Xantrex RM1012 User's Manual
Contents
1. 2 12 Miscellaneous hints 2 12 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 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 Indek HSS ee Sees eS oP sass SS see See as IxX 1 Important Safety Information WARNING A Before using your Inverter Charger read and save these safety instructions General precautions 1 Before using the2. Disconnect the negative connection first at the inverter charger terminal and then disconnect the positive at the battery terminal 3 Ifyou are replacing batteries make sure they are the same kind and capacity as you are currently using 4 Disconnect the ground wire if the unit must be removed from its mounting bracket Connecting To connect to the batteries 1 Ensure shorepower is disconnected and the inverter charger is off 2 Connect the ground wire if it was previously removed CAUTION Reverse Polarity Do not connect cables in reverse polarity If you do the fuse will blow the fuse and the unit could be damaged 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 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 Tighten to a torque of 14 5 ft lbs 10 Check that the inverter is operating by enabling it from the toggle switch as explained in Using the toggle switch on page 2 9 Replacing the fuse WARNING Correct fuse type To reduce the risk of fire and electrical hazards replace the
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 Introduction Operating features Inverter charger Inverter features 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 Xantrex HD offers the following inverter features e 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 2
4. depends on variables such as e type of load e ambient temperature e 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 The way in which an AC load draws power may determine how effectively it can be powered from the inverter charger 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 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 DC loads Problem loads Planning for AC loa
5. Table 2 1 Battery The information in Table 2 1 assumes condition e e 2 4 there is a properly maintained 400 amp hour battery bank the batteries have not been damaged by deep discharge and are relatively new Planning for AC loads Factors Consider these factors when you are calculating loads apecune load 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 9 Table 2 41 Typical operating time with fully charged 400 amp hour batteries t Appliance Watts Minutes 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 Average The inverter charger shuts down after 24 hours if it does not detect a load or loads less than 20 W Based
6. 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 Ifpossible plug the inverter charger into an AC source outlet that is protected by a Ground Fault Circuit Interrupting GFCT 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 Important Safety Information Never smoke or al
7. 0 watts for 24 hours This feature prevents the inverter from draining the batteries if it is left on without a load Charger features Operating features Xantrex HD offers the following charger features e 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 5 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 Variables affecting AC loads Type of loads AC loads Resistive loads Inductive loads 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 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
8. 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 LST 1W8 1 800 52 VOLVO 1 800 528 6586 www volvotrucks com Contents I
9. Invert mode AC output neutral is connected to AC ground chassis Charge mode AC output neutral is connected to AC input neutral AC input neutral is always isolated form AC ground Specifications Rating curves and charging profiles Output Power VA 3000 2500 2000 1500 1000 oa Q oO 3 4 5 6 7 8 910 Time minutes 100 40 to 25C 40C 4 55C gt lt 70C 85C 40 to 77 F 104 F 131 F 158 F 185 F Figure A 1 Output surge rating Charger current Amps 40 20 o 20 40 Ambienttem perature C Figure A 2 Charging current versus temperature derating curve Rating curves and charging profiles Bulk Absorption Charge Float Charge Charging __ Bulk VolisSeting N O O O O O O OO Started Float Volts Setting DC Voltage Constant Current Cae Reduced Voltage Constant Voltage Load current on demand DC Current Time Figure A 3 Three stage charging profile A 8 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 c
10. Unit over temperature and has shut down Fast blink Slow blink Ambient temperature too high and unit has shut down Slow blink N A Over current Very slow blink N A Auto shutdown Inverter has shut down because no load has been detected in 24 hours or the load is too small to detect 4 4 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 How long have you had the inverter Serial number Battery types and sizes Appliances running at shutdown Were the LEDs flashing and if so what pattern slow blinks fast blinks Was the ambient temperature extremely hot or cold Were any DC appliances affected Has this happened before 4 6 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 three stage charging profile used by the unit Note that all specifications are subject to change without notice Specifications Physical specifications Physical specifications Enclosure Sealed dust and water re
