Transportation Products Cooper Bussmann Inverter 1000W / 1800W INSTALLATION GUIDE
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.
Important Safety Instructions WARNING: Limitations on Use – The Cooper Bussmann Inverter is not to be connected to life support devices. CAUTION: Risk of injury – To avoid risk of injury, use only 12Vdc, lead-acid, rechargeable batteries (i.e. GEL, AGM, and Flooded). Other types of batteries may burst, resulting in personal injury and/or damage. Do not expose inverter to rain, snow, spray, or water. Do not cover/obstruct ventilation systems.
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.
CONTENTS Installation ............................................................................ pg 6 Configuration ........................................................................ pg 24 Specifications .......................................................................
1. INSTALLATION Chapter 1 offers information as a guide to installing a Cooper Bussmann Inverter/Battery Charger.
Materials List The 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 1ea M6x1.
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. Prior to engaging in any service, all AC and DC power sources need to be disconnected and all AC and DC devices and generators need to be disabled.
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) AC cable (i.e.
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.
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. In the case of multiple sources, an automatic or manual AC source selector switch can be used. The AC source going into the inverter must have a neutral conductor bonded to ground (i.e. 3-prong wall cable).
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.
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). Follow any instructions from the battery manufacturer being used. WARNING: Fire hazard – Ensure the ventilation openings are not covered or obstructed to reduce risk of fire.
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. The inverter has a ground stud on the side near the DC end. Use this to connect the inverter’s chassis to ground; usually the vehicle’s chassis or DC negative bus ground using a properly insulated copper wire.
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. Eliminate potential trouble areas by installing clamps, protecting wiring harnesses with plastic wrap, and installing grommets in feed through holes.
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. This section will explain how to hardwire the inverter with AC input and output.
CAUTION: Reverse polarity – Connecting wires improperly (i.e. the neutral wire into the line termination) will cause the inverter to break down and possibly cause permanent damage. 11. It is very important to not confuse the connections (i.e. putting the line conductor into the neutral termination).
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. 4. Locate the terminal blocks. The whole area will be labeled “AC OUTPUT” and there will be three terminations: (GND) (L) (N) 5.
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. IMPORTANT: It is important to note the generator must have its own neutral bonded to ground. If the generator’s neutral is not bonded to ground, a bonding jumper must be installed.
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. The connectors chosen will need to create a permanent, low-resistance connection. 4. Attach terminals to both ends of cables. One end for the connection to the battery, and the other end for connection to the inverter.
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. The wiring used for grounding should be bare copper or provided with green insulation. THIS LUG IS NOT FOR AC GROUNDING.
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. STEP 8: Test Installation WARNING: Shock hazard – AC power from a utility/grid will still pass through the inverter to the AC output even with the inverter turned OFF.
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 ≈ 90Vac). WARNING: Shock hazard – Utility/grid power will always pass through the inverter to the AC output even if the inverter is turned OFF.
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 The inverter can operate from several different types of lead-acid batteries. It is important to make sure the battery type is configured on the unit for optimum charging process before installing batteries.
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 To change display: By default, the screen will display the input voltage in [Volts] and the “Input Voltage (V)” LED indicator will be illuminated. 1. Press the Select button once.
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 The screen will display the setting (either AL0 or AL1) briefly and then return to the previous screen. Note: The alarm setting will revert back to default (ON) when the Inverter button is turned OFF then ON again.
Charging Current Guidelines AC Input Circuit Branch Breaker or fuse size (Amps) 15 20 30 Charger DC Current Setting (Amps) Maximum By-pass AC Current Available (Amps) 12-110-1000-B2 12-110-1800-B4, 12-110-1000-B4 12-110-1000-B2 12-110-1800-B4, 12-110-1000-B4 2 5 10 20 2 5 10 20 2 5 10 20 2 10 20 40 2 10 20 40 2 10 20 40 13.5 12.5 11 8.5 18.5 17.5 16 13.5 28.5 27.5 26 23.5 13.5 11 8.5 3.5 18.5 16 13.5 8.5 28.5 26 23.5 18.
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: Input voltages Low Setting Mid Setting High Setting Nominal DC Input 12.5VDC 13.0VDC 13.0VDC Input voltage operating range 10.5 – 16.0VDC 11.8 – 16.0VDC 12.2 – 16.
Utility to Inverter AC input recovery from Inverter to Utility 100 VAC Utility to Inverter and Inverter to Utility hysteresis 5 VAC minimum Maximum AC output by‐ pass current 20 Arms AC transfer time – Inverter to Utility 20 Seconds nominal AC transfer time –Utility to Inverter < 50 ms Time delay on transfer from Inverter to Utility 20 s +/‐ 2s Voltages +/‐ 5V Battery Charger AC input operating range 95 – 135VAC AC input range with full power 105V – 135VAC AC input current with no load
DC Output Current: Model Maximum DC Output current (Adc) Setting 1 Setting 2 Setting 3 Setting 4 12-110-1000-B2 2 +/- 0.5 5 +/- 0.5 10 +/- 1 20 +/- 2 12-110-1800-B4 2 +/- 0.
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 Shock Must operate per specification during and after the test. 30G Peak, 11 ms, ½ Sine Wave Environmental Specifications Temperature Cycling Per SAE J1455, Rev. JUN2006, Sec. 4.1, Test 4.1.3.1 Fig. 2B* Must operate per specification during and after the test. Thermal shock Per SAE J1455, Rev.
Reverse Polarity Test Per SAE J1455 Sec. 4.11.1 –24 Vdc Applied to DC Terminals The inverter shall present no safety hazard. Internal fuses will open in the inverter system, requiring factory service for replacement. Regulatory Requirements UL 458 Comply with the requirements of the standard. UL Mark CSA C22.2, No. 107.1 Comply with the requirements of the standard.
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 AC Output: AC NEMA outlet with knockouts for AC Input and optional AC output. All AC output connections are GFCI protected. Hardware Included: Printed Instruction manual 25 foot RJ11 cable for remote mounting of control panel 2 ea M8x1.
DC Input AC Input AC Output Model Minimum Wire Size (AWG) Required UL Listed Fuse (Amp) Minimum Wire Size (AWG) Recommended Branch Circuit (Amp) Minimum Wire Size (AWG) Recommended Fuse (Amp) 12‐110‐1000 3 125 12 15 14 N/A (See Note) 12‐110‐1800 1 200 12 20 12 N/A (See Note) 12‐110‐1000‐B2 3 125 12 20 14 N/A (See Note) 12‐110‐1000‐B4 3 125 12 20 14 N/A (See Note) 12‐110‐1800‐B4 1 200 10 30 12 N/A (See Note) Note ‐ AC output fuse is not required as all models feat
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 Setting (+/‐ 0.3V) Display Audible Alarm Comment Over Voltage Shutdown Lo or HI 16.0 VDC E02 Beep @ 1 Hz Note 1 Over Voltage Recovery Lo or HI 15.
AC Output Overload Protection and Warning and Shutdown Model Condition Power (W) Dis‐ play Audible alarm V<11.4 11.411.8 Warning (+/‐100W) 950 1000 1100 E06 Beep @ 0.33Hz Shutdown (+/‐100W) 1050 1100 1200 E03 Beep @ 1 Hz Warning (+/‐200W) 1750 1850 2000 E06 Beep @ 0.
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 > 100°C Max. Charge current reduced to 0A > 70°C System shutdown (no auto‐reset) Charger Transformer AC Transfer Relay Note: Max.
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.
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.
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 LE
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 The following Fault codes are provided on digita
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 equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
