Transportation

Products

Cooper Bussmann Inverter

1000W / 1800W
INSTALLATION GUIDE
About Cooper Bussmann

In a worldwide transportation marketplace Cooper Bussmann is your leading source for safe and
reliable electrical power and machine control solutions

We’re experts on the effects of cold and heat, vibration, high moisture, harsh chemicals and
transient power fluctuations. We know vehicle power and control systems from the smallest to
largest platforms, and will partner with you to develop reliable products and systems.

With combined industry history and experience reaching back more than 90 years, the
engineering strength and proven track record of the Cooper Bussmann®, Sure Power and Martek
Power brands provide you the ability to accelerate product development in “smart” systems and
create innovative, industry-leading solutions. These solutions range from straightforward
products from our catalog to next generation systems that will create efficiencies not yet realized.

The Cooper Bussmann mission is to respond completely and uniquely to OEM requirements for
vehicle electronic products and control solutions, providing cost reduction and customization

We are committed to continuous new product development and offer you a competitive
advantage through R&D expertise and a technology portfolio that minimizes excessive tooling
and time required to produce OEM-specific solutions.

Cooper Bussmann, a division of Cooper Industries, has a global manufacturing footprint. Our
facilities are ISO 9000-2001 and TS16949 certified to meet the highest quality and environmental
standards.

Warranty Terms

Seller provides products as-is and makes no representations or warranties,

Express or implied, statutory or otherwise, regarding the products, their fitness for any particular purpose,
their merchantibility, their quality, their noninfringement, or otherwise.

Contact Information

Phone: 800.845.6269
Fax: 503.692.9091
www.cooperbussmann.com

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Important Safety Instructions

 WARNING: Limitations on Use – The Cooper Bussmann Inverter is not to be connected

to life support devices.

 CAUTION: Risk of injury – To avoid risk of injury, use only 12Vdc, lead-acid, rechargeable
batteries (i.e. GEL, AGM, and Flooded). Other types of batteries may burst, resulting in personal
injury and/or damage.
 Do not expose inverter to rain, snow, spray, or water.
 Do not cover/obstruct ventilation systems.
 Use wire in good condition and at appropriate ratings.
 Attachments not recommended by Cooper Bussmann may be damaging to inverter.
 Do not use inverter after being dropped, hit, or damaged.
 Do not disassemble the inverter. Risk of shock, fire, and void of warranty may occur.
 Remove all AC or DC connection before maintenance, cleaning, or circuit work.
 Provide inverter an equipment-grounding conductor connected to AC input ground.
 Insure cables are routed properly, secured and protected from chaffing.

 WARNING: Explosion hazard – Working with batteries can be very dangerous. It is

crucial to follow all steps completely while servicing the unit. It is possible for the inverter to
produce arcs and/or sparks, do not install or use inverter near flammable materials (i.e. gas-
powered machines, fuel tanks, or any components connected to a fuel supply). Follow any
instructions from the battery manufacturer being used.

Personal Precautions When Working with Batteries

 WARNING: risk of electrical shock, burn from high short-circuit current, fire
or explosion from vented gases.
 Follow the instructions and precautions from the battery manufacturer (i.e. cap removal,
or charging rates)
 Follow battery instructions for water and battery acid levels from the battery
manufacturer.
 Ventilate the area near the batteries as much as possible.
 Do not smoke or produce flame/spark near engine or batteries.
 Use caution when handling tools around batteries.

 Remove all metal items (i.e. rings, bracelets, watches) from person when working with
batteries.
 Work within voice range of other people.
 Wear eye and clothing protection while working, and avoid touching eyes during
installation.
 Upon battery acid contacting skin or clothing, wash immediately with soap and water.
Upon contacting eye(s), flood immediately with running cold water for at least twenty
minutes and seek medical attention.

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  DC CONNECTION PRECAUTION(s) – Only make DC output connections or
disconnections after setting all unit switches to OFF position and opening AC disconnect(s).

It is recommended to review TMC RP 160 and RP 163 which include wiring and selection
recommendations.

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CONTENTS

Installation pg 6

Configuration pg 24

Specifications pg 28

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1. INSTALLATION

Chapter 1 offers information as a guide to installing a Cooper Bussmann Inverter/Battery

Charger. It will cover the following:

 Materials list

 Safety instructions

 Sample installation tools and materials

 Installation procedures for mounting and connecting the product

ground, AC cabling, DC cabling, and grounding techniques

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Materials List

The Cooper Bussmann Inverter package includes the items listed

below:

 1 Cooper Bussmann Inverter unit

 Owner’s / Installation Guide
 25 foot RJ11 cable for remote mounting of control panel
 2 ea M8x1.25 Nuts with Lock Washer and Flat Washer for Battery
Positive and Battery Negative
 1ea M6x1.00 Nuts with Lock Washer and Flat Washer for Chassis
Ground Connection
 One Red and one Black Insulating Boot for covering up to 00 awg
Battery Positive and Battery Negative Connections
 2ea cable clamps for retention of hardwired AC Input and AC Output
 2ea ground lugs for chassis ground connection of hardwired AC input
and AC output

Figure 1-1 What’s in The Box

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Safety Instructions

 WARNING: Shock hazard – All wiring of connectors or otherwise should be

done by a technician, electrician, or person with electrical experience.
 At the beginning of this guide there is a section of warnings and cautions,
take note of any precautions concerning the installation.
 Prior to engaging in any service, all AC and DC power sources need to be
disconnected and all AC and DC devices and generators need to be
disabled.
 Follow proper cable routing and strain relief guidelines

Installation Codes

Installation codes vary depending on specific industry, location and application of

inverter.

It is the installer’s responsibility to ensure that all applicable installation

requirements are met.

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Installation Tools and Materials

To install the Cooper Bussmann Inverter, the following tools/materials are

recommended:

 Wire strippers
 Mounting screws or bolts
 #2 Phillips screwdriver
 Wrench or socket for DC terminals (1/2 inch or 13mm)
 AC cable (i.e. 3-prong, standard wall cable), sized appropriately for load/application
 Wire nuts or crimp connectors for AC wire and appropriate tools
 DC cable, sized appropriately for load/application
 Lugs for DC cables to mount on size M8 x 1.25 studs. DC stud terminals and
appropriate tools(i.e. crimping tool)
 Lug for Chassis Ground cable to mount on size M6 x 1.00 stud. DC stud terminal and
appropriate tools(i.e. crimping tool)
 AC and DC disconnects and over-current protective devices

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STEP 1: Determine an installation type

Installation of the inverter will involve many common components, some

which are shown below. Figure 1-2 shows some of those components and their
relevance with each other in a standard heavy truck or recreational vehicle
installation.

