Xantrex PROwatt 600 Owner's Manual

PROwatt™ 600
Inverter

Owner’s Guide

PROwatt 600 Inverter

Owner’s Guide

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to 1 MW utility­scale systems for wind, solar, batteries, fuel cells, microturbines, and backup
power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and
variable speed drives that convert, supply, control, clean, and distribute electrical
power.

Trademarks

PROwatt is a trademark of Xantrex International. Xantrex is a registered
trademark of Xantrex Technology Inc.

Other trademarks, registered trademarks, and product names are the property of
their respective owners and are used herein for identification purposes only.

Notice of Copyright

PROwatt 600 Owner’s Guide © January 2001 Xantrex International. All rights
reserved.

Disclaimer

While every precaution has been taken to ensure the accuracy of the contents of
this guide, Xantrex International assumes no responsibility for errors or
omissions. Note as well that specifications and product functionality may change
without notice.

Date and Revision

January 2001, Revision 1

Part Number

445-0115-01-01

Contact Information

Web: www.xantrex.com
Email: [e-mail]
Phone: [phone]
Fax: [phone]

About This Guide

Purpose

The PROwatt 600 Owner’s Guide contains information that
enables individuals to install, operate, and troubleshoot the
PROwatt 600 Inverter.

Scope

The guide provides safety guidelines, detailed information
for designing an installation, procedures for installing the
inverter, as well as operating and troubleshooting
information. It does not provide details about particular
brands of batteries. You need to consult individual battery
manufacturers for this information.

Audience

The guide is intended for anyone who needs to install and
operate the PROwatt™ 600 Inverter.

About This Guide

Organization

This guide has four chapters and four appendixes.

Chapter 1, “Introduction”, outlines the main performance and
safety features of the PROwatt 600 Inverter. Reading this
chapter will give you a clear understanding of the inverter’s
capabilities.

Chapter 2, “Installation”, outlines the inverter’s main
physical features. This information will give you a good
orientation to the product before you install it. The chapter
then goes on to explain how to plan and complete an effective
installation.

Chapter 3, “Operation”, provides information about turning
on and operating the inverter. Details are provided about how
to read the front panel indicators to monitor the system. The
chapter also provides information about battery charging and
routine maintenance.

Chapter 4, “Troubleshooting”, explains how to identify and
solve problems that can occur with the inverter.

Appendix A, “Specifications”, provides the electrical and
physical specifications.

Appendix B, “Battery Types and Sizes”, provides
background information about battery types as well as
information that will allow you to calculate the size and
number of batteries your system requires.

Appendix C, “Alternators and Charging Systems”, describes
charging system components and explains how to design a
charging system for your installation.

Appendix D,“Product and System Information” , contains the
product’s warranty, explains how to return a product for
service, and describes how to prepare for a call to Xantrex
Customer Service.

iv

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in
personal injury or loss of life and appear in this
form.

CAUTION

Cautions identify conditions or practices that could
result in damage to the PROwatt unit or to other
equipment.

About This Guide

Note

:

Notes describe additional information which may

add to your understanding of how to use the inverter.

Related Information

You can find more information about Xantrex
Technology Inc. as well as its products and services at

www.xantrex.com

v

vi

Important Safety Information

WARNING

Before installing and using your PROwatt
Inverter, read and save these safety instructions.

General Precautions

1. Before installing and using the inverter, read all
appropriate sections of this guide and any cautionary
markings on the inverter and the batteries.

2. Do not operate the inverter if it has received a sharp
blow, been dropped, or otherwise damaged. If the unit is
damaged, see “Warranty” on page 42 and “Return

Material Authorization Policy” on page 43.

3. Do not dismantle the inverter; it contains no user
serviceable parts. Attempting to service the unit yourself
could cause electrical shock or fire.

remain charged after all power is disconnected.

page 43 for instructions on obtaining service.

™

600

Internal capacitors

See

4. To reduce the risk of electrical shock, disconnect both
AC and DC power from the inverter before working on
any circuits connected to the inverter. Turning off the
front panel On/Off will not reduce this risk.

5. Protect the inverter from rain, snow, spray, and bilge
water.

6. To reduce the risk of overheating or fire, keep the
ventilation openings clear, and do not install the inverter
in a zero-clearance compartment.

vii

Explosive Gas Precautions

Explosive Gas Precautions

1. Batteries generate explosive gases during normal
operation. Be sure you follow all relevant instructions
exactly before installing or using your inverter.

2. This equipment contains components which tend to
produce arcs or sparks. To prevent fire or explosion, do
not install the inverter in compartments containing
batteries or flammable materials or in locations that
require ignition-protected equipment. This includes any
space containing gasoline-powered machinery, fuel
tanks, as well as joints, fittings, or other connections
between components of the fuel system.

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.

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 could 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
or the like to metal, and thus cause a severe burn.

6. If you need to remove a battery, always remove the
positive terminal from the battery first. Make sure all
accessories are off so you don’t cause an arc.

viii

Precautions For Using Rechargeable Appliances

Precautions For Using Rechargeable
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 PROwatt
can power this charger or adapter safely.

Some rechargers for small nickel-cadmium batteries can be
damaged if connected to the PROwatt 600 Inverter. Do not
use the following with the PROwatt 600 Inverter:

• 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 chargers display a warning label stating that
dangerous voltages are present at the battery terminals

AC Wiring Warning

Do not connect the PROwatt 600 Inverter to AC distribution
wiring.

