IRIS QuietPower 1800 Operator's Manual

Iris Technology Corporation [CAGE 78535]
949.975.8410 tel / 949.975.8498 fax Toll free 866.240.9540 / www.iristechnology.com
QuietPower 1800 (QP-1800) DC to AC Power Inverter
TM 11460A-OR/1 A
APRIL 2010
PCN 500 114600 00
Operator’s Manual Operator’s Manual
Document 287.F701 / 100412 / Rev 12 APR 2010
Supersedes Document 287.F701 / 070901 / Rev 01 SEP 07
Iris Technology Operator's Manual QuietPower 1800 (QP-1800) Doc 287.F701 / 100412
Notice of Copyright
Iris Technology QuietPower Inverter (QP-1800) Owner‟s Manual. © APR 2010 Iris Technology Corporation. All rights reserved.
Disclaimer
Unless specifically agreed to in writing, Iris Technology Corporation (Iris): (a) makes no warranty as to the accuracy, sufficiency, or suitability of any
technical or other information provided in its manuals or other documentation. (b) assumes no responsibility or liability for loss or damage, whether direct,
indirect, consequential, or incidental, which might arise out of the use of such information. The use of such information will be entirely at the users risk.
Document Number
TM 11460A-OR/1 A / PCN 500 114600 00
287.F701 / 100412 / Rev 12 APR 2010 Supersedes Document 287.F701 / 070901 / Rev 01 SEP 07
U. S. Government Copyright Release
Iris Technology Corporation grants permission to the U.S. Government to reprint this technical manual for use as needed. This permission includes but is not limited to posting on U.S. Government websites. This document is subject to periodic revision and the user is encouraged to check the Iris Technology website (www.iristechnology.com) for the most current version of this document.
Trademarks
Any references to copyrighted or trademarked names referred to in this document are the properties of their respective owners.
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TABLE OF CONTENTS
TABLE OF CONTENTS ......................................................................................................................................... 3
APPENDICES ..................................................................................................................................................... 5
LIST OF FIGURES ............................................................................................................................................... 5
LIST OF TABLES ................................................................................................................................................. 5
SYMBOLS AND CONVENTIONS ............................................................................................................................ 6
SPECIFIC WARNINGS AND HAZARDS OF THIS DEVICE .......................................................................................... 7
GENERAL SAFETY PRECAUTIONS ..................................................................................................................... 10
EXPLOSIVE GAS PRECAUTIONS ........................................................................................................................ 11
PRECAUTIONS WHEN WORKING WITH BATTERIES............................................................................................. 11
FCC INFORMATION .......................................................................................................................................... 12
DEPARTMENT OF DEFENSE PRODUCT EVALUATION .......................................................................................... 12
SECTION 1 INTRODUCTION
1.1 INTRODUCTION ................................................................................................................................................ 13
1.2 EQUIPMENT IDENTIFICATION AND DESCRIPTION ................................................................................................. 14
1.3 INVERTER KEY FEATURES ................................................................................................................................. 16
1.3.1 INVERTER FUNCTION ........................................................................................................................................ 16
1.3.2 CONTROL PANEL .............................................................................................................................................. 16
SECTION 2 INSTALLATION
2.1 GENERAL ......................................................................................................................................................... 18
2.2 REQUIREMENTS FOR INSTALLATION .................................................................................................................. 18
2.3 INSTALLING THE INVERTER ............................................................................................................................... 18
2.4 LOCATING THE INVERTER ................................................................................................................................. 19
2.5 MOUNTING THE INVERTER ................................................................................................................................ 21
2.5.1 CONTROL PANEL ORIENTATION ......................................................................................................................... 22
2.6 WIRING THE INVERTER ..................................................................................................................................... 22
2.6.1 MAKING DC WIRING CONNECTIONS .................................................................................................................... 22
2.6.2 DC GROUNDING (ON-VEHICLE) .......................................................................................................................... 24
2.6.3 DC GROUNDING (OFF-VEHICLE) ......................................................................................................................... 24
SECTION 3 OPERATION
3.1 GENERAL ......................................................................................................................................................... 25
3.2 PRINCIPLES OF OPERATION .............................................................................................................................. 25
3.3 OUTPUT WAVEFORM ......................................................................................................................................... 25
3.4 CONTROL PANEL .............................................................................................................................................. 26
