Xantrex XPower 400R, XPower 400 Plus Owner's Manual

by

XPower Powerpack
400 PLUS and 400R

Owner's Guide

by

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobile units to one MW
utility-scale 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

XPower is a trademark of Xantrex International. Xantrex is a registered
trademark of Xantrex International.

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

Xpower™ Powerpack 400 Plus and 400R Owner’s Guide
© July 2004 Xantrex International. All rights reserved.

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

July 2004 Revision A

Part Number

975-0162-01-01

Contact Information

Telephone: [phone] (toll free in North America)

1-360-925-5097 (direct)

Fax: [phone] (toll free in North America)

1-360-925-5143 (direct)

Email: [e-mail]

Web: www.xantrex.com

About This Guide

Purpose

The purpose of this Owner’s Guide is to provide explanations
and procedures for installing, operating, maintaining, and
troubleshooting the XPower Powerpack 400 Plus and
XPower Powerpack 400R.

The Guide provides safety guidelines, detailed planning and
setup information, as well as information about operating and
troubleshooting the unit.

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in
personal injury or loss of life.

CAUTION

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

i

About This Guide

Important: These notes describe an important action item

or an item that you must pay attention to.

Note: These notes describe additional information which

may add to your understanding of how to use the product.

References to XPower Powerpack

In this guide, both the XPower Powerpack 400 Plus and the
XPower Powerpack 400R (with radio and air compressor)

are referred to as XPower Powerpack when the information
applies to both models. However, when the information is
specific to one model, then reference is made specifically to
the XPower Powerpack 400 Plus or to the XPower
Powerpack 400R.

Related Information

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

ii 975-0162-01-01

Important Safety Instructions

The XPower Powerpack 400 Plus and XPower Powerpack
400R generate a type of AC power similar to a normal
household wall outlet. Operating the XPower Powerpack
incorrectly or misusing it may damage the equipment or
create hazardous conditions for the user.

Important: Before using your XPower Powerpack 400 Plus and
XPower Powerpack 400R, be sure to read and save these safety
instructions.

Warnings and Cautions

WARNING: Shock hazard. Keep away from
children.

The XPower Powerpack generates the same potentially lethal AC
power as a normal household wall outlet. Do not insert foreign
objects into the AC Outlet, the DC Power Socket, the Jump-Start
Cable Port, or the ventilation holes. Do not expose this product to
water, rain, snow, or spray.
Do not open the XPower Powerpack except to replace the internal
battery. Have a qualified technician complete any service work.

CAUTION

Do not connect any AC appliance with the neutral conductor
connected to ground to the XPower Powerpack.

iii

Important Safety Instructions

CAUTION

Do not expose the XPower Powerpack to temperatures over 104 °F
(40 °C).

-

WARNING: Explosion hazard

Do not use this product where there are flammable fumes or gases,
such as in the bilge of a gasoline- powered boat, or near propane
tanks. Do not use this product in an enclosure containing
automotive-type lead acid batteries. These batteries, unlike the
sealed AGM battery in XPower Powerpack, vent explosive
hydrogen gas which can be ignited by sparks from electrical
connections.
When working on electrical equipment, always ensure someone is
nearby to help you in an emergency.

WARNING: Heated surface

Ensure at least 2" (5 cm) air space is maintained on all sides of the
XPower Powerpack. During operation, keep away from materials
that may be affected by high temperatures such as blankets, pillows
and sleeping bags.

WARNING: Fire haz ard

Never allow jump-start cables’ red and black clamps to touch each
other or another common metal conductor. This could cause
damage to the unit and/or create a sparking/explosion hazard.
Always disconnect the jump-start cables from the unit after use and
clip the plastic guard over the jump-start cable port.

WARNING: Fire haz ard

Jump-start cable clamps must be connected positive to positive (red
clamp to battery “+”) and negative to negative (black clamp to
battery “-”). A reverse polarity connection (positive to negative)
may cause damage to the unit and/or create a sparking/explosion
hazard.

iv 975-0162-01-01

Important Safety Instructions

WARNING: Fire haz ard

The jump-start feature is designed for short term operation only—
less than 4 seconds. Operating the jump-start feature for more than
4 seconds may cause damage to the unit. Allow the XPower
Powerpack to cool down for at least 3 minutes after each jump­start.

WARNING: Risk of explosion, fire or burns

The battery terminals exposed at the Jump-Start Cable Port have
enough energy present to cause a spark, creating an explosion
hazard, or to cause burns if a metal object contacts both terminals.
Always clip the plastic guard over the Port when not in use.

