consumption ......................................................................................................... 23 0 ) ¨' % $ & % $ # !" ( SRC12-1500 INVERTER/CHARGER 3 Owners Manual 1 Introduction Thank you for purchasing Vanner's SRC12-1500 Inverter/Charger. We are confident that you will be satisfied with its performance and its many features. With proper installation and care, you can look forward to years of service from this high performance product. This document will describe the operation, technical specifications, installation procedures, and accessories. If you require additional information please contact Vanner at 800-227-6937 (800-AC Power) or 614-771-2718. WARNING: Before you install and use your inverter/charger be sure to read and save these safety instructions. PLEASE NOTE YOUR MODEL AND SERIAL NUMBER HERE FOR FUTURE REFERENCE Model Number Serial Number _____________________________________________________________ _____________________________________________________________ Date of Installation _____________________________________________________________ 4 @ 9 ¨7 5 4 6 5 4 3 12 8 SRC12-1500 INVERTER/CHARGER Owners Manual 1.1 Specifications
Specifications Continuous Output Power Rating Output Surge Capacity DC Input Voltage DC Input Voltage Range AC Output Voltage AC Output Frequency AC Output Wave Form DC Input Amps Inverter OFF Inverter On, in Load Demand (asleep)* Inverter ON with No AC Load Inverter ON with AC Load Battery Charger Charging Output Capacity* Bulk Voltage* Float Voltage* AC Input Voltage AC Input Current for charging Transfer Switch AC Passthrough Other Specifications AC Input AC Output Ambient Operating Temperature Cooling Chassis Dimensions Weight * Determined by programming DIP switch setting Model SRC12-1500 1500 Watts @ 25°C (77°F) Ambient 1100 Watts @ 40°C (104°F) Ambient 2600 Watts 12 VDC, Nominal 10.5 VDC min., 16.0 VDC max. 120 VAC RMS ± 10% 60 Hz ± 0.1% Modified Sine Wave 0.025 Amps Typical 0.055 Amps Typical 0.7 Amps Typical AC Output Load Watts ÷ 10 (approx) 55 Amps (High) / 15 Amps (Low) 14.2 VDC (flooded), 14.1 VDC (gel) 13.2 VDC (flooded), 13.6 VDC (gel) 120 VAC 60Hz 12.3 Amps max 12 Amps 15 Amp AC Input Line Cord 15 Amp GFCI Receptacle -40° to +104°F, -40° to + 40.0°C Thermostatically Controlled Fan Powder Coated Aluminum 10.4"W x 6.0"H x 14.4"D 25 lbs. P I ¨G E D F E D C AB H SRC12-1500 INVERTER/CHARGER 5 Owners Manual STANDARD FEATURES 1.2 Standard Features
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. True RMS regulated 120 volt ±10% AC 60 Hz Quasi-sine wave output Output Short circuit / overload protection through electronic sensing Input and Output circuit breakers Automatic shutoff for Low Battery Automatic shutoff for Overload Automatic momentary shutoff/restart for Over temperature Load Demand enable/disable switch Built-in GFCI receptacle protected by a 15 amp AC output circuit breaker. Capable of single wire control Three Stage Battery Charger Selectable high/low Charge Rate Charging settings for gel or wet batteries Automatic Transfer Switch with 5 second acceptance time delay Thermostatically controlled cooling fan brings cooling air in through the back panel. Indicator lights for ON/OFF/Load Demand status, Low Battery Warning/Shutoff, Over Temperature Shutoff, Overload Warning/Shutoff, and Bulk/Absorption Charge Stage, Float Charge Stage. Please note: The Battery Charger and Automatic Transfer Switch are operational only when AC input power (shore power) is present. The charger is ON when shore power is present. 1.3 Definitions
Quasi Sine Wave: Quasi Sine Wave is sometimes called "modified sine wave" or "modified square wave." The inverter AC output wave shape is rectangular with the height being proportional to battery voltage. The inverter varies the wave width as needed to maintain 120 volt true RMS output. A true RMS volt meter is required to accurately show the quasi sine wave inverter AC output voltage. True RMS 120vac means a 40 watt incandescent light bulb looks like 40 watts. Most AC loads, including computers, will operate with no problem on quasi sine wave. Inexpensive motors may have a more noticeable electrical "hum." An average responding volt meter will display AC voltages ranging from 95 to 135 volts, inversely proportional to battery voltage, and the AC voltage displayed will change as battery voltage changes. Load Demand Feature and Load Demand Mode: The Load Demand Feature is an energy conserving feature which allows the inverter to enter the `Load Demand Mode' (go to sleep) when the inverter is ON and the AC load has been less than 5 watts for approximately 5 seconds. The `Load Demand Mode' is often also described as `stand-by mode' or `sleep mode'. While in the `Load Demand Mode' the inverter does not produce 120 volts AC. When an AC load greater than 5 watts is sensed, the inverter will turn fully ON. Some electronic or variable speed loads may not turn ON while the inverter is in Load Demand Mode. (The load waits to see AC power and the inverter waits to see the load.) For these loads, the Load Demand Feature can be turned OFF by setting Selector Switch 1 to the OFF position. This will cause the inverter to remain fully ON, producing 120 Volts AC whenever the inverter switch is ON regardless of AC load. Automatic Transfer Switch: The Automatic Transfer Switch automatically allows input power from an external AC power source, such as shore power or a generator, to pass through the inverter output circuit for use by inverter loads. 6 ` Y ¨W U T V U T S QR X SRC12-1500 INVERTER/CHARGER Owners Manual 1.4 Parts and Accessories
