Xantrex Technology RM1012 User Manual

Heavy Duty Inverter/Charger
1000 Watt Weatherproof

Owner’s Guide

Model RM1012
For Volvo Trucks

About Xantrex

Xantrex Technology develops, manufactures, and markets advanced power electronic products. The
company’s products convert raw electrical power from any source into high-quality power required by
electronic and electrical equipment.

Trademarks

Xantrex HD is a trademark of Xantrex International. Xantrex is a registered trademark of
Xantrex International.
© 2001 Xantrex International. All rights reserved.

Notice of Copyright

Xantrex™ Heavy Duty Inverter/Charger Owner’s Guide © November 2001 Xantrex International.

Disclaimer

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

November 2001, Revision 2

Part number

445-0128-01-01 (Volvo)

Contact information

Volvo Trucks North America, Inc.
P.O. Box 26115 Greensboro, NC 27402

Volvo Trucks Canada, Inc.
6490 Vipond Drive, Mississauga, Ontario L5T 1W8

1-800-52-VOLVO (1-800-528-6586)

www.volvotrucks.com

Contents

Important Safety Information

General precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v

Precautions when working with batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v

Precautions for using appliances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi

1Introduction

Introduction to the Xantrex HD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2

Operating features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

2Operation

Planning for AC loads- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Type of loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

AC loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
DC loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Problem loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Ambient temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3
Calculating size of an AC load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4
Driving the truck while operating AC and DC loads - - - - - - - - - - - - - - - - - - -2–7

Using the toggle switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9

Operating the Inverter/Charger- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

Turning the inverter on and running loads - - - - - - - - - - - - - - - - - - - - - - - - -2–11
Running in extremes of hot or cold temperatures - - - - - - - - - - - - - - - - - - - - 2–11
Restarting after a shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Battery charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Using shorepower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Miscellaneous hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

iii

Contents

3Maintenance

Checking terminals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Disconnecting and connecting Xantrex HD from the batteries - - - - - - - - - - - - - -3–3

Disconnecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Connecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Replacing the fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–4

Removing and reconnecting AC cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–6

4 Troubleshooting

Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2

Common problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2
Blinking lights on the remote switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–3

Calling your authorized Volvo dealer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–5

A

Specifications

Physical specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

Inverter specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

Charger specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Transfer and general specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5

Rating curves and charging profiles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

iv

Important Safety Information

WARNING

Before using your Inverter/Charger, read and save these safety
instructions.

General precautions

1. Before using the inverter/charger, read all appropriate sections of
this guide and any cautionary markings on the inverter and the
batteries.

2. Use only a grounded AC extension cord when connecting to AC
input power (shorepower). Do not remove or attempt to defeat the
ground connection to any shorepower source in any way.

3. If possible, plug the inverter/charger into an AC source outlet that is
protected by a Ground Fault Circuit Interrupting (GFCI) device;
either a breaker or outlet.

4. Do not operate the inverter/charger if it has received a sharp blow,
been dropped, or otherwise damaged. If the unit is damaged, return
it to your authorized Volvo dealer.

5. Do not dismantle the inverter/charger; it contains no user­serviceable parts. Attempting to service the unit yourself could
cause electrical shock or fire. Internal capacitors remain charged

after all power is disconnected.

6. To reduce the risk of electrical shock, turn off the inverter/charger
from the remote switch, then disconnect both AC (shorepower) and
DC (battery) power from the unit before working on any circuits
connected to it. Turning off the remote On/Off switch alone will not
reduce this risk.

Precautions when working with batteries

1. Follow all instructions published by the battery manufacturer and
the manufacturer of the equipment in which the battery is installed.

2. Make sure the area around the battery is well ventilated.

v

Important Safety Information

3. Never smoke or allow a spark or flame near the engine or battery.

4. Use caution to reduce the risk of dropping a metal tool on the
battery. It could spark or short circuit the battery or other electrical
parts and cause an explosion.

5. Remove metal items like rings, bracelets, and watches when
working with lead-acid batteries. These batteries produce a short­circuit current high enough to weld a ring, other metal jewellery or
tools, thus causing severe burns.

6. If you need to remove a battery, always remove the negative
terminal from the battery first. Make sure all accessories are off so
you don’t cause an arc.

7. Before making the final connection to a battery, be sure the polarity
is correct; negative-to-negative, and positive-to-positive.

8. When you are making the final connection to a battery, you will see
a spark and hear a loud pop. This is normal.

Precautions for using appliances

Most battery-operated equipment uses a separate charger or transformer
that is plugged into an AC receptacle and produces a low voltage output.
If the label on the AC adapter or charger states that the adapter or
charger produces a low voltage AC or DC output (less than 30 volts),
the inverter/charger can power this charger or adapter safely.

Some rechargers for small nickel-cadmium batteries can be damaged if
connected to the inverter/charger. Do not use the following loads and
appliances:

• Small battery-operated appliances like flashlights, razors, and night
lights that can be plugged directly into an AC receptacle to
recharge.

• Chargers for battery packs used in hand power tools. These types of
chargers display a warning label stating that dangerous voltages are
present at the battery terminals.

vi

1

Introduction

Chapter 1, “Introduction” describes the main

performance and protection features of the
inverter/charger.

Introduction

Introduction to the Xantrex HD

Features The Xantrex HD inverter/charger is a weatherproof, modified sine wave

inverter/charger designed to be mounted on main frame rail of the truck. It
is a sealed, dust and water resistant unit weighing approximately 30
pounds (13.6 kg). Figure 1-1 shows its main features.