WARNING: Fire haz ard

Do not leave the compressor unattended while operating. The
compressor is designed for short term operation only. Operation of
the compressor over an extended period of time will cause the
compressor unit to overheat and may cause damage. Allow the
compressor to cool down for 10 minutes after each 10 minutes of
continuous operation.

975-0162-01-01 v

Important Safety Instructions

Precautions When Working With Batteries

WARNING: Explosion and fire hazard

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 in vicinity of the
engine or batteries.

4. Be careful not to drop a metal object on the battery or
allow a metal tool to simultaneously touch the positive
and negative cable ends or battery terminals. It might
spark or short-circuit the battery or other electrical parts
and cause an explosion.

5. Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with a lead-acid
battery. A lead-acid battery produces a short-circuit
current high enough to weld a ring or other similar
objects to metal, causing 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.

7. Someone should be within range of your voice, or close
enough to come to your aid when you work near a lead­acid battery.

8. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, and eyes.

9. Wear complete eye protection and clothing protection.
Avoid touching your eyes while working near batteries.

vi 975-0162-01-01

Important Safety Instructions

10. If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid enters your
eyes, immediately flood them with running cold water for
at least twenty minutes and get medical attention
immediately.

11. Keep a supply of baking soda on hand in the area of the
batteries. Baking soda neutralizes lead-acid battery
electrolyte.

975-0162-01-01 vii

Important Safety Instructions

Precautions for Using Rechargeable
Appliances

CAUTION

The output of the inverter is non-sinusoidal.

Most rechargeable battery-operated equipment uses a
separate charger or transformer that is plugged into an AC
receptacle and produces a low voltage charging output.

Some chargers for rechargeable batteries can be damaged if
connected to the XPower Powerpack 400 Plus and XPower
Powerpack 400R.

Do not use the following with the XPower Powerpack 400
Plus and XPower Powerpack 400R:

• Small battery-operated appliances like flashlights, razors,
and night lights that can be plugged directly into an AC
receptacle to recharge.

• Some chargers for battery packs used in hand power
tools. These affected chargers display a warning label
stating that dangerous voltages are present at the battery
terminals.

Note

: If you are unsure about using your rechargeable appliance

with the XPower Powerpack, contact the equipment manufacturer
to determine the rechargeable appliance’s compatibility with the
modified sine wave (non-sinusoidal) AC waveform.

viii 975-0162-01-01

Contents

Important Safety Instructions

Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii
Precautions When Working With Batteries- - - - - - - - - - - - - - - vi
Precautions for Using Rechargeable Appliances - - - - - - - - - - viii

1

Introduction

About the XPower Powerpack - - - - - - - - - - - - - - - - - - - - - - 1–1
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - 1–1

Automatic overload- - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Low Battery Protection - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Jump-Start Cables Safety Feature - - - - - - - - - - - - - - - - - 1–2

2

Features

Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
XPower Powerpack Features - - - - - - - - - - - - - - - - - - - - - - - 2–2

Front Panel Detail - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Rear Panel Detail (XPower Powerpack 400R only) - - - - - 2–5
Air Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10

ix

3

Operation

Operating Conditions and Guidelines - - - - - - - - - - - - - - - - - 3–1
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Using XPower Powerpack for the First Time - - - - - - - - - - - - 3–3
Recharging with the AC Charger - - - - - - - - - - - - - - - - - - - - 3–3
Using the light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Operating AC Appliances - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Understanding AC Appliances - - - - - - - - - - - - - - - - - - - 3–4

Run Time on Typical AC Appliances - - - - - - - - - - - 3–5
High Surge Appliances - - - - - - - - - - - - - - - - - - - - - 3–5
Trouble Appliances - - - - - - - - - - - - - - - - - - - - - - - 3–6
Operating Several Appliances at Once - - - - - - - - - - - 3–6

Operating an AC Appliance - - - - - - - - - - - - - - - - - - - - - 3–6
Operating 12 V DC Appliances - - - - - - - - - - - - - - - - - - - - - 3–8
Jump-Starting a Vehicle’s Engine - - - - - - - - - - - - - - - - - - - -3–10
Using the Air Compressor - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Over-Temperature Safety Protection - - - - - - - - - - - - - - -3–12

Inflating Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3–14
Using the Radio: XPower Powerpack 400R - - - - - - - - - - - - -3–15

Power Draw- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–16

Listening to the AM Band - - - - - - - - - - - - - - - - - - - - - -3–16
Connecting to an External Battery- - - - - - - - - - - - - - - - - - - -3–16

