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Legend L2012

Trace Engineering Legend, Legend Series II, Legend L2012, Legend L2512, Legend L3012 Owner's/operator's Manual

Owner/Operator's Manual
Part Number 3179
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Table of Contents
INTRODUCING THE LEGEND SERIES II.............................................................1
IMPORTANT SAFETY INSTRUCTIONS...............................................................2
GENERAL PRECAUTIONS........................................................................................2
PERSONAL PRECAUTIONS......................................................................................4
FEATURES ............................................................................................................7
PROTECTION CIRCUITRY........................................................................................7
Automatic Low Battery Cut Out.......................................................................7
Automatic High Battery Cut Out......................................................................7
High Temperature Cut Out..............................................................................7
Over Current Cut Out......................................................................................8
Battery Type Optimization...............................................................................8
Charge Rate Regulation ..................................................................................8
Shore Power Amps Monitoring........................................................................9
VAC Dropout ...................................................................................................9
SEARCH MODE CIRCUITRY ....................................................................................9
IMPULSE PHASE CORRECTION .............................................................................10
TRUE RMS VOLTAGE REGULATION......................................................................10
CRYSTAL CONTROLLED TIME BASE......................................................................11
STAND-BY BATTERY CHARGER ............................................................................11
TRANSFER SWITCHING SPEED.............................................................................11
AUTOMATIC INVERTER TO CHARGER TRANSITION..................................................11
UNIT IDENTIFICATION .......................................................................................12
MODEL IDENTIFICATION .......................................................................................12
SERIAL NUMBER..................................................................................................13
CONTROLS & INDICATORS ..............................................................................15
QUICK INSTALL..................................................................................................19
INSTALLATION ...................................................................................................23
LOCATING THE INVERTER.....................................................................................23
VENTILATION.......................................................................................................23
MOUNTING..........................................................................................................24
DC WIRING.........................................................................................................25
Safety Instructions.........................................................................................25
DC Cabling Connections...............................................................................25
Ground Cable Connection.............................................................................27
Battery Cable Sizing......................................................................................28
DC Over Current Protection..........................................................................28
AC WIRING ........................................................................................................31
AC and DC Wiring Separation......................................................................31
AC Wire Connections....................................................................................31
Ground Fault Interrupting Outlets (GFCI’s)...................................................33
Neutral-to-Ground Switching.........................................................................35
Disabling Neutral Ground Switching.............................................................37
OPERATION........................................................................................................38
BATTERIES.........................................................................................................41
TERMINOLOGY....................................................................................................41
TYPES................................................................................................................42
Starting Batteries ..........................................................................................42
Deep-Cycle Batteries....................................................................................42
Sealed Gel Cell.............................................................................................42
ENVIRONMENT....................................................................................................43
Location.........................................................................................................43
Enclosures ....................................................................................................43
Temperature..................................................................................................43
BATTERY BANK SIZING........................................................................................44
Estimating Battery Requirements .................................................................44
Battery Bank Sizing Example & Worksheet..................................................45
MONTHLY MAINTENANCE.....................................................................................47
Preparation....................................................................................................47
Attire..............................................................................................................47
Tools .............................................................................................................47
Equipment.....................................................................................................48
Supplies ........................................................................................................48
Procedure......................................................................................................48
Battery Enclosure and Batteries ...................................................................48
Terminals & Lugs..........................................................................................48
Cables...........................................................................................................49