3.4.1 TO OPERATE THE QUIETPOWER INVERTER: ........................................................................................................ 27
3.5 POWERSAVE MODE .......................................................................................................................................... 27
3.6 INVERTER OPERATING LIMITS AND PROTECTION FEATURES ................................................................................ 28
3.7 PERFORMANCE GRAPHS AND SPECIFICATIONS .................................................................................................. 30
3.7.1 POWER DERATING CURVE ................................................................................................................................. 30
3.7.2 EFFICIENCY CURVE .......................................................................................................................................... 31
3.7.3 TECHNICAL SPECIFICATIONS ............................................................................................................................. 32
3.8 USAGE GUIDELINES FOR THE QP-1800 .............................................................................................................. 33
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SECTION 4
TEST AND TROUBLESHOOTING
4.1 GENERAL ......................................................................................................................................................... 34
4.2 TESTING .......................................................................................................................................................... 34
4.3 TROUBLESHOOTING ......................................................................................................................................... 35
4.3.1 FAULT CONDITIONS AND INDICATORS ................................................................................................................ 35
4.3.2 TROUBLESHOOTING TIPS .................................................................................................................................. 36
SECTION 5 PREVENTATIVE MAINTENANCE
5.1 GENERAL ......................................................................................................................................................... 37
5.2 INSPECT AND CLEAN ........................................................................................................................................ 37
5.2.1 INSPECTION ..................................................................................................................................................... 37
5.2.2 CLEANING ........................................................................................................................................................ 38
5.3 NATO CABLE REPLACEMENT ............................................................................................................................. 39
5.3.1 NATO CABLE REMOVAL ..................................................................................................................................... 39
5.3.2 NATO CABLE INSTALLATION .............................................................................................................................. 40
5.4 STORAGE ........................................................................................................................................................ 41
5.5 PREPARATION FOR SHIPMENT ........................................................................................................................... 41
SECTION 6 CORRECTIVE MAINTENANCE
6.1 GENERAL ......................................................................................................................................................... 42
6.2 INSPECT AND CLEAN ........................................................................................................................................ 42
6.2.1 INSPECTION ..................................................................................................................................................... 42
6.2.2 CLEANING ........................................................................................................................................................ 43
6.3 FUSE REPLACEMENT ........................................................................................................................................ 44
6.3.1 FUSE REMOVAL ................................................................................................................................................ 44
6.3.2 FUSE INSTALLATION ......................................................................................................................................... 45
SECTION 7 WARRANTY AND SERVICE
7.1 GENERAL ......................................................................................................................................................... 46
7.2 WARRANTY ...................................................................................................................................................... 46
7.3 WARRANTY SERVICE ........................................................................................................................................ 47
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APPENDIX A VEHICLE CONSIDERATIONS
A.1 VEHICLE ALTERNATOR ...................................................................................................................................... 48
A.2 MILITARY BATTERIES ........................................................................................................................................ 48
A.3 LOAD AND RUNTIME.......................................................................................................................................... 50
APPENDIX B
TECHNICAL ADDENDUM
B.1 QP-1800 PERFORMANCE WITH VEHICLE AND ENVIRONMENTAL FACTORS ............................................................ 51
B.1.1 TEMPERATURE EFFECTS ON BATTERY PERFORMANCE ....................................................................................... 51
B.1.2 AGE AND CONDITION OF THE VEHICLE BATTERY ................................................................................................. 52
B.1.3 CONDITION AND INTEGRITY OF THE VEHICLE CABLING ........................................................................................ 52
B.1.4 LOOSE CONNECTIONS ...................................................................................................................................... 52
B.2 OPERATION WITH SURGE SUPPRESSION POWER STRIPS ..................................................................................... 52
