IK0800510 ­ Cooper Bussmann Inverter Information/Diagnostics

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Countries:

CANADA, UNITED STATES Document ID: IK0800510

Availability:

ISIS

Revision:

2

Major System:

ELECTRICAL SYSTEM

Created:

2/23/2015

Current Language: English

Last Modified: 5/13/2015

Other Languages: NONE

Author:

Viewed:

Chris Moody

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Title : Cooper Bussmann Inverter Information/Diagnostics
Applies To : ProStar/LoneStar with 0008XDM,0008XDN

Change Log
4/29/15 ‐ Initial Release
5/4/15 ‐ Change Title to reflect name on Inverter label

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Table of Contents
Click on the items below to jump to each section:

Introduction

Common Symptoms - Inverter
Inoperative

Configuration Guide

Operational Specifications

Parts Information

Warranty Information

Fault Codes and Troubleshooting

Introduction
International ProStar and LoneStar vehicles use the 1800W inverter with AGM batteries.
The Cooper Bussmann Inverter is designed to create either 1kW / 1.8kW of pure sine wave 115VAC 60Hz power from a 12V battery source. The units low Total
Harmonic Distortion ( 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 (High setting):

> 12.2  0.3 VDC and < 16.0  0.3 VDC
DC Input Warning and Shutdown

Condition

UVSD setting

Setting
±
Display
0.3Vdc

Audible alarm

Comment

Over voltage instant shutdown

Lo, mid or hi

16.0

E02

Beep @ 1 Hz

Note 1

Over voltage recovery

Lo, mid or hi

15.5

--

--

Note 2

Under voltage instant shutdown

Lo, mid or hi

10.0

--

--

Note 3

Under voltage shutdown

Lo

10.5

E01

Beep @ 1 Hz

Note 4

Under voltage warning

Lo

11.0

E05

Beep @ 0.33 Hz

­­

Under voltage recovery

Lo

12.0

--

--

­­

Under voltage shutdown

Mid

11.8

E01

Beep @ 1 Hz

Note 4

Under voltage warning

Mid

12.1

E05

Beep @ 0.33 Hz

­­

Under voltage recovery

Mid

12.6

--

--

­­

Under voltage shutdown

Hi

12.2

E01

Beep @ 1 Hz

Note 5

Under voltage warning

Hi

12.2

E05

Beep @ 0.33 Hz

­­

Under voltage recovery

Hi

13.0

--

--

­­

1.
2.
3.
4.
5.

Unit will shut down instantly and restart automatically if voltage returns to less than 15.5V within 30 seconds
If DC voltage is not less than 15.5V within 30 seconds, unit will require manual reset by power button
Unit will shut off instantly if DC voltage drops below 10V regardless of settings
Unit will shut off if DC voltage is below shutdown for 10 seconds
Unit will shut off if DC voltage is below shutdown for value for 3 minutes

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.

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

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IK0800510 ­ Cooper Bussmann Inverter Information/Diagnostics

Page 4 of 9

• AC input and AC output: AC Input Line and Neutral reverse connection cannot be detected. Input and output ac terminals are labeled and unit should be
installed by a professional installer.
• Charger DC output protection: Reverse polarity on DC terminal will open the CD input fuses in the Cooper Bussman Inverter.
This damage is not covered under warranty.
AC output protection
External AC source applied to the inverter AC output may damage the inverter. This damage is not covered by warranty.
Troubleshooting
The following Fault codes are provided on digital display when system Fault/Warning occurs:

Fault Codes - Displayed in LCD
E01

DC Input Under-Voltage Shutdown. Unit is detecting an input DC voltage which is too low and it is shutting down. This fault can be caused by a discharged
or undersized battery. Incorrect DC wiring length and gauge or fault DC connection can also cause this fault.

E02

DC Input Over-Voltage Shutdown. This fault could be due to a problem in the vehicle charging system. Unit will resume normal operation when voltage
returns to the allowed input voltage range.

E03

Inverter Output Overload (or Short Circuit) Shutdown. Unit is being severely overloaded. Reduce the load.
If this fault occurs in shore power mode the unit must be reset. To reset, remove AC loads and turn inverter power off and on.