CABLING & HOOK-UP CONFIGURATIONS...............................................................49
Parallel Connection.......................................................................................50
Series Connection.........................................................................................50
Series – Parallel Connection.........................................................................51
THREE-STAGE BATTERY CHARGER..............................................................52
CHARGING PROFILE............................................................................................52
GENERATOR REQUIREMENTS ..............................................................................54
THEORY OF INVERTER OPERATION...............................................................55
WAVEFORM........................................................................................................55
REGULATION.......................................................................................................56
APPLICATIONS...................................................................................................57
RESISTIVE LOADS................................................................................................57
INDUCTIVE LOADS ...............................................................................................57
PROBLEM LOADS.................................................................................................58
OPTIONS..............................................................................................................61
THE RC6 REMOTE CONTROL ..............................................................................61
THE RC7 REMOTE CONTROL ..............................................................................62
BATTERY TEMPERATURE SENSOR (BTS) .............................................................63
BATTERY CABLES................................................................................................63
APPENDIX A: TROUBLESHOOTING.................................................................65
APPENDIX B: OTHER PRODUCTS FROM TRACE ENGINEERING................67
APPENDIX C: REFERENCE TABLES & GRAPHS............................................69
TYPICAL POWER CONSUMPTION OF COMMON APPLIANCES ...................................69
ENGLISH TO METRIC WIRE CONVERSION CHART ..................................................70
MINIMUM RECOMMENDED BATTERY CABLE SIZE (IN FREE AIR)..............................70
RECOMMENDED MINIMUM AC WIRE SIZES...........................................................71
COMMON BATTERY CHARGING RATES..................................................................71
LEGEND SERIES II CHARGING GRAPH ..................................................................72
LEGEND SERIES II EFFICIENCY CURVE.................................................................73
LEGEND PERFORMANCE GRAPH ..........................................................................74
APPENDIX D: SPECIFICATIONS.......................................................................75
APPENDIX E: DIMENSIONS ...............................................................................77
APPENDIX F: LIMITED WARRANTY .................................................................79
APPENDIX G: LIFE SUPPORT POLICY ............................................................82
INDEX...................................................................................................................83
TABLE OF FIGURES
Figure 1, Power Output Versus Temperature...................................................................24
Figure 2, Battery to Inverter Cable Connection..............................................................26
Figure 3, DC Wiring Diagram..........................................................................................30
Figure 4, AC Terminal Block............................................................................................31
Figure 5, AC Wiring Diagram..........................................................................................32
Figure 6, Typical Mobile Installation Diagram................................................................34
Figure 7, Neutral-to-Ground Switching without external AC source...............................35
Figure 8, Neutral-to-Ground Switching with External AC...............................................36
Figure 9, Disabling Neutral-to-Ground Switching...........................................................37
Figure 10, Three-Stage Charging Profile.........................................................................52
Figure 11, RC6 Remote Control Faceplate Display.........................................................61
Figure 12 , RC7 Remote Control ......................................................................................62
TABLE OF TABLES
Table 1, Minimum Recommended Battery Cable Size (In free air)...................................28
Table 2, Current Carrying Ability of Wire In Free Air at 75°C.......................................29
Table 3, Recommended Minimum AC Wire Sizes .............................................................33
Table 4, Typical Appliance Watts .....................................................................................46
Table 5, Bulk and Float Setpoints.....................................................................................54
INTRODUCING THE LEGEND SERIES II
Introducing the Legend Series II
The Legend Series II inverter/chargers are specially designed for after market installation in recreational vehicles.
The Legend Series II inverter/chargers feature:
ü Easy installation ü 2000, 2500, or 3000 watt continuous power output ü Automatic three-stage battery charging ü Over-current, over-temperature, and high/low battery voltage protection ü UL listed to UL 458 standards ü 5-year limited warranty ü Front-panel wiring terminals for maximum accessibility ü Optional RC6 remote On/Off, voltmeter, ammeter, charge status and error indicator ü Optional full-function, programmable RC7 remote control provides digital metering and user
configuration
ü Adjustable charging rate and battery type selection ü Adjustable power-saving search mode ü Automatic battery temperature compensation (with battery temperature sensor [BTS]
option).
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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IMPORTANT SAFETY INSTRUCTIONS
Important Safety Instructions
SAVE THESE INSTRUCTIONS
This manual contains important safety and operating instructions as prescribed by UL specifications for inverters used in land vehicle applications. This manual covers inverters and inverter/chargers models: L2012, L2512, and L3012 Legend Series II inverter/chargers.
The entire Legend series of inverters is UL listed to the general UL specification #458 covering power inverters for land vehicle applications.
General Precautions
1. Before using the inverter/charger, read all instructions and cautionary markings on (1) the inverter/charger, (2) the batteries, and (3) all appropriate sections of this instruction manual.
2. CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell, or absorbed mat type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.
