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

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power
electronics and controls with products from 50 watt mobi le units to one MW
utility-scale systems for wind, solar, bat teries, fuel ce lls, microturbines, and
backup power applications in both grid-connected an d st and-alone systems.
Xantrex products include inv erters, battery chargers, pro grammable power
supplies, and variable spee d drives that convert, supply, cont rol, clean, and
distr ib u t e el ec tr i cal power.

Trademarks

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

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

Notice of Copyright

Xpower™ Powerpack 400 and 400 Plus Owner’s Guide
© October 2005 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 SUIT AB ILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.

(b) AS SUMES 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 Revis ion

October 2005 Revision B

Part Number

975-0057-01-01

Contact Information

Phone: [phone]
Fax: [phone]
Website: www.xantrex.com/support

About This Guide

Purpose

The purpose o f this Owne r’s Guide is to pr ovide explanations
and procedures for installing, operating, maintaining, and
troubleshooting the XPower Powerpack 400 and XPower

Powerpack 400 Plus.

The Guide provides safety guidelines, detaile d planning and
setup infor mation , as well as inf ormation about ope rating a nd
troubleshooting the unit.

Conventions U s ed

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 equi pment.

Important: These notes describe an important action item

or an item that you must pay attentio n to.

i

About This Guide

Note: These notes describe additional information which

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

Refere nce s to XPower Powerpack

In this guide, both the XPower Powerpack 400 and the

XPower Powerpack 400 Plus (with the air compr ess or ) are

referred to as X Po w er Po w erp a ck when the information
applies to both models. However, when the inf ormation is
specific to o ne mo d el, then reference is made specifically to
the XPower Powerpack 400 or to the XPower Powerpack

400 Plus.

Related Information

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

ii 975-0057-01-01

Important Safety Instructions

The XPower Powerpack 400 and XPower Powerpack 400

Plus generate a type of AC power similar to a normal

household wall outl et . Operati ng the XPower Power pack 400

and XPower Powerpack 400 Plus incorrectly or misusing it

may damage the equipment or creat e hazar dous conditions
for the user.

Important: Before using yo ur XPower Powerpack 400 and

XPower Powerpack 400 Plus, be sure to read and save these

safety instructions.

Warnings and Cautions

WARNING: Shock hazard. Keep Away from
Children.

The XPower Powerpack 400 and XPower Powerpack 400

Plus generates the same potentia lly lethal AC power as a

normal household wall outlet. Do not insert foreign obje cts
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 400 and XPower

Powerpack 400 Plus except to replace the internal battery.

Have a qualified te chnician complete any service work.

CAUTION

Do not connect any AC appliance with the neut ral conductor
connected to ground to the XPower Powerpack 400 and

XPower Powerpack 400 Plus.

iii

Important Safety Instructions

CAUTION

Do not expose the XPower Powerpack 400 and XPower

Powerpack 400 Plus 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- powere d 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 400 and XPower Powerpack 400 Plus, vent

explosive hydrogen gas which can be ignited by sparks from
electric al connections.

When wor k ing on el ectri ca l equip me n t, always ensure
someone is nearby to help you in an emerge ncy.

WARNING: Heated surface

Ensure at least 2" (5 cm) air spac e is maintained on all sides
of the XPower Powerpack 400 and XPower Powerpack 400

Plus. During operation, keep away from materials tha t may

be affecte d by high temperatures suc h as blankets, pillows
and sleeping bags.

WARNING: Fir e hazard

Never allow jump-sta rt cables’ red and bla ck 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 dis con nect the jump-start cables from the
unit after use and clip the plastic guard over the jump-start
cable port.

iv 975-0057-01-01

Important Safety Instructions

WARNING: Fir e hazard

Jump-start c able clamps must be connected positive to
positive (red cl amp to battery “+”) and negative to negative
(black clam p to batt ery “-”). A reverse polarity connection
(positive to negative) may cause damage to the unit and/or
create a sparking/e xplosion hazard.

WARNING: Fir e hazard

The jump-sta rt feature is designed for short te rm operation
only—less than 4 seconds. Operating the jump-start feature
for more than 4 seconds may c ause damage to the unit. Allow
the XP ower Powerpack 400 and XPower Powerpa ck 400 Plus
to cool down for at least 3 minutes afte r each jump-start.

WARNING: Risk of exp losion, fire or burns

The battery termin als exposed at the Jump-S tart Cable Port
have enough energy present to cause a spark, cre ating an
explosion hazar d, or to cause burns if a metal object contac ts
both terminals. Always clip the plastic guard over the Port
when not in use.

W ARNING: Fire Hazard -

XPower Powerpack

400 Plus

Do not leave the compresso r unatt ended whil e operating. The
compressor is designe d for short term operation only.
Operation of the compre ssor 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 cont inuous operation.