B.3 OPERATION WITH DOWNSTREAM EMC COMPONENTS .......................................................................................... 52
B.4 FREQUENTY ASKED QUESTIONS (FAQS). ............................................................................................................ 53
LIST OF FIGURES
FIGURE 1: FRONT PANEL OF THE QP-1800 ........................................................................................................ 17
FIGURE 2: REAR PANEL OF THE QP-1800 .......................................................................................................... 17
FIGURE 3: APPROVED MOUNTING ORIENTATIONS OF THE QP-1800 ..................................................................... 21
FIGURE 4: CONTROL PANEL ROTATION AND ATTACHMENT .................................................................................. 22
FIGURE 5: INVERTER NATO CABLE .................................................................................................................... 22
FIGURE 6: VEHICLE GROUNDING REQUIREMENTS FOR THE QP-1800 ................................................................... 24
FIGURE 7: QUIETPOWER INVERTER TRUE SINE WAVE OUTPUT ............................................................................ 25
FIGURE 8: QP-1800 CONTROL PANEL ................................................................................................................ 26
FIGURE 9: OUTPUT POWER (W) DERATING CURVE .............................................................................................. 30
FIGURE 10: EFFICIENCY (%) AND HEAT DISSIPATION (W) .................................................................................... 31
FIGURE 11: INVERTER COVER REMOVAL ........................................................................................................... 45
FIGURE 12: FUSE REMOVAL AND REPLACEMENT. ............................................................................................... 45
FIGURE 13: RUNTIME HOURS VS AMPS OVER TEMPERATURE .............................................................................. 51
FIGURE 14: ENERGY FLOW ............................................................................................................................... 54
LIST OF TABLES
TABLE 1: QUIETPOWER SYSTEM AND COMPONENT PARTS LIST ........................................................................... 14
TABLE 2: OPERATING LIMITATIONS .................................................................................................................... 28
TABLE 3: SYSTEM TRIP VOLTAGES .................................................................................................................... 28
TABLE 4: TECHNICAL SPECIFICATIONS ............................................................................................................... 32
TABLE 5: FAULT CONDITIONS AND INDICATORS .................................................................................................. 35
TABLE 6: TROUBLESHOOTING TIPS .................................................................................................................... 36
TABLE 7: INSPECTION (EXTERNAL) .................................................................................................................... 37
TABLE 8: CLEANING (EXTERNAL) ....................................................................................................................... 38
TABLE 9: INSPECTION (INTERNAL) ..................................................................................................................... 42
TABLE 10: CLEANING (INTERNAL) ...................................................................................................................... 43
TABLE 11: COMPARISON OF MILITARY BATTERY SPECIFICAITONS ........................................................................ 49
TABLE 12: SAMPLE LOAD AND RUNTIME TABLE .................................................................................................. 50
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Iris Technology Operator's Manual
- NOTE -
Provides useful additional information for the user.
CAUTION
The hazard may result in minor or moderate damage to equipment and may render it inoperative.
WARNING
A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
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Symbols and Conventions
The following conventions are used in this manual to communicate hazards to the operator, device or associated equipment that may occur with improper installing, operating, maintaining and servicing this equipment. These symbols are also used to make the operator aware of the inherent and potential hazards associated with this type of equipment.
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WARNING
FIRE AND SHOCK HAZARD. MAKE SURE THE CABLE IS DISCONNECTED FROM 24 VDC POWER SOURCE PRIOR TO INSTALLING CABLE ONTO INVERTER TERMINALS. FAILURE TO DISCONNECT CABLE FROM 24 VDC POWER SOURCE (NATO PLUG) FIRST MAY RESULT IN FIRE, SEVERE ELECTRIC SHOCK, OR DEATH.
WARNING
BEFORE MAKING CONNECTIONS, ROUTE THE POSITIVE AND NEGATIVE BATTERY WIRES DIRECTLY TO THE DC CONNECTION TERMINALS ON THE QUIETPOWER INVERTER FIRST.
WARNING
SHOCK HAZARD. MAKE SURE GROUND CONNECTIONS ARE MAINTAINED BETWEEN THE INVERTER, VEHICLE, AND GROUND ROD (IF APPLICABLE). FAILURE TO DO SO COULD RESULT IN A POTENTIAL SHOCK HAZARD.
WARNING
DO NOT DISASSEMBLE THE QUIETPOWER INVERTER. ONLY QUALIFIED ELECTRONICS MAINTENANCE TECHNICIANS ARE PERMITTED TO REPLACE THE FUSE. ATTEMPTS TO SERVICE THE INVERTER BY UNQUALIFIED PERSONNEL MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE. REFER TO SECTION 7, WARRANTY AND SERVICE, FOR INSTRUCTIONS ON SERVICING THE INVERTER.
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Specific Warnings and Hazards of this Device
The following are specific warning, cautions and hazards related to the installation, use, maintenance and service of this device.
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WARNING
MAKE SURE INVERTER IS ELECTRICALLY DISCONNECTED FROM 24 VDC POWER SOURCE (NATO PLUG) PRIOR TO SERVICING. FAILURE TO DISCONNECT INVERTER FROM 24 VDC POWER SOURCE (NATO PLUG) FIRST MAY RESULT IN FIRE, SEVERE ELECTRIC SHOCK, OR DEATH.
WARNING
DO NOT DISASSEMBLE THE QUIETPOWER INVERTER. ONLY QUALIFIED ELECTRONICS MAINTENANCE TECHNICIANS ARE PERMITTED TO REPLACE THE FUSE. ATTEMPTS TO SERVICE THE INVERTER BY UNQUALIFIED PERSONNEL MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE. REFER TO SECTION 7, WARRANTY AND SERVICE, FOR INSTRUCTIONS ON SERVICING THE INVERTER.