4

Maintenance

Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Recharging the XPower Powerpack Battery - - - - - - - - - - - - - 4–2

Recharging with the AC Charger- - - - - - - - - - - - - - - - - - 4–2

Recharging with the DC Charging Cable - - - - - - - - - - - - 4–3

Recharging with a Generator’s Regulated 12 V DC Outlet 4–5

Recharging From a Solar Panel - - - - - - - - - - - - - - - - - - - 4–6
Replacing the Internal Battery - - - - - - - - - - - - - - - - - - - - - - 4–6

Battery Life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

x 975-0162-01-01

Obtaining a Replacement Battery - - - - - - - - - - - - - - - - - 4–7

Replacing the Battery - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Replacing the Incandescent Light - - - - - - - - - - - - - - - - - - - - 4–9
Replacing the External Fuse - - - - - - - - - - - - - - - - - - - - - - - -4–10

5

Troubleshooting

Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–1

Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - 5–1

Television Interference - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - 5–2

A

Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

B

Warranty and Product Information

Warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Return Material Authorization Policy - - - - - - - - - - - - - - - - - B–5
Out of Warranty Service - - - - - - - - - - - - - - - - - - - - - - - - - - B–7
Information About Your System - - - - - - - - - - - - - - - - - - - - - B–8

975-0162-01-01 xi

xii

1 Introduction

About the XPower Powerpack

Easy-to-use and designed for years of reliable service, the
XPower Powerpack can run many AC appliances and 12 V
DC appliances whenever you need power for work or play, at
home or on the road.

XPower Powerpack:

• Powers 115 V AC appliances

• Powers 12 V DC appliances

• Jump-starts vehicle engines

• Provides lighting for emergency use

• Inflates tires and small sports equipment with a 250 psi
air compressor.

In addition, the XPower Powerpack 400R comes with:

• An AM/FM radio with digital alarm clock.

Comprehensive Protection

Automatic overload

The XPower Powerpack has built-in protection against output
overload. If you connect to the AC Outlet(s) an appliance that
draws more than 320 W, or one which draws excessive surge
power, the power to the AC Outlet automatically shuts off.

1-1

Introduction

Overheating

The XPower Powerpack is protected from overheating. If the
inverter exceeds a safe temperature, power to the AC Outlet
automatically shuts off.

Low Battery Protection

Low battery protection protects the internal battery from
excessive discharge and possible damage. When the AC
Outlet
when the internal battery is nearly discharged (11.0 V DC)
and the unit turns off at 10.5 V DC.

ON/OFF switch is turned on, an audible alarm alerts you

Jump-Start Cables Safety Feature

The XPower Powerpack comes with a user-replaceable
250 A fuse to protect the unit and vehicle battery from
damage through reverse polarity and short-circuit conditions.

1-2 975-0162-01-01

2 Features

Chapter 2 describes the main features of the XPower
Powerpack. We recommend that you familiarize yourself
with these features before operating the unit.

Materials List

Your XPower Powerpack package includes these items:

❐

XPower Powerpack 400 Plus or XPower Powerpack 400R

❐ Owner’s Guide

❐ AC charger

❐ DC charging cable

❐ Jump-start cables

❐ Accessory bag

❐ Two nozzle adaptors for the compressor

❐ One sports needle adaptor for the compressor.

The XPower Powerpack 400R also includes:

❐ Red “emergency” light cover.

If any of these materials are missing or are unsatisfactory in
any way, please contact Customer Service, see Appendix B.

2-1

Features

XPower Powerpack Features

Front Panel Detail

6

8

1

7

5

4

3

2

XPower Powerpack Features

Feature Description

1 DC Power Socket can:

• Power 12 V DC auto, RV or marine appliances

• Recharge
outlet in a vehicle using the DC Charging Cable.

XPower Powerpack from a 12 V

2 2 AC Outlets are standard 3-prong outlets supplying

3 AC Outlet ON/OFF switch illuminates when the

4 Digital Display displays the inverter’s Output

2-2 975-0162-01-01

120 V AC power for running an AC appliance.

switch is turned on.

Power in W and Battery Charge status in
%FULL.

XPower Powerpack Features

Feature Description

5 Charging Status light illuminates when the

XPower Powerpack is in Charging Status mode

(i.e. AC Charger is connected to the inverter’s
Charger Input Socket and plugged into the
household 120 V AC outlet).

6 Battery Charge % light illuminates (green) when

Battery Charge information is displayed on the
Digital Display.

7 Output Power (W) light illuminates (green) when

Output Power information is displayed on the
Digital Display.

