Xantrex Technology Automobile Battery Charger RM1012 User Manual

Heavy Duty Inverter/Charger  
1000 Watt Weatherproof  
Owner’s Guide  
Model RM1012  
For Volvo Trucks  
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Precautions for using appliances- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi  
1 Introduction  
2 Operation  
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  
iii  
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Contents  
3 Maintenance  
Disconnecting and connecting Xantrex HD from the batteries - - - - - - - - - - - - - -3–3  
Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–2  
Physical specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2  
Charger specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4  
Transfer and general specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5  
Rating curves and charging profiles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6  
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1  
iv  
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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. 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.  
v
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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.  
vi  
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Introduction  
1
Chapter 1, “Introduction” describes the main  
performance and protection features of the  
inverter/charger.  
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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.  
x
x
x
x
x
x
x
Figure 1-1 Features of the inverter/charger  
1–2  
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Introduction to the Xantrex HD  
Feature  
x
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.  
x
Battery temperature sensor  
x
x
x
x
AC output to vehicle  
AC input from shorepower  
Remote toggle switch connection. The connection must be  
secure for the inverter to work  
Negative terminal connecting to negative terminal of battery  
x
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  
1–3  
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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.  
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.  
1–4  
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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/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  
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1–6  
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Operation  
2
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.  
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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. 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  
Inductive 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.  
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.  
2–2  
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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.  
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  
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  
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  
2–3  
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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  
500  
0
4
5
6
7 8  
9
2
1
3
10  
100  
Time (minutes)  
-40 to 25C  
– 40 to 77 F  
40C  
104 F  
55C  
131 F  
70C  
158 F  
85C  
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.  
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  
The information in Table 2-1 assumes:  
condition  
there is a properly maintained 400 amp-hour battery bank  
the batteries have not been damaged by deep discharge and are  
relatively new  
2–4  
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Planning for AC loads  
Factors  
Consider these factors when you are calculating loads:  
affecting 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  
2–5  
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Table 2-1 Typical operating time with fully-charged 400 amp-hour batteries †  
Appliance  
Watts Minutes  
10 20 30 40 50  
Hours  
1
2
3
4
5
6
9
18 24  
Electric shaver  
15  
Table fan  
15  
Video game  
25  
Reading Lamp  
40  
Notebook computer  
Computer printer  
Hand-held vacuum cleaner  
19 in TV/VCR combo  
75  
100  
100  
100  
180  
*
3 cu. ft. refrigerator  
Electric blanket  
Electric buffer  
Electric drill 1/2”  
Halogen work light  
Coffee maker  
Toaster  
200  
400  
500  
750  
800  
1000  
1200  
1500  
Microwave oven  
Hair dryer  
* 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).  
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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  
1110 W (DC)  
AC Loads  
(1000 W)  
Xantrex HD  
Alternator  
(130 A)  
12 Volt Battery  
Driver Installed  
Loads  
38 A  
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.  
2–7  
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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.  
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  
Comment  
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.  
2–8  
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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  
settings  
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.  
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  
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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.  
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  
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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. You may notice some appliances  
halt or dim momentarily while another is starting up.  
Running in extremes of hot or cold temperatures  
Hot  
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.  
Cold  
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  
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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.  
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  
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).  
Output  
power  
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.  
Connect  
delay to AC  
power  
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 then will  
illuminate steadily.  
Load failure  
If any loads fail to operate, or the inverter shuts down, refer to Chapter 4,  
“Troubleshooting” for suggestions.  
2–12  
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Maintenance  
3
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.  
3–1  
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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.  
3
1
2
Figure 3-1 Lifting the terminal cap  
3–2  
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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.  
Disconnect the negative connection first at the inverter/charger  
terminal and then disconnect the positive at the battery terminal.  
3. If you 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.  
3–3  
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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. Tighten to a torque of 14.5 ft-lbs (+/-10%).  
5. 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 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.  
Littelfuse Mega® Fast Blow, 250 A, 32 V; part number 298250  
Bussmann® 250 A 48 V; part number AMG-250  
To replace the fuse:  
1. Lift the fuse cover off as shown in Figure 3-2.  
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).  
3–4  
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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.  
3
1
2
Figure 3-2 Removing the fuse cover  
3–5  
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Maintenance  
Removing and reconnecting AC cables  
To remove the AC cables:  
x 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:  
x 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.  
Power to vehicle  
Shorepower  
Turn these counterclockwise  
to remove  
Figure 3-3 AC input and output cables  
3–6  
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Troubleshooting  
4
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.  
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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.  
high battery—when the battery voltage exceeds 16 Vdc  
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  
Troubleshooting reference  
Symptom  
Possible Problem  
Remedy  
Loads will not start when there Inverter not turned on  
is no shorepower  
Turn the inverter on  
Batteries at low voltage  
Recharge batteries by running the  
engine or connect to shorepower  
Inverter too hot  
Wait until inverter has cooled  
down  
Loads stop running almost as  
soon as they start  
Load is too heavy  
Reduce the load  
Batteries at low voltage level  
Recharge batteries by running the  
engine or plug into shorepower  
Bad battery cable or corroded  
battery terminals  
Check cable and connectors  
Test and replace, if necessary  
Batteries in poor condition  
4–2  
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Troubleshooting  
Table 4-1  
Troubleshooting reference (Continued)  
Symptom  
Possible Problem  
Remedy  
Loads stop operating without  
warning after they have been  
running for awhile  
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.  