Part Number SR10 011486 D011663 D011664 011756 04522 03637 IFM1 D06638 D06639 D06781 Name Silent Runner Series Remote SR10 Remote Cable DC Wiring Kit 200 Amp Cube Fuse Kit 200 Amp Cube Fuse 200 Amp ANL Fuse ANL Fuse Holder Interface Module Remote Inverter Panel Remote Charger Panel Remote ON/OFF Rocker Switch Description Remote Display with On/Off Switch 10 foot Cable for SR10 Remote 6½ ft 2ga Cables and Passthrough Grommet Cube Fuse, Nut and Mounting Bar Stud Bussmann FS-HVBF-200 Cube Fuse Bussmann ANL-200 fuse Fuse holder for ANN and ANL fuses Interface to allow remote control of inverter via customer supplied ON/OFF switch(s), and to accept remote display panels for inverter and charger. Inverter Display Panel (Requires IFM1) Charger Display Panel (Requires IFM1) ON/OFF Rocker Switch w/ 8' cable (Requires IFM1) 2 SAFETY INSTRUCTIONS READ ME This manual contains important safety and operating instructions for the Vanner Incorporated Silent Runner Series Power Inverter/Charger System. The SR-Series Inverter/Charger is designed to be compliant with UL 458, Power Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles. SAVE THESE INSTRUCTIONS WARNING This equipment employs components that tend to produce arcs and sparks. To prevent fire or explosion, DO NOT install in confined areas or compartments that contain batteries or flammable materials. Risk of electrical shock. Use only the circuit breaker(s) specified in the installation and operating instructions supplied with this inverter. Other types may fail to operate properly when connected to this equipment. Read Owners Manual BEFORE wiring or powering up. DO NOT cover or obstruct ventilation openings. DO NOT mount in zero-clearance compartments. Overheating may result which may diminish system capacity. The output of this device in not sinusoidal. The SR-SERIES inverter has a total harmonic distortion of 34.6 percent and maximum single harmonic of 24 percent. WARNING CAUTION CAUTION NOTICE 2.1
1 2 General Precautions
Do not expose the SR-Series Inverter to direct water spray or snow. To reduce the risk of a fire hazard, do not cover or obstruct the ventilation openings. p i ¨g e d f e d c ab h SRC12-1500 INVERTER/CHARGER 7 Owners Manual 3 Do not install this unit in a zero-clearance compartment. The result may be overheating or diminished performance. 4 To avoid the risk of fire, electric shock, or injury to persons, do not use attachments, breakers, fuses, etc. not recommended or sold by Vanner Incorporated. 5 Vanner recommends that all DC and AC electrical wiring be performed by a certified electrician or technician to ensure compliance with all proper national and local wiring regulations. 6 To avoid a risk of fire and/or electric shock, always verify wiring connections are in good electrical condition. All external conductors must use proper wire size to avoid dangerous overheating or diminished performance. 7 If the Vanner inverter system has been dropped or damaged in any way, do not operate until its operation has been verified to be safe by a qualified technician. 8 To reduce the risk of electric shock always disconnect the AC and DC connections to the Vanner Inverter system before attempting any maintenance. Simply turning the unit off does not prevent electric shock. 9 The SR-Series inverter system must be properly grounded in accordance with local and national codes and ordinances before operation. For most installations the negative (ground) conductor should be bonded to the grounding system at one and only one point in the system. 10 Do not disassemble the SR-Series Inverter/Charger. See the service section of this manual for instructions on obtaining service for your Inverter/Charger. Attempting to service the unit yourself may result in a risk of electrical shock or fire. 2.2 Explosive Gas Precautions
This equipment contains components, which tend to produce arcs or sparks. To prevent fire or explosion do not install in compartments containing batteries or flammable materials or in locations which require ignition-protected equipment. This includes any space containing gasolinepowered machinery, fuel tanks, or joints, fittings, or other connection between components of the fuel system. Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed. 2.3
1 2 3 4 5 6 7 Precautions When Working with Batteries
