Xantrex Technology 975-0057-01-01 User Manual

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, mic roturbines, and
backup power applica tions in both grid-connected and stand- alone systems.
Xantrex products include inverters, battery char gers, programmable power
supplies, an d variable speed drives that convert, supply, control , cl ea n, and
distrib u t e el ec tr i cal powe r.

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 pro perty of
their respecti ve owners and are used herein for identification purposes only.

Notice of Copyright

Xpower™ Powerpack 400 and 400 Plus Owner’ s Guide
© October 2005 Xantrex Internation al . All ri ghts 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 INCIDENT AL, 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 of t his Owner’ s Guide is to provi de 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 we ll as infor mation abou t operat ing and
troubleshooting the unit.

Conv en t io n s 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.

Important: These notes describe an important action item

or an item that you must pay attention 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 compress or ) are

referred to as XP ow er P ow erp a ck when the information
applies to both models. However, when the information is
specific to one mod el, then ref ere nc e is made specifically to
the XPower Powerpack 400 or to the XPower Powerpack

400 Plus.

Relat ed Inf o rmation

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. Oper ating 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.

W arnings 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 outle t. Do not inse rt 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.

CAUTION

Do not connect any AC appliance with the neutral 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- powered boat, or
near propane tanks. Do not use this product in an enclosure
containing automoti ve-type lead acid batteries. These
batteries, unlike the sealed AGM battery in XPower

Powerpack 400 and XPower Powerpack 400 Plus, vent

explosive hydrogen gas whic h can be ignited by sparks from
electrical conne ctions.

When work ing on el ectri ca l equi pment, always ens u re
someone is nearby to help you in an emergenc y.

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 tempe ratures such as blankets, pillows
and sleeping bags.

WARN ING: Fire hazard

Never allow jump-star t cables’ red a nd black clamps to to uch
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.

iv 975-0057-01-01

Important Safety Instruct i ons

WARN ING: Fire hazard

Jump-start cable clamps must be connected positive to
positive (red clamp to batt ery “+”) 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/explosion hazard.

WARN ING: 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 cau se damage to the unit. Allow
the XPower Powerpack 400 and XPower Powerpack 400 Plus
to cool down for at least 3 minutes after each jump-start.

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 compresso r unattended whil e operat ing. The
compressor is designed for shor t term operation only.
Operation of the compressor over an extended period of time
will cause the compressor unit to ove rh eat and may cause
damage. Allow the compressor to cool down for 10 minutes
after each 10 minutes of continuous ope ration.

975-0057-01-01 v

Important Safety Instructions

Precautions When Working With Batteries

WARNING: Explosion and Fire H azard

1. Follow all instructions published by the battery
manufacturer and the manufacturer of the equipment in
which the battery is instal led.

2. Make sure the area around the battery is well-ventilate d.

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-circ uit the battery or other electr ical parts
and cause an explosion.

5. Remove personal metal items such as rings, bracelets,
necklaces , and watc he s when wo rk ing w ith a lead -acid
battery. A lead-acid battery produces a short-circuit
current high enough to weld a ring or other simi lar
objects to metal, causing a severe burn.

6. If you need to remove a battery, always remove the
positive terminal f rom 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 batteri es.

vi 975-0057-01-01

Important Safety Instruct i ons

10. If battery acid contac ts skin or clothing, wash
immediately with soap and water. If acid enters your
eyes, immediately flood them with runni ng 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.

975-0057-01-01 vii

Important Safety Instructions

Precautions for Using Rechargeable
Appliances

CAUTION

The output of the inverter is non-sinusoidal.
Most rechargea ble battery-operate d equipment uses a

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

Some chargers for recha rgeable batteries can be damaged if
connected t o 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-ope rated appliances like flashlights , razors,
and night lights that can be plugge d directly into an AC
receptacle to rec h arge .

• Some chargers for batte ry 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 w ith the XPower Powerpack 400 and XPower

Powerpack 400 Pl us, con tact the equipm ent manufa cturer t o

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

viii 975-0057-01-01

Contents

Important Safety In str uctions

Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii
Precautio ns Wh en Wo rk ing W i th Ba tter ie s- - - - - - - - - - - - - - - vi
Precautions for Using Rechargeable Appliances - - - - - - - - - - viii

1

Introduction

About the XPo wer Powe r p ack - - - - - - - - - - - - - - - - - - - - - - 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 (XP ower Powerpack 400 Plus only) - - - - 2–5
Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

3

Operation

Operating Condition s 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

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 Vehicl e’s Engine- - - - - - - - - - - - - - - - - - - -3–10
Using the Air Compressor: XPower Powerpa ck 400 Plus - - - -3–12

Over-Temperature Safety Protection - - - - - - - - - - - - - - -3–13

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

Inflating Small Sport s Equipment - - - - - - - - - - - - - - - - -3–15
Connecting to an External Batte ry- - - - - - - - - - - - - - - - - - - -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 Incandesc ent Light - - - - - - - - - - - - - - - - - - - -4–11
Replacing the External 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

Warran ty an d Return

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

975-0057-01-01 xi

xii

1 Introduction

About the XP ower Po werpack

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

XPower Powerpack can run many AC appliances and 12 V

DC appliances whenever you need power f or work or play, at
home or on the road.

XPower Powerpack:

• Powers 115 V AC appliance s

• Powers 12 V DC appliances

• Jump-starts vehic le engines

• Provides lighting fo r 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 a gainst output
overload. If you conne ct t o the AC Outlet (s) an applia nce tha t
draws more than 320 W, or one which draws excessive surge
power, the power to the AC Ou tle t aut omatically shut s off.

Overheat ing

The XPower Powerpack is protected from overheating. If the
inverter excee d s a safe t emperature, 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 Pow e rp ack com es wit h a user-rep laceable
250 A fuse to protect the unit and vehic le battery from
damage through reverse polarity and short-circuit conditions.

1-2 975-0057-01-01

2 Features

Chapter 2 describes the main feat ures of the XPower

Powerpack. We recommend that you familiarize yourself

with these features before operating the unit.

Materials List

Your XPower Powerpack pa ckage inc ludes the se items:

p XPower Powerpack 400 or XPower Powerpack 400 Plus
p Owner’s Guide
p AC Charger
p D C Ch a rging Ca b le
p Jump-Start Cables
p Accessory bag

The XPower Powerpack 400 Plus also includes:

p two nozzle adapt ors for the comp r es sor
p 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

WA.

2-1

Features

XPower P owerpack Features

Front Panel Detail

6

7

8

1

5

4

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.