E04

Inverter Over-Temperature Shutdown. Unit is shutting down to protect itself from thermal damage. Place the unit in a location with lower ambient
temperature or improve air flow around the unit.

E05

DC Input Under-Voltage Warning. Unit is detecting an input DC voltage which is too low and it is warning the user that it will shut down within 10 seconds.
This fault can be caused by a discharged or undersized battery. Incorrect DC wiring length and gauge can also cause this fault.

E06

Inverter Output Overload Warning. Inverter is detecting an overload and it is warning that it is going to shut down within 10 seconds. Reduce load and
inverter will keep operating normally.

E07

Inverter Over­Temperature Warning. Inverter is approaching its maximum operating temperature and it will shut down within 10 seconds. Reduce load or/and
move the inverter to a location with lower ambient temperature or better air flow.

E08

Not used

E09

Not used

E10

Charger Output Over Voltage Shutdown. Battery charger has detected a battery voltage above normal operating range.
Vehicle charging system may be damaged.

E11

Battery not accepting charge. Inverter is trying to charge the battery, but battery voltage is not increasing over time. Battery may be damaged

E12

Transfer Relay Over-Temperature Shutdown. Relay that switches inverter to shore power mode is running at an unusually high temperature and unit it is
shutting down to protect itself. This could be due to an overload condition in shore power mode.
Reduce the load and unit will return to normal operation

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

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

( Back to Top )

Fault Code Troubleshooting
Inverter Inoperative
Step

Symptom Verification
Attempt to power on inverter from the display panel

#1

Does inverter turn on?

Decision
Yes: Restore truck to operating condition and
contact supervisor. Discuss conditions when
symptom occurred with customer.

No: Go to Step 2

Step

Power To Inverter

Decision

#2
Check for minimum of 12v at inverter.

Yes: Got to step 3

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IK0800510 ­ Cooper Bussmann Inverter Information/Diagnostics

is 12v or more present at inverter

Step

#3

No: Determine cause of missing 12v, repair and
retest

Ground to Inverter
Check for ground to inverter.

Page 5 of 9

Decision
Yes: Got to Step 4

Is ground present at inverter?
No: Determine cause of missing ground to inverter,
repair fault, and retest.

Step

#4

Check Display Panel Connections

Decision

Remove display panel and inspect cable connections Yes: make repairs as necessary. The cable and/or
for damaged pins, chaffing or other issues. The cable is display can be replaced individually. Retest
housed within the sleeper harness. Check for rubbing, operation after repairs.
sharp bends in the cable or sharp edges.
Are any issues identified with cable or connections?
No: Replace inverter. Retest for proper system
operation

Fault Code E01/E05/E11

Step

#1

Step

Inspect Battery Cables and
Connections

Decision

1. Inspect Battery Cable Connections per IK0800482
2. Inspect Battery Cable Connections at the inverter

Yes: Go to Step 2

Were cables free of corrosion/issues?

No: Perform all necessary repairs and retest for symptom

Battery Test

Decision
Yes: Go to step 3

Perform Battery Test (IK0800482)
#2

Did Batteries Pass testing
No: Perform all necessary repairs and retest for symptom

Step

Voltage Drop Test Positive Cable
Check voltage drop between batter to inverter cables

#3

Decision
Yes: Replace positive cable

Was voltage drop greater than .3v?
No: Perform all necessary repairs and retest for
symptom

Step

Voltage Drop Test Negative Cable

Decision
Yes: Replace negative cable

Check voltage drop between batter to inverter cables
#4
Was voltage drop greater than .3v?

No: Restore truck to operating condition and contact
supervisor.

Inverter Turns on but is inoperative(Associated with code E03,E06)

Step

Symptom Verification

Decision
Yes: Go to Step 2

#1

Does inverter turn on and display show E03 plus an
alarm sound?
No: Interview driver for further information. Inquire about
loads that might have been used at the time of concern.

Step

Check for load

Decision

#2
Are there loads plugged into Inverter that draw beyond
the inverter specification of 1800watts? Unplug all loads