Always have someone within range of your voice to come to your aid when you work near a lead-acid battery. Have access to plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. Always wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 20 minutes and get medical attention immediately. NEVER smoke or allow a spark of flame in the vicinity of batteries. Gases produced by batteries are explosive. Be careful when working with metal tools around batteries. Potential for spark exists or short-circuit of the battery or other electrical part that may cause an explosion. Never charge a frozen battery. Battery temperature needs to be above 32°F (0°C) before charging. 8 y ¨w u t v u t s qr x SRC12-1500 INVERTER/CHARGER Owners Manual 3 Component Identification
SRC12-1500 Component Identification Figure 2 ON OFF/RESET BATTERY INVERTER LOW OVER TEMP STEADY=INVERTER ON BLINK=STANDBY/LOAD DEMAND 1 2 3 19 20 (1) ON/OFF/Reset Push Button The ON/OFF Switch is a pushbutton switch used to turn the inverter function ON/OFF and is used as a RESET Switch. (Note: The charger function is controlled ON/OFF by the presence/absence of shore power.) When an automatic shutdown has occurred due to a fault, one of the fault indicator lights will be displayed until the inverter is RESET. Reset the inverter by turning the ON/OFF Switch OFF or by turning a remote switch OFF. d ¨
17 16
OUTPUT 120 VAC 60Hz
REMOTE OR IFM1 OVER BULK/ LOAD ABSORPTION FLOAT INVERTER CONTROL TERMINAL CHARGE RATE BATTERY TYPE LOAD DEMAND 1
OFF ON 15
AC OUTPUT INV/CHG INVERTER CONTROL TERMINAL IFM1/REMOTE 2 3 4 5 FLOODED 55A REMOTE ON OFF GEL 15A IFM1 1 2 3 4 5 CHARGER 4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 SRC12-1500 INVERTER/CHARGER 9 Owners Manual Inverter Indicator Lights
(2) INVERTER Indicator Light
Light Display No light Solid Green Blinking Green Blinking Green Description Inverter is OFF. Inverter is ON and is producing AC power. Two blinks per second. Inverter is in Load Demand Mode. One blink per second. Inverter switch is ON. Shore power is present. (3) BATTERY LOW Indicator Light
Light Display Description Red Light is ON The inverter is ON but battery voltage has decreased to less than 11 volts DC. Automatic inverter shutdown for low battery at 10.5 volts is imminent unless the battery voltage is increased. The inverter has shut itself OFF due to a low battery voltage caused by voltage to the inverter dropping below 10.5 volts. The Inverter ON/OFF Switch must be cycled to reset and restart the inverter. Blinking Red Light (4) OVER TEMPERATURE Indicator Light
Light Display Description Red Light is ON The inverter has shut itself OFF due to excessive heating. Check for blocked vents or any type of air obstruction to the inverter. The Inverter will automatically restart when the inverter cools down. (5) OVERLOAD Indicator Light
Light Display Blinking Red Charger Indicator Lights
(6) BULK/ABSORPTION Indicator Light
Light Action Blinking Yellow Description The unit is in Charger Mode (shore power is present) and the charger is in either the BULK STAGE or ABSORPTION STAGE of the battery charging cycle. (See `Battery Charger Theory of Operation' for battery charging performance details.) (7) FLOAT Indicator Light
Light Action (See `Battery Charger Theory of Operation' for charger performance details.) Description 10 n m ¨k i h j i h g ef l
Description The inverter has shut itself OFF due to overload. The Inverter ON/OFF Switch must be cycled to reset and restart the inverter. SRC12-1500 INVERTER/CHARGER Owners Manual
The unit is in Charger Mode (shore power is present) and the charger is in the FLOAT STAGE of the battery charging cycle. Solid Green Remote Control Terminals
(8) REMOTE PANEL OR IFM1 Jack
Eight-wire modular jack for use with optional SR10 Remote or IFM1. (The six-conductor IFM1 cable will work in this jack.) (9) INVERTER CONTROL TERMINAL A 1/4" spade connector for use with an external 12v source for inverter remote control. Configuration switches 4 and 5 must be UP to activate this feature. The inverter will turn ON when a continuous 12 volt signal is applied, and turn OFF when the 12 volt signal goes away. The SR10 Remote Control Panel is required to initially turn the inverter ON after connection to battery voltage. Configuration Switches
(10) LOAD DEMAND ON/OFF (Switch 1)
Turn Load Demand Function ON/OFF. See definition of Load Demand in Section 1.3. With Load Demand ON the inverter operates only when a load greater than 5 Watts is applied. Some electronic or variable speed loads may not turn ON while the inverter is in Load Demand. (11) (12) BATTERY TYPE Wet/Gel (Switch 2) Select wet or gel battery charging voltages. CHARGING RATE High/Low (Switch 3) Select 55amp charge rate in High or 15 amp charge rate in Low. (13) REMOTE CONTROL Selector IFM1/Remote (Switch 4) (14) Set to Remote for use with SR10 Remote. Set to IFM1 for use with IFM1 or no remote. INVERTER CONTROL TERMINAL Enable/Disable (Switch 5) Activates function of Inverter Control Terminal when Switch 4 is in Remote. When enabled, a continuous 12v signal is REQUIRED to turn the inverter function ON. SR10 Remote is REQUIRED to initially turn the inverter ON after connection to battery voltage. Additional Features
(15) (16) (17) 15 Amp INV/CHG Circuit Breaker