3. Do not expose inverter/charger to rain, snow or liquids of any type. The inverter is designed for interior mounting only. Protect the inverter from splashing when used in vehicle applications.
4. Do not disassemble the inverter/charger; take it to a qualified Trace Engineering Service Center when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.
5. To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning. Turning off the inverter will not reduce this risk.
6. WARNING - RISK OF EXPLOSIVE GASES WORKING IN VICINITY OF A LEAD ACID BATTERY MAY BE DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE SERVICING EQUIPMENT IN THE VINCINTITY OF THE BATTERY, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. Provide ventilation to outdoors from the battery compartment. The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the compartment. Vent the battery compartment from the highest point. A sloped lid can also be used to direct the flow to the vent opening location.
To reduce the risk of battery explosion, follow these instructions and those published by battery manufacturer and any manufacturer of any equipment you intend to use in the
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IMPORTANT SAFETY INSTRUCTIONS
vicinity of batteries. Review cautionary markings on these products and all other products being used.
7. No terminals or lugs are required for hook-up of the AC wiring. AC wiring must be no less than 10 AWG (5.3 mm2) copper wire and rated for 75°C or higher. Battery cables must be rated for 75°C or higher and should be no less than the minimum wire size recommended by this manual.
Crimped and sealed copper ring terminal lugs with a 5/16” hole should be used to connect the battery cables to the DC terminals of the inverter/charger. Soldered cable lugs are also acceptable. See section Batteries and Chargers for correct battery cable size and length for your application.
8. Torque all AC wiring connections to 15-20 inch-pounds. Torque all DC cable connections to 10­12 foot-pounds.
9. CAUTION: To reduce the risk of fire, use only input circuits provided with the correct ampere branch circuit protection in accordance with the National Electric Code, ANSI/ NFPA70
10. Use the correct tools to make AC/DC wiring connections: wire strippers, ½” (13mm) open-end wrench or socket, Phillips screw driver #2, and ¼” flat blade screwdriver (6mm).
11. This inverter/charger should be used with a battery supply of 12-volts DC nominal voltage.
12. Do not install this inverter/charger on or near flammable materials (plywood, chemicals, gasoline, etc.)
13. The unit is designed for mounting on a flat surface only. Do not mount on a wall or hang inverted.
14. No AC or DC disconnects are provided as an integral part of this inverter. Both AC and DC disconnects must be provided as part of the system installation. See Installation section on Page 23 of this manual.
15. No overcurrent protection for the battery supply is provided as an integral part of this inverter. Overcurrent protection of the battery cables must be provided as part of the system installation. See Installation section of this manual.
16. No overcurrent protection for the AC output wiring is provided as an integral part of this inverter. Over-current protection of the AC output wiring must be provided as part of the system installation. See the Installation section of this manual.
17. GROUNDING INSTRUCTIONS - This inverter/charger should be connected to a grounded, permanent wiring system. For most installations, the negative battery conductor should not be bonded to the vehicle chassis ground. Connection of the large green chassis ground terminal on the side of the inverter will create the battery negative to vehicle chassis ground. All installations should comply with all national and local codes and ordinances.
18. AC Grounding Instructions – The inverter/charger includes neutral to ground switching for the AC electrical system. The AC system in mobile installations must have the neutral physically isolated from the ground throughout the load distribution powered by the inverter.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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IMPORTANT SAFETY INSTRUCTIONS
Personal Precautions
1. Someone should be within range of your voice to come to your aid when you work near batteries.
2. Have plenty of fresh water and soap nearby in the event that battery acid contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. Wash your hands when done.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately flood eyes with running cool water for at least 15 minutes and get medical attention immediately.
5. Baking soda neutralizes lead acid battery electrolyte. Vinegar neutralizes spilled NiCad and NiFe battery electrolyte. Keep a supply on hand in the area of the batteries.
6. NEVER smoke or allow a spark or flame in vicinity of a battery or generator.
7. Be extra cautious when working with metal tools on and around batteries. It could short­circuit the batteries or other electrical parts, producing a spark that could cause an explosion.