975-0057-01-01 v

Important Safety Instructions

Precautions When Working With Batteries

WARNING: Explosion and Fire Hazard

1. Follow all instructions publishe d by the battery
manufacturer an d the manufacturer of the equipment in
which the battery is installed.

2. Make sure the are a aroun d the battery is well-ventilated.

3. Never smoke or all ow a spark or flame in vic inity of the
engine or batterie s.

4. Be careful not to drop a metal obje ct on the batte ry or
allow a metal tool to simultaneously touch the positive
and negative cable ends or battery terminals. It m ight
spark or short-cir cuit the battery or other electrica l parts
and cause an explosion.

5. Remove persona l metal items such as rings, bracel et s,
necklac es , and wa tc hes when wo rk ing w ith a lea d -acid
battery. A lead-acid battery produces a short-circuit
current high enough to weld a ring or other similar
objects to m etal, 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 plent y 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 bat teries.

vi 975-0057-01-01

Important Safety Instructions

10. If battery acid conta cts skin or clothing, wash
immediately with soap and water. If acid enters your
eyes, immediate ly flood them with runni ng cold water for
at least twenty minutes a nd 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.

975-0057-01-01 vii

Important Safety Instructions

Precautions for Using Rechargeable
Appliances

CAUTION

The output of the inverter is non-sinusoidal.
Most recharge able battery- operated equipment uses a

separate charger or transform er that is plugged into an AC
receptacle and produces a low voltage charging output.

Some chargers f or rechargeable batteries can be damaged if
connected to the XPower Powerpack 400 and XPower

Powerpack 400 Plus.

Do not use the following with the XPower Powerpa ck 400

and XPower Powerpack 400 Plus:

• Small battery- operated applianc es like flashl ights, razors,
and night lights that can be plugged directly into an AC
receptacl e to rec h arge.

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

Note: If you are unsure about using your rechargeable

applian ce with the XPower Powerpack 400 and XPower

Powerpack 400 Plus, conta ct the e quipment m anufac turer t o

determine the rech argeable appliance’s compatibility with
the modified sinewave (non-sinusoidal) AC waveform.

viii 975-0057-01-01

Contents

Important Safety Instructions

Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii
Precauti o ns Wh en W o rki ng W ith 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
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
Air Compressor (XPower Powerpa ck 400 Plus only) - - - - 2–5
Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

3

Operation

Operating Conditions and Guidelin es - - - - - - - - - - - - - - - - - 3–1
Choosing a Location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Using XPower Powerpa ck for the First Time - - - - - - - - - - - - 3–3
Recharging with the AC Charger - - - - - - - - - - - - - - - - - - - - 3–3
Using the light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

ix

Operating AC Appliances - - - - - - - - - - - - - - - - - - - - - - - - - 3–5

Understanding AC Appliances - - - - - - - - - - - - - - - - - - - 3–5

Run Time on Typical AC Appliances - - - - - - - - - - - 3–5
High Surge Appliances - - - - - - - - - - - - - - - - - - - - - 3–6
Trouble Appliances - - - - - - - - - - - - - - - - - - - - - - - 3–6
Operating Several Appliances at Once - - - - - - - - - - - 3–7

Operating an AC Appliance - - - - - - - - - - - - - - - - - - - - - 3–7
Operating 12 V DC Appliances - - - - - - - - - - - - - - - - - - - - - 3–8
Jump-Starting a Vehicle’s Engine - - - - - - - - - - - - - - - - - - - -3–10
Using the Air Compressor: XPower Powerpack 400 Plus - - - -3–12

Over-Temperatur e Safety Protection - - - - - - - - - - - - - - -3–13

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

Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3–15
Connecting to an Externa l 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 4–6

Recharging From a Solar Panel- - - - - - - - - - - - - - - - - - - 4–7
Replacing the Internal Battery - - - - - - - - - - - - - - - - - - - - - - 4–7

Battery Life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Obtaining a Replacement Battery - - - - - - - - - - - - - - - - - 4–8

Replacing the Battery - - - - - - - - - - - - - - - - - - - - - - - - - 4–9
Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–11
Replacing the Incande scent Light - - - - - - - - - - - - - - - - - - - -4–11
Replacing the Exter nal Fuse- - - - - - - - - - - - - - - - - - - - - - - -4–12

x 975-0057-01-01

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

Warr ant y and Re tu rn

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

975-0057-01-01 xi

xii

1 Introduction

About the XPower Powerpack

Easy-to-use and designed for years of reliable service, the

XPower Powerpack ca n run many AC applia nces 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 emerge ncy use
In addition, the XPower Powerpack 400 Plus:

• Comes with a 250 psi air compressor for infla ting tires
and small sports equipment.