Input CIRCUIT BREAKER (bottom breaker) protects the input cord. 15 Amp AC Output Circuit Breaker 120V, 60Hz @ 15A Max. AC Output Output CIRCUIT BREAKER (top breaker) protects AC Output at the receptacle. x w ¨u s r t s r q op v SRC12-1500 INVERTER/CHARGER 11 Owners Manual (18) (19) (20) (21) (22) (23) 120V, 60Hz @ 15A Max. AC Input Air Exhaust Vents
Keep two inches clearance around vent area Mounting Flanges with 5/16" diameter mounting holes Air Intake Vents (rear and left side) Chassis Ground Bonding Lug
Keep two inches clearance around vent area Use 8 AWG or larger copper conductor to connect chassis bonding lug to the vehicle chassis. Positive DC Input Connection (Red) BE AWARE that, as a large number of capacitors become charged upon completion of the DC circuit, THERE WILL BE A LARGE SPARK when the last battery connection is made. The spark is normal and will occur every time batteries are connected. (24) Negative DC input Connection (Black) BE AWARE that, as a large number of capacitors become charged upon completion of the DC circuit, THERE WILL BE A LARGE SPARK when the last battery connection is made. The spark is normal and will occur every time batteries are connected. 4 4.1 INSTALLATION Unpacking the Inverter
Inspect the shipping container and equipment for loose or damaged parts. If any damage is found, immediately notify the freight carrier. 4.2 Inverter Installation Considerations The wiring of your inverter installation should conform to the National Electric Code (NEC) and any other state or local codes in effect at the time of installation. These codes have been written for your protection and their requirements should be followed. Mounting Locate a secure, dry, flat horizontal or vertical surface large enough to mount the inverter. The location should be as close to the battery as possible without being in the same compartment and should provide adequate ventilation to maintain room temperature while the inverter is operating. The location must allow unobstructed cooling air flow at sides and bottom of the unit, and the location must be free from road spray, dripping water or other moisture contamination. A recommended minimum clearance of 2 inches (51 mm) should be maintained on all sides of the unit. 12 ¨ } | ~ } | { yz SRC12-1500 INVERTER/CHARGER Owners Manual 4.3 DC Wiring Considerations BE AWARE that, as a large number of capacitors become charged upon completion of the DC circuit, THERE WILL BE A LARGE SPARK when the last battery connection is made. The spark is normal and will occur every time batteries are connected. 1. 2. 3. 4. 5. The DC cables should be as short as possible. See Battery Cable Sizing Table for proper size. It is more electrically efficient to run the lower current AC wiring longer distances. Route the DC positive and negative cables as close together as possible, and use cable ties to keep them together. This reduces electromagnetic radiation that could interfere with sensitive electronics. Do not use the vehicle chassis as the DC negative conductor. Use a cable the same size as the DC positive to go directly from the inverter to the battery negative (-). Route the AC and DC power wiring separately and with as much physical separation as possible from low voltage wiring such as audio and video signal wires. DC power input cables which pass through steel or other ferrous metal walls need to pass through the same hole. If two holes are required, cut a slot connecting the two holes to prevent a transformer effect. Do not allow wire fragments or metal shavings to enter the inverter in any way. WARNING: DC INPUT WIRING CONNECTIONS A DC fuse is REQUIRED to properly protect the inverter and the DC cables. DC input studs have been provided to accommodate cable terminals with 5/16" hole. Good DC connections and proper wire sizing are critical for the performance and safe operation of the inverter system. The positive and negative DC inputs have color coded covers to protect the "live" connection from any shorting materials. The table below shows the recommended minimum cable size which should be used. Wire sizing charts published in the NEC may allow a greater amp capacity than we recommend. We have sized the cable for a minimum voltage drop to maintain better performance of your inverter installation. For best performance, wire the DC negative directly back to the battery, do not use the vehicle chassis as the DC negative conductor. The wiring of your inverter installation should conform to the National Electric Code (NEC) and any other state or local codes in effect at the time of installation. Article 551 of the NEC requires the overcurrent protective device shall be installed in an accessible location on the vehicle within 18 in. (457 mm) of the point where the power supply connects to the vehicle circuits. Wire and Fuse Size Chart Wire Size AWG
Ring Terminal AMP or UL recognized equal #2 322870 #1/0 321867 Bussmann Fuse Vanner part number Fuse Holder Vanner part number ¨
AMP Product Information Center: 800-522-6752 Max wire length, in feet, between SRC12-1500 and battery to keep voltage drop under 0.1 volt. The chart assumes wire carries no other load and wire temperature is below 80ºC.
