IK0800510 - Cooper Bussmann Inverter Information/Diagnostics

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Countries:

CANADA, UNITED STATES, MEXICO Document ID: IK0800510

Availability:

ISIS, FleetISIS, NotSIR

Revision:

9

Major System:

ELECTRICAL SYSTEM

Created:

2/23/2015

Current Language: English

Last Modified: 11/15/2018

Other Languages: NONE

Author:

Viewed:

Charles Schroeder

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Title : Cooper Bussmann Inverter Information/Diagnostics
Applies To : ProStar/LoneStar built after 05/12/2014 with 0008XDM,0008XDN feature codes

Change Log
Please refer to the change log text box below for recent changes to this article:
11/15/2018 ‐ Added link to the 1200W Xantrex Power Inverter
10/27/2017 ‐ Author updated for feedback purposes
06/06/2016 ‐ Removed non working Table of Contents
10/05/2015 ‐ Added Electrical Outlet Breaker Inspection step to Failed Inverter Operational checks in the fault code troubleshooting section.
08/03/2015 ‐ Author updated for feedback purposes
05/04/2015 ‐ Change Title to reflect name on Inverter label




Introduction
International ProStar and LoneStar vehicles built after 05/12/2014 will use the 1800W inverter with AGM batteries.
◦ For information on the 1200W Xantrex Freedom X Inverter, please reference IK0800579 ‐ Xantrex 1200W Power Inverter
Information

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

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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
± 0.3Vdc

Display

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. Unit will shut down instantly and restart automatically if voltage returns to less than 15.5V
within 30 seconds
2. If DC voltage is not less than 15.5V within 30 seconds, unit will require manual reset by power
button
3. Unit will shut off instantly if DC voltage drops below 10V regardless of settings
4. Unit will shut off if DC voltage is below shutdown for 10 seconds
5. 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
• 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:

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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.
Also inspect electrical outlet as seen in step 2 of this code's diagnostics.

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 Over‐Temperature 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 Operational Checks

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Step

Symptom Verification

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Decision

Attempt to power on inverter from the
display panel

Yes: Go to Step 2

Does inverter turn on?

No: Go to Step 3

#1

Step

Symptom Verification
Inspect the electrical outlet

Decision
Yes: Press the reset button, and retest with a
load (Microwave, Refrigerator, etc...).
Release the truck if the inverter is able to
support the load. If issue is still present go to
Step 3.

#2

Is an amber light on like illustrated above?

Step

No: Go to Step 3

Power To Inverter
Check for minimum of 12v at inverter.

Decision
Yes: Got to step 4

#3 is 12v or more present at inverter
No: Determine cause of missing 12v, repair
and retest

Step

Ground to Inverter
Check for ground to inverter.

Decision
Yes: Got to Step 5

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

Step

Check Display Panel Connections

Decision

Remove display panel and inspect cable
Yes: make repairs as necessary. The cable
connections for damaged pins, chaffing or other and/or display can be replaced individually.
issues. The cable is housed within the sleeper Retest operation after repairs.
harness. Check for rubbing, sharp bends in the
#5 cable or sharp edges.
Are any issues identified with cable or
connections?

No: Replace inverter. Retest for proper
system operation

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Fault Code E01/E05/E11

Step

Inspect Battery Cables and Connections
1. Inspect Battery Cable Connections per
IK0800482

2. Inspect Battery Cable Connections at the
#1 inverter
Were cables free of corrosion/issues?

Step

Decision
Yes: Go to Step 2

No: Perform all necessary repairs and retest for
symptom

Battery Test

Decision
Yes: Go to step 3

#2 Perform Battery Test (IK0800482)
Did Batteries Pass testing

Step

No: Perform all necessary repairs and retest for
symptom

Voltage Drop Test Positive Cable

Decision

Check voltage drop between batter to inverter Yes: Replace positive cable
cables
#3

Step

Was voltage drop greater than .3v?

No: Perform all necessary repairs and retest
for symptom

Voltage Drop Test Negative Cable

Decision
Yes: Replace negative cable

Check voltage drop between batter to inverter
#4 cables
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

#1
Does inverter turn on and display show E03
plus an alarm sound?

Yes: Go to Step 2

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No: Interview driver for further information.
Inquire about loads that might have been used
at the time of concern.

Step

Symptom Verification
Inspect the electrical outlet