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

power for running an AC appliance.

XPower Po werpack from a 12 V outlet in a vehicle

3

2

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 % FULL.

5

Charging Status l ig h t il lumin a 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 illum inates (green) when Output Power

information is displayed on the Digital Display.

8 Display Function button, when press ed, allows fo r re ading Battery

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

Not

shown

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

Control Panel Operatio n

Required

How to ...

Moni to r to ta l
AC power
consumed by
the
applications
powered from
the
Powerpack’s 2
AC outlets

Condit io n Required Acti on N ote

Inverter’s ON/OFF
switch is turned ON;
Output Power (W)
light illuminates
(green);
AC charger is
unplugge d 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 the Powe rp ack ’ s
AC outlets.

In order to save the
battery power and
ensure lo nger inverter
run time, press Display
Function button to turn
off the Digital Disp lay.
Press Display Fu nction
button again to turn the
displ a y O n fo r A C
power read ing.

975-0057-01-01 2-3

Features

How to ...

Required
Condit io n Required Acti on N ote

Monitor
Battery
Charging
status

Check Battery
Charge status

Inverter’s ON/OFF
switch is turned to
OFF;
All ap pli an ces m u 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 ap pli an ces m u 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 Powerpack’s
Charge r Input Socket.

No action required.

A flashi ng green

Charging Status

light in dicat es th at th e
Powerpac k’s battery
needs recharging and
that the AC charger is
charging the battery.

A steady gr een

Charging Status

light in dicat es th at th e
Powerpac k’s battery
is fully charged and
the Powerpack is
ready for use.

Push and hol d the

Display Function

button.

The green Battery
Charge (%) li ght wi ll
come on and the
Digital Display will
show th e remaining
batter y capacity in %.

Recharging with the
supplied AC charger is
a true “plug-in-and­forget ” ch arging
method.
W e recommend leaving
the AC charger
connected when the
Powerpack is not in use
to perm anently
maintain the battery in
fully charged condition.

This function is
disabled when the AC
charge r is plugged in to
the Charger Input
Socket, or when the
inverter main switch is
ON.
For accura te 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

Feature Description

1 On/Off switch turns the compressor unit on and off .
2

Pressure gauge shows t he PSI (lb./in

2

)

3

3 Valve connector with connector hose

Nozzle Adaptor Compartment is integrated into AC charger compartment.

975-0057-01-01 2-5

Features

Left Side View

1

2
3

3
4

Feature Description

1 5 W incandescent ligh t illuminates for about 30 hours when the

battery is full y charged.

2 Light On/Off Switch
3 Jump-Start Cable Port supplies high power DC current. The

cables connect to the Jump-Star t Cable Port when jump-starting a
vehicle’s battery or when connecting an external battery to the

XPower Powerpack. The jump-start cable connection is designed

so that the cables cannot be inserted incorrectly into the Jump-St art
Cable Port.

4 Plastic Guard for covering jump-start cable port.

2-6 975-0057-01-01

Storage Compartment

4

5

XPower Powerpack 400 Plus shown

Feature Description

XPower Powerpack Features

3

2

1

1

2 Charger Input Socket for use with the AC Charger supplied (see

3 External Replaceable Fuse is rated at 250 A, 32 V. Located

4 Compressor Nozzle Adaptor Compartment
5 AC Charger Compartment may be used for storing the AC

975-0057-01-01 2-7

AC Charger lets you recharge the
standard AC wall outlet and can only be used to recharge the
internal batt ery of the
charger co mp a r tment.

1).

behind fuse cover.

Charger.

XPower Po werpack. Can be stored in AC

XPower Powerpack from a

Features

Accessories

1

3

Feature Description

1 Detachable heavy-duty jump-sta rt cabl es

2

2

3 Acces so ry ba g

Not
Shown

2-8 975-0057-01-01

DC Charging Cable lets you recharge the
from a 12 V system in a car, SUV, RV or a boat. This can be stored
in the storage compartme nt.

Nozzle packet (XPower Powerpack 400 Plus only) contains 2
nozzle adaptors and s ports needle adaptor, in the st orage
comp artment on th e ba ck o f the un it .

XPower Powerpack

3 Operation

Chapter 3 explains how to operate the XP ow er Po werpack
efficiently. This chapter covers:

• Recharging the XPower Powerpack for first time use

• Using the built in light

• Operating AC appliances and 12 V DC appliances

• Jump-starting a vehicle ’s engine

• Connecting to an external batter y for additional run time

• Using the compressor on the XPower Powerpack 400

Plus.

Operating Conditions and Guidelines

CAUTION

Read all operating instr uctions before operating the XPower

Powerpack.

CAUTION

Do not use the XPower Powerpack to operate any AC
appliances or 12 V DC appliances while rech arging with the
AC Charger.

The AC Charger may fail if AC appliances or 12 V DC
appliances are opera ted while the AC Charger is connecte d.

CAUTION

The XPower Pow e rp ack is not intended for use as a UPS
(Uninterruptible Power Supply).

3-1

Operation

Choo sing a Loca tion

WARN ING: Fire or explosion

The XPower Pow e rp ack con tai ns co m ponents that tend to
produce arcs or sparks. To prevent fire or explosion, do not
operate the XPower Powerpack in compartments containing
batteries or flammabl e mater ials, or in locations that require
ignition-pro tected equipment.

The XPower Powerpack should be operated onl y in a location
that meets thes e requ i rem ent s :

:

Dry

Cool

Ventilated

Safe

Protected
from batter y
gases

Do not allow water or other liquids to drop or splash on the

XPower Powerpack.

Ambient air temperature should be between 32 and 104ºF
(0 and 40ºC)—the cooler the better within this range.

Leave at least 2" (5 cm) cleara nce around the XPower

Powerpack for air flow. Ensure that the ventilation

openings are not obstructed.
Do not oper ate the unit in th e same compartmen t as

batteries or in any compartment capable of storing
flammable liquids like gasoline.

Do not operate the unit where it will be exposed to battery
gases. These gases are very corrosive, and prolonged
exposure will damage the

XPower Powerpack.

3-2 975-0057-01-01

Using XPower Powerpack for the First Time

Using XPower Powerpack for the First Time

n

Important: Prior to operating your AC appliance or 12 V

DC appliance, ensure that the battery of the XP ower

Powerpack is fully charged. If the battery has been fully

discharge d, r echarging with the AC Charger may take up to
35 hours.