12 20 ANN200 or FS-HVBF-200 Cube Fuse 04522 0117586 Bussmann 4164 (Required with ANN Style fuse) 03637 Crimp the ring terminals using AMP ROTA-CRIMP 600850 (2/0 - 8ga). SRC12-1500 INVERTER/CHARGER 13 Owners Manual
AMP Tooling Assistance Center: 800-722-1111 4.4 DC Wiring Installation Procedure
1. Make sure power to the vehicle wiring harness is disconnected. Verify that the inverter is turned OFF by checking that the ON-OFF/RESET Inverter Switch is in the OFF-RESET position. (The button should NOT be pushed in.) 2. Select a location for the unit. An ideal installation location has the following characteristics: a. Close to the battery (usually within six feet). b. Protected from the weather. c. Well ventilated. 3. Prepare DC cable end with appropriate terminals. Verify battery positive cable is disconnected from battery. Install cables in the following manner: Connect the positive cable to the positive DC input terminal. Tighten stud nut to a maximum of 120 lb./in. of torque. Install the protective plastic cover with the supplied hardware. Connect the negative cable to the negative DC input terminal. Tighten stud nut to a maximum of 120 lb./in. of torque. Install the protective plastic cover with the supplied hardware. 4. Route the negative and positive DC input cables from the inverter to the battery but do not connect to battery at this time. Protect cables with grommets or other appropriate means where they may contact hard, sharp edges throughout the installation path. 5. Install fuse in the positive DC input cable between the battery and inverter. Fuse must be installed within 18 in. of the battery or DC wiring bus system to comply with safety agency installation requirements. Be sure to mount fuse in an easily accessible location for replacement. It is also "good practice" to note on the inverter to check the fuse condition before involving any troubleshooting procedure. 6. Connect Bonding Lug. ( Component Item 22 ). Use 8 AWG or larger copper conductor to connect chassis bonding lug to the vehicle chassis. 7. Connect the negative DC input cable to the battery negative (-) terminal. Connect the red, positive DC input cable to the in/line fuse near the battery positive (+) terminal. 4.5 AC Wiring Installation Procedure
1. Connect AC loads to the inverter GFCI receptacle. When the AC input cord is connected to shore power, shore power will pass through the GFCI receptacle. 2. The Vanner SR12-1500 has been tested with the following GFCI outlet's: Manufacturer Hubbell Hubbell Hubbell Leviton Leviton Model GFR5252W GFR5252WA GFR5252I 1591 6599-I 4.6 Optional SR10 Remote Monitor/Control Panel Installation The optional SR10 Remote Monitor/Control Panel requires an eight-conductor 1:1 modular cable, 14 ¨
AC POWER CONTROL Power On 1 Standby/ Bulk Charge Fault 2 System ON System OFF SRC12-1500 INVERTER/CHARGER Owners Manual Vanner 011486 ten foot cable, an Ethernet cable, or equal. The cable is not included with the panel. ¨ SRC12-1500 INVERTER/CHARGER 15 Owners Manual SR10 Remote Indicator Display Description LED 1 1 1 2 2 Light Display* No Light Solid Green Blinking Green No Light Solid Red Description Inverter is OFF Inverter is ON and producing AC power or Charger is in Float Charge Stage Two blinks per second - Inverter is in Load Demand Mode One blink per second - Charger is in Bulk or Absorption Charging Stage No Fault Conditions Inverter is in Overtemp/Overload/or Battery Low Mode *Note: When shore power is present the display applies to Charger functions. When shore power is not present, the display applies to inverter functions. Steps 1. Locate a suitable place to install the remote panel such as a flat surface near the power control/distribution panel or driver's compartment. The mounting surface should have sufficient back space to accommodate the remote panel's min. depth and cable routing requirements of 1 ½". Cut surface material large enough to accommodate the remote cable connector and board area leaving sufficient surface material to attach panel with #8 mounting screws. Route the 10-ft. interface cable (011486) from the remote panel mounting area to the inverter being careful to avoid unprotected sharp corners or moving parts. Turn off inverter, then plug the interface cable into the inverter's front panel "Remote/IFM1" connector. Verify that dip Switch 4 is set to Remote. Plug the other end of the cable into the remote panel. Mount the remote panel using two #8 screws. 2. 3. 4. 5 SYSTEM START-UP AND TESTING PROCEDURES
WARNING: THESE PROCEDURES ARE TO BE PERFORMED ONLY BY A QUALIFIED INSTALLER. After the inverter has been properly mounted with sufficient ventilation, DC cables have been connected, AC wiring has been completed, and all remote connections have been checked, the Start-up and Testing procedure may now be performed . 5.1
1 2. 3. 4 Inverter Start-up and Testing