8. Remove personal metal items such as rings, bracelets, necklaces and watches when working with a battery. A battery can produce a short-circuit current high enough to weld a ring, or the like, to metal causing severe burns.
9. Never attempt to charge a frozen battery.
10. If a remote or automatic generator-start system is used, disable the automatic starting circuit, and/or disconnect the generator from its stating battery while servicing to prevent accidental starting during servicing.
11. If necessary to remove any batteries, always remove the grounded terminal from the battery first. Make sure all accessories are off, so as not to cause an arc.
12. Be sure area around battery is well ventilated.
13. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
14. Study all battery manufacturer's specific precautions (such as removing or not removing cell caps while charging) and recommended rates of charge.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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IMPORTANT SAFETY INSTRUCTIONS
15. Add ONLY distilled water in each cell until battery acid reaches level specified by battery manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully follow manufacturer's recharging instructions.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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FEATURES
Features
All Legend Series II inverters include extensive protection circuitry, Search Sense Mode, Impulse Phase Correction, true RMS voltage regulation, crystal-controlled timing, three-stage battery charging, and an internal AC transfer relay.
Protection Circuitry
The inverter is protected from high-battery voltage, low-battery voltage, over-heating, and over­current conditions. When the inverter senses one of these situations, it will protect itself by disconnecting from the loads, and will signal an error condition by a red flashing of the LED indicator.
The low-battery cutout, high-battery shut down, and over-temperature protection circuitry resets automatically. If an over-current condition continues for more than 20 seconds, the inverter will shutdown and must be reset with the power button. If the error condition is remedied before the 20­second period has elapsed, the inverter will automatically reset.
Automatic Low Battery Cut Out
The Legend inverter/charger protects your batteries from damage caused by over-discharging by automatically shutting itself off when battery voltage falls to a preset level. This feature is called the Low Battery Cut Out (Auto LBCO). Your Legend inverter/charger comes from the factory with the Auto LBCO enabled; LBCO voltage is set at 11.1 volts. You can adjust the cutoff voltage to 8.5 volts (Auto LBCO disabled) using the optional RC7 remote control. See The RC7 Remote Control section on Page 62 for more information about the configuring LBCO.
Automatic High Battery Cut Out
When battery voltage rises above 15.6 volts, the inverter shuts down to protect electronics that may be operating off of it (high battery voltage results in high AC peak voltage). The inverter automatically resumes operating when battery voltage drops below 15.6 volts. High battery voltage can occur only through using an unregulated charging source, such as an unregulated solar or other DC generator or alternator. To remedy this problem, disconnect any external charging sources.
High Temperature Cut Out
The inverter is protected from overheating due to excessive loading or charging. When the internal temperature of the inverter exceeds its design limits, the inverter will disconnect itself and shut down. After a sufficient cooling period, the inverter will automatically reset and resume operation. Some causes of high internal temperatures include excessive loading, high ambient temperatures, inadequate ventilation, and an inoperative cooling fan. To remedy, reduce loads or reduce ambient temperatures by relocating, insulating, and/or ventilating the inverter enclosure (See the Installation section on Page 23 for more information).
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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FEATURES
Over Current Cut Out
Series II inverter/chargers are protected from over-current conditions. When the load being run demands more current than the inverter can safely supply, the inverter will momentarily shutdown, turn off if it encounters an over-current condition for approximately 20 seconds (a prolonged short­circuit) or if the AC output is connected to another AC power source (shorepower or generator).
Battery Type Optimization
Series II inverter/chargers are designed to prevent damage to and extend the useful life of your batteries by regulating the charging voltage and duration. To do this, the inverter/charger must be configured for the type of batteries in the system. The Series II is pre-configured for optimum charging of gel cell type batteries at 14.1 volts in bulk charging mode, and 13.5 volts in float charging mode. For liquid lead-acid batteries, you can reset the Series II using the RC7 remote control to bulk charge at 14.5 volts and float charge at 13.4 volts. For a complete discussion of batteries and battery charging techniques, see the Batteries and the Three-Stage Battery Charger sections of this manual.
