Xantrex XPower Inverter 5000 Installation Manual

XPower Inverter 5000

Installation Guide

by

This guide for use by qualified installers only

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products ranging from small mobile units to 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 Inverter 5000 Installation Guide © September 2008 Xantrex International. All rights reserved.

Exclusion for Documentation

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREXTM”)
(

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 LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER
SPECIAL, 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; AND

(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH

STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT
BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE
VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision

September 2008 Revision C

Document Part Number

975-0411-01-01

Product Part Number

813-5000

Contact Information

Telephone: [phone] (toll free North America)

1 408 987 6030 (direct)
Fax: [phone] (toll free North America)
Email: [e-mail]
Web: www.xantrex.com

This guide for use by qualified installers only

About This Guide

Purpose

The purpose of this Installation Guide is to provide explanations and
procedures for installing the XPower Inverter 5000.

Scope

The Guide provides safety guidelines and procedures for installing the
inverter. It does not provide details about particular brands of batteries.
You must consult individual battery manufacturers for this information.

Refer to Xpower Inverter 5000 Owner’s Guide (doc. part number: 975­0376-01-01) for operational instructions.

Audience

The Guide is intended for qualified installers including licensed
technicians and electricians. It is intended for installers with knowledge
and experience in installing electrical equipment, knowledge of the
applicable installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards.

Organization

This Guide is organized into two chapters and one appendix.
Chapter 1 describes the standard features of the XPower Inverter 5000, as

well as its protection features. It also provides information on the different
parts of the XPower Inverter 5000.

Chapter 2 describes installation procedures including planning, wiring,
and mounting the XPower Inverter 5000.

Appendix A contains physical and electrical specifications of the XPower
Inverter 5000.

iii

This guide for use by qualified installers only

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:

but they are 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,

iv 975-0411-01-01

This guide for use by qualified installers only

Important Safety Instructions

IMPORT ANT : Read and save this Installation Guide for
future reference.

This chapter contains important safety instructions for the XPower
Inverter 5000.

WARNING: Shock, fire, and heat hazard. Risk of
injury to persons.

1. Before installing and using the XPower Inverter 5000, read all
instructions and cautionary markings on or provided with the XPower
Inverter 5000, the batteries, and all appropriate sections of this guide.

2. Do not expose the XPower Inverter 5000 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 5000 in a
zero-clearance compartment. Overheating may result.

3. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition, adequately rated, and not undersized. Do
not operate the XPower Inverter 5000 with damaged or substandard
wiring.

4. Do not install or operate the XPower Inverter 5000 if it has received a
sharp blow, been dropped, or otherwise damaged in any way. If the
XPower Inverter 5000 is damaged, see the Warranty section.

5. Do not disassemble the XPower Inverter 5000. It contains no user­serviceable parts. See Warranty for instructions on obtaining service.
Attempting to service the XPower Inverter 5000 yourself may result
in a risk of electrical shock or fire. Internal capacitors remain charged
after all power is disconnected.

v

This guide for use by qualified installers only

Safety

6. To reduce the risk of electrical shock, disconnect DC power from the
XPower Inverter 5000 before attempting any maintenance or cleaning
or working on any circuits connected to the XPower Inverter 5000.
Turning off controls will not reduce this risk.

7. The XPower Inverter 5000 must be provided with equipment­grounding conductors connected to the vehicle chassis as described in
“Chassis Ground Wire Sizing” on page 2–8 and “Output Conductor
Selection for Hardwire Installation” on page 2–8.

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 to
reduce the risk of battery explosion.

2. 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 5000.

3. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower
Inverter 5000 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.

4. Make sure the area around the battery is well ventilated.

5. Never smoke or allow a spark or flame near the engine or batteries.

6. 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.

7. 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.

vi 975-0411-01-01

This guide for use by qualified installers only

Safety

WARNING: Risk of personal injury due to burns or
battery acid

8. Remove all metal items, like rings, bracelets, and watches when

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

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

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

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

contacts skin, clothing, or eyes.

11. Wear complete eye protection and clothing protection. Avoid

touching your eyes while working near batteries.

12. 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.

Precautions for Using Rechargeable Appliances

CAUTION: Risk of equipment damage

The output of the XPower Inverter 5000 is not sinusoidal and may not be
compatible with all loads. Follow the recommendations below.

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 5000. Do not use the following with the
XPower Inverter 5000:

• 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.

975-0411-01-01 vii

This guide for use by qualified installers only

viii

Contents

Important Safety Instructions

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

1 Quality Power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–1

Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

AC Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
DC Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
Remote Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6

2 Designing Your Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1

Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Choosing an Appropriate Location and Mounting Orientation - - - - - - - - - - - - - 2–4
Selecting Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6
Selecting a DC Input Fuse or Circuit Breaker - - - - - - - - - - - - - - - - - - - - -2–7
Chassis Ground Wire Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Output Conductor Selection for Hardwire Installation - - - - - - - - - - - - - - - 2–8

Installing the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9

Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Installing the Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Connecting the AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16

Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

975-0411-01-01 ix

This guide for use by qualified installers only

x

1

Introduction

The XPower Inverter 5000 is 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.

Quality Power

The XPower Inverter 5000 is designed for use in recreational vehicles
(RVs), light and heavy duty truck applications, and other in-vehicle
applications.

• The inverter provides up to 4000 W of continuous power. It is

• The inverter’s high surge capability lets you handle many hard-to-

• The cooling fan in the inverter is thermally activated and comes on

designed to handle loads such as microwaves, refrigerators, freezers,
circular saws, and small air compressors.

start loads, including large TVs, refrigerators, and freezers.

when the inverter becomes warm. The fan turns off automatically
after the inverter has cooled.

This guide for use by qualified installers only

1–1