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.

Operating features
1–5
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/pass-
through 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.

1–6

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
2–2
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 r i ab le 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.

Planning for AC loads
2–3
DC 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.
Problem 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
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.
Temperature
and power
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

Operation
2–4
intersection of the time and temperature will indicate approximately the
output power of the unit. For example, between – 40 °F (– 40 °C) and
77 °F (25 °C), you will get 3000 watts for approximately two minutes or
2500 watts for 3 minutes.
Figure 2-1 Output power versus time and temperature
Calculating size of an AC load
Operating time To determine how long you can run your appliances:
1. List all the AC loads you think you will use and determine their
power requirement. You can usually find this information on a label
near the power cord on the appliance.
2. Look in Table 2-1 to find its operating time or the operating time of a
similarly sized appliance. The operating times shown in the table are
the maximum time the appliance will operate. The unit will shut
down after that time so the battery is not drained past a safe level.
3. To find the running time for several appliances running
simultaneously add the total watts of the appliances and look for an
appliance with similar power requirement in Table 2-1.
Battery
condition
The information in Table 2-1 assumes:
• there is a properly maintained 400 amp-hour battery bank
• the batteries have not been damaged by deep discharge and are
relatively new
0
500
1000
1500
2000
2500
3000
1 10 100
Time (minutes)
Output Power (VA)
-40 to 25C 40C 55C 70C 85C
23456789
– 40 to 77 F 104 F 131 F 158 F 185 F

Planning for AC loads
2–5
Factors
affecting load
Consider these factors when you are calculating loads:
• Loads that exceed 1000 watts may be run for a short time (less than
five minutes)
• Loads which run continuously, (reading light, TV, computer) should
not exceed more than 1000 watts in total
• Poor battery condition, low battery capacity, low battery temperature,
and high ambient temperature will shorten the operating times listed
in the table
• The presence of DC loads will reduce the operating times

Operation 2–6
* Average
The inverter/charger shuts down after 24 hours if it does not detect a load (or loads less than 20 W).
†Based on four minute operation timeout and shutdown at 11.8 V for loads more than 150 W
and 12.3 V timeout and shutdown for loads less than 150 W at 77 °F (25 °C).
Table 2-1 Typical operating time with fully-charged 400 amp-hour batteries †
Appliance Watts Minutes Hours
10 20 30 40 50 1 2 3 4 5 6 9 18 24
Electric shaver 15
Table fan 15
Video game 25
Reading Lamp 40
Notebook computer 75
Computer printer 100
Hand-held vacuum cleaner 100
19 in TV/VCR combo 100
3 cu. ft. refrigerator *180
Electric blanket 200
Electric buffer 400
Electric drill 1/2” 500
Halogen work light 750
Coffee maker 800
Toaster 1000
Microwave oven 1200
Hair dryer 1500

Planning for AC loads
2–7
Driving the truck while operating AC and DC loads
Recharging Driving your truck does not guarantee that the battery is being fully
recharged by the alternator if you are running a combination of large AC
and DC loads.
The alternator must provide more power than the combined DC and AC
loads draw for your battery to fully recharge.
Example This example shows what happens if the alternator is overloaded.
Figure 2-2 AC and DC loads powered by the alternator
The alternator is charging at 130 amps while the truck is being driven at
highway speeds and there is a 1000 W (AC) load.
12 Volt Battery
Alternator
(130 A)
Xantrex HD
DC Loads
AC Loads
(1000 W)
Driver Installed
Loads
Factory Installed
Loads
92 A
1110 W (DC)
38 A

Operation
2–8
The efficiency of the inverter/charger is approximately 90%, which means it
is drawing about 1100 W (DC) from the battery or 92 amps. This leaves
38 amps for all DC loads. If the DC loads require more than 38 amps, the
battery will actually discharge even though the alternator is running.
Indication If the alternator is overloaded the:
• battery voltage gauge on the dashboard begins dropping from
approximately 14 V towards 12 V
• inverter LED signals a low battery with a slow blink
• inverter shuts down at 11.8 V and AC loads will stop operating
• battery voltage gauge will climb again as the alternator now has enough
power to charge the battery
Solutions You can reduce the AC or DC load on the battery or, for continuous
operation of large AC and DC loads you can consider installing a larger
alternator.
Comment Small alternator overloads may not be immediately noticeable and can take
several hours to discharge the batteries. Large overloads will discharge the
battery in a shorter time.
At low engine RPMs the alternator current will drop significantly causing
alternator overload to occur even with reduced AC and DC loads.