Figure 1-2 Typical Recreational Vehicle and Fleet Vehicle Installation

AC Shore Power – [“shore power” refers to AC input power from a utility grid, generator, or
other AC source.] To charge batteries and pass power on to an AC load, a source of nominal

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 120Vac, 60Hz is needed. This source is predominantly the utility grid (wall power, power
company) or an AC generator. In the case of multiple sources, an automatic or manual AC
source selector switch can be used.

The AC source going into the inverter must have a neutral conductor bonded to ground (i.e. 3-prong
wall cable). When the inverter is passing AC power through, it relies on the input being grounded to
ensure the power delivered to a sub-panel is bonded. See “AC Output Neutral Bonding” on page 12
for further information on bonding relay operation.
*Please note that the grid power source utilized must be branch breaker or branch fuse protected at 30
Amp maximum.

Generator – The inverter is capable of handling most generators that produce nominal
120Vac, 60Hz sine wave AC power. The current limit for DC charging is programmable to as little
as 2A, therefore a very small generator would be sufficient.

AC Disconnect and Over-Current Protection Device –

The inverter is required by safety and electrical codes to have AC and DC input/output over-
current protection (i.e. circuit breakers and/or fuses), as well as disconnect devices. The
following are suggested protective measures for each configuration:

AC Input: The branch fuse or branch circuit breaker (hard wired) used on the source
of the inverter must be rated to a max 30A and must also be approved for use on 120Vac
systems. The wire used between the breaker and the inverter needs to be sized
accordingly to pass the same amount of current rated for the fuse.

AC Output: The fuse or circuit breaker on the output should not be rated any higher
than that of the input. The wire between the inverter and the AC output breaker should
be rated to carry the amount of current rated for the fuse. Any subsequent wiring from
this output breaker to the loads must be sized accordingly for the current being passed to
each individual load. All models feature an integrated 20 Amp AC output breaker.

Disconnect Devices: Each fuse or breaker system requires a method for disconnecting. If
the devices used are circuit breakers, these will serve as the disconnects. If they are fuses,
separate AC disconnect switches will be necessary ahead of the fuses; these switches will be a
branch circuit with proper current characteristics and rated to 120Vac.

AC Distribution Panels – A usual system will incorporate distribution centers ahead of the
inverter and between the inverter and the loads (AC load panel). AC source panels will include a
main circuit breaker, serving as the over-current protection and the disconnect switch for the AC
power supply. AC load panels can utilize an AC output circuit breaker, and breakers for each
subsequent load circuit.

CAUTION: Equipment damage – Do not connect the output of the inverter to what is
known as a “multi-wire branch circuit.”

AC Cabling – AC cabling includes but is not limited to all wires/cables between the AC source
and the inverter, and all the cabling between the inverter and AC outputs (panels, circuit
breakers, and loads). Wiring type and size varies with installation and load. Installation codes

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 will recommend solid or stranded wires, overall size of conductors, and type/temperature ratings
of insulation around the wire.

Ensure AC breakers and fuses are sized appropriately for current, insulation for voltage, and
ambient temperature ratings. Table 1-1 gives examples of wiring sizes based on the breaker
rating. Examples are based on use with a 2-conductor-plus-ground (3-prong) cable rated at
75°C.

AC Output Neutral Bonding – AC input neutral and output neutral must be isolated from
each other. This being noted, the neutral conductor of the inverter AC output circuit (i.e. AC
output neutral) is automatically connected to the safety ground during inverter operation. When
using an AC utility power source and the inverter is in charging mode, this connection is not
present.

DC Cabling – DC cabling includes but is not limited to all cables and connectors between the
batteries, the DC disconnect and breakers/fuses, and the inverter. Heavy truck or RV
installations normally require multi-strand, insulated cables for flexibility and durability; they also
usually require over-current protection devices. DC cables must be copper and must be rated to
at least 75°C. The cables should also terminate with lugs that fit the DC stud terminals on the
inverter (m8 x 1.25). Choosing small cables may result in variable device functionality.

DC Disconnects and Over-Current Devices – The DC system from the inverter to the
battery must be equipped with an over-current device and disconnect. Typically this consists of a
circuit breaker, a “fused-disconnect,” or a separate fuse with a DC disconnect. Do not confuse
AC circuit breakers with DC circuit breakers as they are not interchangeable. The rating size of
the cables must match rating of fuses or breaker selected. Breaker or fuse and disconnect
should be situated as close as possible to the battery, on the positive cable.

Batteries – The inverter sources input power from a 12VDC deep cycle battery or group of
batteries. The inverter converts the 12VDC input power to 120VAC output.

Ground Fault Circuit Interrupters (GFCIs) – In the case where the current to ground
exceeds specified value, but is less than the rating to blow the circuit breaker, a GFCI device will
de-energize the circuit. This protects from electric shock and is usually required for wet/damp
locations.

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STEP 2: Choose a Location for Inverter Mounting

WARNING: Fire and Explosion hazard – It is possible for the inverter to produce arcs and/or sparks, do
not install or use inverter near flammable materials (i.e. gas-powered machines, fuel tanks, or any
components connecting to a fuel supply). Follow any instructions from the battery manufacturer being
used.

WARNING: Fire hazard – Ensure the ventilation openings are not covered or obstructed to reduce risk of
fire. Installing the inverter in a compact compartment will be detrimental and may result in overheating.

Location(s) must conform to these required parameters:

 Dry: Do not allow water or other fluids to splash or drip on to the inverter.
 Cool: Ambient, air temperature should be between 0°C and 50°C (32°F and 122°F).
Power linearly derates from 100% at 25°C to 70% at 50°C.
 Ventilated: Provide a minimum of 5 inches (13cm) of clearance at the DC end of
inverter for air flow. Also give at least 1inches (2.5cm) on each side, and 2 inches (5cm)
at the AC end. Do not allow ventilation to be obstructed.
 Safe: Do not install the inverter in the same compartment as flammable liquids,
batteries, or any unsafe materials.
 Close-in: Avoid excessive cable lengths, especially between inverter and battery banks.
 Batteries: Never allow battery acid to come in contact with the inverter or the wiring to
and from the devices. It is also important to be aware of the corrosive gases that may be
coming into contact with the inverter.