Place the System On/Off switch on the inverter in the OFF position. Place the Load Demand switch on the front panel, Switch 1, to the ON position to test Load Demand function. It can be changed later if this feature is not preferred. Place the Wet/Gel Setup switch to the correct position for the installed battery type. Verify that the external breakers, or receptacles are reset and connect an AC load, such as a 100Watt light. 16 ª © ¨§ ¥ ¤ ¦ ¥ ¤ £ ¡¢ ¨ SRC12-1500 INVERTER/CHARGER Owners Manual 4 7. 8. 9. 10. Connect both battery cables to battery and turn on the battery DC power to the inverter (if battery switch is used). Do not connect shore/utility (generator) power at this time. Place the System On/Off switch on the Inverter panel to the ON position. Place the System On/Off switch on the Remote panel (if used) to the ON position. Plug AC output test light (eg. 100 watt trouble light) into 15A convenience receptacle and turn on to verify inverter produces AC power and the Load Demand function allows the unit to power up from stand-by mode. Applying any AC load greater than 5 Watts should wake up the inverter from Load Demand "stand by" mode. Connect and activate AC shore/power (or generator). When shore/utility power (or generator) has been connected the inverter the following should occur: If AC test light is off. · Inverter Light will blink slowly · Charge Bulk or Charge Float mode Lights will illuminate. (If the battery is fully charged, it will advance from Bulk mode to Float mode after a time delay). If AC test light is on. · Inverter Light will blink. · Battery charge stage Lights will illuminate as described above. · The AC output test light should be on, indicating the presence of shore power and correct operation of the AC Transfer switch. 11. 12. 13. 14. Disconnect the AC shore power input. The AC output test light blinks momentarily, indicating the operation of the Transfer switch connection to connect the AC loads to the inverter output. The Inverter Light on the inverter control panel has a solid green light indicating correct inverter operation. At this point, apply AC loads up to the inverter's rated capacity to verify full-power operation. Disconnect all AC loads. The Inverter Light blinks, indicating that the inverter has returned to Load Demand mode. If the Load Demand function is not appropriate for the intended application, change the Load Demand Switch, Switch 1, to the OFF position. This will allow the inverter to be fully ON continuously unless switched off with the On/Off front panel switch or remote control. 15. 16. 5.2 Procedure to Check Battery Charger Operation
Due to the amount of time to perform this procedure, verifying the battery charger function, it may be postponed to a convenient time. Determine the correct charger output amps and place the front panel switch (3) position to match this value. To test the battery charger operations, first discharge the battery by placing a large AC load (approx. 50% of the unit's rated capacity) on the system and operating the inverter with AC input ´ ³ ¨± ¯ ® ° ¯ ® «¬ ² SRC12-1500 INVERTER/CHARGER 17 Owners Manual disconnected. The AC load will discharge the battery over a time relative to the amount of battery capacity, size of load, and ambient temperature. When the battery charge level is low, the Battery Low Light turns on and will stay on until the battery voltage has dropped to the Battery Low shutdown. The inverter then shuts off and the Light begins to blink. The battery voltage has decayed to 10.5 Vdc. Now, apply shore power and observe the battery charger operation. The system begins with the Charger-Bulk Light blinking, indicating bulk charge operation. This supplies a constant current charge output. Connect an ammeter to the DC cables between the inverter and the battery to monitor the current (DC amps), and a volt meter to the battery to monitor the battery voltage rising. After some time, the battery voltage rises to the Absorption voltage (14.4 VDC for wet batteries or 14.1 VDC for gel batteries). The Charger-Bulk light continues to flash, indicating the charger is in Bulk or Absorption mode. The battery voltage remains constant (Absorption voltage value), and the charger output current tapers off. After approximately twenty minutes, the charge advances to Float mode. The Charger Float Light turns ON and the battery voltage drops to the float voltage value (13.2 VDC for wet batteries or 13.6 VDC for gel batteries). The charger will remain in this stage until shore power is removed or until the battery will again accept the bulk charge amperage. 6 THEORY OF OPERATION Battery Charger Operation The SRC12-1500 incorporates an automatic, three-stage battery charger. This design enables the unit to automatically charge batteries, maintaining the battery's integrity and reducing the likelihood of premature failure. The battery charger is designed to be used with lead-acid type batteries including sealed and gel types, but not for nickel-cadmium (Ni-Cad) or nickel-iron types. There are three automatic charge stages; Bulk, Absorption, and Float. Bulk Charge Stage The Bulk Charge Stage (fixed current) provides a fixed charging current for rapid charging of the battery bank. The charger output current is adjustable, 15-Amp or 55-Amp, to match the charging requirements of the battery. The Bulk Stage is initiated when the battery will accept the charging amps selected. As the battery accepts charge the battery voltage will rise to the charger's Bulk Voltage value, 14.4 VDC for flooded batteries, or 