Xantrex RM1012 User manual

Owner’s Guide

Heavy Duty Inverter/Charger

1000 Watt Weatherproof

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.

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

iii

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

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

ASpecifications

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

Important Safety Information

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 user-

serviceable 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.

WARNING

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

instructions.

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 short-

circuit 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.

1 Introduction

Chapter 1, “Introduction” describes the main

performance and protection features of the

inverter/charger.

Introduction

1–2

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.

Figure 1-1 Features of the inverter/charger

①

③

②

④

⑦

⑤

}

Introduction to the Xantrex HD

1–3

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

the battery compartment as shown in Figure 1-2.

Figure 1-2 Location of the inverter/charger

Feature Description

①Positive terminal connecting to positive terminal of battery

②Over-current protection fuse which blows in case of a fault

within the unit or if it is connected to the battery with reverse

polarity.

③Battery temperature sensor

④AC output to vehicle

⑤AC input from shorepower

}Remote toggle switch connection. The connection must be

secure for the inverter to work

⑦Negative terminal connecting to negative terminal of battery

Introduction

1–4

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.

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