Xantrex XPower Inverter 1000 User Guide

XPower Inverter 1000

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 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

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

December 2003 Revision A

Part Number

975-0127-01-01

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct)

Email: customerservice@xantrex.com

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 Inverter 1000.

Scope

The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the unit. 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 XPower Inverter 1000.

iii

About This Guide

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 unit or other equipment.

Important:

not as serious as a caution or warning.

Related Information

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

These notes describe things which are important for you to know, but

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Important Safety Instructions

WARNING

This chapter contains important safety and operating instructions. Read and keep this Owner’s Guide for future reference.

1. Before installing and using the XPower Inverter 1000, read all instructions and cautionary markings on the XPower Inverter 1000, the batteries, and all appropriate sections of this guide.

2. Do not expose the XPower Inverter 1000 to rain, snow, spray, or bilge water. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the XPower Inverter 1000 in a zero-clearance compartment. Overheating may result.

3. Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk of fire, electric shock, or injury to persons.

4. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the XPower Inverter 1000 with damaged or substandard wiring.

5. Do not operate the XPower Inverter 1000 if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the XPower Inverter 1000 is damaged, see the Warranty section.

6. Do not disassemble the XPower Inverter 1000. It contains no userserviceable parts. See Warranty for instructions on obtaining service. Attempting to service the XPower Inverter 1000 yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.

7. To reduce the risk of electrical shock, disconnect both AC and DC power from the XPower Inverter 1000 before attempting any maintenance or cleaning or working on any circuits connected to the XPower Inverter 1000. Turning off controls will not reduce this risk.

8. The XPower Inverter 1000 must be provided with an equipmentgrounding conductor connected to the AC input ground.

Safety

Explosive gas precautions

WARNING: Explosion hazard

1. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your XPower Inverter 1000.

2. This equipment contains componentnts which tend to produce arcs or sparks. To prevent fire or explosion, do not install the XPower Inverter 1000 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.

3. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed.

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Precautions When Working With Batteries

WARNING: Explosion or 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 near the engine or batteries.

4. Use caution to reduce the risk or 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 all metal items, like rings, bracelets, and watches when

working with lead-acid battereis. Lead-acid batteries produce a short circuit current high enough to weld metal to skin, causing a severe burn.

6. Have someone within range of your voice or close enough to come to

your aid when you work near a lead-acid battery.

7. Have plenty of fresh water and soap nearby in case battery acid

contacts skin, clothing, or eyes.

8. Wear complete eye protection and clothing protection. Avoid

touching your eyes while working near batteries.

9. If battery acid contacts skin or clothing, wash immediately with soap

and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

Safety

10. If you need to remove a battery, always remove the ground terminal

from the battery first. Make sure all accessories are off so you don’t cause a spark.

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Safety

Precautions for Using Rechargeable Appliances

CAUTION: Equipment damage

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 small rechargeable batteries can be damaged if connected to the XPower Inverter 1000. Do not use the following with the XPower Inverter 1000:

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

If you are unsure about using your rechargeable appliance with the XPower Inverter 1000, contact the equipment manufacturer to determine the rechargeable appliance’s compatibility with the modifed sinewave (non-sinusoidal) AC waveform.

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Contents

Important Safety Instructions

Introduction

Quality Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1 Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Features

Materials List- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1 AC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 DC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Installation

Designing Your Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1

Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Choosing an Appropriate Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Calculating Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6

Calculating Size of DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Calculating Size of Chassis Ground Cable - - - - - - - - - - - - - - - - - - - - - - - 3–7

Calculating Fuse/Circuit Breaker Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8

Installing the XPower 1000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9

Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12

Grounding Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12 Chassis Ground Screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13

Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

975-0127-01-01 ix

Operation

Turning the Inverter On and Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1 Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Turning the Inverter Off Between Charges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3 Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Inverter Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

High Surge Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Trouble Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

Routine Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

XPower 1000 unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5 Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

Troubleshooting

Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2

Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2

Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

Specifications

Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1 Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1 Mounting Templates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2

Battery Types

Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1

Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1

Deep-Cycle Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2 Battery Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4

Battery Sizing Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4

Battery Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5 Using Multiple Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6

Two Batteries Connected In Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6

Two Separate Battery Banks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6

Battery Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7

Alternators and Charging Systems

Charging System Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–1

Charging With an Engine Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2

Using a Standard Vehicle Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2 Using an Alternator Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2

Using a High-Output Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2 Charging From AC Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3 Charging From Alternative Energy Sources - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3

Contents

Warranty and Return Information

- - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

975-0127-01-01 xi

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1 Introduction

Congratulations on your purchase of the XPower Inverter 1000! The XPower Inverter 1000 has been designed to give you quality power, ease of use, and reliability.

Please take a few moments to read this chapter to familiarize yourself with the main performance features and protection features of the XPower

1000.