Recharging with the AC Charger

Note: The Battery Charge (%) reading on the digital

display is only accurat e when the XPower Powerp ack has
been disconnected fro m all appliances and all charging
sources for fifteen minutes.

Recharging with the AC Charger is a true “plug-in-and­forget” charging method. We recommend leaving the AC
Charger connect e d wh en the XPower Powerpack is not in
use.

To recharge w ith the AC Charge r:

1. Disconnect any 12 V DC appliances and turn the light
off.

2. Turn the AC Outlet On/Off switch to Off.

3. Plug the AC Charger into a standard AC wall outlet.

4. Insert the AC Charger cable end into the Charger Input
Socket located in the storage compartment of the unit.

The green Charging Status light changes from flashing to
steady when charging is complete (about 35 hours if the
battery is completely disc harged).

975-0057-01-01 3-3

Operation

Important: The 35 hour charging time for the XPower

Powerpack assumes that there is 120 V at the AC wall

outlet. If t he volta ge is l ess tha n 120 V AC, it may ta ke more
than 35 hours to fully rechar ge the XPower Powerpack. If,
after 35 hours of charging, the green Charging Status light
is still flashing , con tinue to charge the unit for another 15
hours.

Important: If you keep the XPower Powerpack in storage,

the battery will discha rge over time. Remember to recharge
the battery every three months to keep the XPower

Powerpack operational.

Note: Once fully charge d, the cha rging current

automatically reduces to a maintenance charge mode, and
the XPower Powerpack may be left permanently connected
to the AC Charger.

Using the light

The XPower Pow e rp ack has a built in incandescent light
which will operat e for about 30 hou rs b efore the u nit needs to
be recharged. The ON/OFF switch is located beneath the
light. The light can be adjusted up and down by pushing
against the top or bottom of the rim around the lens.

3-4 975-0057-01-01

Operating AC Appliances

Understanding AC Appliances

AC appliances are rated by how much electrical power (in
watts) they consume. XPower Powerpack can power most
appliances wit hin its continuous power rating (320 W, 2.7 A).

Some appliances may be diff icult or impossible to operate
from the XPower Powerpack. They may have high surge
requirements or should not be run from the XPower

Powerpack. See “High Surge Appliances” on page 3–6 and

“Trouble Appliances” on page 3–6.

Run Time on Typical AC Appliances

Note: The fewer watts an AC applianc e use s, the longe r the

XPower Powerpack will operate before recharging is

required.
Typi ca l AC app l ian ces tha t can be used o n the XPower

Powerpack are listed in Table 3-1.

Operating AC App liances

Table 3-1

AC Applia nc e

Cordless tel ephone (sta nd by) 5 40
Home securit y system 5 40
Clock radio 8 22
Portab l e stereo 10 17
Fluorescent work light 14 10
Firepl ace fan 20 8
Laptop computer 25 6
Table lamp 40 3
Color TV – 13" 60 2 h 30 min.
3/8 “ drill 190 20 min.

a. Repres ents actual power consu mption as measured on sample appliances.
b. Operating times assume a fully charged 20 Ah battery and may vary based

975-0057-01-01 3-5

AC Applianc es and Run Times

on model/brand of appliance.

Watts

a

Hours

b

Operation

High Surge Appliances

The wattage rating of AC appliances is the average power
used by the appliance. Appliance s such as televisions,
computer monitors and appli ances with motors consume
much more pow e r than the ir aver ag e rati n g when they are
first switched on.

Although XPower Powerpack can supply momentary surge
power up to 600 W, some appliances may exceed the
capabilities of the XPower Powerpack and trigger the
inverter’s safety overload shutdown circuit.

Trouble Appliances

t

CAUTION

The output of the Powerpack’s inverter is non-sinusoidal.
Some equipment may be da maged by the inverter’s modified
sine wave output (non-sinusoidal).

Some appliances, including the types listed below, may be
damaged if they are connected to the inverter:

• Electronics that modul ate RF (radio frequency) signals
on the AC line will not work and may be damaged.

• Speed controllers found in some fans, power tools,
kitchen appliance s, a nd other loads may be damaged.

• Some chargers for small rechargeable b atteries can be
damaged. See “Precautions for Using Rechargeable

Appliances” on page viii f or details.

• Metal halide arc (MHI) lights can be damaged.

Note: If you are unsur e about powe ring any de vice with the

inverter, contact the manufacturer of the device.

3-6 975-0057-01-01

Operating Several Appliances at Once

You can run several AC applianc es if the t otal ra ting of all the
appliances (in watts ) does not exceed 320 W. You can run
appliances using an AC power bar.

Run time, however, will decrease accordingly with the
number of appliances being ope rated and the AC power being
consumed.

Operating an AC Appliance

Before operating your AC appliance, ensure that the battery
of the XPower Powerpack is fully charged. See “Recharging

with the AC Charger” on page 3–3 for de ta ils .

To operate an AC appliance:

1. Open the protective covering on the right side of the

XPower Powerpack. Turn the AC Outlet On/Off switch

to the On position.
The switch illuminat es to indicate AC power is available

at the AC Outlets.

2. Plug the AC appliance into one of the AC Outlets and
turn the appliance on. XPower Powerpack will operate
most devices rated up to 320 W.

Operating AC App liances

3. Recharge the XPower Powerpack as soon as possible
after each use.

When using the XPower Powerpack to operate an AC
appliance and the low battery warning sounds, the
warning gives you time to shut your AC appliance of f
before loss of AC power.

If you ignore the warning, the XPower Powerpack
automatically tur ns off a few minutes later to prevent
battery damage.

In the event of an overload, low battery voltage or
overheating, the XPower Powerpack automatically shuts
down.

975-0057-01-01 3-7

Operation

Operating 1 2 V DC Appl iances

The XPower Pow e rp ack can o perat e 1 2 V DC au to, RV,
marine, or other portable app liances that draw 12 A or less
from a 12 V DC power outlet or from a vehicle’s lighter
socket.

CAUTION Equipment damage

The DC Power Socket does not automati cally swi tch off
when the internal battery is discharged. To protect the
internal battery against damage resulting from total
discharge, We recommend that the A C Ou tlet O n/O ff swit ch
is turned On when using the XPower Powerpack to operate a
12 V DC appliance.

Having the AC Outlet On/Off swit ch turned On enables the
alarm to warn you when the 12 V DC appliance has nearly
depleted the intern al battery.

Note: The fewer watts a 12 V DC appliance draws, the

longer the XPower Powerpack will operate before
recharging is r equired.