Consult Appendix A, “Specifications” for more detailed information
about the unit.

⑦

①

}
②
③

1–2

④

Figure 1-1 Features of the inverter/charger

⑤

Feature Description

Introduction to the Xantrex HD

①
②

③
④
⑤
}

⑦

Location The inverter/charger is mounted on the main rail of the truck adjacent to

the battery compartment as shown in Figure 1-2.

Positive terminal connecting to positive terminal of battery

Over-current protection fuse which blows in case of a fault
within the unit or if it is connected to the battery with reverse
polarity.

Battery temperature sensor

AC output to vehicle

AC input from shorepower

Remote toggle switch connection. The connection must be
secure for the inverter to work

Negative terminal connecting to negative terminal of battery

Figure 1-2 Location of the inverter/charger

1–3

Introduction

Operating features

Inverter/charger The inverter/charger operates as an inverter and as a charger depending

upon the operational conditions. When the unit is inverting, it is said to be
in invert mode and is referred to as an inverter. When the unit is charging,
it is in charge mode and is referred to as a charger.

The unit can only operate in charge mode when external AC power
referred to as “shorepower” is connected.

Inverter
features

Xantrex HD offers the following inverter features:

• Ability to run many of the same appliances that you use at home

You can operate TVs, VCRs, satellite receivers, computers, hair
dryers, and small power tools for example. You can also run multiple
loads up to 1000 watts in total.

• Surge capability

Xantrex HD will manage loads up to 3000 watts for short periods of
time as long as the peak current is less than 36 A peak.

• Low voltage shutdown

The inverter shuts off when your batteries reach a predetermined
voltage set in the microprocessor to ensure you will always have
enough engine starting power. Low voltage shutdown also monitors
frequency and voltage, and protects against overload, short circuits
and over-temperature.

• Automatic shutdown when the unit does not detect a load greater than
20 watts for 24 hours

This feature prevents the inverter from draining the batteries if it is
left on without a load.

1–4

Operating features

Charger
features

Xantrex HD offers the following charger features:

• 50 amp charging, when shorepower is connected, to ensure your truck

batteries are always charged

• Automatic transfer to invert mode

When your truck’s AC shorepower cord is disconnected, the unit
automatically switches to invert mode. When AC shorepower is
available again, the inverter automatically switches to charging/pass­through mode.

• Load management capability which temporarily reduces charging

current to the batteries when a large AC load is applied to the inverter
output. This capability helps reduce the chance of tripping the
shorepower breaker.

1–5

1–6

2

Operation

Chapter 2, “Operation” explains how to calculate

the size of the loads you can run from the
Xantrex HD Inverter/Charger. It also provides
guidelines to help you run loads safely and
efficiently.

Operation

Planning for AC loads

AC load AC load refers to an AC product you want to operate from the

inverter/charger. Loads include most products that you can plug into a
standard 120 volt household electrical outlet.

Va ri a bl e s
affecting AC
loads

The Xantrex HD inverter/charger inverter can power a wide range of
loads. The size of the load and the length of time you can operate it
depends on variables such as

• type of load

• ambient temperature

• size, state of charge, temperature, and condition of batteries.

The larger your battery capacity and the higher the state of charge, the
longer the inverter/charger can run your AC loads. Battery capacity is
reduced as battery temperature lowers.

Type of loads

AC loads

The way in which an AC load draws power may determine how
effectively it can be powered from the inverter/charger.

Resistive loads Toasters, coffee pots and incandescent lights are examples of loads which

do not need a high start-up current to start running. They use a resistive
heater element to generate heat or light. They are the simplest and most
efficient for an inverter/charger to run. Large resistive loads, such as
electric stoves and water heaters, are impractical since their high current
demands quickly drain the batteries.

Inductive loads TVs, VCRs, stereos, computers, and electric motors (power tools,

vacuum cleaners, for example) are examples of AC loads which surge on
start up, that is, they require a high startup current compared to a resistive
load such as toasters or coffee pots. These loads are known as inductive or
electronic loads. Depending upon the size of the motor, it can take as
much as six times its running current to start it than it does to keep it
running once it has started. This surge can sometimes exceed the
inverter/charger’s maximum output rating and the inverter will shut
down.

2–2

DC loads

Problem loads

Planning for AC loads

DC loads are those that run off the 12 V electrical system on the truck. A
few examples of DC loads are:

• marker lights, headlights, cab lighting, other lights using DC power

• DC refrigerators

• CBs

• factory-installed radios or sound systems

DC loads and the inverter/charger both rely on the batteries for power.
Many DC loads running at one time will shorten the operating times of
AC loads.

These are loads you should not operate from inverter/charger because
they may be damaged or may not operate properly:

• dimmer switches

• some small rechargeable hand power tool chargers

• small battery-operated appliances such as flashlights, razors, night

lights

• variable speed motors

Ambient temperature

Ambient
temperature

Temperature
and power

The ambient temperature, that is, the air temperature around the
inverter/charger will affect its output power.

The air temperature around the inverter may be much hotter than away
from the vehicle. If your truck is standing on hot pavement, the
temperature may be quite high near the inverter.

Generally, the output power decreases as the temperature increases. For
example, at 77 °F (25 °C) the unit delivers 1000 watts for as long as you
have sufficient battery power. At 104 °F (40 °C) it delivers 1000 watts for
up to 10 minutes before shutting down or 750 watts continuous, or 2000
watts for 2 1/2 minutes.

Figure 2-1 shows the relationship between ambient temperature and the

length of time the unit will supply an output power level. Choose the
curve with temperature range most closely approximating that of the
inverter/charger location, then look for the time in minutes. The

2–3