The PROwatt is designed to be connected directly to standard
electrical and electronic equipment. Do not connect it to
household or recreational vehicle AC distribution wiring. Do
not connect it to any AC load circuit in which the neutral
conductor is connected to ground (earth) or to the negative of
the DC (battery) source. Doing so will destroy the unit.

ix

x

Contents

General Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii

Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - viii

Precautions When Working With Batteries - - - - - - - - - - - - - - viii

Precautions For Using Rechargeable Appliances - - - - - - - - - - - ix

AC Wiring Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ix

1Introduction

Quality Power and Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - 2

Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

2 Installation

AC Wiring Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

PROwatt 600 Materials- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Front Panel (AC End) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Back Panel (DC End) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - 6

Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

Planning Your Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - 7
Choosing a Charging System - - - - - - - - - - - - - - - - - - - - - - - - 7

Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

Mounting the Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

xi

Contents

Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - 9

Grounding Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Connecting DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Cabling Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Cabling Procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

3Operation

Turning the Inverter On and Off- - - - - - - - - - - - - - - - - - - - - - - 16

Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - 16

Turning the Inverter Off Between Charges- - - - - - - - - - - - - - - - 16

Reading the Front Panel Indicators - - - - - - - - - - - - - - - - - - - - - 17

Green POWER LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Red FAULT LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Inverter Loads- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Problem Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Trouble Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Battery Charging Frequency - - - - - - - - - - - - - - - - - - - - - - - - - 20

Routine Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

4 Troubleshooting

Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - 22
Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - 23

A

Specifications

Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

B

Battery Types and Sizes

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

xii

Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - 28
Deep-Cycle Lead-Acid Batteries - - - - - - - - - - - - - - - - - - - - - 29

Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - 31

Battery Sizing Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

Battery Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

Two Batteries Connected In Parallel- - - - - - - - - - - - - - - - - - - - 34

Battery Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

C

Alternators and Charging Systems

Charging System Requirements - - - - - - - - - - - - - - - - - - - - - - - 38

Charging With an Engine Alternator - - - - - - - - - - - - - - - - - - - - 38

Using Your Vehicle’s Standard Engine Alternator - - - - - - - - - 38
Using an Alternator Controller - - - - - - - - - - - - - - - - - - - - - - 39

Contents

Using a High-Output Alternator - - - - - - - - - - - - - - - - - - - - - 39

Charging From AC Power- - - - - - - - - - - - - - - - - - - - - - - - - - - 39

Charging From Alternative Energy Sources - - - - - - - - - - - - - - - 40

D

Product and System Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - 43

Return Material Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 43

Information About Your System - - - - - - - - - - - - - - - - - - - - - - 45

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

xiii

xiv

1

Introduction

Congratulations on your purchase of the
PROwatt™ 600 Inverter! As part of the
PROwatt Inverter family, the PROwatt 600
has been designed to give you quality power,
ease of use, and outstanding reliability.

Please take a few moments to read this
chapter to familiarize yourself with the
PROwatt 600’s main performance and
protection features.

Quality Power and Ease of Use

Quality Power and Ease of Use

The PROwatt 600 Inverter is a professional-quality, mid­range inverter designed to handle a variety of household and
commercial applications including large screen TVs, VCRs,
computer systems, bread makers, blenders, fans, and small
power tools.

Superior features and rugged durability have been combined
with extreme ease of use:

• The unit is compact, light weight, and easy to install.

• The easy-to-read indicators on the front panel.

• Low standby battery demand means you don’t have to
worry about draining your battery if you leave the
inverter on for a few days. When the inverter is on but is
not powering any loads, the draw on the battery is less
than 300mA.

Comprehensive Protection

The PROwatt 600 Inverter comes equipped with numerous
protection features to guarantee you safe and worry-free
operation:

Low battery alarm

discharged to 10.7V or lower.

Automatic low voltage shutdown feature

from becoming completely discharged if the battery voltage
drops below 10V.

High voltage shutdown feature

input voltage rises to 15V or more.

Over temperature shutdown feature

the temperature rises above an acceptable level.

Alerts you if the battery has become

Protects the inverter if the

Protects the battery

Turns the inverter off if

2

2

Installation

Chapter 2 explains how to install the

PROwatt 600 Inverter.

Installing the PROwatt 600 is
straightforward. Here’s a summary of the
five main steps:

• Plan the installation.

• Choose a location.

• Mount the inverter.

• Connect the chassis ground.

• Connect the DC cables.

Remember: the better your planning, the
better the performance you will receive from
the PROwatt 600 Inverter.

3

AC Wiring Warning

AC Wiring Warning

WARNING

Do not connect the PROwatt 600 Inverter to AC
distribution wiring.

The PROwatt is designed to be connected directly to standard
electrical and electronic equipment. Do not connect it to
household or recreational vehicle AC distribution wiring. Do
not connect it to any AC load circuit in which the neutral
conductor is connected to ground (earth) or to the negative of
the DC (battery) source. Doing so will destroy the unit.

Safety Instructions

Before you install the PROwatt 600:

• Review the “Important Safety Information” on page vii.

• Read and follow all Warnings and Cautions in this
chapter.

PROwatt 600 Materials

Your PROwatt 600 Inverter package includes:

• 1 PROwatt 600 Inverter

• 1 Owner’s Guide

If either of these items is missing or is unsatisfactory in any
way, please contact Xantrex Customer Service:

Phone:

Fax:

Email:

1-800-670-0707

1-800-994-7828

[e-mail]

As soon as you unpack your inverter, be sure to record the
product information asked for on page 45. Then take a minute
to familiarize yourself with the front and back panel features.

4

Front Panel (AC End)

Front Panel (AC End)

POWER LED

On/Off Switch

POWER

ON

OFF

FAULT LED

FAULT

Figure 1 Front Panel (AC End)

AC Power Receptacles

Ventilation

Openings

OUTPUT

115Vac

60Hz

Back Panel (DC End)

Negative and Positive
DC Cabling Terminals

Figure 2 Back Panel (DC End)

Chassis Ground

Screw

Ventilation

Openings

5