11. W 10 5to 16 Vdc input at 40 to 185 F 40 C 85 C Output frequency 60 0 0 1 Hz 40 F to 185 F 40 C to 85 C ambient temperature Power factor allowed All 0 to 1 leading or lagging Peak efficiency Greater than 93 at 12 6 Vdc input at 77 F 25 C Idle power consumption Less than15 W inverting with 120 Vac output and no load Auto shutdown mode Inverter output is less than 15 5 W and battery is less than 13 Vdc for 24 hours Specifications Inverter specifications continued Shutdowns and Restarts DC low voltage shutdown pear 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 0 Vdc same as DC high voltage shutdown there is no hysteresis Charger specifications All charging specifications are at nominal conditions 77 F 25 C 14 0 Vdc at 50 A charging 120 Vac 60 Hz unless otherwise specified Charger specifications Charging method Three stage charging with battery temperature compensation See Figure A 3 e Algorithm for generic flooded batteries only e No equalization mode AC
12. able 2 6 over temperature shutdown 4 2 overload shutdown 4 2 IX 2 P physical specifications A 2 problem loads 2 3 R rating curves output surge rating A 5 razors see problem loads rechargeable tools see problem loads remote switch blinking lights on the 4 3 resistive load see AC load type of resistive loads examples of 2 2 restarting after shutdown 2 11 S safety information v safety monitoring feature 1 4 servicing no user serviceable parts v shorepower definition 1 4 shutdown automatic 2 12 restarting after 2 11 size of AC load calculating 2 4 surge capability 1 4 surge loads examples of 2 2 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 condition for shutdown 4 2 derating curves for A 5 disconnecting from batteries 3 3 location in truck 1 3 main features 1 2 maintaining 3 1 turning on 2 11 Xantrex HD features figure 1 2 Index IX 3
13. alling 4 5 auto shutdown feature 1 4 automatic shutdown 2 12 automatic transfer between AC and DC 1 5 batteries charging with Xantrex HD 2 12 nickel cadmium vi precautions for working with v battery cables disconnecting 3 3 battery condition effect on AC loads 2 5 battery operated appliances see problem loads battery packs vi breaker switch resetting 2 12 C charger features 1 5 charger specifications A 4 charging current 1 5 common problems suggestions for 4 2 connect delay to AC power 2 12 current vs temperature derating curve A 6 D DC loads effect on alternator 2 7 effect on operating times of AC loads 2 3 derating curves current vs temperature A 6 dimmer switch see problem loads disconnecting Xantrex HD from batteries 3 3 explosive fumes 3 4 extension cord length of 4 4 Index F flashlights see problem loads fuse over current protection 1 3 fuse replacing 3 4 H high battery shutdown 4 2 I inductive load see AC loads inverter features 14 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 disconnecting battery cables 3 3 replacing the fuse 3 4 nickel cadmium batteries vi O operating time of AC loads t
14. ds DC loads are those that run off the 12 V electrical system on the truck A few examples of DC loads are e marker lights headlights cab lighting other lights using DC power e DC refrigerators e CBs e 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 e dimmer switches e some small rechargeable hand power tool chargers e small battery operated appliances such as flashlights razors night lights e variable speed motors Ambient temperature Ambient The ambient temperature that is the air temperature around the temperature 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 Generally the output power decreases as the temperature increases For and power 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
15. en will illuminate steadily If any loads fail to operate or the inverter shuts down refer to Chapter 4 Troubleshooting for suggestions 3 1 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 Figure 3 1 Lifting the terminal cap 3 2 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 Remove the inverter charger cables from the battery
16. fuse with a fuse of the same type and rating Using the wrong fuse type can damage the unit and void your warranty The inverter charger over current protection fuse shown in Figure 1 1 protects the unit from internal failure or reverse polarity when connecting it to the battery If it blows for any reason replace it with only the fuse types listed below e e Littelfuse Mega Fast Blow 250 A 32 V part number 298250 Bussmann 250 A 48 V part number AMG 250 To replace the fuse l 2 Lift the fuse cover off as shown in Figure 3 2 Remove the spent fuse and install the new fuse Be sure to use a lock washer when replacing the nuts Tighten to a torque of 4 5 5 ft lb 5 5 7 5 Nm 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 Figure 3 2 Removing the fuse cover 3 5 Maintenance Removing and reconnecting AC cables To remove the AC cables gt 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 gt Insert the plug firmly Turn the connector housing clockwise 1 2 turn until you feel resistance then anot
17. her 1 8 turn until it locks into place ower to vehicle Shorepower Turn these counterclockwise to remove Figure 3 3 AC input and output cables 3 6 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 e 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 high battery when the battery voltage exceeds 16 Vdc e overload when the AC load connected to the inverter exceeds the rated load over temperature when the internal temperature thresholds are reached This table lists problems you may encounter and offers suggestions to fix them Refer to Table 4 2 and Table 4 3 for explanation of the blinking LEDs Table 4 1 Symptom Troubleshooting reference Possible Problem Remedy Loads will not start when there is no shorepower Inverter not turned on Batteries at low voltage Inverter too hot Turn the inverter on Recharge batteries by running the engine or connect to shorepower Wait until inverte