3-8 975-0057-01-01

Operating 12 V DC Appliances

T ypical 12 V DC appliances that can be used on the XPower

Powerpack are listed in Table 3-2.

Table 3-2

12 V DC Appliance

5 W incandesc ent ligh t (bui lt
into th e un it)

Cellular telephone
Stereo/CD pl ayer 10 17
Portable Cooler 30 4

a. Repres ents actual power consu mption as measured on sample appliances.
b. Operating times assume a fully charged 20 Ah battery and may vary bas ed

c. Repres ents talks time available fro m 10 recharge cycles.

12 V DC Appliances and Run Times

Watts

530

c

on model or brand of appliance.

630

a

Hours

b

To operate a 12 V DC appliance:

1. Open the protective cover on the left side of the XPower

Powerpack.

2. Plug the 12 V DC appliance into the DC power socket on
the left side of the unit, and turn the 12 V DC appliance
on (if required).

If the 12 V DC appliance draws more than 12 A (or has a
short-circuit de fect), the internal circuit breaker of the

XPower Powerpack shuts off the power to the 12 V DC

appliance. If this occurs, unplug the 12 V DC appliance,
and the internal circui t brea ker automatically resets after
a few seconds.

3. Fully recharge the XPower Powerpack as soon as
possible after each use.

As the DC power socket is internally wired directly to the
internal battery, extended operation of a 12 V DC
appliance may result in excessive battery discharge. See
Caution for “Equipment damage” on page 3–8.

975-0057-01-01 3-9

Operation

Jump-Starting a Vehicle’s Engi n e

You can use the XPo wer Po w er p ack to jump - s t a r t a ve h i c l e
or boat engine that has a 12 V starting battery using the plied
Jump-Start Cables.

WARN ING: Fire hazard

Never allow cabl es’ 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/e xplosion hazard.
Always disconnect the clamps for the unit after use and clip
the plastic guard over the jump-start cable port.

WARN ING: Fire hazard

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

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.

Important: Closely follow these instructions for jump-

starting your vehicle as they may be different from the
instructions supplied with other jump-start products or
jump-start cables.

3-10 975-0057-01-01

Jump-Starting a Veh i cle’s Eng ine

To jump-start a vehicle or boat engine:

1. Turn off the vehicle or boat ignition and all accessories.

2. Engage the park or emergency brake and place the
transmission in park for an autom atic or neutral for a
manual.

3. If jump-starting a boat engine, purge the engine
compartment and bilge of all fumes before jump-starting.

4. Connect the cables to the Jump-Start Cable Port on the
left side of the XPower Pow e rp ack.

5. Position the XPower Powerpack on a flat, stable surface
near the battery and away from all moving parts of the
engine.

6. Connect the red positive (+) clip of the cables to the
positive (+) terminal of the engine battery.

The battery’s positive terminal is usually larger in
diameter than the ne gative te rminal. In most vehicle s, the
battery’s positive terminal has a red wire connected to it.

7. Connect the black negative (–) clip of the cables to the
engine block, cylinder head, or other stationary heavy
metal part of the motor, or to the negative (–) battery
terminal.

Before starting the engine, make sure the XPower

Powerpack and the cables are cl ear of belts an d fans. Do

not crank the engine for more than 4 seconds.

WARN ING: 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 to cool down for at least 3 minutes
after each jump-start.

8. Remove the red positive (+) clip and then the black
negative (–) clip from the vehicle’s battery terminal.

9. Remove the cables from the Jump-Start Cable Port.

975-0057-01-01 3-11

Operation

Important: Recharge the XPower Powerpack as soon as

possible aft er eac h us e. Se e “Recharging the XPower

Powerpack Battery” on page 4–2.

Using the Air Compressor: XPower

P owe rpack 400 Plus

WARNING: Fire Hazard

The compressor is designed for short term operation only.
Operating the compressor over an extended period of time

will cause the compressor unit to ove rh eat which could lead
to fire. Allow the compressor to cool down for 10 minutes
after each 10 minutes of continuous ope ration.

WARNING: Fire Hazard

Do not leave the compressor unattended while in operation.
Keep out of reach of children.

WARNING: Risk of personal injury or
damage to equipment

Never leave the compressor unattended while in operation.
The compressor is capable of infl ating to 250 PSI. Do not
exceed the recommended pressure of either the compressor or
the object being inflat ed. If either recommended pressure is
exceeded, an explosion may result.

3-12 975-0057-01-01

Using the Air Compressor: XPower Powerpack 400 Plus

Over-Temperature Safety Protection

It is recommended that you follow the warnings and turn the
compressor off f or 10 minutes after every 10 minutes of
operation. However, the XPower Power pack 400 Plus is
equipped with an over- temperature safety protection feature
that a u tomatically turns th e c o mpre s sor off if i t b e g ins to
overheat. Once the compresso r cools down to its normal
operating temperat ure it will automatically turn on again and
continue inflating. You should turn the compressor off at the
power switch if this safety feature engages, and allow the
compressor to cool for 15 minutes before re-starting.

WARNING: Risk of personal injury or
damage to equipment

Never leave the compressor unattended once it has switched
itself of f due to over heating. It wil l tur n on a gain a nd conti nue
inflating when its inte rnal temperature drops.

Turn the compressor off at the power switch after each use or
any time the compressor turns off automatically.

Inflating Tire s

Table 3-3

Tires PSI Other Inflatables PSI

520-13 26 Football 13
A-78-14 26 Ba sketball 9
E78-14 30 Volleyball 5
H-78-14 24 Lawn Tractor Tire 22

HR-78-15 28

Bicycle Tires

27-1 ¼ 85
20-1 ½ 40

975-0057-01-01 3-13

Pressure Specifications for Common Items

Operation

Note: The informat io n in the table i s for refe ren c e onl y.

For precise pres su re s peci fi ca tion s , refe r to the inf o rma tion
supplied with the article to be inflated.

CAUTION

If the pressure gauge on the compressor indicates more than
twice the recommended pressure for the object you are
inflating, and you have only started to inflate the object, the
valve connector is incor rec tly connected to the valve stem.
This may damage the XPower Powerpack 400 Plus. Remove
and reattach the valv e con n ecto r to the valv e stem .

To inflate your vehicle, motorcycle, or bicycle tires:

1. Place the valve connector securely on the tire va lve ste m,
push it as far as possible to allow normal airflow, and
close the thumb l atch. If necessary , use a supplied nozzle
adapter.

2. Turn the compressor on, and inflate your tir e to the
recommended pressure. Use Table: Pressure
Specifications for Common Items as a guide only.

