Xantrex Technology 200 User Manual

Owners Guide

t 1-800-670-0707 (toll free in North America) 1-604-422-2777 (direct)

f 1-604-420-2145 e CustomerService@xantrex.com

www.xantrex.com

XPower Powerpack

400 and 400 PLUS

975-0057-01-01 Printed in China

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

April 2003 Revision 2

Part Number

975-0057-01-01

Contact Information

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

1-604-422-2777 (direct)

Fax: 1-604-420-2145

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 Powerpack 400 and XPower

Powerpack 400 Plus.

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.

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 and the

XPower Powerpack 400 Plus (with the 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 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

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Important Safety Instructions

The XPower Powerpack 400 and XPower Powerpack 400

Plus generate a type of AC power similar to a normal

household wall outlet. Operating the XPower Powerpack 400

and XPower Powerpack 400 Plus incorrectly or misusing it

may damage the equipment or create hazardous conditions for the user.

Important: Before using your 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 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 400 and

XPower Powerpack 400 Plus except to replace the

internal battery. Have a qualified technician complete any service work.

iii

Important Safety Instructions

CAUTION

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

Powerpack 400 and XPower Powerpack 400 Plus.

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 gasolinepowered 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 electrical connections.

When working on electrical equipment, always ensure someone is nearby to help you in an emergency.

iv 975-0057-01-01

Important Safety Instructions

WARNING: Heated surface

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

Powerpack 400 Plus. During operation, keep away

from materials that may be affected by high temperatures such as blankets, pillows and sleeping bags.

WARNING: Fire hazard

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 hazard

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.

975-0057-01-01 v

Important Safety Instructions

WARNING: Fire hazard

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 400 and XPower Powerpack 400 Plus 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 Hazard -

XPower

Powerpack 400 Plus

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.

vi 975-0057-01-01

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.

975-0057-01-01 vii

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.

viii 975-0057-01-01

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 and XPower

Powerpack 400 Plus.

Do not use the following with the XPower Powerpack 400

and XPower Powerpack 400 Plus:

• 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 400 and XPower

Powerpack 400 Plus, contact the equipment manufacturer to

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

975-0057-01-01 ix

Contents

Important Safety Instructions

Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii Precautions When Working With Batteries- - - - - - - - - - - - - - - vii Precautions for Using Rechargeable Appliances - - - - - - - - - - - ix

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

Features

Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1

XPower Powerpack Features - - - - - - - - - - - - - - - - - - - - - - - 2–2

Front Panel Detail- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Air Compressor (XPower Powerpack 400 Plus only) - - - - 2–5 Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6 Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

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 - - - - - - - - - - - - - - - - - - - - - 3–6 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-Temperature Safety Protection - - - - - - - - - - - - - - -3–13

Inflating Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3–15 Connecting to an External Battery- - - - - - - - - - - - - - - - - - - -3–17

Maintenance

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

Recharging with the AC Charger- - - - - - - - - - - - - - - - - - 4–3

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

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

xii 975-0057-01-01

Replacing the Battery - - - - - - - - - - - - - - - - - - - - - - - - - 4–8 Replacing the Incandescent Light - - - - - - - - - - - - - - - - - - - -4–11 Replacing the External Fuse- - - - - - - - - - - - - - - - - - - - - - - -4–11

Troubleshooting

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

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

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

Specifications

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

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

975-0057-01-01 xiii

xiv

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

In addition, the XPower Powerpack 400 Plus:

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

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.

Overheating

The XPower Powerpack is protected from overheating. If the inverter exceeds a safe temperature, 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 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.

1-2 975-0057-01-01

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

Yo ur XPower Powerpack package includes these items:

❐ XPower Powerpack 400 or XPower Powerpack 400 Plus

❐ Owner’s Guide

❐ AC Charger

❐ DC Charging Cable

❐ Jump-Start Cables

❐ Accessory bag

The XPower Powerpack 400 Plus also includes:

❐ two nozzle adaptors for the compressor

❐ One sports needle adaptor for the compressor

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

XPower Powerpack Features

Feature Description

1 DC Power Socket can:

• Power 12 V DC auto, RV or marine appliances

• Recharge

2 2 AC Outlets are standard 3-prong outlets supplying

120 V AC power for running an AC appliance.

XPower Powerpack from a 12 V

outlet in a vehicle using the DC Charging Cable.

3 AC Outlet ON/OFF switch illuminates when the

switch is turned on.

4 Digital Display displays the inverter’s Output

Power in W and Battery Charge status in % FULL.

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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 ON/OFF 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.

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.

975-0057-01-01 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; 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.

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.

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XPower Powerpack Features

Air Compressor (XPower Powerpack 400 Plus only)

Feature Description

1 On/Off switch turns the compressor unit on and

off.

Pressure gauge shows the PSI (lb./in

)

3 Valve connector with connector hose

Nozzle Adaptor Compartment is integrated into AC charger compartment.

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