14.1 VDC for gel batteries. When battery voltage reaches the Bulk Voltage Value the Bulk Charging Stage is complete. At this point, the battery is approximately 80-percent charged. Absorption Charge Stage During Absorption Charge Stage (fixed voltage), the charger's output voltage remains fixed at the Bulk Charge value and the output current will decrease as the battery becomes fully charged. The Absorption Stage ends after twenty minutes and the charger advances to the Float Stage. Float Charge Stage When the charger enters Float Stage, its output voltage is reduced to the float voltage value 13.2 VDC for flooded batteries, or 13.6 VDC for gel batteries. This setting is sufficient to keep the battery charged, but not so high as to boil or over-charge the batteries. The charger will remain in Float Stage until the battery will accept the Bulk Charge Output Amps selected. 18 ¾ ½ ¨» ¹ ¸ º ¹ ¸ · µ¶ ¼ SRC12-1500 INVERTER/CHARGER Owners Manual Figure 1 Battery Charging Graph Automatic Power Transfer Switch Theory of Operation The function of the Automatic Transfer Switch is to automatically accept AC input power from shore or generator, and use this power to operate inverter loads and to provide power for battery charging. Upon loss of AC input power, the transfer switch automatically switches the AC loads back to inverter power. Transfer time is approximately 30 milliseconds (0.030 seconds). The 0.030 second transfer time allows all but the most sensitive loads to transfer from inverter power to shore power and back to inverter power without interruption. AC input voltage is monitored for proper tolerance at all times. When the AC input is within tolerance for approximately 5 seconds, the power is passed through to the output circuit and the SRC12-1500 automatically switches from inverter mode to battery charger mode. The unit automatically switches back to inverter mode when input power is disconnected or when input power is no longer within tolerance. See specifications page for AC input voltage tolerances. The 5 second delay occurs only if the inverter is fully ON when input power becomes available. There is no 5 second time delay if the inverter is in the `Load Demand Mode' when input power becomes available. The factor that determines whether the unit is in `inverter mode' or `battery charger mode' is the presence or absence of `in-tolerance' input power. Whenever `in-tolerance' input power becomes available the unit automatically switches from inverter mode to charger mode. The transfer switch switches both AC hot and AC neutral. For safety purposes the inverter output neutral is connected to the inverter chassis ground only when the unit is in inverter mode. This is a requirement of the National Electric Code for all systems of this type that neutral should be connected to ground only at the source of AC power, which is the inverter when in inverter mode. When an external AC input (shore power, generator) is available, the SRC12-1500 transfer switch system breaks the connection between neutral and inverter chassis ground. The neutral-to-ground connection for passthrough power is then provided by the AC input source. È Ç ¨Å Ã Â Ä Ã Â Á ¿À Æ SRC12-1500 INVERTER/CHARGER 19 Owners Manual 7 PREVENTIVE MAINTENANCE There are no user serviceable components inside the inverter. For service refer to the Vanner Incorporated Service Department or other qualified service personnel. 7.1 Maintenance Items For continued reliability and safety, a monthly maintenance program should be implemented to include the following: 1. 1 2 3 Check to insure that all DC and AC wiring connections are secure and corrosion free. Check air ventilation openings for dust and other obstructions Examine receptacle, indicators and switches for cracks and breaks. Examine for any surfaces that are discolored or deformed due to excessive heat. 7.2 Troubleshooting Procedures The following are the most common questions heard by Vanner service professionals. If your situation does not apply to the following categories, please contact your local Vanner Incorporated Service Center or the Vanner Incorporated Customer Service department: 1-800-AC-POWER (1-800-227-6937). Please have your model and serial number available when consulting customer service. ALWAYS CHECK THE FOLLOWING FIRST: DC Fuse condition AC output and input breakers Check all GFCI breakers as equipped throughout AC system Unit On/Off and Remote On/Off switch positions Check battery connections for tightness or corrosion Check battery voltage at battery and inverter Symptom Solution Symptom Solution ON Light does not light steadily after pushing in the ON/OFF/RESET Switch. Light flashes two blinks per second in Load Demand Stand-by mode. Light flashes one blink per second when utility power is present. Inverter Light does not illuminate Reset On/Off Switch on unit and remote Disconnect remote switch and attempt starting with unit On/Off switch Check DC fuse condition Verify battery voltage is above 10.5 volts at inverter ON light fully illuminates. AC load does not run. Check and reset AC circuit breakers. Check and reset any GFCI breakers in AC circuit. Verify AC load and wiring are in proper condition. BATTERY