Charge Rate Regulation
Batteries can overheat if the charge rate is too high. The Series II inverter/charger protects your batteries by enabling you to limit the charge rate using the RC7 remote control. The charge rate is set at the factory to 100% of maximum, which may be up to 140 amps depending upon the model you have purchased (see Appendix D: Specifications to determine the maximum possible charge rate for your model). For smaller battery banks, this may be too high.
The highest charge rate recommended is determined by dividing the battery bank’s amp hour capacity by a factor of three or five (3 for gel cell - 5 for lead acid).
Battery Bank Capacity in Amp Hours Recommended Charge Rate in Amps
gel cell liquid lead-acid
125 40 25 250 80 50 500 140 100
Setting the charge rate at the highest recommended level is best when the objective is to charge the batteries as quickly as possible. A much lower setting can be used in installations where AC power is typically available for periods of several hours. There is more than sufficient time for a 400-amphour battery bank to be recharged in 24 hours at a 25-amp setting.
Example: 25 amps X 24 hours = 600 amp/hrs.
Caution: Excessively high charge rates can overheat a battery. If battery bank capacity is low, set the battery charge rate to the minimum setting.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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FEATURES
Shore Power Amps Monitoring
Series II models monitor the current drawn by the built-in charger and any AC loads. These current requirements may exceed the amperage rating of the shore power circuit breaker. To prevent unnecessary tripping of this circuit breaker, the inverter limits the current draw to a maximum between five and 30 amps, set by using the RC7 remote control. Shore power amps is pre-set at the factory to a maximum of 25 amps.
VAC Dropout
Series II model inverter/chargers monitor the voltage of the AC power passing through to the charger and AC loads. When AC voltage falls below a pre-set level, the inverter automatically transfers from AC power to DC power. This dropout voltage is factory pre-set to 40 volts. You can re-set this voltage from 40 to 100 volts using the RC7 remote control. Using a lower voltage results in less frequent transfers from AC to DC power, but may cause undesirable operation of some AC loads, including brown-outs and damage.
Search Mode Circuitry
The Legend Series II inverters feature circuitry that minimizes power drain by reducing the inverter’s output to small test pulses when there is no load connected to the inverter. These pulses are used to detect the presence of a load. When a load is detected the inverter’s output goes to full voltage. The sensitivity of the detection threshold is adjustable from about five watts to 40 watts using the RC7 remote control. This feature is defeated (turned Off) at the factory and can only be activated using the RC7 remote control.
Example: With the threshold set to detect a 40 watt load, a 50 watt load will bring the unit to full output voltage. However, a 30-watt load will leave the inverter in its energy saving search mode state. If the sensitivity is increased by setting the control to 10, a 20 watt load will bring the inverter out of the search mode, while a five-watt load will not.
When in the search mode, the green Power LED will blink. At full output voltage, the LED will remain lit. When the inverter is used as an un-interruptable power supply, the search mode function should be defeated. A neon type nightlight can also be used as a good indicator to determine if the inverter is in search mode. Simply plug the light into any AC outlet that is connected to the inverter’s output. When the inverter is in the search mode the light will blink. If the inverter is running a load, the light will be on continuously.
Exceptions: (Murphy’s Law) Unfortunately, things don’t always work the way the manual says they will.
Example A: If the threshold is set to detect a 40-watt load and a 30-watt incandescent light is turned on, the inverter will detect the light. The light is a bigger load than 40 watts when its filaments are cold. When the light gets hot it becomes a 30-watt load. Since this is below threshold of 40-watts, the inverter will not detect it and the light will go out. This will cause the light to cycle repeatedly.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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FEATURES
Example B: If the threshold is set to detect a 30-watt load and a 40-watt fluorescent light is turned on, the inverter will not detect the light. The light presents a smaller load than 30 watts until the gas in the fluorescent tube ionizes.
Example C: There are some appliances that draw power even though they are turned off. TVs with instant on circuitry microwave ovens with digital displays and VCRs are examples. These loads present a dilemma. If the sensitivity is set higher than the combination of these loads, then an auxiliary load must be used to bring the inverter out of the search mode before the appliances can be turned on. If the sensitivity is set lower than this combination of loads, the loads will be left on and will put an additional drain on the batteries. Three such 15-watt loads would amount to an additional 90 amp/hours per 24 hours in a 12 VDC system.
