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.
Contents Important Safety Information General precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Precautions when working with batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Precautions for using appliances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi 1 Introduction Introduction to the Xantrex HD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2 Operating features - - - - - - - - - - -
Contents 3 Maintenance Checking terminals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–2 Disconnecting and connecting Xantrex HD from the batteries - - - - - - - - - - - - - -3–3 Disconnecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 Connecting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 Replacing the fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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.
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.
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.
Introduction to the Xantrex HD Location Feature Description ① ② Positive terminal connecting to positive terminal of battery ③ ④ ⑤ Battery temperature sensor } Remote toggle switch connection. The connection must be secure for the inverter to work ⑦ Negative terminal connecting to negative 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.
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.
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.
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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. Variables affecting AC loads The Xantrex HD inverter/charger inverter can power a wide range of loads.
Planning for AC loads 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.
Operation 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.
Planning for AC loads 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
Typical operating time with fully-charged 400 amp-hour batteries † Appliance Watts Electric shaver 15 15 25 40 75 100 100 100 180 Minutes Hours 10 20 30 40 50 1 Table fan Video game Reading Lamp Notebook computer Computer printer Hand-held vacuum cleaner 19 in TV/VCR combo 3 cu. ft.
Planning for AC loads 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.
Operation 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.
Using the toggle switch Using the toggle switch Location The inverter/charger is controlled from the remote toggle switch on the control panel in the cabin as shown in Figure 2-3. Toggle switch Figure 2-3 Switch settings Remote switch The switch is used to disable the inverter. The charger is always on as long as shorepower is connected. If the switch is … The inverter is … On Providing AC to the vehicle when there is no shorepower and the battery voltage is acceptable.
Operation Switch LEDs The LEDs provide information about the operating state of the inverter/charger. Under normal operating conditions the lights will behave like this: AC LED: Illuminated when there is shorepower. Blinks slowly (once per second) when first connecting to shorepower then lights steadily or it will continue to blink if the AC voltage is not within range (100 V to 130 V). Inverter LED: Illuminated when the unit is inverting and there is no shorepower.
Operating the Inverter/Charger Operating the Inverter/Charger This section provides guidelines for operating the Xantrex HD. Turning the inverter on and running loads To run loads: • Put the switch in the On position by pressing down. • Check that the inverter LED is illuminated and AC LED is off if you are not connected to shorepower. • Connect appliances one at a time to the inverter. Don’t connect too many high-surge appliances at once.
Operation Battery charging When you are connected to shorepower, the AC LED is illuminated and the unit is both passing power through to the appliances and charging the batteries. To avoid low voltage problems, make sure your connection cord to shorepower is not too long and that it is heavy enough to support the loads you are running. A 14 or 12 gauge extension cord is recommended.
3 Maintenance Chapter 3, “Maintenance” provides procedures for checking the terminal connections on the inverter/charger, disconnecting Xantrex HD from the batteries, changing the overcurrent protection fuse, and removing or connecting the AC input and output cables.
Maintenance Checking terminals To check that the battery cables are firmly connected, you will need to remove the terminal caps. To remove the terminal cap: 1. Using a flathead screwdriver as shown in Figure 3-1, place the blade in the lip of the cap and push it gently against the cap until it lifts off. 2. To replace the cap, place it over the terminal and push down until it snaps into place.
Disconnecting and connecting Xantrex HD from the batteries Disconnecting and connecting Xantrex HD from the batteries Before doing any work with your batteries or with the inverter/charger, review “Important Safety Information” on page v. Disconnecting WARNING: Explosion or Fire Make sure the battery compartment is well ventilated. Flammable fumes are often present when working with batteries. To disconnect from the battery: 1. Disconnect the shorepower cable and turn the inverter/charger off. 2.
Maintenance WARNING: Explosion or Fire Do not complete the next step if flammable fumes are present. Explosion or fire may result. Thoroughly ventilate the battery compartment before making this connection. 3. Connect the positive battery cable from the inverter/charger to the positive terminal on the battery; then the negative to the negative with the last connection made at the Xantrex HD terminal to prevent sparks. You may hear an audible “pop” and see a spark when you make the last connection. 4.
Replacing the fuse . CAUTION: Do not overtighten fuse nuts! 3. Replace the fuse cover by placing it over the fuse and pressing down until it snaps into place. If the fuse blows a second time without being able to operate the unit, do not change the fuse again. Call your authorized Volvo dealer.
Maintenance Removing and reconnecting AC cables To remove the AC cables: ➣ Grasp the knurled surface of the connector housing as shown in Figure 3-3 and turn counter clockwise approximately one-half turn. Gently pull the cable out by grasping the connector. To reconnect: ➢ Insert the plug firmly. Turn the connector housing clockwise 1/2 turn until you feel resistance, then another 1/8 turn until it locks into place.
4 Troubleshooting Chapter 4, “Troubleshooting” provides information to help you identify common problems which may occur. Read this chapter before calling your authorized Volvo dealer. If you cannot solve the problem, record the details as suggested on page 4–5, then call your dealer.
Troubleshooting Troubleshooting Common problems The unit shuts down during operation for four main reasons: • • • • low battery—when the battery reaches approximately 11.8 Vdc (for loads greater than 150 watts) for more than four minutes, or 12.3 Vdc for loads less than 150 watts.