LOW light illuminates when AC load is applied. Check battery connections. Check battery condition. Recharge battery if voltage is less than 10.5 VDC. Check the charging system for proper operation (vehicle alternator, generator). Symptom Solution Symptom Solution 20 Ò Ñ ¨Ï Í Ì Î Í Ì Ë ÉÊ Ð SRC12-1500 INVERTER/CHARGER Owners Manual Symptom Solution OVERTEMP light illuminates. Something has caused the unit to overheat. Check for obstruction of air flow to the cooling fan or from ventilation holes. Verify AC load is within unit's rated capacity. OVERLOAD light illuminates with AC load applied. Verify AC load is within unit's rated capacity. DC fuse blows when connecting DC input cables. Check for reverse polarity: red cable to battery positive (+), black cable to battery negative (-) The unit may be damaged and require repair service. Excessive audible buzzing during inverter operation but inverter operates loads. Check mounting bracket bolt tightness Remount inverter with rubber insulator washers AC loads do not seem to be fully energized when operating from inverter power. Check AC output voltage at convenience receptacle with a "True RMS" meter. Check for overheated DC or AC wiring Unit does not operate and a "burnt wire" smell emits from inverter. Disconnect AC loads and battery immediately Unit may require service Symptom Solution Symptom Solution Symptom Solution Symptom Solution Symptom Solution Ü Û ¨Ù × Ö Ø × Ö Õ ÓÔ Ú SRC12-1500 INVERTER/CHARGER 21 Owners Manual 8 8.1 APPENDICES Problem Loads Although modified sine wave inverters will operate most AC loads, some loads may exhibit problems because the wave form is different than the pure sine wave of utility power. This is due to the square wave components and that the peak voltage is not quite as high as a pure sine wave. Loads that may exhibit problems include motor speed controls found on ceiling fans and air conditioner fans; light dimmer controls; clocks; microwave ovens (cooking time may vary and the clock may be erratic); video monitors and TVs (may have lines in the picture); AM radios (may pick a noise); laser printers; copying machines; fluorescent lights; and power supplies in some electronic devices. Rechargeable battery devices may also overheat and be damaged by the inverter. If you desire to operate a rechargeable battery device on the inverter you should first power it up and closely observe it for a period of time to ensure that it does not run too hot. Ampere-Hour (A-H): A unit of measure for a battery's electrical storage capacity, obtained by multiplying the discharge current in amperes by the time in hours of discharge. The rating is usually for a discharge period of 20 hours and an end voltage of 10.5 volts. Example: A battery which delivers 5 amperes for 20 hours has a capacity of 100 A-H. 5 amperes x 20 hours = 100 Amp-Hr.) The reason the A-H rating is misunderstood is simple. A battery that has a rating of 100 AH cannot always deliver 100 A-H. The underlying reason is the efficiency with which the battery converts its chemical energy into electric energy. The A-H capacity of a battery is affected in the following ways: Discharge Rate: A battery becomes less efficient as the discharge current increases. For example, a typical 100 A-H battery is specified to be able to deliver 5 amps for a period of 20 hours. If the discharge current were increased to 25 amps, the capacity will be reduced to approximately 75 A-H (25 amps x 3 hours = 75 A-H). Operating Temperature: A battery becomes less efficient at lower temperatures. Most battery manufacturers specify the battery A-H capacity at 80øF. At a temperature of 32øF, the same battery will have only about 65% of its rated capacity even though it may be fully charged. At a temperature of 0øF, a battery's capacity will be reduced to about 40% of its rated capacity. Battery Age: As a battery is used, some of the active material on the battery plates will deteriorate and become useless. As the battery gets older, there will be less and less useful material left on the plates and the operating time will become noticeably shorter. A battery will age faster (loose active material from its plates faster) if it is deeply discharged regularly, if it is left in a discharged state for extended periods of time, or if it is repeatedly overcharged. 22 æ å ¨ã á à â á à ß ÝÞ ä SRC12-1500 INVERTER/CHARGER Owners Manual 8.2 DC Power Consumption An inverter takes in DC power, and produces AC power to operate attached loads. In general, we can see a direct relationship between DC input power and AC output power. This allows us to establish the following rule: For every 10 watts of AC output power, an inverter requires one amp of DC input power on a 12 volt input inverter. Example: An inverter powering a 1,000 watt AC load requires 100 amps DC. 1000 watts/10 = 100 amps Using our rule, we can determine the requirements for an electrical system needed to power our inverter (typically, an alternator and battery combination, or a photovoltaic panel and battery combination). Inverter DC Input Current Requirements A DC to AC inverter converts DC power into AC power. For the purposes of this discussion, power (watts) is equal to the