18. input voltage 100 130 Vac AC input frequency 54 66 Hz Minimum battery voltage 8 Vde The charger does not operate below this level Maximum charger input current 13 0 Aac mms Maximum charge rate 50 5 Adc See Figure A 2 Charger efficiency Greater than 80 Absorption charge voltage 14 3 0 3 Vdc at 77 F 25 C Float charge voltage 13 4 0 3 Vdc at 77 F 25 C Transfer and general specifications Charger specifications continued Temperature compensation 0 023 Vde 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 3 Vdc Transfer and general specifications Transfer and general specifications AC input bypass current 20 Aac maximum continuous at 77 F 25 C Derates after 30 C to 5 Aac at 185 F 85 C Transfer speed 10 40 ms typical AC low voltage transfer 90 5 Vac AC low voltage restart 95 5 Vac 30 second delay AC high voltage transfer None Standby off consumption lt 0 7 at 12 5 Vdc with charger and inverter both off Operating temperature range 40 F to 185 F 40 C to 85 C Storage temperature range 40 F to 185 F 40 C to 85 C Altitude limit 15 000 feet 5000 metres AC neutral to ground bonding
19. low a spark or flame near the engine or battery 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 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 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 Before making the final connection to a battery be sure the polarity is correct negative to negative and positive to positive 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 vi 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 e Small battery operated appliances like flashlights razors and night ligh
20. mportant Safety Information General precautions Vv Precautions when working with batteries v Precautions for using appliances vi 1 Introduction Introduction to the Xantrex HD 1 2 Operating features 1 4 2 Operation 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
21. old or damaged Blinking lights on the remote switch Check cables and connectors Replace batteries This table describes the different sequences of blinking lights you may encounter when the inverter is enabled switch is on or the unit is charging switch is off Light sequences are described as follows Fast blink Slow blink Very slow blink Light is on for 1 4 second and off for 1 4 second Light is on for 1 2 second and off for 1 2 second Light is on for one second and off for one second 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 AC output load may be too great Extension cord to shorepower may be too long or not of sufficient conductor size resulting in voltage drop Table 4 3 explains the inverter LED flashing pattern when the unit is in invert mode or in charge mode Table 4 3 Inverter LED blink patterns Unit in invert Unit in charge mode mode Condition Slow blink N A Low battery Fast blink Fast blink High battery Fast blink Slow blink
22. 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 uoneiado 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 92 A Xantrex HD AC Loads 1000 W eS dl Alternator 12 Volt Battery Driver Installed 130 A ee nstalle 38A Factory Installed Loads DC Loads 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 Operation Indication Solutions Comment 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 If the alternator is overloaded the e battery voltage gauge on the dashboard begins dropping from approximately 14 V towards 12 V e inverter LED signals a low battery
23. r has cooled down Loads stop running almost as soon as they start 4 2 Load is too heavy Batteries at low voltage level Bad battery cable or corroded battery terminals Batteries in poor condition Reduce the load Recharge batteries by running the engine or plug into shorepower Check cable and connectors Test and replace if necessary Table 4 1 Symptom Troubleshooting reference Continued Possible Problem Troubleshooting 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 Ambient temperature is too high Reduce number of loads Allow inverter to cool and restart Start the truck to recharge the batteries Disconnect appliances and let the unit cool down Inverter will not work even after toggling switch and batteries are charged and the inverter is cold Remote switch may be disconnected at the unit not likely Fuse on the unit shown in Figure 1 1 may have blown not likely Check that the remote switch is firmly connected Replace fuse or return unit to an authorized Volvo dealer AC voltage at receptacles reads low Wrong type of volt meter being used Use a true RMS meter In inverter mode times to shutdown are getting shorter for the same kind of AC load Bad battery cable or corroded battery terminals Batteries too
24. sistant 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 Ibs 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 25 threaded holes accessible from bottom only one in each corner and or battery hold down bar over center top of cover Recommended torque 5 6 ft lb 7 8 Nm Battery cable 2 0 AWG Minimum maximum 6 feet long each way Battery size 300 Ah acceptable 400 Ah recommended 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 Vdce 16 0 Vdc Input DC voltage rating 12 Vdc Output voltage 120 Vac RMS Output voltage regulation 108 to 125 Vac under steady state 0 to 1000 W load with 11 8 to 14 5 Vdc input at 25 C 108 to 132 Vac up to 1000
