Xantrex IP1012 Installation Guide
Xantrex
™
Heavy Duty Inverter•Charger 1012
with Ignition Protection
Installation Guide
About Xantrex
Xantrex Technology develops, manufactures, and markets leading advanced power electronic and control products
for the Distributed, Mobile, and Programmable Power markets. The company’s enabling technology converts raw
electrical power from any central, distributed, or backup power source into high-quality power required by electronic
and electrical equipment.
Trademarks
Xantrex is a registered trademark of Xantrex International. © 2002 Xantrex International. All rights reserved.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used
herein for identification purposes only.
Notice of Copyright
Xantrex™ Heavy Duty Inverter•Charger 1012 with Ignition Protection Installation Guide © May 2002 Xantrex
International.
Disclaimer
Xantrex manufactures its products from parts and components that are new or equivalent to new, in accordance with
industry-standard practices.
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”):
(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 ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
May 2002, Revision 1
Part number
445-0173-01-01 Rev 1
Contact information
Telephone: 1-800-670-0707 (toll free in North America)
1-604-420-1585 (outside North America)
Fax: 1-800-994-7828 (toll free in North America)
1-604-420-1591 (outside North America)
Email: CustomerService@xantrex.com
Web: www.xantrex.com
Contents
Important Safety Instructions
Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viii
FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ix
1 Installation Planning
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
AC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Shorepower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Disconnect and Over-Current Protection Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Distribution panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4
AC wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
AC Output Neutral Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
DC Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
DC Cabling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
DC Disconnects and Over-Current Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Locating the Inverter•Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
2 Installing the IP1012
About the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Installing the IP1012 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Mounting the Inverter•Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Connecting the AC Input Flexible Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Wiring considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5
AC Input Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5
Connecting the AC Output Flexible Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Connecting the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Mounting Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Mounting to the Negative Battery Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Mounting to the Side of the Battery Case - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Mounting the Remote Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Contents
Starting the Inverter•Charger- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
Testing the Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
3 Battery Types and Sizes
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1
Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1
Deep-Cycle Lead-Acid Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Estimating Battery Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Battery Sizing Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Battery Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Using Multiple Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Two Batteries Connected In Parallel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Two Separate Battery Banks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Battery Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Index–1
iv
Figures
Figure 1-1 Typical IP1012 installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2
Figure 2-1 Mounting holes on base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Figure 2-2 Mounting the IP1012- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Figure 2-3 Bracket mounting option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5
Figure 2-4 AC input terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Figure 2-5 Making the AC input connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Figure 2-6 Connection order for DC cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Figure 2-7 Connection at DC terminal of the IP1012 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Figure 2-8 Connection at the battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Figure 2-9 DC Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Figure 2-10 BTS on Negative Battery Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Figure 2-11 BTS Attached to Battery Case- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Figure 2-12 Connecting the battery temperature sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Figure 2-13 Remote switch dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15
Figure 2-14 Final mounting of the remote switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
Figure 3-1 Configuration for Normal Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Figure 3-2 Configuration for Heavy Loads- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
445-0173-01-01 Rev 1 v
vi 45-0173-01-01 Rev 1
Important Safety Instructions
WARNING
This section contains important safety and operating
instructions as prescribed by UL and CSA standards for
inverter•chargers used in residential, RV, and other
applications. Read and keep this Installation Guide for future
reference.
1. Before using the inverter•charger, read all instructions and cautionary
markings on the charger, the batteries, and all appropriate sections of this
guide.
2. While this unit is sealed, Xantrex does not recommend that it be
continuously exposed to rain, snow, spray, or bilge water. Do not install the
charger in a zero-clearance or small-clearance compartment. It may reduce
the usable power range.
3. Use only attachments recommended or sold by the manufacturer. Doing
otherwise may result in a risk of fire, electric shock, or injury to persons.
4. The inverter•charger is designed to be permanently connected to your AC
and DC electrical systems. Xantrex recommends that all wiring be done by
a certified technician or electrician to ensure adherence to the local and
national electrical codes applicable in your application.