8 Display Function button, when pressed, allows for

reading Battery Charge status on the Digital

Display. Toggles Digital Display’s power

ON/OFF.

Not

shown

Control Panel Operation

Required

How to...

Monitor total
AC power
consumed by
the
applications
powered from
the
Powerpack’s 2
AC outlets

Condition Required Action Note

Inverter’s
switch is turned ON;

Output Power (W)

light illuminates
(green);
AC charger is
unplugged from the
wall AC outlet.

Audible Alarm (inside the unit) sounds in the event
of overheating or low battery protection on inverter.

ON/OFF

No action required.
The Digital Display
will show the AC
power drawn from the
inverter by the
applications powered
from the Powerpack’s
AC outlets.

In order to save the
battery power and
ensure longer inverter
run time, press Display
Function button to turn
off the Digital Display.
Press Display Function
button again to turn the
display on for AC
power reading.

975-0162-01-01 2-3

Features

How to...

Required
Condition Required Action Note

Monitor
Battery
Charging
status

Check Battery
Charge status

Inverter’s ON/OFF
switch is turned to

OFF;

All appliances must be
disconnected from the
AC and DC power
outlets;

ON/OFF switch of

The
the incandescent light
must be turned to

OFF;

The AC charger must
be plugged into the
Powerpack’s Charger
Input Socket and also
in to a household AC
outlet.

Inverter’s

ON/OFF

switch is turned to

OFF;

All appliances must be
disconnected from the
AC and DC power
outlets;

ON/OFF switch of

The
the incandescent light
must be turned to

OFF;

The AC charger must

be plugged into

not

the Powerpack’s
Charger Input Socket.

No action required.

A flashing green

Charging Status

light indicates that the
Powerpack’s battery
needs recharging and
that the AC charger is
charging the battery.

A steady green

Charging Status

light indicates that the
Powerpack’s battery
is fully charged and
the Powerpack is
ready for use.

Push and hold the

Display Function

button.

The green Battery
Charge (%) light will
come on and the
Digital Display will
show the remaining
battery capacity in %.

Recharging with the
supplied AC charger is
a true “plug-in-and­forget” charging
method.
We recommend leaving
the AC charger
connected when the
Powerpack is not in use
to permanently
maintain the battery in
fully charged condition.

This function is
disabled when the AC
charger is plugged in to
the Charger Input
Socket, or when the
inverter main switch is

ON.

For accurate Battery
Charge reading, allow
15 minutes between
charging/use and
battery capacity check.

2-4 975-0162-01-01

XPower Powerpack Features

Rear Panel Detail (XPower Powerpack 400R only)

123 4

5

6

7

12

11

Feature Description

1 FM antenna
2 Frequency indicator light
3 Power OFF button
4 Time set button
5 Tuning dial
6 Hours set button
7 Minutes set button
8 Vo l u m e d i a l
9 Alarm set button

10

8

9

10 Alarm clock ON/OFF button
11 AM band button/ON
12 FM band button/ON

975-0162-01-01 2-5

Features

How to...

Radio Operation

Required
Condition Required Action Note

Listen to
the radio

Set the
clock

Set the
alarm

Turn off the
radio to
show the
time.

Turn off the
radio to
show the
time.

Press the AM band button
(11) or the FM band button
(12).
To turn off the radio, press
the power

OFF button (3).

To adjust hour, press and
hold Time Set button (4),
and press hours set button
(6).
To adjust minutes, press and
hold (4), and press minutes
set button (7).

To adjust hour, press and
hold Alarm Set button (9),
and press hours set button
(6).
To adjust minutes, press and
hold (9), and press minutes
set button (7).

When radio is on, the
station frequency is
displayed. When
radio is off, the time is
displayed.

The clock uses a 12­hour (AM/PM) time
format.

The alarm clock uses
a 12-hour (AM/PM)
time format.

Use the
alarm clock

Set the
alarm, turn
off radio to
show time.

Press Alarm Clock

ON/OFF

button (10). “¤” shows on
the display screen.

When the alarm clock
turns the radio on, the
power off button (3)
does not work. To
turn off the radio,
press Alarm Clock

ON/OFF (10), then

press (3).

Improve
reception

Radio
tuned to

Adjust the direction and
length of the FM antenna.

N/A.

FM station.

2-6 975-0162-01-01

Air Compressor

XPower Powerpack Features

2

1

3

Feature Description

1 ON/OFF switch turns the compressor unit on and off.
2

Pressure gauge shows the PSI (lb./in2)

3 Valve connector with connector hose

Nozzle Adaptor Compartment is integrated into AC charger
compartment.

975-0162-01-01 2-7