One solution is to turn these items off at the wall. Use an extension cord with a rocker switch, a switch at the outlet, or the appropriate circuit breaker. Another solution might be to place all these phantom loads on a separate circuit with its own disconnect.
This circuit determines how much power the inverter draws when there are no loads. The inverter’s transition from the no load state to full output voltage is fast, eliminating delays when operating devices such as hand tools. Additionally, the threshold sensitivity of the search mode is user adjustable (with the optional RC7 remote control), and it may be disabled.
Impulse Phase Correction
This circuitry improves the shape of the output waveform while the inverter is running reactive loads. It allows the inverter to closely duplicate the characteristics of standard public power. With this design approach, the limitations of the modified sine wave format are largely overcome. The primary benefit is realized when the inverter is running induction motors and fluorescent lights. Induction motors are commonly used to run drill presses, fans, and bandsaws.
When an inductive load is driven, it tries to return a large portion of the energy that it has received. This returned energy can be thought of as going ‘backwards’ through the household wiring to the motor, giving the motor an extra push and making it run smoothly. Impulse phase correction provides a similar path for this ‘backwards’ energy. The Legend line of inverter/chargers will run small motors at full speed, start larger ones, and run both efficiently.
True RMS Voltage Regulation
With battery voltages from 11 to 15 VDC and power levels up to the continuous power rating, the inverter will deliver true RMS regulated power. This insures that while battery voltages and power levels change, the inverter will deliver the correct output voltage.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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FEATURES
Crystal Controlled Time Base
Proper frequency regulation is assured with the use of a crystal. Battery voltage and power have no effect on the inverter’s operating frequency.
Stand-by Battery Charger
The Stand-by feature includes an internal battery charger and automatic transfer relay. This allows the unit to operate as a battery charger or an inverter (but not at the same time). An external source of AC power (i.e. shore power or generator) must be supplied to the inverter’s AC input to allow it to operate as a battery charger. When the unit is operating as a charger its AC output is powered by the external AC source. See the Three-Stage Battery Charger section beginning on Page 52 for an in-depth description of this charger.
Transfer Switching Speed
While this inverter is not designed specifically to operate as an un-interruptable power supply (UPS) system, its transfer time is normally fast enough to hold up computers in the event of a power outage. The transfer time is a maximum of 32 milliseconds (two 60Hz AC cycles). Success as UPS will vary with computer models, and cannot be guaranteed. If this is an issue, buy a small, dedicated UPS for the specific application.
Automatic Inverter to Charger Transition
The inverter automatically becomes a battery charger whenever AC power is supplied to its AC inputs. There is a minimum 20-second time delay from the time the inverter senses that AC is present at its input to when the transfer is made. This delay is built in to provide time for a generator to spin-up to a stable voltage and avoid relay chattering. The inverter’s AC input is internally connected to the inverter’s AC output while in the battery charger mode. The maximum power that can be handled by the inverter’s internal wiring and transfer relay is 30 amps.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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UNIT IDENTIFICATION
Unit Identification
This section describes the marking and location of the model and serial number for Legend Series II inverter/chargers. Use this section to determine the type and model of your inverter/charger.
Model Identification
Trace Engineering inverters are specifically designed to meet the growing demand for high-reliability, high-quality inverters and chargers for alternative energy systems and vehicle applications. This manual covers the Legend Series II inverters with various options and configurations. To determine the model and features of your inverter, check the model number found on the identification placard on the right side of the inverter.
Consider the following unit with a L2012 model number:
L 20 12
Model Power Input Voltage
Model: The first letter indicates the model, in this case the Legend Series . Legend Series II inverters are designed for after-market installations in recreational and other mobile vehicles. They are housed in a white enclosure and employ neutral-to-ground switching.
Power: The first and second positions in the model number indicate the continuous AC power output in hundreds of watts. Power levels available include 2000, 2500, and 3000 watts. In the example above, 20 would stand for a 2000-watt (two kilowatt), continuous-output inverter.