STEP 3: Mount the Inverter

To mount:
1. Remove the inverter from packaging and check that all components are present.
2. Select the mounting location (see illustration Figure 1-3). One of the following approved
orientations is required:
 Under horizontal surface (1)
 Horizontal position on vertical surface (2)
 On horizontal surface (3)
3. Using the inverter as a template, mark and drill pilot-holes for the desired mounting
location.
4. Fasten the inverter to the mounting surface using pan-head wood or sheet metal screws
if mounting to a wall or bulkhead. Do not block vents on bottom of inverter.

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 Figure 1-3 Approved Mounting Orientation

Connecting the Equipment Ground:

WARNING: Fire hazard – Improper grounding may result in a fire hazard. It is crucial to never
operate the inverter without ensuring the equipment is properly connected to ground.

The inverter has a ground stud on the side near the DC end. Use this to connect the inverter’s
chassis to ground; usually the vehicle’s chassis or DC negative bus ground using a properly
insulated copper wire. There are no restrictions on length for the equipment ground cable.
General practice is to not have a ground cable within one (1) AWG of the supply cable.

STEP 4: Connect the AC input wires. (optional for AC Input)

WARNING: Fire, Shock, and Energy hazard – Ensure all other wiring is
disconnected from all sources before beginning these steps. Wiring to and from the inverter
should be done to proper wiring codes. DO NOT connect any AC input source to the output
terminals of the inverter.

Wire Routing guidelines

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 Suggested cable size for DC input connections is 00 gauge. See Table 1-1 for the fuse rating required at
the battery end of the positive DC input cable.

Build the cables before rough fitting them to the vehicle. Note any points that will require special attention
to avoid chafing or exposure to heat sources. Eliminate potential trouble areas by installing clamps,
protecting wiring harnesses with plastic wrap, and installing grommets in feed through holes.

To prevent chafing, cables, plumbing, and installed equipment should not come into hard contact with
each other. Because the bodywork and structure can flex during operation, at least a quarter inch
clearance is advised between cables and nearby equipment. Do not route cables in high heat areas
without adequate thermal protection. Avoid exposure to chemical damage by using protective conduit or
wrap.

Torque DC input cable fasteners to 12.2 -13.6 Nm

Torque Chassis Ground cable fastener to 6.6 – 7.3 Nm

DC Input  AC Input  AC Output 

Branch Circuit 
Protection 
Minimum  Minimum  Required ‐   Minimum 
Wire Size  Required Fuse  Wire Size  Recommended  Wire Size  Recommended 
Model  (AWG)  (Amp)  (AWG)  Fuse (Amp)  (AWG)  Fuse (Amp) 
12‐110‐1000  3  125  12  15  12  N/A (See Note) 
12‐110‐1800  1  200  12  20  12  N/A (See Note) 
12‐110‐1000‐B2  3  125  12  20  12  N/A (See Note) 
12‐110‐1000‐B4  3  125  12  20  12  N/A (See Note) 
12‐110‐1800‐B4  1  200  10  30  12  N/A (See Note) 

Note - AC output fuse is not required as all models feature a 20 Amp AC output breaker

Table 1-1

General AC wiring considerations

AC Wiring Connectors – AC wires are fixed to their respective barrier strip terminals by
clamp screws. The amount of insulation to be stripped off the individual wires should not be so
much that it is visible outside the connector.

AC and DC Wiring Separation – Do not mix DC and AC wiring configurations. Do not

use the same conduit or panel. If wires must cross, only do so at 90° to one another. If

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 necessary, examine applicable codes for specific AC and DC wiring proximities. Figure 1-4 is an
illustration of the AC wiring compartment.

Figure 1-4 AC Wiring Compartment

AC Wiring and GFCIs – AC input must be hardwired to the inverter. AC loads can either be
plugged into the GFCI mounted to the front panel of the inverter, or hardwired directly to the
panel. This section will explain how to hardwire the inverter with AC input and output. All AC
wiring (source to inverter, inverter to AC panels, AC panels to circuit breakers, and GFCIs) must
be rated to at least the current rating of the fuses and/or circuit breakers, and also must be
insulated to at least 120Vac. Multi-strand wire is recommended. Typically, 30A circuit breaker
requires a 10AWG wire.

The knockouts for AC input and output hardwiring are located on the front sidewalls. Make sure
to read the labels on the inverter for proper input and output wiring.

AC Input Connections
1. Ensure AC and DC power are OFF.
2. Install required circuit breaker to the AC input wiring system.
3. Remove mounting screws holding the GFCI AC receptacle and take off the front panel.
4. Leave the GFCI inside the inverter, but remove the knockout from the sidewall.
5. Locate the terminal blocks. The whole area will be labeled “AC INPUT” and there will be
three terminations:
 (GND)
 (L)
 (N)
6. Strip enough of the input cable jacket as to expose the three wires, about 2 inches
(50mm).
7. Strip approximately 3/8 inches (10mm) of insulation from each wire. The terminal blocks
will accept wire sizes up to 10AWG.
8. Feed the AC input cable into the knockout hole. Facing the front panel of the inverter this
should be on the left, and the label should read “AC INPUT.”
9. Using a screwdriver, loosen the terminal screws.
10. Fasten the ground (GND) wire first.

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 CAUTION: Reverse polarity – Connecting wires improperly (i.e. the neutral wire into the
line termination) will cause the inverter to break down and possibly cause permanent
damage.

11. It is very important to not confuse the connections (i.e. putting the line conductor into the
neutral termination). From the AC cable, typical wire-color schemes are as follows:

 BARE COPPER or GREEN or GREEN/YELLOW insulation is GROUND wire

 BLACK or BROWN insulation is the LINE wire
 WHITE or BLUE insulation is the NEUTRAL wire

Confirm proper wires are in correct termination and tighten screws. Leave some wiring
slack inside the compartment.