3. Turn the compresso r off after app rop ri ate p res su re is
reached.

4. Open the thumb latch and remove the valve connector
from the valve stem.

5. Check air pressure with a pressure gauge.

Note: Leave the thumb latch in the open position for

storing to relieve pressure on the internal mechanisms.

3-14 975-0057-01-01

Using the Air Compressor: XPower Powerpack 400 Plus

Inflating Small Sports Equipment

You can use the compressor to inflate small sports e quipment
such as balls (soccer balls and footballs).

CAUTION

The XPower Pow e rp ack cannot be used to inflate large
capacity inf lata b les su ch as float tubes , large air mattresses,
and inflatable boat s. The se types of products require
extended inflating tim es which may damage the compressor.

To inflate small sports equipment:

1. Place the valve connector fully on or into the valve
receptacle on the item. Go to Step 4.

OR
If necessary, use a supplied nozz le ad ap tor.

2. Choose the appropriate nozzle adaptor, insert the nozzle
adaptor into the valve stem and close the thumb latch.

3. Insert nozzle adaptor into the valve receptacle of the
item.

4. Turn the compressor on and inflate to appropriate
pressure.

WARNING: Fire Hazard

Allow the compressor to cool down for 10 minutes after eac h
10 minutes of continuous operation.

5. Turn the compressor off befo re rem o v ing n ozzl e ad apt o r
from valve stem.

6. Remove nozzle adaptor from valve connector and store
in storage compartment.

Note: Leave the thumb latch in the open position for

storing to relieve pressure on the internal mechanism.

975-0057-01-01 3-15

Operation

Connecting to an External Battery

You can extend battery operating times by connecting the

XPower Powerpack to a larger ex ternal battery.

For example, an external 60 Ah battery gives approximately
four times the operating time of the XPower Powerpack
internal 20 Ah battery.

WARN ING: Fire hazard

Never allow j ump-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.

WARN ING: Fire hazard

Jump-start cable clamps must be connected positive to
positive (red clamp to batt ery “+”) 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/explosion hazard.

WARNING: Acid spills

Use a sealed, non-spillable battery for indoor use. Common
auto and marine batteries are not suitable for indoor use
unless their fumes are vented outdoors. Common auto and
marine batteries contain acid, which is hazardous if spilled.
Wear eye protection and protective clothing when connecting
the XPower Powerpack to an external battery.

3-16 975-0057-01-01

Connecting to an External Battery

To connect the XPower Powerpack to an external battery
using the jump-start cables:

1. Connect the cables to the Jump-Start Cable Port on the
left side of the XPower Pow e rp ack.

2. Connect the red positive (+) clip of the cables to the red
positive (+) terminal of the external battery.

3. Connect the black negative (–) clip of the cables to the
black negative (–) terminal of the external battery.

WARNING: Sparking and Explosion

Do not remove the cables from the Jump-Start Cable Port
when the positive and negative clamps are connected to the
terminals of the ext ernal ba tter y.

To disconnect the cables from an external battery and
from the XPower Powerpack:

1. To disconnect the XPower Powerpack from the ext ernal
battery when the external battery is discharged or no
longer needed, remove the red positive (+) clip, and then
remove the black negative (–) clip.

2. Remove the cables from the Jump-Start Cable Port.

3. Recharge the XPower Powerpack as soon as possible
after use.

CAUTION

Do not recharge the XPower Powerpack when an external
battery is connected. The AC charger may be damaged.

975-0057-01-01 3-17

3-18

4 Maintenance

Chapter 4 provides informat ion on mainta ining your internal
battery, recharging options for the internal battery, and
replacing user-replaceable parts.

Routine maintenance is req uired to keep your XPower

Powerpack opera ting properly. Occasionally clean the

exterior of the unit with a damp cloth to remove the
accumulat ed dus t an d dir t.

WARNING: Shock hazard

Disconnect all sources of AC power and DC power before
performing any type of maintena nce.

Batter y Maintena n c e

All recharge able batteries gradually discharge when left
standing, and you need to recharge them periodically to
maintain maximum battery capac ity. The AC Charger
supplied with the XPower Powerpack is designed to regulate
the char ging process, ensuring that the battery is always ful ly
charged but never overcharged. To ensure safe recharging
and maximum battery life, recharge the XPower Powerpack
only with the supplied charger or approved battery chargers.

s.

CAUTION

Due to inherent self-discharge, lead acid batteries must be
charged at least every 3 months, especially in a warm
environment. Leaving a battery in a discharged state, or not
recharging every 3 months, may result in permanent battery
damage and poor jump-start perfor mance.

4-1

Maintenance

CAUTION

Do not attempt to rechar ge the XPower Powerpack battery if
it is frozen . Gradual ly warm th e froz en batte ry to 32 °F (0 °C)
before recharging.

Recharging the XPower Powerpack Battery

To check the battery’s charge level, press the Display
Function button.

Note: Battery Charge (%) status is only accurate when

the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.

You can recharge the batter y using:

• the fully automatic “plug- in-and-forget” AC Charger.

• the DC Charging Cable to recharge from your vehicle as
you drive.

• a generator equipped with a regulated 12 V battery
charging outlet.

• a solar panel.

Rechar ging with the AC Charger

Recharging with the AC Charger is a true “plug-in-and­forget” charging method.

CAUTION

Do not operate AC or DC appliances while the XPower

Powerpack is being recharged with the AC Charger.

The AC Charger may be permanently damaged if AC
appliances or 12 V DC appliances are operated while the AC
Charger is connected.

4-2 975-0057-01-01

Recharging the XPower Powerpack Battery

To recharge w ith the AC Charge r:

1. Disconnect any 12 V DC appliance and turn the light
swit c h to Off.

2. Turn the AC Outlet On/Off switch to Off.

3. Plug the AC Charger into a standard AC wall outlet.

4. Insert the AC Charger cable end into the Charger Input
Socket locat ed in the ch arg er storage compar tm ent .

5. While the XPower Powerpack is recharging, the green
Charging Status light is flashing. If the battery is
completely discha rged, a typical recharge may take up to
35 hours. When fully charged, the green Charging
Status light changes to steady and the XPower

Powerpack is ready to use.

Important: The 35-hour charging time for the XPower

Powerpack assumes that there is 120 V at the AC wall

outlet. If t he volta ge is l ess tha n 120 V AC, it may ta ke more
than 35 hours to fully rechar ge the XPower Powerpack. If,
after 35 hours of charging, the green Charging Status light
is still flashing and not steady, continue to charge the unit
for another 15 hours.