Shorepower not connected  
Ambient temperature is too  
high  
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)  
Check that the remote switch is  
firmly connected  
Fuse on the unit (shown in  
Figure 1-1) may have blown  
(not likely)  
Replace fuse or return unit to an  
authorized Volvo dealer  
AC voltage at receptacles  
reads low  
Wrong type of volt meter being Use a true RMS meter  
used  
In inverter mode, times to  
shutdown are getting shorter  
for the same kind of AC load  
Bad battery cable or corroded Check cables and connectors  
battery terminals  
Batteries too old or damaged  
Replace batteries  
Blinking lights on the remote switch  
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:  
L
Fast 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  
Slow blink  
Very slow blink  
4–3  
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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  
Fast blink  
Fast blink  
Fast blink  
N/A  
Low battery  
Fast blink  
Slow blink  
Slow blink  
High battery  
Unit over temperature and has shut down  
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  
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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?  
4–5  
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4–6  
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Specifications  
A
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.  
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Specifications  
Physical specifications  
Physical specifications  
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  
Mounting method  
Upright only  
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  
Battery size  
#2/0 AWG Minimum, maximum 6 feet long,  
each way  
300 Ah acceptable; 400 Ah recommended  
A–2  
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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  
Output power continuous  
Surge rating  
Modified sine wave  
1000 VA continuous at 77 °F (25 °C)  
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  
Input DC voltage rating  
Output voltage  
10.5 Vdc–16.0 Vdc  
12 Vdc  
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 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  
Peak efficiency  
All (0 to 1, leading or lagging)  
Greater than 93% at 12.6 Vdc input at 77 °F  
(25 °C)  
Idle power consumption  
Auto-shutdown mode  
Less than15 W (inverting with 120 Vac output  
and no load)  
Inverter output is less than 15 ±5 W and battery  
is less than 13 Vdc for 24 hours  
A–3  
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Specifications  
Inverter specifications (continued)  
Shutdowns and Restarts  
DC low voltage shutdown  
1. 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)  
2. 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.  
Algorithm for generic flooded batteries  
only  
No equalization mode  
AC input voltage  
100–130 Vac  
54–66 Hz  
AC input frequency  
Minimum battery voltage  
8 Vdc  
The charger does not operate below this level  
Maximum charger input current  
13.0 Aac rms  
Maximum charge rate  
Charger efficiency  
50 ± 5 Adc. See Figure A-2  
Greater than 80%  
Absorption charge voltage  
Float charge voltage  
14.3 ± 0.3 Vdc at 77 °F (25 °C)  
13.4 ± 0.3 Vdc at 77 °F (25 °C)  
A–4  
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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 ± 0.3 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  
90 ±5 Vac  
AC low voltage transfer  
AC low voltage restart  
AC high voltage transfer  
Standby/off consumption  
95 ±5 Vac, 30 second delay  
None  
< 0.7 at 12.5 Vdc with charger and inverter  
both off  
Operating temperature range  
Storage temperature range  
Altitude limit  
– 40 °F to +185 °F (– 40 °C to +85 °C)  
– 40 °F to +185 °F (– 40 °C to +85 °C)  
15 000 feet (5000 metres)  
AC neutral to ground bonding 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  
A–5  
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Specifications  
Rating curves and charging profiles  
3000  
2500  
2000  
1500  
1000  
500  
0
7 8  
4
5
6
9
1
2
3
10  
100  
Time (minutes)  
55C  
-40 to 25C  
– 40 to 77 F  
40C  
70C  
85C  
185 F  
158 F  
104 F  
131 F  
Figure A-1 Output surge rating  
6
0
0
0
0
0
0
0
5
4
3
2
1
- 4  
0
- 2  
0
0
2
0
4
0
6
0
8
0
A
m
b
i e  
n
t
t e  
m
p
e
r
a
t u r e ( C  
)
Figure A-2 Charging current versus temperature derating curve  
A–6  
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Rating curves and charging profiles  
Absorption Charge  
Float Charge  
Bulk  
Charging  
Started  
Bulk Volts Setting  
Float Volts Setting  
DC Voltage  
Constant Current  
@ Maximum  
Charge Rate  
Reduced Voltage  
Load current on demand  
Constant Voltage  
DC Current  
Time  
Figure A-3 Three-stage charging profile  
A–7  
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A–8  
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Index  
battery packs vi  
breaker switch  
resetting 2–12  
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  
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
see AC load  
battery-operated vi  
D
authorized dealer, calling 4–5  
auto shutdown feature 1–4  
automatic shutdown 2–12  
automatic transfer between AC and DC  
1–5  
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  
B
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  
E
explosive fumes 3–4  
extension cord, length of 4–4  
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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  
R
H
high battery shutdown 4–2  
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  
I
inductive load see AC loads  
inverter features 1–4  
inverter specifications A–3  
L
LEDs  
blinking patterns 4–2  
safety information v  
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  
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  
M
maintenance  
checking terminal connections 3–2  
disconnecting battery cables 3–3  
replacing the fuse 3–4  
N
nickel-cadmium batteries vi  
O
operating time of AC loads (table) 2–6  
over temperature shutdown 4–2  
overload shutdown 4–2  
IX–2  
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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  
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  
IX–3  
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