5. To avoid a risk of fire and electric shock, make sure that existing wiring is
in good condition and that wire is not undersized. Do not operate the
inverter•charger with damaged or substandard wiring.
6. Do not operate the inverter•charger if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the unit is damaged, see the
Warranty section in Appendix B, “Product and System Information” in the
Operation Guide.
vii
Important Safety Instructions
7. Do not disassemble the inverter•charger. See Appendix D, “Product
and System Information” in the Operation Guide for instructions on
obtaining service. Attempting to service the unit yourself may result
in a risk of electrical shock or fire. Internal capacitors remain charged
after all power is disconnected.
8. To reduce the risk of electrical shock, disconnect both AC and DC
power from the inverter•charger before attempting any maintenance
or cleaning or working on any circuits connected to the unit. Turning
off controls will not reduce this risk.
9. The inverter•charger must be provided with an equipment-grounding
conductor connected to the AC input ground.
Explosive Gas Precautions
1. Working in the vicinity of lead-acid batteries is dangerous. Batteries
generate explosive gases during normal operation. Therefore you
must read this guide and follow the instructions exactly before
installing or using your inverter•charger.
2. The IP1012 has been approved as Ignition Protected. It may be
installed in areas containing gasoline tanks and fittings which require
Ignition Protected equipment. Xantrex recommends, nevertheless,
that it is safest not to install electrical equipment in these areas.
3. 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
1. Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
4. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.
viii 445-0173-01-01 Rev 1
FCC Information to the User
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 when the equipment is operated in a residential environment.
This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction guide,
may cause harmful interference to radio communications. However, there
is no guarantee that 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 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 the 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.
Important Safety Instructions
445-0173-01-01 Rev 1 ix
x 445-0173-01-01 Rev 1
1
Installation Planning
Chapter 1 provides information to help you plan for a
suitable installation for the IP1012. The chapter provides a
system diagram showing the components of an installation,
and provides information about each component. It also
discusses other installation considerations such as neutral to
ground bonding and the physical location of the unit.
Installation Planning
Introduction
All types of inverter•charger installations, residential or mobile, share
common components. This chapter describes each component.
The system shown in Figure 1-1 is a basic installation. If your
requirements are more complex than this, Xantrex recommends that you
consult a qualified installer or electrician.
DC Input/Output
AC Input
AC Output
JUNCTION
BOX
Main AC Panel
Shorepower
JUNCTION
BOX
Chassis ground
AC Subpanel with
GFCI
AC Loads
Generator
DC fuse or
circuit breaker
Vehicle start
battery
12 Volt
deep cycle battery
Battery
isolator
Chassis ground
Figure 1-1 Typical IP1012 installation
1–2 445-0173-01-01 Rev 1
AC Components
Shorepower
A source of 120 volt, 60 Hz alternating current
JUNCTION
JUNCTION
BOX
BOX
Note: Throughout this manual, the term “shorepower” refers to AC input
power from a utility grid, high-quality generator, or other source.
Disconnect and Over-Current Protection Device
To meet UL 458, and electrical code requirements, the inverter•charger
AC inputs and outputs must be provided with over-current protection
(such as a circuit breaker or fuse) and a disconnect device on both the AC
input and output:
is needed to provide energy for charging
batteries and to pass through to AC loads. This
source could be the utility grid (power
company) or an AC generator. Multiple sources
of good-quality shorepower can be used
Introduction
AC Input The circuit breaker or fuse used to
JUNCTION
JUNCTION
BOX
BOX
protect the
IP1012 Inverter•Charger must be
rated no more than 15 amps and must be
approved for use on 120 VAC branch circuits.
This circuit breaker or fuse is often in the
shorepower source. If the shorepower rating is
more than 15 amps, you need to add an
additional 15 amp breaker or fuse at the
junction box or electrical panel to which the IP1012 AC input is wired.