If there is no need to hardwire the AC OUTPUT, make sure the GFCI is in its proper
location and install the front panel back on to the inverter. If hardwiring the AC
OUTPUT is required, continue with the procedure below.

STEP 5: Connecting AC OUTPUT wires (optional for hardwire AC

output)

WARNING: Shock, fire, and energy hazard – Ensure all sources have been
disconnected from power before continuing. Wiring of the inverter should be in accordance with
wiring codes.

WARNING: Shock hazard and equipment damage - DO NOT connect any AC

input source to the output terminals of the inverter. Connecting an AC voltage source to the
output of the inverter will cause serious damage, and possibly hazardous conditions may occur,
even if the inverter is OFF.

The Cooper Bussmann Inverter will not operate if connected to high-power

consumption loads.
The inverter is not meant to operate loads that consume more than 1000 Watts or 1800 Watts
(depending on the inverter model being used).

The GFCI AC receptacle has been approved by Cooper Bussmann and cannot be removed from
the inverter. The AC receptacle must be utilized, unless the AC output is hardwired.

WARNING: Shock, fire, and energy hazards – Ensure all other wiring systems are
disconnected and/or disabled before continuing. Wiring of the inverter should be in accordance
with wiring codes. DO NOT connect any AC input source to the output terminals of the inverter.

To make a hardwire connection with the AC OUTPUT of the inverter follow

this procedure:

17
 1. Ensure AC and DC power are OFF
2. Install required circuit breaker to the AC load wiring system.
3. Remove the knockout from the sidewall. Do not run the AC input and output wirings
through the same knockout.
4. Locate the terminal blocks. The whole area will be labeled “AC OUTPUT” and there will
be three terminations:
 (GND)
 (L)
 (N)
5. Strip enough of the input cable jacket as to expose the three wires, about 2 inches
(50mm).
6. Strip approximately 3/8 inches (10mm) of insulation from each wire. The terminal blocks
will accept wire sizes up to 10AWG.
7. Feed the AC output cable into the knockout hole. Facing the front panel of the inverter
this should be on the right, and the label should read “AC OUTPUT.”
8. Using a screwdriver, loosen the terminal screws.
9. Fasten the ground (GND) wire first.

CAUTION: Reverse polarity - Connecting wires improperly (i.e. the neutral wire into the line
termination) will cause the inverter to break down and possibly cause permanent damage.

10. It is very important to not confuse the connections (i.e. putting the line conductor into the
neutral termination). From the AC cable, typical wire-color schemes are as follows:

 BARE COPPER or GREEN or GREEN/YELLOW insulation is GROUND wire

 BLACK or BROWN insulation is the LINE wire
 WHITE or BLUE insulation is the NEUTRAL wire

Confirm proper wires are in correct termination and tighten screws. Leave some wiring
slack inside the compartment.

11. Connect the AC wires coming from the AC OUTPUT to the AC load panel.

Make sure the GFCI is in its proper location and install the front panel
back on to the inverter.

AC wiring WITH an Inverter Subpanel – In this wiring configuration, the AC input to

the inverter comes from a main AC panel with its own input circuit breaker. The AC output is
then routed to a separate inverter subpanel with a dedicated circuit breaker attached.

IMPORTANT: It is important to note the generator must have its own neutral bonded to
ground. If the generator’s neutral is not bonded to ground, a bonding jumper must be
installed. The input AC panel and the inverter subpanel must not have a permanent neutral
to ground bond installed.

AC wiring WITHOUT an Inverter Subpanel – This wiring configuration has the AC

input to the inverter coming from an AC source directly. The AC must then be protected by a
branch AC breaker or fuse, see Table 1-1 for fuse recommendations. The AC output is
routed to the main AC panel which is protected by AC circuit breakers.

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 IMPORTANT: It is important to note the generator must have its own neutral bonded to
ground. If the generator’s neutral is not bonded to ground, a bonding jumper must be
installed. In this case, the main AC panel must not install a permanent neutral to ground
bond.

STEP 6: Connect the DC input wires

CAUTION – Proper polarity must be observed here. Ensure positive is connected to positive, and
negative is connected to negative. Perform this observation at the inverter and the battery.
Reversing this connection will damage the inverter and will invariably be detected by the
manufacturer.

WARNING: Fire hazard – Proper wire must be used in all connections. The temperature
rating of the wire must be at least 75°C. All connections must be snug, loose connections may
overheat.

The procedure below will illustrate how to connect the battery leads to the terminals on the DC side
(back of the inverter). Figure 1-5 below shows the rear of the inverter. Keep the cable lengths as
short as possible. Also make sure the cables are rated to a current at least equal to the rating of the
circuit breaker or fuse used in line with the cables. It is important the cables are insulated to the
correct voltage as well.

Routing DC cables through an electrical distribution panel or battery isolator will result in an
undesired, additional voltage drop.

Figure 1-5 DC End

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 To make connections to DC terminals:
1. Ensure the inverter is OFF and no connections are being made to DC or AC circuits.
2. Remove nuts and washers from the DC terminals of the inverter.
3. Depending on the size of the connectors chosen, strip about ¾ inches of insulation from the
cables. The connectors chosen will need to create a permanent, low-resistance connection.
4. Attach terminals to both ends of cables. One end for the connection to the battery, and the
other end for connection to the inverter. Confirm no stray wires are left hanging out of the
connector or terminal. Connectors should be crimped properly to the cables using approved
connectors and tools.
5. Installation of a fuse and fuse holder to the positive cable is required. The fuse must:
 Be placed on the positive cable and close to the battery
 Be rated for DC circuits
 Exhibit an Ampere Interrupting Capacity (AIC) exceeding the short-circuit current
available from the battery (Class T fuse).
6. Turn the battery selector/disconnect switch to OFF to avoid sparking when making
connection
7. Attach connector of positive cable to the positive DC terminal of the inverter.
8. Install flat washer then the lock washer and nut back on to the inverter. Tighten the nut to
12.2 – 13.6 Nm. The connection should be tight enough that the ring terminal does not move
on the DC terminal.

CAUTION – A loose connection at any terminal may cause the wires to overheat and melt
insulation, they will also cause an excessive voltage drop.

CAUTION – Over-tightening any of the lugs and nuts may cause damage to the DC input
terminals.