Comprehensive Protection

Automatic overload

The XPower Powerpack has built-in prote ction against out put
overload. If you c onnect t o the AC Outl et(s ) an app lianc e that
draws more than 320 W, or one which draws excessive surge
power, the power to the AC O u tle t aut omatically shut s off.

Overheating

The XPowe r Powerpack is protected from overheating. If the
inverter ex cee d s a safe temp e rat u re, power to the AC Outlet
automatically shuts off.

1-1

Introduction

Low Battery Protection

Low battery protection protects the internal battery from
excessive discharge and possible damage. When the AC
Outlet On/Off switch is turned on, an audible alarm alerts you
when the internal battery is nearly discharged (11.0 V DC)
and the unit turns off at 10.5 V DC.

Jump-Start Cables Safety Feature

The XPow er Pow e rp ack com es with a use r-rep laceable
250 A fuse to protect the unit and vehic l e batte ry from
damage through rever se polarity and short-circuit conditions .

1-2 975-0057-01-01

2 Features

Chapter 2 describes the main features of the XPower

Powerpack. We recommend that you familiarize yourself

with these feature s before operating the unit.

Materials Lis t

Your XPower Powerpack package includes these items:

p XPower Powerpack 400 or XPower Powerpack 400 Plus
p Owner’s Guide
p AC Charger
p DC Charging Cable
p Jump-Start Cables
p Accessory bag

The XPower Powerpack 400 Plus also includes:

p two nozzle ad apt o rs for the co mpressor
p One sports needle adaptor for the compressor

If any of these m aterials are missing or are unsatisfactory in
any way, please contact Customer Service, see Appendix

WA.

2-1

Features

XPower Powerpack Features

Front Panel Detail

8

1

7

XPower Powerpack Features

Feature Description

1 DC Power Socket can:

• Power 12 V DC auto, RV or marine appliances

• Recharge
using the DC Charging Cable.

XPow er Po werpack from a 12 V outlet in a vehicle

6

5

4

3

2

2 2 AC Outlets are standard 3-prong outlets supplying 120 V AC

power for running an AC appliance.

3 AC Outlet ON/OFF switch illuminates when the switch is turned

on.

2-2 975-0057-01-01

XPower Powerpack Features

Feature Description

4 Digital Display displays the inverter’s Output Power in W and

Battery Charge status in % FUL L .

5

Charging S tatus l ight illu mina tes whe n th e

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 p ressed , al lows fo r readi ng Battery

Charge status on the Digital Display. Toggles Digital Display’s
power ON/OFF.

Not

shown

Audible Alarm (ins ide the unit) sounds in the even t of overheating
or low battery prot ection on inverte r.

Control Panel Operation

Required

How to ...

Condit io n Required Acti on N ot e

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

Inverter’ s ON/OFF
switch is turned ON;
Output Power (W)
light illuminates
(green);
AC charger is
unplugged from the
wall AC ou tle t.

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

In orde r to save the
battery power and
ensure longer inverter
run time, press Display
Function button to turn
off the Dig ital Display.
Press Displ ay Function
button again to turn the
display On fo r A C
power reading.

975-0057-01-01 2-3

Features

How to ...

Required
Condit io n Required Acti on N ot e

Monitor
Battery
Charging
status

Check Battery
Charg e status

Inverter’ s ON/OFF
switch is turned to
OFF;
All appli an ces mu st b e
disconnected from the
AC and DC power
outlets;
The ON/OFF switch
of 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 appli an ces mu st b e
disconnected from the
AC and DC power
outlets;
The ON/OFF switch
of the incandescent
light must be turned to
OFF;
The AC charger must

not

be plugged into
the Powe rpack’s
Charger Input Socket.

No action required.

A flashing green

Charging Status

light in di cates th at th e
Powerpack’s battery
needs recharging and
that the AC charger is
charging the battery.

A steady green

Charging Status

light in di cates th at th e
Powerpack’s battery
is fully charged and
the Pow erpack is
ready for use.

Push and hold the

Display Func tion

button.

The green Batt ery
Charge (%) li ght will
come on an d the
Digital Display will
show the remaining
battery capacity in %.

Recharging with the
supplied AC charger is
a true “plug-in-and­forget” char gi ng
method.
W e recommend leaving
the AC charger
connected when the
Powerpack is not in use
to permanen t ly
maintain the battery in
fully charged conditi on.

This funct ion 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.

2-4 975-0057-01-01

XPower Powerpack Features

Air Compressor (XPower Powerpack 400 Plus only)

2

1

3

Feature Description

1 On/Off switch turns the compressor unit on an d of f.
2

Pressure gauge shows the PSI (lb./in

2

)

3 Valve connector with connector hose
Nozzle Adaptor Com partment is integrated into AC charger compartment.

975-0057-01-01 2-5