Quality Power

The XPower 1000 is a quality inverter designed for recreational vehicle (RV) and truck applications.

• The XPower 1000 provides up to 1000 watts of continuous power. It is designed to handle loads such as 600 watt microwaves, TVs, VCRs, and midsized power tools.

• The XPower 1000’s high surge capability lets you handle many hardto-start loads, including large TVs and small refrigerators.

• The XPower 1000’s low standby battery demand means you don’t have to worry about excessive drain on your battery if you leave the inverter on for a few days. When the XPower 1000 is on but no power is being supplied to a load, the inverter draws less than 300 mA from the battery.

• The cooling fan in the inverter is thermally activated and comes on when the XPower 1000 becomes warm. The fan turns off automatically after the inverter has cooled.

1–1

Introduction

Ease of Use

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

• The XPower 1000 is compact, light weight, and easy to install.

• Loads can be powered directly from the AC outlets.

Comprehensive Protection

The XPower 1000 is equipped with numerous protection features to guarantee safe and trouble-free operation:

Low battery alarm Alerts you if the battery has become discharged to

11.0 V or lower.

Low battery voltage shutdown Shuts the XPower 1000 down automatically if the battery voltage drops below 10.5 volts. This feature protects the battery from being completely discharged.

High battery voltage shutdown Shuts the XPower 1000 down automatically if the input voltage rises to 15 volts or more.

Overload shutdown Shuts the XPower 1000 down automatically if a short circuit is detected in the circuitry connected to the inverter’s output, or if the loads connected to the inverter exceed the inverter’s operating limits.

Over temperature shutdown Shuts the XPower 1000 down automatically if its internal temperature rises above an unacceptable level.

1–2 975-0127-01-01

2 Features

Chapter 2 describes the main features of the XPower 1000.

Xantrex recommends that you familiarize yourself with them before installing and operating the inverter.

Materials List

Your XPower 1000 package includes:

• One XPower 1000 inverter

• Two M6 lock washers (on the DC input cable terminals)

• Two M6 nuts (on the DC input cable terminals)

• Owner’s Guide

If any of these materials are missing or are unsatisfactory in any way, please contact Customer Service. Contact infomation is available on page WA–1.

As soon as you unpack your inverter, be sure to record the product information in the form on page WA–6.

2–1

Features

AC Panel

Figure 2-1

AC Panel

Feature Description

On/Off Switch turns the inverter’s control circuit on and off. This

switch is not a power disconnect switch. Disconnect AC and DC power before working on any circuits connected to the inverter.

2 Power light is a green light indicating the On/Off Switch is on and

AC voltage is present at the inverter’s AC outlets.

3 Fault light is a red light indicating the inverter has shut down due to

low or high battery voltage, unit overload, or over temperature.

4 3-Prong AC Outlets:

XPower 1000 delivers a combined total of 1000 watts of continuous AC power across two outlets.

5 Ventilation Opening must not be obstructed for the proper

operation of the inverter. When the inverter is mounted, the ventilation opening must not point up or down.

6 Mounting Flange allows you to mount the inverter permanently.

2–2 975-0127-01-01

DC Panel

Figure 2-2

DC Panel

Feature Description

1 Chassis Ground Screw connects to vehicle chassis, DC grounding

bus or to engine’s negative bus.

2 Positive DC Cabling Terminal always connects to the cable

connected to the positive terminal of the battery.

3 Negative DC Cabling Terminal always connects to the cable

connected to the negative terminal of the battery.

4 Ventilation Opening must not be obstructed for the proper

operation of the inverter. When the inverter is mounted, the ventilation opening must not point up or down.

5 Serial number of your unit

6 Mounting Flange allows you to mount the inverter permanently.

975-0127-01-01 2–3

2–4

3 Installation

Chapter 3 provides information on cables and fuses to help you plan for your installation and provide procedures for installing the XPower 1000.

Xantrex highly recommends that you read the entire chapter before beginning the installation procedures so that you can plan an installation that is suited to your power needs.

Designing Your Installation

Before doing anything else, you need to determine how you are going to use your XPower 1000, and then design a power system that will give you maximum performance. The more thorough your planning, the better your power needs will be met. In particular, you will need to:

• Be aware of installation codes

• Calculate your battery requirements

• Choose an effective charging system

• Choose an appropriate location

• Calculate the cable size for your XPower 1000

• Select the correct fuses or circuit breakers

Study Figure 3-1, “Configuration for Normal Loads” on page 3–2 and Figure 3-2, “Configuration for Heavy Loads” on page 3–3 for an example of a setup for normal or heavy loads in a vehicle. When you have decided upon your configuration, then you can calculate battery requirements.

3–1

Installation

Figure 3-1

3–2 975-0127-01-01

Configuration for Normal Loads

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