Input Voltage: The number (12) following the power rating indicates an inverter/charger that is designed to convert 12VDC input to 120VAC output, and charge 12VDC batteries when powered by 120VAC.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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UNIT IDENTIFICATION
Model Number
Operating Range
Serial Number
The unit identification placard on the right side panel of the inverter/charger will show the serial number, model number, listings, ratings, and date of manufacture.
Inverter Continuous Duty
Rating in Watts
Pass-Thru
Current Capacity
AC Input/Output Phase,
Waveform, Frequency and
DC Input Voltage
Testing Laboratory
Certification Number and Standards Identification
U
U
Model Prefix
Charger Continuous Duty
Current Rating at DC
Bulk/Float Charging Rates
L
Date of Manufacture
L
Serial Number and
Product Code: AV=3012,
AW=2012, AX=2512
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CONTROLS & INDICATORS
N
CAUTION
Controls & Indicators
The Legend Series II inverter/chargers feature a two-position On/Off rocker switch, tri-color status indicator, battery temperature sensor (BTS) port, remote control port, and a charger circuit breaker on the front panel.
4 3
7
6
5
2
1
12
11
8
10
9
1. On/Off Switch: Turns the inverter on or off.
ON: the inverter transforms 12-volt direct current from the batteries into 120-volt, 60 Hz alternating current whenever AC current is not present at the AC Input Hot 1 terminal.
When 120-volt AC is present at the AC Input Hot 1 terminal, the inverter will pass the current through to any AC loads connected to the inverter, and the standby battery charger will charge the batteries.
OFF: the inverter will not create AC power from the batteries, but will pass through AC current when it is present at the AC Input Hot 1 terminal. The standby battery charger will charge the batteries regardless of the position of the On/Off switch.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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CONTROLS & INDICATORS
NOTE:
The three-stage standby battery charger is always “On”. Whenever AC power is present at the AC Input Hot 1 terminal, the charger will charge the batteries connected to the battery positive and battery negative terminals. The On/Off switch has no effect upon the charger.
2. LED Indicator
All Legend Series II inverter/chargers feature a tri-color LED on the front panel that will light green, orange, or red to indicate the operating mode, battery or charger status, or an error condition.
Green:
Solid: inverter is providing AC power from the batteries Slow Flashing: (once each second) inverter is in search mode Fast Flashing: (four times each second) charger is charging in Float mode at 13.5 volts,
the factory setting for gel cell batteries. Float mode for liquid lead-acid batteries is 13.4 volts, configured using the RC7 remote control. See the Three-Stage Battery Charger section on Page 52 for a complete description of three-stage battery charging, and on Page 62, The RC7 Remote Control section.
Orange
Solid: charger is in Bulk mode, the initial charging mode. Bulk mode for gel cell batteries is
set at the factory at 14.1 volts. Bulk mode voltage for liquid lead-acid batteries is set at 14.5 volts. Use the RC7 remote control to configure the inverter for liquid lead-acid batteries.
Flashing: charger is in Absorption charge. In Absorption stage, the charger maintains the Bulk voltage at up to the maximum charge rate for 90 minutes.
Red
Solid: an over-current event has occurred. An over-current condition is caused by too
many loads on the unit (excessive current demand). When this occurs, the inverter/charger instantaneously detaches from the loads. If, after a ten-second delay, the current demand on the unit is not excessive, the unit will automatically resume inverting. If the current demand remains excessive, the unit will shut itself off and must be manually restarted by turning the unit Off, then On again.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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CONTROLS & INDICATORS
Flashing: (followed by a five-second pause) an error condition has occurred
Once = battery voltage is below Low Battery Cut-Out factory setting of 11.1 volts
(see Protection Circuitry section on Page 7 for a description of LBCO). The inverter will automatically restart when battery voltage rises to 12.5 volts.
Twice = battery voltage is over 15.6 volts and inverter has shut down (see Page 7). The inverter will automatically resume operating when battery voltage has dropped below 15.6 volts.
Three = inverter is overheating and has shut off to protect itself. Reduce loads or provide adequate ventilation. The inverter will automatically restart when cool.
Four = a charger fault has occurred. Return unit to an authorized Trace Service Center for servicing.
