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.
© 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

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

Contents
iv
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

v
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
vi
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.