Troubleshooting Table 4-1 Troubleshooting reference (Continued) Symptom Possible Problem Remedy Loads stop operating without warning after they have been running for awhile Shorepower not connected Too many appliances have reduced battery voltage to shutdown level Reduce number of loads. Allow inverter to cool and restart. Start the truck to recharge the batteries.
Troubleshooting Table 4-2 explains the blinking pattern of the AC input LED when the inverter is connected to shorepower. Table 4-2 Interpreting AC input LED blink patterns Inverter LED AC input LED Condition Off ON Connected to shorepower within 100 to 130 Vac range and battery charger is operational Off Very slow blink • • • • Delay on transfer from the inverter to shorepower AC power is not in range (outside 100 to 130 Vac range) Battery is not being charged.
Calling your authorized Volvo dealer Calling your authorized Volvo dealer If none of the troubleshooting suggestions work, you will need to call your authorized Volvo dealer. If possible, note the circumstances surrounding the failure. They may help the service technician diagnose the problem quickly.
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A Specifications Appendix A “Specifications” contains the Xantrex HD product specifications, which include the inverter, charger, and transfer specifications. It shows derating curves for output surge, current versus temperature, and pass-through current. It also illustrates the threestage charging profile used by the unit. Note that all specifications are subject to change without notice.
Specifications Physical specifications Physical specifications A–2 Enclosure Sealed; dust and water-resistant Dimensions Approximately. 8.5" (21.8 cm)H x 7” (17.7 cm)W x 13.0"(33.0 cm)D, excluding DC ground connector (similar to Group 31 battery dimensions) Net weight 30 lbs. maximum without mounting brackets or external cables External finish Base - Clear anodized aluminium. Cover -Black polycarbonate/ABS plastic Mounting Orientation Upright only Mounting method Four M8x1.
Inverter specifications Inverter specifications All inverter specifications are at nominal conditions; 77 °F (25 °C,) 1000 W resistive load, 12 Vdc inverting, 120 Vac, unless otherwise specified. Inverter specifications Output wave form Modified sine wave Output power continuous 1000 VA continuous at 77 °F (25 °C) Surge rating 3000 VA for 2 min at –40 °F to 77 °F (–40 °C to 25 °C) See Figure A-1 for output at different temperatures. Operating voltage range 10.5 Vdc–16.
Specifications Inverter specifications (continued) Shutdowns and Restarts DC low voltage shutdown 1. 2. Battery voltage drops below 11.8 ±0.15 Vdc at heavy loads (more than 150 W) or 12.3 Vdc at light loads (less than 150 W) for more than 4 min and 10 sec (± 30 s) Battery voltage is below 10.5 ± 0.2 Vdc for 3 seconds DC low voltage restart 12.5 ± 0.15 Vdc DC high voltage shutdown 16.0 ± 0.2 Vdc DC high voltage restart Less than 16.
Transfer and general specifications Charger specifications (continued) Temperature compensation – 0.023 Vdc/ °C from -2 °C to 85 °C. Below -2 °C, the charger voltage defaults to the – 2 °C voltage Overvoltage shutdown Greater than or equal to 15.3 ± 0.
Specifications Rating curves and charging profiles Output Power (VA) 3000 2500 2000 1500 1000 500 0 2 1 4 3 6 5 7 8 9 10 100 Time (minutes) -40 to 25C 40C 55C 70C 85C – 40 to 77 F 104 F 131 F 158 F 185 F Figure A-1 Output surge rating R M 1 0 1 2 M a x .
Rating curves and charging profiles Bulk Charging Started Absorption Charge Float Charge Bulk Volts Setting Float Volts Setting DC Voltage Constant Current @ Maximum Charge Rate Reduced Reduced CurrentVoltage and Voltage Constant Voltage Load current on demand DC Current Time Figure A-3 Three-stage charging profile A–7
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Index A AC cables, removing or connecting 3–6 AC load calculating size 2–4 definition 2–2 factors affecting 2–2 types of 2–2 AC power, connect delay 2–12 alternator, effects of overloading 2–7 ambient temperature effect on operation 2–2, 2–11 effect on output power 2–3 appliances see AC load battery-operated vi authorized dealer, calling 4–5 auto shutdown feature 1–4 automatic shutdown 2–12 automatic transfer between AC and DC 1–5 B batteries charging with Xantrex HD 2–12 nickel-cadmium vi precautions for
Index F P flashlights see problem loads fuse, over-current protection 1–3 fuse, replacing 3–4 physical specifications A–2 problem loads 2–3 H high battery shutdown 4–2 I inductive load see AC loads inverter features 1–4 inverter specifications A–3 L LEDs blinking patterns 4–2 load management capability 1–5 loads see AC load 2–2 loads, effect of large loads on alternator 2–7 low AC, causes of 4–4 low battery shutdown 4–2 low voltage shutdown 1–4 M maintenance checking terminal connections 3–2 disconn
Index T temperature see ambient temperature temperature and power, relationship of 2–3 temperature and time derating curve (figure) 2–4 terminals caps, removing 3–2 three-stage charging profile A–6 time, running time of AC loads 2–4 toggle switch purpose 2–9 torques for fuse replacement 3–4 transfer specifications A–5 troubleshooting reference 4–2 U using Xantrex HD, guidelines for 2–11 V variable speed motor see problem loads X Xantrex HD as a charger 1–4 as an inverter 1–4 common problems 4–2 conditio