25. that it is heavy enough to support the loads you are running A 14 or 12 gauge extension cord is recommended If the AC LED flashes slowly about twice per second this means the AC voltage is out of range and your batteries are not charging Using shorepower If you are running too many appliances you may either trip the 15 amp truck breaker or the shorepower breaker Reduce the load and reset the affected breaker Note that the charger will automatically reduce battery charging if other AC loads are connected This helps to prevent nuisance tripping of the shorepower breaker Miscellaneous hints Automatic shutdown Output power Connect delay to AC power Load failure 2 12 The inverter automatically turns off if it has not detected any AC loads for 24 hours or the loads are so small the inverter cannot detect them such as an alarm clock or very small television less than 10 20 watts Remember that the total output of the inverter charger is 1000 watts and not 1000 watts per outlet if there is more than one Note The Xantrex HD does not provide any warning before it shuts down If you need to operate a critical AC load be sure there are no heavy loads connected and that the batteries have been recently charged If you are connected to shorepower the AC LED should be on and the inverter LED off The AC LED may blink slowly when you first apply shorepower because of a connect delay about 30 seconds but th
26. 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 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 3000 2500 2000 1500 1000 Output Power VA 1 2 3 4 5 6 7 8 910 100 Time minutes 40 to 25C 40C 4 55C gt lt 70C 85C 40 to 77 F 104 F 131 F 158 F 185 F 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 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 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
27. ts 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 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 4 Kag NS see Ht a eae ll M N A SA Figure 1 1 Features of the inverter charger Introduction to the Xantrex HD Feature Description 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 OAO 80 AC input from shorepower Remote toggle switch connection The connection must be secure for the inverter to work D Negative terminal connecting to negative terminal of battery
28. ts 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 If the LED is blinking once every two seconds very slow blink it means the unit has shut down to avoid draining the batteries A fast blinking Inverter LED light indicates a unit fault Refer to Chapter 4 Troubleshooting for more information Note Some switches may also have a center position The center position also enables the inverter Inverter disabled off when switch pushed up Inverter LED AC LED Inverter enabled on when switch is pushed down Figure 2 4 Inverter charger switch positions 2 10 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 e Put the switch in the On position by pressing down e Check that the inverter LED is illuminated and AC LED is off if you are not connected to shorepower e Connect appliances one at a time to the inverter Don t connect too many high surge appliances at once You may notice some appliances halt or dim momentarily while another is starting up Running in extremes of hot or cold tempera
29. tures Hot Cold In extremely hot conditions the inverter may shut down sooner than it would in normal or cold temperatures The unit may be hotter than the outside air temperature when parked on hot pavement for example When the ambient temperature is high reduce the number of loads In extreme cold temperatures your batteries may have less stored energy At 0 F 18 C your battery has only half the standby power than it has at 77 F 25 C Restarting after a shutdown If the appliances stop operating suddenly it usually means that the battery voltage is too low or you have drawn too much power for too long Try restarting the inverter by turning the switch off then on again If you are running several loads try disconnecting one or two of them If it doesn t start right away let the inverter rest a few minutes then try again The batteries should be recharged as soon as possible If it still refuses to power your loads start the vehicle to charge the batteries Note Turning the switch off then on again to restart after a shutdown should only be considered a temporary measure The batteries likely need to be recharged 2 11 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
30. with a slow blink e inverter shuts down at 11 8 V and AC loads will stop operating e battery voltage gauge will climb again as the alternator now has enough power to charge the battery 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 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 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 Remote switch Switch The switch is used to disable the inverter The charger is always on as long settings 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 Off Providing pass through AC to the vehicle only if there is shorepower The inverter is disabled and will not provide AC power in the absence of shorepower 2 9 Operation Switch LEDs The LEDs provide information about the operating state of the inverter charger Under normal operating conditions the ligh
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