Five or more: Not used with the Legend Series inverter/chargers.
3. BTS Port: An optional battery temperature sensor (BTS) can be plugged in at the RJ-11 four-
conductor connector. The BTS provides information that enables the three-stage standby battery charger to “fine tune” the battery charge rates for better charging performance, greater efficiency and longer life.
4. Stacking Port (not used). The Series II model is not a stackable unit.
5. Remote Control Port: The Legend Series II can be controlled up to 50 feet from the unit by
plugging in a remote control (RC6 or RC7). See the Options section for a complete description of the RC6 and RC7 remote controls.
• The RC6 reports DC voltage, charging or inverter current, and turns the inverter on and off..
• The RC7 is a full function, programmable remote control with backlit LCD, battery capacity
and other meters.
6. Battery Positive Terminal
7. Vehicle Chassis Ground Terminal
8. Battery Negative Terminal
9. AC Safety Ground
10. External Chassis (equipment) Ground
11. AC Terminal Block
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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CONTROLS & INDICATORS
12. Charger Circuit Breaker: 25 amps in the L2012 and L2512, 30 amps in the L3012. Press breaker to reset.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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QUICK INSTALL
Quick Install
Experienced installers, licensed electrical contractors, and knowledgeable laymen may follow the installation overview in this section. All others are urged to read the entire Installation section before installing the inverter/charger.
1. Unpacking – Before beginning, unpack the inverter/charger, record the serial number on the inside cover of this booklet and on the warranty card. Retain packing materials for future use. Ensure that all components listed on the Packaging Materials sheet are included. If any components are missing, please call Customer Service at (360) 435-8826.
2. Mounting – Mount the unit securely in a horizontal position in a clean, dry, ventilated enclosure. Do not mount the unit in the same enclosure as vented or maintenance-free type vented batteries. Bolt the unit down securely. Allow adequate clearance to allow access to the front panel.
3. DC Cabling
• Ensure that the On/Off switch on the front panel of the inverter is in the Off position before you begin the installation.
• Connect a cable from the positive terminal of the battery or battery bank to the battery positive (red) terminal of the inverter. See Minimum Recommended Battery Cable Size (In free air) in Appendix C to determine the proper size cable to use for the inverter model and length of run needed for your specific application. The National Electric Code (NEC) requires the use of a DC fuse or disconnects in this cable within 18-inches of the batteries. See Appendix C to determine the correct size fuse or breaker to use.
• Connect an appropriate sized cable from the battery’s negative terminal to the negative (black) terminal on the inverter. Torque all terminals to 12 foot-pounds.
• Connect a cable from the Vehicle Chassis Ground (green terminal) on the inverter to chassis ground (usually the frame of the vehicle).
4. DC Loads
• Connect a cable from the positive battery terminal to the positive buss of your DC load center.
• Ground all of your DC loads to your vehicle’s chassis, or connect a cable from the ground bus of
the DC load center to the vehicle chassis.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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QUICK INSTALL
N
CAUTION
5. AC In Cabling
• See Recommended Minimum AC Wire Sizes in Appendix C to determine the appropriate AC wire size.
! Caution:
This inverter/charger includes neutral to ground switching for the AC electrical system. The AC system in mobile installations must have the neutral physically isolated from the ground throughout the load distribution powered by the inverter.
• Disconnect any and all sources of AC power from the vehicle.
• Remove the knockout from the front or either side of the inverter chassis and install a strain relief
or conduit in which to route the AC cabling in and out.
• Connect the black wire from an appropriately sized three-conductor AC cable from the hot side of the AC power supply (shore power connector) to the terminal labeled “AC Input Hot 1” on the inverter.
• Connect the white wire from the neutral side of the AC power source to the terminal labeled “AC Input Neutral” on the inverter.
• Connect the green wire from the ground of the AC power source to one of the two green wires (AC Safety Ground) bolted to the chassis of the inverter/charger.
Trace Engineering Co. Inc. Tel (360) 435-8826 Part Number 3179 5916 195th Street, NE Fax (360) 435-2229 Effective August 6, 1998 Arlington, WA 98223 USA www.traceengineering.com Page
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