The wire used between the breaker and the inverter•charger input must be
sized to match the circuit breaker, in accordance with the electrical codes
or regulations applicable to your installation.
AC Output The circuit breaker or fuse
must be rated at no more than 15 amps and must
JUNCTION
JUNCTION
BOX
BOX
be approved for use on 120 VAC branch
circuits. The wire used between the
inverter•charger and the AC output breaker
must be sized to match the AC output circuit
breaker’s rating (#14 AWG or larger). The wire
from the AC output breaker to your loads must
be matched to the rating of the AC output
breakers.
445-0173-01-01 Rev 1 1–3
Installation Planning
GFCI requirements Installations in recreational vehicles may require
GFCI protection of branch circuits connected to the AC output of the
inverter•charger. In addition, electrical codes require GFCI protection of
certain receptacles in residential installations.
Tes te d G F CI s Compliance with UL standards requires that Xantrex
test and recommend specific GFCIs. Xantrex has tested the GFCIprotected 15 amp receptacles listed in Table 1-1 and found that they
function properly when connected to the AC output of the
Table 1-1 Tested GFCI Models
Manufacturer Model number
Pass &Seymour / Legrand 1591-WCN
Leviton 6598W
Bryant GFR82FTI
Hubbell GF5252GYA
Yatai Switch YT15-G
IP1012.
Disconnect Devices: Each system requires a method of disconnecting
the AC circuits. If the over-current protection device is a circuit breaker, it
will also serve as the disconnect. If fuses are used, separate AC
disconnect switches are needed ahead of the fuses.
Distribution panels
Most systems incorporate distribution centers
both ahead of the inverter•charger and between
JUNCTION
JUNCTION
BOX
BOX
the inverter•charger and the loads (the AC load
panel). A source panel includes a main circuit
breaker, which serves as over-current protection
and as a disconnect for the AC shorepower
supply line. Additional circuit breakers serve
individual circuits, one of which serves the
inverter•charger. The AC load panel can
incorporate both the main 15 amp breaker or
fuse with disconnect if the AC output cable is directly wired into the
panel.
Note: The IP1012 is designed to be connected only to single phase
wiring circuits (line, neutral, and ground)
1–4 445-0173-01-01 Rev 1
Introduction
AC wiring
Definition AC wiring includes all the wires and connectors
between the AC source and the inverter•charger
JUNCTION
JUNCTION
BOX
BOX
and all wiring between the inverter•charger and
the AC panels, circuit breakers, and loads.
Size and type The type and size of the wiring varies with the installation and load. For
marine and some RV applications, flexible multiple-strand wire is
required. For residential installations, solid armored cable is often used.
Local installation codes may specify solid or stranded, overall size of the
conductors, and type and temperature rating of the insulation around the
wire. Xantrex recommends stranded wire for high-vibration
environments.
Size and AC
breaker rating
AC wiring must be sized to match the current rating of the AC breakers
you provide on the input and output AC circuits in accordance with the
electrical codes or regulations applicable to your installation. Xantrex
recommends a breaker size of 15 amps, and minimum wire size of
14 AWG.
Other codes and regulations may be applicable to your installation.
AC Output Neutral Bonding
Bonding system The IP1012 provides an non-defeatable system that automatically
connects the neutral conductor of the inverter AC output circuit to safety
ground (“bonding” it) during inverter operation, and disconnects it (“unbonding” it) when the inverter•charger is connected to AC shorepower.
This system is designed to conform to installation codes that require
single-phase AC sources such as inverters and generators to have their
neutral conductors tied to ground in the same way that the neutral
conductor from the utility is tied to ground.
Transfer relay These same codes specify that the neutral can only be connected to
ground in one place at any one time. Any AC source feeding the IP1012 is
required to have its neutral already connected to ground. Therefore, to
keep from connecting the neutral to ground in a second place, the transfer
relay breaks its own neutral ground connection when connected to
shorepower.
445-0173-01-01 Rev 1 1–5
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