Once the battery is fully charged, the charging voltage
and current automat ically reduces to a maintenance level
and the XPower Powerpack may be left permanentl y
connected to the AC Charger. If your utility power is
interrupted, the charging process automatically restarts
when power returns.

Recharging with the DC Charging Cable

Using the DC Charging Cable, the XPower Powerpack can
be recharged while you drive your vehicle.

Important: Although the charge regulation circuitry in the

XPower Powerpack does not operate with this c harging

method, most vehicle voltage regulators will ensure that the

XPower Powerpack is not overcharged.

975-0057-01-01 4-3

Maintenance

WARN ING: Fire and Explosion Haza rd

Do not use this rechargi ng method if your vehicle has
abnormally high voltage e lec trical syst ems that operate a bove
15 V DC. This may lead to accumulations of hydrogen,
causing exposure to fire and explosion hazard.

CAUTION

Do not operate AC or DC appliances while the XPower

Powerpack is being recharged with the DC Charging Cable

from your vehicle.

To recharge the XPower Po w e rp ack while you drive using
the DC Charging Cable:

1. While the vehicle engine is running, plug one end of the
DC Charging Cable into the DC Power Socket of the

XPower Powerpack.

2. Plug the opposite end of the DC Charging Cable into the
vehicle’s lighter socket or 12 V accessory outlet.

3. Once the XPo wer Po w er p ack is fully charged or if your
vehicle’s engine is not running, disconnect the DC
Charging Cable fro m both sockets.

Most of the XP o w er Pow er p ack’s capacity will be
restored in four hours while the vehicle engine is
running.

Note: The green Charging Status light will not illuminate

when the XPower Powerpack is recharg ed through the DC
Charging Cab le .

Note: Battery Charge (%) indicator is only accur ate whe n

the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.

4-4 975-0057-01-01

Recharging the XPower Powerpack Battery

Important: Do not leave the XP ow er Po werpack

permanently connect ed to the vehi cle’s lighter socket or
12 V accessory outlet.

975-0057-01-01 4-5

Maintenance

Recharging with a Generator’s Regulated 12 V DC
Outlet

WARN ING: Fire and Explosion Haza rd

The generator output must be intende d for ba ttery charging
and have an output of 15 V or less. An unregulated output or
one that exceeds 15 V DC can damage the battery.

This may lead to accumulations of hydrogen, causing
exposure to fire and explosion hazard.

Refer to the Owner’ s Guide accompanying your genera tor f or
detailed inst ructi ons on connec ting the g enerator to a uni t l ike
the XPower Powerpack.

You can recharge the battery of the XP ower Powerpack using
a generator in sev era l ways:

• Using the AC Charger to rechar ge the XPower

Powerpack from a generator is possible, but would

require extended generator running time.

• Using a generator which has an auxili ary regulated 12 V
DC output designed for char ging 12 V batteries. Most
generators are equippe d with them. Use this power
source for fast er chargin g.

• Using a generator with a regulat ed 12 V DC lighter
socket. Follow the connection instructions in

“Recharging with the DC Charging Cable” on page 4–3.

Most of the XP o w er Pow er p ack’s battery capacity will be
recharged in a few hours.

Note: Battery Charge (%) indicator is only accur ate whe n

the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.

4-6 975-0057-01-01

Recharging From a Solar Panel

Small, unregulated 12 V solar panels rated to produce a
maximum of 2.5 A (or 30 W) can be used to charge the

XPower Powerpack through the Charger Input Socket.

You will need to purchase a standard 5.5 mm OD x 2.5 mm
(0.217” x 0.10”) ID DC Coaxial (barrel type ) connector to
mate with the Charger Input Socket.

To recharge with a solar panel:

1. Connect the solar panel’s red positive (+) wire to the
coaxial plug’s inner contact.

2. Connect the solar panel’s black negative (–) wire to the
plug’s outer contact.

Once the connector is inserted into the Charger Input
Socket and the solar panel is placed in the sun, the

XPower Powerpack charge s automatically just as with

the AC Charger. See “Recharg ing w ith the AC Cha rger ”

on page 4–2.

It takes about ten hours in direct sunlight to recharge the

XPower Powerpack from a 2.5 A solar panel.

Replacing the Internal Battery

Replacing the Internal Battery

Battery Life

The high quality battery use d in the XPower Powerp ack will
serve as a reliable power source for years when properly
maintained.

To maximize battery life, it is important to recharge the

XPower Powerpack battery after each use.

Important: Recharge the XPower Powerpack fully at least

every three months if it is placed in storage or in a vehicle
trunk. Store in a location that maintains a temperature range
between 32 and 86 °F (0 and 30°C).

975-0057-01-01 4-7

Maintenance

CAUTION

Discharging the internal battery below 10.0 V will damage
the battery and shorten its lif e.

Obtaining a Replacement Battery

Replacement batteries are available from stores that
specialize in and have a selection of lead acid, AGM
(Absorbed Glass Mat) batter ie s.

Refer to Table 4-1 for a listing of batteries approved for use
with th e XPower Powerpack:

Table 4-1

Replacement Battery Where to Buy

Panasonic
#LC–X1220P
(12 V 20 Ah)

EnerSys
#NPX–80
(12 V 20 Ah)

Approved Replacement Batteries

Panasonic:
Tel: [phone]
web: www.pasc.panasonic.com

Digi-Key
Tel: [phone]

EnerSys
Tel: [phone] (Eastern US)
Tel: [phone] (Western US)

web: www.EnersysStationar y.com

4-8 975-0057-01-01

Replacing the Batte ry

WARNING: Shock or Electrical Hazard

Read this entire section before disassembling the unit.
Before attempting to replace the internal battery, make sure

you:

• Disconnect any charging cables, 12 V DC appliances,
and AC appliances from the XPower Powerpack.

• Turn off the AC Outlet On/Off switch and turn off the
light switch.

• Remove the jump-start cables.

WARNING

If you do not know how to safely remove and install batter ies,
have this task perfo rm ed by a qua lifi ed serv ice t ech ni ci an.

Replacing the Internal Battery

WARN ING: Fire hazard

When installing the replacement battery, make sure the
battery polarity is co rrect. Reverse polarity will damage the

XPower Powerpack and could cause serious injury.

To replace the battery:

1. Place the XPower Powerpack upright on a stable, level
surface.

2. On the XPower Powerpack, unscrew the four fasteners
on the battery cover. Place the fasteners in the cover for
safe keeping.