CAUTION: Reverse polarity – Permanent fuse damage in the inverter will be caused if the
polarity of the wires is switched. Positive must go to positive, and negative must go to
negative. Replacement of this fuse must be performed by the manufacturer.

9. Double check the cable that was just installed is the positive cable connecting the DC
terminal of the inverter to the disconnect/battery selector switch, and then from there the fuse
holder. Also ensure the other end of the fuse holder is connected to the positive terminal of
the battery.

WARNING: Explosion or fire – DO NOT continue with the following steps if flammable
materials or fumes are in the area. Battery disconnect/selector switch must be in OFF
position or the following steps may result in explosion or fire. Proper ventilation is crucial.

10. Connect the negative cable from the negative post of the battery to the negative DC terminal
of the inverter.
11. Install flat washer then the lock washer and nut back on to the inverter. Tighten to 12.2-13.6
Nm.

The image below displays how the terminals should look after installation.

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 Figure 1-6 DC Cable Connections

Grounding: The grounding lug located on the sidewall of the inverter at the DC terminal end is
used to connect the inverter chassis to the battery system’s negative connection or grounding bus, as
required by electrical regulations. The wiring used for grounding should be bare copper or provided
with green insulation. THIS LUG IS NOT FOR AC GROUNDING. For heavy trucks or recreational
vehicles: use copper wire and connect it between the inverter grounding lug and the vehicle’s DC
grounding point (vehicle chassis or assigned grounding bus). Tighten to 6.6 - 7.3 Nm.

STEP 7: OPTIONAL - Mount removable display in remote location

(25ft max)

The communications cable for optional mounting of the display should be at maximum 25 feet.
Mounting the display flush into a wall or panel requires an opening about 3.25in x 1.25in and
1.5in deep (8.25cm x 3.18cm and 3.81cm deep).

Mounting the display panel:

1. The location for the panel should be dry, out of direct sunlight, free of corrosive fumes,
and suitable for mounting an electronic device.
2. Draw the area to cut away with a pencil on the wall.
3. Cut away the area and pilot-drill the mounting holes into the wall.
4. Put the communication cables into the wall and route to the opening.
5. The cable connector can be placed in either jack on the panel.
6. Put the panel in the opening and fasten it into the wall securely.

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 7. Route the cable to the inverter and insert the connection into the jack located near the
battery select dip switch.

IMPORTANT: The communications cable should not be in parallel or in the same conduit as
the AC and/or DC wires. If required, only cross the wires at 90° angles of each other.

STEP 8: Test Installation

WARNING: Shock hazard – AC power from a utility/grid will still pass through
the inverter to the AC output even with the inverter turned OFF. Turning the
inverter OFF with the button will not disconnect DC or AC input power, this must
be done manually.

Prior to use:
1. Verify the inverter is inverting DC battery power AND delivering AC power to the outputs.
2. For installations where AC input and output are hardwired to the inverter, verify the
inverter transfers from inverter power to utility/grid power when the utility/grid power is
present.

Prior to system testing, close the DC fuse and disconnect or the DC circuit
breaker to start supplying the inverter with DC power.

Testing in INVERT MODE –

1. If hardwired, ensure utility/grid power is not present.
2. Press the “Inverter” button ≈ ISEC to turn the inverter on. The status LED on the panel
will glow yellow and the display screen will illuminate.
3. Using an appliance within the inverter’s range, plug it into the GFCI on the front of the
inverter, or plug it into an AC outlet hardwired to the inverter.
4. Turn ON the appliance and verify it functions properly.

If the appliance functions as expected, the installation is a success! If it

was a hardwire installation, continue reading.

Testing in UTILITY/GRID MODE –

1. Using the same appliance from the previous test (must be within power range of inverter),
plug it into the GFCI of the inverter.
2. Connect the utility/grid power source.

The inverter will transfer the appliance to utility/grid power. The status LED
on the panel will change from yellow to a ten-second flashing yellow for
≈ 20 Sec and then green. If the appliance then functions as expected, the
installation is a success!

22
 Note: If the INVERTER button on the inverter is ON, the inverter will automatically supply the
appliance(s) with inverted power from the battery upon the utility/grid power source failing or
becoming disconnected. The same will happen if the utility/grid voltage falls too low (less than
≈ 90Vac).

WARNING: Shock hazard – Utility/grid power will always pass through the inverter to the
AC output even if the inverter is turned OFF.

23
2. CONFIGURATION
This chapter will address optimal inverter function for specific, electrical system
requirements.

Covering the following:

 Loading battery types on to the main unit

 Customizing the display, alarm, and current settings

Setting Battery Types on Main Unit

The inverter can operate from several different types of lead-acid batteries. It is
important to make sure the battery type is configured on the unit for optimum
charging process before installing batteries.

WARNING: Fire hazard – Programming the incorrect battery type may result in
battery damage and a fire risk.

Battery Type Setting O/P Voltage VDC (Tolerance +/- 0.2Vdc)

Bulk Absorption Float

Fixed 13.5 13.5 13.5 13.5

Flooded 14.4 14.4 13.5

Gel 14.2 14.2 13.8

AGM 14.3 14.3 13.4

Table 2-1

24
Customizing Display, Alarm, and Charging Current Settings

The display panel is capable of adjusting the following:

 What is presently displayed on the screen

 Enable/Disable the audible alarm
 Modifying the charging current

To change display:

By default, the screen will display the input voltage in [Volts] and the “Input Voltage (V)” LED indicator
will be illuminated.

1. Press the Select button once. Screen display the DC input current in [Amperes] and the “Input
Current (A)” LED indicator will illuminate.
2. Press the Select button once more. Screen display the AC output power in [kilowatts] and the
“Output power (KW)” LED indicator will illuminate.
3. Press the Select button once more (third time). Screen display the DC input voltage in [Volts]
and the “Input Voltage (V)” LED indicator will illuminate.

25
To adjust alarm settings:

By default, the alarm is ON.

Press and hold the Select button for two seconds. The screen will display one of two things:

“AL0” – this indicates the alarm is OFF

“AL1” – this indicates the alarm is ON

The screen will display the setting (either AL0 or AL1) briefly and then return to the previous
screen.

Note: The alarm setting will revert back to default (ON) when the Inverter button is turned OFF
then ON again.