CAUTION
Review the Important Safety Instructions found at the beginning of this manual and read this entire section, paying particular attention to the CAUTION and WARNING statements, before proceeding with the installation.
CAUTION
It is recommended that you read the entire wiring instruction Section first before attempting to wire the Inverter
CAUTION
Make sure cable is connected properly: positive (+), red wire to left post and negative (-), black wire to right post. Connecting cable improperly may result in internal damage to inverter.
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CAUTION
Do not disassemble the QuietPower inverter. Only qualified electronics maintenance technicians are permitted to replace the fuse. Attempts to service the inverter by unqualified personnel may result in a risk of electric shock or fire. Refer to section 7, warranty and service, for instructions on servicing the inverter.
CAUTION
Do not use harsh or abrasive cleaners on the QuietPower inverter or NATO cable. Do not use petroleum-based products of any kind. Damage can result if these precautions are not followed. Use only a non-abrasive cloth dampened with soap and water to clean inverter and NATO cable. Do not attempt to flush the unit with liquids of any kind.
CAUTION
If you are installing the NATO Cable for the first time, install the red terminal cover on the red lead and the black terminal cover on the black lead.
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General Safety Precautions
The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.
Keep away from live circuits. Operating personnel must at all times observe all safety
regulations. Do not replace components or make adjustments inside the equipment with the voltage supply turned on. Under certain conditions, dangerous potentials may exist when the power control is in the OFF position. To avoid casualties, always remove power and discharge. Ground a circuit before touching it.
Do not service or adjust alone. Under no circumstances should any person reach into
or enter the enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.
Resuscitation. Personnel working with or near high voltages should be familiar with
modern methods of resuscitation. Such information may be obtained from the Red Cross (www.redcross.org).
Save these instructions. This Owner‟s Manual contains important safety and operating
information for the QuietPower Inverter.
The QuietPower Inverter has a Ground Fault Circuit Interrupter (GFCI) and a Circuit
Breaker for your safety. These features are critical to the safe operation of this system and must not be disabled.
Do not expose the QuietPower Inverter to rain, snow, spray, bilge or dust. To
reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the QuietPower Inverter in a zero-clearance compartment. Overheating may result.
Do not use attachments not recommended or sold by Iris Technology. Doing so
may result in a risk of fire, electric shock, or injury to persons.
The QuietPower Inverter is designed to connect to a military vehicle 24 VDC power
system through an available and/or supplied NATO Cable.
Do not operate the QuietPower Inverter with damaged wiring. To avoid a risk of fire
and electric shock, make sure that existing wiring is in good electrical condition.
Do not operate the QuietPower Inverter if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the QuietPower Inverter has been
damaged, refer to Section 7, Warranty and Service.
Do not disassemble the QuietPower Inverter. Only qualified electronics maintenance
technicians are permitted to replace the fuse. Attempts to service the inverter by unqualified personnel may result in a risk of electric shock or fire. Refer to Section 7, Warranty and Service, for instructions on servicing the inverter.
To reduce risk of electrical shock, disconnect the DC power from the QuietPower
Inverter before attempting any maintenance or cleaning or working on any equipment and circuits connected to the QuietPower Inverter. Turning off controls
will not reduce this risk.
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Explosive Gas Precautions
This equipment contains components which can 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 gasoline-powered 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 gasses 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.
Precautions When Working With Batteries
Do not work alone. Someone should be within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
Wear complete eye protection and clothing protection. Avoid touching eyes while
working near batteries.
Wear eye protection to keep corrosion from coming in contact with eyes, when
cleaning battery terminals and before making connections.
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 or flame in vicinity of battery or engine. Do not drop a metal tool on the battery, nor allow metal to contact the battery
terminals or vehicle chassis. The resulting spark or short-circuit on the battery or other electrical part may cause an explosion.
Remove personal metal items such as rings, bracelets, necklaces, and watches
when working with a lead-acid battery. A lead-acid battery produces a short-circuit
current high enough to weld a ring or the like to metal, causing a severe burn.
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FCC INFORMATION
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. However, there is no guarantee that the interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
Consult the dealer or an experienced radio/TV technician for help.
Department of Defense Product Evaluation
This equipment has been tested extensively by the Department of Defense (DoD) and is approved and recommended for use in wheeled military vehicles. Contact Iris Technology for details about obtaining a copy of these data (Restricted Distribution, FOUO).