975-0057-01-01 4-9

Maintenance

Fasteners

3. Disconnect the wires on the battery only.

4. After removing the old battery, position the new battery
close to the back of the XPower Powerpack.

Make sure the positive battery terminal is next to the red
positive ( +) i nternal ca ble and the bla ck n egati ve ter minal
is next to the black negative (–) internal cable.

5. Securely fasten the bolt and washer that holds the red
positive (+) cable to the positive (+) battery terminal and
the black negative (–) cable to the negative (–) battery
terminal.

6. Do not overtighten the bolt. Consult the battery
manufacturer for torque specifications.

7. On the XPower Powerpack, replace the battery cove r and
the four fasteners.

8. Dispose of the old battery in an environmentally
responsible manner.

4-10 975-0057-01-01

Recycling

The XPower Pow e rp ack is designed to provide years of
service. However, when the internal battery reaches the end
of its service life, you will need to replace it as describe d in
your manual.

Because the internal battery contains lead, which can be
hazardous if exposed to the environment, the old internal
battery should be recycl ed or safe ly disposed of at your local
recycling depot.

Do not dispose of the old internal batte ry with common
household waste. Please ask your local authorities about
recycling se rvi ces that are av ail ab le in y our area.

Replacing the Incandescent Light

T o replace a light bulb:

1. Turn the light switch off.

2. Unscrew the cover and lens.

3. Gently grasp the bulb and pull to remove the light
reflector assembly an d the bulb.

Recycling

4. While holding the light reflector assembly, gently
unscrew the black knob at the back of the assembly.

5. Remove the old bulb and insert a replacement bulb of the
same type and rating into the light reflector assembly.

6. Holding the light reflector assembly, gently screw the
black knob on to the back of the assembly.

7. Reattach the lens and cover.

975-0057-01-01 4-11

Maintenance

Replacing the External Fuse

The replacement fuse must be rated at 250 A, 32 V DC. See

page 2–7 for a diagram. To replace the external fuse:

1. Remove the fuse cover.

2. Unscrew the two bolts on the fuse.

3. Replace the fuse. Ensure that the replacement fuse is
rated at 250 A, 32 V DC and is of the same type.

4. Tighten the fuse with the two bolts.

5. Replace the fuse cover.

4-12 975-0057-01-01

5 Troubleshooting

Trouble shooting will help you identif y the common problems
than can occur with the XPower Pow e rp ack.

Read this chapter before calling Customer Service.
If you cannot solve the pr oblem with the XPower Powerpack,

record the information asked for on “Information About Your

System” on page WA–4 and then contact your dealer.

Common Probl ems

Buzz in Audio Equipment

Some inexpe nsi v e ster eo syst em s hav e ina d equ at e intern a l
power-supply f iltering and may buzz slightly when powered
by the XPower Powerpack. The best solution to eliminate the
buzzing is to use an audio system with a good quality filter.

Television Interference

The XPower Powerpack is shielded to minimize interference
with TV signals. If TV signals are weak, you may see
interference in the form of lines scrolling across the TV
screen. Try one of the following suggestions to minimize or
eliminate the interference:

• Use an extension cord to increase the distance between
the XPower Powerpack and the TV, antenna, and cables.

• Adjust the orientati on of the XPower Powerp ack ,
television, antenna, and cables.

• Maximize TV signal strength by using a better ant enna.
Use a shielded antenna cable where possible.

• Try a dif fere nt TV. Different models vary c onsidera bly in
their susceptibility to interference.

5-1

Troubleshooting

Troubleshooting Reference

WARN ING: Electric shock hazard

Do not remove the cover of the XPower Po w er p ack or
disassemble the XPower Powerpack except to replace the
internal batter y or 250 A fuse. The XPower Powerpa ck does
not contain any interna l user- ser viceabl e parts and attemp ting
to service the unit yourself could result in electrical shock or
burn.

Table 5-1

Problem Possible Cause Soluti on

AC appliance
will not
operate;
audible alarm
is not
sounding.

AC appliance
will not
operate;
audible alarm
is sounding.

Troubleshooting reference

AC appliance rated
more than 320 W, the
safety overloa d has
tripped.

AC appliance is rated
less than 320 W, high
starting surge has
tripped the safety
overload.

Battery has di schar ged
to 10.5 V.

Inverter has
overheated due to p oor
ventilation or
excessively warm
environmental
conditions.

Use an AC appliance with a power
rating less tha n 320 W.

AC appliance may excee d the

XPower Powerpack’s surge

capabilit y . Use an AC appliance wit h
a starting surge within the XPowe r

Powerpack surge rating.

Turn the AC Outlet On/Off switch
off and recharge the XPower

Powerpack.

Turn the AC Outlet On/Off switch
off and allow the XPower

Powerpack to cool for 15 m inutes or

more. Clear blocked fan opening or
remove objects covering the unit,
then restart the XPower Powerpack.
Move to a cooler environment.

5-2 975-0057-01-01

Troubleshooting Reference

Table 5-1

Problem Possible Cause Soluti on

Overload
shutdown

Over­temperature
shutdown

Alarm sounds Internal battery is

Measured AC
output voltag e
is too low.

Troubleshooting reference

Appliance power
requirements exc ee d
the cap ab i lity of th e

XPower Powerpack.

Inverter has
overheated due to p oor
ventilation or
excessively warm
environmental
conditions.

nearly discharged.
(11. 0 V).
If you ignore this
warning, the XPower

Powerpack

automati cally switche s
off when the b at te r y
reaches 10.5 V.

Use of an
averag e- re a d in g , A C
voltmeter to read
output volt age.

Unplug the appliance and confirm
that the appliance’s power
requirement is 320 W or less before
attempting to restart t he appliance.

Turn of f the AC Outlet On/Off
switch, and let the XPower

Powerpack cool down.

Turn the AC outlet ON/OFF switc h
OFF and recharge the XPower

Powerpack.

The modified sinewave (MSW)
output of the XPower Powerpack
requires a true RMS reading meter,
such as t h e Fluke 87 seri es, for
accurate measurement.

Battery is al m o st fu l ly
discharged.

975-0057-01-01 5-3

Press Display Function button to
verify batt ery sta tus and recha rg e the

XPower Powerpack as necessary.

“Battery Charge %” reading on the
digital display is only acc urate when
the XPower Powerpack has been
disconnecte d from all applianc es and
all chargi ng sources for fifteen
minutes.

Troubleshooting

Table 5-1

Problem Possible Cause Soluti on

Run time is
less than
expected.