To adjust the charging current:

By default, the charging current is as follows:

 20A for the 12-110-1000-B2

 40A for the 12-110-1800-B4, 12-110-1000-B4

1. Press and hold the Inverter button for five seconds. This brings the inverter into Charge
Current Setting Mode.
2. Press the Select button to switch between the different current ratings in [Amps].
 2 – 5 – 10 – 20 for the 12-110-1000-B2
 2 – 10 – 20 – 40 for the 12-110-1800-B4, 12-110-1000-B4
3. To choose a current setting, stop at the value displayed and wait five seconds to set it.
Once the current is set, the display will return to the previous screen.

Unit performance can be maximized using Table 3-1 below.

26
 Charging Current Guidelines
AC Input Circuit
Branch Breaker Maximum By-pass AC Current
Charger DC Current Setting (Amps)
or fuse size Available (Amps)
(Amps)
12-110-1800-B4, 12-110-1800-B4,
12-110-1000-B2 12-110-1000-B2
12-110-1000-B4 12-110-1000-B4
15 2 2 13.5 13.5
5 10 12.5 11
10 20 11 8.5
20 40 8.5 3.5
20 2 2 18.5 18.5
5 10 17.5 16
10 20 16 13.5
20 40 13.5 8.5
30 2 2 28.5 28.5
5 10 27.5 26
10 20 26 23.5
20 40 23.5 18.5

Table 3-1 Charging Current Guidelines

27
 SPECIFICATIONS

Appendix A is the location for product performance information and electrical

specifications for the 1000W and 1800W Cooper Bussmann Inverter.

Important: Specs are subject to changes without notice.

Technical Specifications:
Input voltages

Low Setting Mid Setting High Setting

Nominal DC Input 12.5VDC 13.0VDC 13.0VDC

Input voltage operating

11.0 – 16.0VDC 11.8 – 16.0VDC 12.2 – 16.0VDC
range

Input voltage 11.5VDC and greater < 0.9a DC

No load input current
(inverter on)
Input voltage less than 11.5VDC < 1.5a DC

No load input current

< 1.0mA (Inverter button off and no utility power connection)
(inverter off)

 All DC Voltage tolerances +/‐ 0.3VDC

AC Outputs

1000W 1800W

Continuous output power 1000W (8.3a) 1800W (15a)

Surge output power (5

1200W 2000W
seconds)

Surge output power 2000W (200ms) 3600W (300ms)

Operating Temperature
0C to +50C 0C to +50C
Range

 Output power rated at 25⁰C, continuous power de‐rated linearly to 70% at 50⁰C

AC Transfer

95 VAC
AC input transfer from

28
Utility to Inverter

AC input recovery from

100 VAC
Inverter to Utility

Utility to Inverter and

Inverter to Utility 5 VAC minimum
hysteresis

Maximum AC output by‐

20 Arms
pass current

AC transfer time –
20 Seconds nominal
Inverter to Utility

AC transfer time –Utility

< 50 ms
to Inverter

Time delay on transfer

20 s +/‐ 2s
from Inverter to Utility

 Voltages +/‐ 5V
Battery Charger

AC input operating range 95 – 135VAC

AC input range with full

105V – 135VAC
power

AC input current with no

< 0.50 Arms
load

Input current full load < 6 Arms (12‐110‐1000‐B2) 11.5 Arms (12‐110‐1000‐B4, 12‐110‐1800‐B4)

AC input frequency 60 Hz +/‐ 5 Hz

Operating Temperature
0C to +50C (Allow for 1.5 Adc charge current reduction above +40C)
Range

DC Output Voltage:

Battery Type O/P Voltage VDC (Tolerance +/- 0.2Vdc)

Setting
Bulk Absorption Float

Fixed 13.5 13.5 13.5 13.5

Flooded 14.4 14.4 13.5

Gel 14.3 14.2 13.8

AGM 14.4 14.3 13.4

29

DC Output Current:

Model Maximum DC Output current (Adc)

Setting 1 Setting 2 Setting 3 Setting 4

12-110-1000-B2 2 +/- 0.5 5 +/- 0.5 10 +/- 1 20 +/- 2

12-110-1800-B4 2 +/- 0.5 10 +/- 1 20 +/- 2 40 +/- 4

12-110-1000-B4

30
Charge Algorithm

31
Mechanical Specifications
MIL-STD-202G,
Method 214A,
Test Condition A
Vibration Must operate per specification during and after the test.
5.35 Grms,
4hr / axis
MIL-STD-202G,
Method 213B,
Test Condition J
Shock Must operate per specification during and after the test.
30G Peak,
11 ms,
½ Sine Wave
Environmental Specifications

Per SAE J1455, Rev.

Temperature JUN2006, Sec. 4.1,
Must operate per specification during and after the test.
Cycling Test 4.1.3.1
Fig. 2B*

Per SAE J1455, Rev.

JUN2006, Sec. 4.1,
Thermal shock Must operate per specification after the test.
Test 4.1.3.2
Fig. 2C*

Per SAE J1455, Rev.

JUN2006, Sec. 4.2,
Humidity Must operate per specification during and after the test.
Fig. 4B*

Per SAE J1455, Rev.

Altitude - Operating JUN2006, Sec. 4.9, Must operate per specification during and after the test.
Table 2*
Per SAE J1455, Rev.
Altitude – Non-
JUN2006, Sec. 4.9, Must operate per specification after the test.
operating
Table 2*
Electromagnetic Specifications

Conducted Per SAE J1113/3,

Manual restart required for pulses 1, 2b, and 4
Immunity Severity Level L6 (0.5W)

Per SAE J1113/4,

Radiated RF
Class C,
Immunity - Bulk
Region 2,
Current Injection
80mA
Per SAE J1113/25 to
500 MHz
Immunity to
Radiated RF Per SAE J1113/27
500 MHz to
2 GHz

Per SAE J1455, Rev.

Load Dump
JUN2006, Sec. 4.11.2.2.1

Per SAE J1455, Rev.

JUN2006, Sec. 4.11.1
Jump Start Test The inverter system should restart without a fault.
24 Vdc Applied to DC
Terminals

32
 Per SAE J1455
The inverter shall present no safety hazard. Internal fuses will
Reverse Polarity Sec. 4.11.1
open in the inverter system, requiring factory service for
Test –24 Vdc
replacement.
Applied to DC Terminals
Regulatory Requirements
Comply with the
UL 458 requirements of the UL Mark
standard.