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Section 1 Introduction
1.1 Introduction
Thank you for your purchase of the QuietPower 1800 Inverter. As a high quality, true sine wave output inverter, you can expect the QuietPower Inverter to deliver exceptional performance and give you years of dependable operation. The true sine wave AC output from the QuietPower Inverter ensures all AC loads operating from the unit perform efficiently and correctly. Since these loads were designed to operate from true sine wave voltage, you can expect these loads to operate the same as if operating from grid/utility supplied power. In some cases, the true sine wave output from the QuietPower Inverter is superior to the power supplied by your utility company.
To get the most out of your QuietPower Inverter, carefully read and follow the instructions in this guide. Pay special attention to the Important Safety Instructions in this guide and to the WARNING and CAUTION statements found throughout the guide and on the product. Please retain all packaging.
Should you have any questions before, during, or after installation, please call Iris Technology's Customer Service Department for help.
Customer Service (Toll Free): (866) 240-9540 Customer Service (Local): (949) 975-8410 Customer Service (Fax): (949) 975-8498 Customer Service (Email): support@iristechnology.com
Record the following information for use when contacting Iris for servicing of the unit. QuietPower Serial #: ___________________________ (Required) Date of purchase: ___________________________ (If Available) Contract reference: ___________________________ (If Available)
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Iris PN / NSN
Image
Description / Components
287A120
6130-01-552-6350
QP-1800 Inverter System NATO Cable (12 ft) Transportation Case
287A107
6130-01-496-6456
QP-1800 Inverter NATO Cable (12 ft)
287A101
6130-01-496-6448
QP-1800 Inverter
287A106
6150-01-497-2515
NATO Cable (12 ft)
287A108
7050-01-551-0600
Transportation Case Outside dimensions:
22.1” x 17.9” x 10.4” (560 x 455 x 265 mm)
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1.2 Equipment Identification and Description
Table 1 lists the QuietPower systems and components that can be ordered. The parts you receive depend on the part number ordered. Three different systems can be ordered, as well as individual components. All inverter options ship with an Operator‟s Manual and Installation Kit. The current revision of the Operator‟s Manual is downloadable from www.iristechnology.com.
Table 1: QuietPower System and Component Parts List
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Iris PN / NSN
Image
Description / Components
287F701
QP-1800 Operator‟s Manual TM 11460A-OR/1 A
PCN 500 114600 00
287A109
Installation Kit
Replacement Fuse (1) Battery Terminal Covers (2) Vibration Isolators (4)
287A125
Vehicle Mounting Plate for use with HMMWV
2870128 (EA)
5920-01-562-3354
Replacement Fuse
Littlefuse Mega 125 (125 A) PN / MEG 125 (EA)
Fuse replacement requires a Qualified Electronics Technician
2870140 (SET)
2870136 (BK)
2870137 (RD)
Battery Terminal Cover (SET) Straight Clamp, 3/0 AWG
BK (Negative) PN / 4271 (EA) RD (Positive) PN / 4272 (EA)
2870140 (SET)
2870110 (EA)
Vibration Isolators (SET) Neoprene Cylindrical Mount M/F, 1/4"-20, 1" Ht, 1" Wd
QuietPower 1800 (QP-1800) Doc 287.F701 / 100412
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1.3 Inverter Key Features
The QuietPower Inverter utilizes advanced high frequency switching technology in the power conversion process. The circuits are similar to those used in power supplies for computers and other electronic equipment. This technology offers several benefits:
Light weight: for easy installation Pure sine wave output: for reduced interference High surge capability: for „hard-to-start” AC loads High frequency switching: for nearly silent operation
Refer to paragraph 3.7, Performance Graphs and Specifications, for complete specifications.
1.3.1 Inverter Function
When connected properly and the power switch is turned to the „I‟ (On) position, the QuietPower Inverter draws power from the 24 VDC (nominal) battery and/or vehicle electrical bus and delivers a true sine wave 115 VAC (nominal @ 15 A) output. As long as the input voltage is maintained within the operating range of the unit, the QuietPower will continue to deliver AC power to the loads connected. High and low battery shutdowns will engage if the battery voltage falls out of the specified range of operation (20-32 VDC).
1.3.2 Control Panel
The Control Panel provides Off/On („O/I‟) control and displays operating information so you can monitor the status of the Inverter and your batteries.
This panel can be removed and re-attached in different orientations so the display information is directed at you in the most convenient fashion for all recommended mounting configurations. The procedure to rotate the panel is found in section 2.5.
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Circuit
Breaker
GFCI
(Ground Fault
Circuit Interrupter)
Off/On
(O/I)
Control
Panel
LCD
Display
Duplex (AC)
Outlet
Serial
Number
Ground
Lug
Isolators (4)
(Not Shown)
Input
Terminals (2)
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Figure 1: Front Panel of the QP-1800
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Figure 2: Rear Panel of the QP-1800
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