Comply with the

CSA C22.2, No.
requirements of the CUL Mark
107.1
standard.

33
MECHANICAL SPECIFICATIONS:

Dimensions:
Finish: Anodized Aluminum,
Terminals: 1045 steel, Bright Tin Plate per ASTM-B545, Class A over, Nickel Plate per ASTM-B689, Type 1
Connectors:
DC Input: M8 x 1.25 Stud
Chassis Ground: M6 x 1.00 Stud
AC Output: AC NEMA outlet with knockouts for AC Input and optional AC output. All AC output
connections are GFCI protected.
Hardware Included:
Printed Instruction manual
25 foot RJ11 cable for remote mounting of control panel
2 ea M8x1.25 Nuts with Lock Washer and Flat Washer for Battery Positive and Battery Negative
1ea M6x1 Nuts with Lock Washer and Flat Washer for Chassis Ground Connection
One Red and one Black Insulating Boot for covering up to 00 awg Battery Positive and Battery Negative Connections.
2ea cable clamps for retention of hardwired AC Input and AC Output
2ea ground lugs for chassis ground connection of hardwired AC input and AC output

Weight: 15lb

Torque DC input cable fasteners to 12.2 -13.6 Nm

Torque Chassis Ground cable fastener to 6.6 – 7.3 Nm

34
 DC Input  AC Input AC Output

Minimum  Required UL  Minimum  Recommended  Minimum 

Wire Size  Listed Fuse  Wire Size  Branch Circuit  Wire Size  Recommended 
Model  (AWG)  (Amp)  (AWG)  (Amp)  (AWG)  Fuse (Amp) 

12‐110‐1000  3  125 12 15 12  N/A (See Note)

12‐110‐1800  1  200 12 20 12  N/A (See Note)

12‐110‐1000‐B2  3  125 12 20 12  N/A (See Note)

12‐110‐1000‐B4  3  125 12 20 12  N/A (See Note)

12‐110‐1800‐B4  1  200 10 30 12  N/A (See Note)

Note ‐ AC output fuse is not required as all models feature a 20 Amp AC output breaker

35


Fault Codes and Trouble Shooting:

Inverter Section

 DC Input Warning and Shutdown

Unit start up voltage (Lo setting): > 10.5 +/‐ 0.3 VDC and < 16.0 +/‐ 0.3 VDC

Unit start up voltage (Mid setting): > 11.8 +/‐ 0.3 VDC and < 16.0+/‐ 0.3 VDC

Unit start up voltage (Hi Setting): > 12.2 +/‐ 0.1 VDC and < 16.0 +/‐ 0.3 VDC

Condition UVSD Setting (+/‐ Display Audible Alarm Comment
setting 0.3V)

Over Voltage Shutdown Lo or HI 16.0 VDC E02 Beep @ 1 Hz Note 1

Over Voltage Recovery Lo or HI 15.5 VDC N/A N/A Note 2

Under Voltage Warning Lo 11.0 VDC E05 .33 Hz ‐‐‐‐

Under Voltage Shutdown Lo 10.5 VDC E01 Beep @ 1Hz Note 1

Under Voltage Recovery Lo 12.0 VDC N/A N/A Note 2

Under Voltage Warning Mid 12.1 VDC E05 0.33 Hz ‐‐‐‐

Under Voltage Shutdown Mid 11.8 VDC E01 Beep @ 1Hz Note 1

Under Voltage Recovery Mid 12.6VDC N/A N/A Note 2

Under Voltage Warning HI 12.2VDC E05 0.33 Hz Note 3

Under Voltage Shutdown HI 12.2VDC E01 Beep @ 1Hz Note 1

Under Voltage Recovery HI 13.0VDC N/A N/A Note 2

Note 1: Unit will shutdown instantly and initiate a 30 second auto reset period. If the
DC input voltage returns to normal within the auto reset period, operation will
resume.

Note 2: If the DC input voltage does not return to normal within the auto reset
period, the unit will latch off.

36
 Once the DC input voltage returns to normal the power button may be pressed to
reset the inverter and resume operation.

Note 3: Warning will be issued at 12.2VDC simultaneous with initiating a 3 minute

timer. Upon time‐out the inverter will shut down.

AC Output Overload Protection and Warning and Shutdown

Model Condition Power (W) Dis‐ Audible alarm
play
V<11.4 11.4<V<11.8 V>11.8

Warning (+/‐100W) 950 1000 1100 E06 Beep @ 0.33Hz

12‐110‐1000‐xx
Shutdown (+/‐100W) 1050 1100 1200 E03 Beep @ 1 Hz

Warning (+/‐200W) 1750 1850 2000 E06 Beep @ 0.33Hz

12‐110‐1800‐xx
Shutdown (+/‐200W) 1850 1950 2100 E03 Beep @ 1 Hz

37
AC Output Short Circuit Protection

A short circuit may be applied to the AC output continuously during inverter mode without damage
to any components. Unit will shut down within 10 seconds, and display will indicate ‘E03’ with the
buzzer beeping @ 1 Hz.

Note: Manual reset is required to restart Inverter after AC Overload or Short Circuit shutdown.
System will automatically reset AC Overload or Short Circuit shutdown error when utility is
available. The supplemental protector or the branch protection specified in the Installation Guide
should be open under bypass short circuit output condition.

Incorrect Connection Protection

Inverter DC Input Protection

AC Input and AC Output:

AC Input Line and Neutral reverse connection cannot be detected. Input and output
ac terminals are labeled, and unit is installed by a professional installer.

Charger DC Output Protection:

Reverse polarity on DC terminal will blow the charger DC input fuses. This damage
is not covered under warranty.

Model DC Output Fuse

12‐110‐1000‐B2 2x25A (Auto Blade)

12‐110‐1000‐B4
3x25A (Auto Blade)
12‐110‐1800‐B4

38
Over Temperature Protection

Location Condition

> 95°C Max. Charge current reduced to half of full load

Charger Transformer
> 100°C Max. Charge current reduced to 0A

AC Transfer Relay > 70°C System shutdown (no auto‐reset)

Note: Max. charge current resumes normal level when Charger Transformer sensor
temperature drops below 90C

Warning (°C) Error code / Audio Shutdown (°C) Error Code / Audio
Location alarm alarm
On Off On Off

Rectifier Diode >90 <88 E07 / >95 <80 E04 /

Extrusion >63 <60 Beep@ 0.33Hz >60 <56 Beep @ 1 Hz

Note: Over temperature shutdown of these sensors is auto reset. Sensor
temperature tolerance is +/‐ 5°C

Reverse Battery Protection

Model DC Input Fuse

12‐110‐1000‐xx 4 x 30A (Auto Blade)

12‐110‐1800‐xx 8 x 30A (Auto Blade)

Note: Reverse polarity on DC Input will open the DC input and fault indication fuses.
Fuses are non replaceable, except at factory.

AC Output Protection

There is no detection method for AC back feed to inverter output. Inverter output
bridge MOSFET and related circuitry component failure are an acceptable failure
mode.

39
Charger and AC Transfer Section
AC Input Surge Protection

‐ 175 J MOV is connected across the Line and Neutral of AC Input

Charger DC Output Over Voltage Shutdown

‐ Battery Over voltage protection: 16.0 +/‐ 0.5Vdc (Error code: E10)
‐ Audio Alarm: Beep @ 1 Hz and AC charger is latched off
‐ Bypass mode is available
‐ To reset error code, remove AC Input and turn unit off and on

40
Dead Battery Charging

Battery voltage must meet the following conditions or Error code E11 will display:

‐ Initial battery voltage must be 10V or higher for charge to commence

‐ In event battery voltage drops below 10V after charge is initiated (Added Load)
Maximum time for battery voltage to rise above 10V in Bulk charge: 15 minutes
‐ Audio Alarm: Beep @ 1 Hz and AC charger is latched off following 15 minute delay
‐ Bypass mode is available
‐ To reset error code, remove AC Input and cycle unit off and on until reset

Parametric Display

The two buttons on the display panel can be used to select what is being displayed on the
screen and to enter into feature select mode. To select what is being displayed on the
screen during inverter mode, press ‘Select’ button to toggle the display to show following:

‐ DC Input Voltage in Vdc with ‘Input Voltage’ LED On

‐ AC Output Power in kW with Output Power’ LED On
‐ Inverter function setting ‘In0/1’ with Input Voltage and Output Power LED Off
‐ Charger current setting in Adc with Input Voltage and Output Power LED Off
‐ Alarm function setting ‘AL0/1’ with Input Voltage and Output Power LED Off
‐ Under voltage shutdown setting ‘sdL/n/h’ with Input Voltage and Output Power LED
Off
‐ Battery Type [FI]=Fixed, ‘FLo’=Flooded, ‘gEL’=Gel, ‘Ag’=AGM

To select what is being displayed on the screen during by‐pass mode, press ‘Select’ button
to toggle the display to show following:

‐ DC Input Voltage in Vdc with ‘Input Voltage’ LED On

‐ Inverter function setting ‘In0/1’ with Input Voltage/Current and Output Power LED Off
‐ Charger current setting in Adc with Input Voltage and Output Power LED Off
‐ Alarm function setting ‘AL0/1’ with Input Voltage and Output Power LED Off
‐ Under voltage shutdown setting ‘sdL/n/h’ with Input Voltage and Output Power LED
Off
‐ Battery Type [FI]=Fixed, ‘FLo’=Flooded, ‘gEL’=Gel, ‘Ag’=AGM

41


To enter feature select mode:

‐ Press and hold the ‘Power’ button for five seconds to enter into the feature select mode.
‐ Press ‘Power’ button to select feature by toggle between Current setting – ‘Cur’ ,
Inverter disable – ‘In’, Alarm setting – ‘AL’, Under Voltage shutdown setting – ‘Sd’ and
Factory default ‘ dEF’.
‐ Once the feature is selected, press the ‘Select’ button to toggle between setting:
‘Cur’: 2A‐ 5A‐10A‐[20A] (select charger current for 12‐110‐1000‐BC)

2A‐5A‐20A‐[40A] (select charger current for 12‐110‐1000‐B4, TS‐12‐110‐

1800‐B4)

‘In’: In0 – [In1[ (inverter disable/enable)

‘AL’: AL0 – [AL1] (alarm disable/enable)
‘Sd’: Shut down low SdL, Shut down mid [Sdn], Shut down high SdH
‘bAt’: Battery type select: [FI]=Fixed, ‘FLo’=Flooded, ‘gEL’=Gel, ‘Ag’=AGM

(under voltage shutdown Lo/ Hi)

‘dEF: Set to factory default (maximum charger current, In1, AL1, Sdn, FI)
‐ Press and hold ‘Select’ for 5 seconds to memorize the setting and it will automatically go
to the next feature setting. The user can carry on the feature select or it will
automatically exit the feature setting mode. Factory defaults are enclosed in brackets []
in the above list.

Fan On/Off setting

Parameter Fan on Fan off

Load >500W <200W

Extrusion temp >60C <55C

Rectifier Diode >70C <60C

Display Panel Indicators / Switches

42
‐ ‘Main’ On/Off momentary switch
‐ ‘Select’ momentary switch
‐ 3 x 7‐segment LED display
‐ ‘STATUS’ LED (tri color)
‐ ‘Battery Voltage’ LED (Green)
‐ ‘Battery Current’ LED (Green)
‐ ‘Output Power’ LED (Green)
‐ Remote communication cable, 6‐wire, 25ft long (P/N 31‐5267‐00)

User Messages / Diagnostics

The following Fault codes are provided on digital display when system Fault/Warning occurs:

E01: DC Input Under‐Voltage Shutdown

E02: DC Input Over‐Voltage Shutdown

E03: Inverter Output Overload (or Short Circuit) Shutdown

E04: Inverter Over‐Temperature Shutdown

E05: DC Input Under‐Voltage Warning

E06: Inverter Output Overload Warning

E07: Inverter Over‐Temperature Warning

E08: Not used

E09: Not used

E10: Charger Output Over Voltage Shutdown

E11: Battery not accepting charge

E12: Transfer Relay Over‐Temperature Shutdown

43
FCC Part 15, Class B

Note: This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. 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 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.

Modifications not expressly approved by the manufacturer could void the user's authority to operated the
equipment under FCC rules

SP180158 d

44