Charging
Status lig h t is

Off when AC
Charger is
connected

Green

Charging
Status lig h t is

flashing
(indicating
recharging)
and Battery
Charge (%)
does not turn
on.

Troubleshooting reference

Intern al batt er y is not
fully char ge d.

AC appliance power
consumption is higher
than expected.

No AC pow er at th e
AC wall outlet.

AC Charger is faulty.

Battery Charg e (% )
reading on digital
display is only
accurat e w h en the

XPower Powerpack

has been disconnected
from all appliances
and all charging
sources for fifteen
minutes.

Recharge using the AC Charger,
until green Charging Status light is
steady.

Check AC appliance powe r or
wattage rating (or current dr aw for
12 V DC appliances) and compare
with Table 3-1 on pa ge 3–5 and

Table 3-2 on page 3–9.

Ensure pow er is availabl e at the AC
wall outlet.

Replace the AC Charger.

Unplug the char ging sourc es and any
appliances a nd le t th e XPower

Powerpack rest for 15 minutes to

obtai n an accurate read ing.

Green

Charging
Status lig h t is

still flashing
and hasn’t
changed to
steady after 50
hours of
charging.

5-4 975-0057-01-01

The voltag e at th e AC
wall outlet is less than
120 V AC.

Intern al batt er y is
permanently damaged.

Use AC wall outlet t hat suppli es 120
V AC.

Replace the battery.

Troubleshooting Reference

Table 5-1

Problem Possible Cause Soluti on

The
compressor
runs but won’t
inflate
(XPower

Powerpack
400 Plus only) .

The
compressor
runs slowly
(XPower

Powerpack
400 Plus only) .

The engine
being jump­started wi ll no t
start.

Troubleshooting reference

The valve connector
may not be securely
placed o n th e val v e
stem.

The item being
inflated may have a
leak.

The compressor may
have overheated from
excessi v e us e.

Batter y vo l tage is too
low.

XPower Powerpack

battery is not fully
charged.

The engine condition
is poor.

Check that the valve connector is
secure ly p laced on the val v e stem
before closing the thumb latch.

Check that the item being inflated
has no leaks.

Check th e compressor ho se for any
breaks or leaks at conne ctions.

Turn off the compresso r and let it
cool down.

Check the condition of the internal
battery. The battery may need to be
recharged or replaced.

Recharge the XPower Powerpack
battery.

Have the engine ser viced.

External fuse (250 A)
is blown.

The engine start
capacity exceeds the

XPower Powerpack

jump-start capability.

975-0057-01-01 5-5

Replace 2 50 A, 32 V fuse with same
type and ratings.

Troubleshooting

Table 5-1

Problem Possible Cause Soluti on

The battery
clamps of the
jump-start
cables measure
zero volts.

The light does
not turn on.

Troubleshooting reference

External fuse (250 A)
is blown.

Light bulb has burnt
out.

Replace 2 50 A, 32 V fuse with same
type and ratings.

Remove lens cover and re place bulb
with one of the same type and rating.

5-6 975-0057-01-01

A Specifications

Electric al Specif ications

\

12 V DC Section

Internal battery type sealed, AGM (Absorbed

Glass Mat) lead acid
Internal battery voltage (nominal) 12 V DC
Internal battery capacity (minimum) 20 Ah
Internal battery CCA rating 200 CCA
DC Power Socket (maximum continuous load ) 12 A with automatic reset
Built-in incandescent light (replaceable) 5 W bulb
Jump-start cable port 50 A
Jump-start fuse (external - user repla ce able) 250 A

A-1

Specifications

AC Power Section

Output power

• Continuous output power

• Five minute AC output power

• AC output surge capacity

320 W
400 W

600 W
Output voltage 115 ± 10 V AC RMS
Output frequency 60 Hz ± 4 Hz
Output wave form modified sinewave
No load current draw <0.20 A DC
Input voltage range 10.5 to 15.0 V DC
Low battery alarm 11.0 V DC
Low battery shutdown 10.5 V DC
High battery volta ge s hutdown Yes, automatic reset
Over temp erature shutdown Yes, auto matic reset
Overload shutdown Yes, automatic reset
AC output short circu it protection Yes, automatic reset
Fuse (internal) 2 x 25 A or 1 x 50 A
Operating temperature range 32 – 104 ºF

(0 – 40 ºC)
Storage temperature range 32 – 86ºF

(0 – 30 ºC)

Internal Battery Charging Controller System

AC Charger bulk char ging current 750 mA
Peak charging voltage (nominal) 14.2 V
Charge restart voltage (nominal) 12.9 V
Float charge after full charge is completed

1 mA

(nominal)
AC Charger input socket maximum current 2.5 A

A-2 975-0057-01-01

an

Air Comp ressor (XPower Powerpack 400 Pl us only)

Physical Specifications

Pressure

Accessories

Jump-start cables 24" (0.61 m), 4 AWG wire

DC charge cable 39" (1 m) 18 AWG with male

AC Charger input 12 0 ± 10 V AC, 60 Hz
Nozzle adaptor (for air compressor on the

XPower Powerpack 400 Plus only)

250 PSI (lb./in

with black and red battery
clamps

to male light er plugs

two nozzle adaptors
one sports needle adaptor

2

)

Physica l Specific ations

XPower Powerpack

Physica l specif ic ati on s

Depth 8" (20.3 cm) 8" (20.3 cm)
Width 16" (40.6 cm) 16" (40.8 cm)

400

XPower Powerpack
400 Plus

Height 9 ½" (24.1 cm) 9 ½" (24.1 cm)
Weight 21.8 lb. (9.9 kg) 23 lb. (10.5 kg)

Important:

All specific ations ar e subje ct to change with out

notice.

975-0057-01-01 A-3

A-4

Warranty an d Return

Warranty

What does this warranty cover? This Limited Warranty is provided by Xantrex
Technology Inc. ( "Xantrex") and cover s defects in workmanship and material s in your

XPower Powerpack 400 and XPower Powerpack 400 Plus. This warranty pe riod last s for
6 mont h s from the date of purchase at the point of sale to you, the or iginal end user

customer. You require proof of purchase to make warranty claims.
What will Xantrex do? Xantrex will, at its option, r epair or replace the defective

product free of charge, provided that you notify Xantrex of the product defect within the
Warranty Period , and provided that Xantrex through inspe ction establishes the existence
of such a defect and that it is covered by this Limited Warranty.

Xantrex will, at its option, use new and/or reconditioned parts in performing warranty
repair and building replace ment products. Xantrex reserves the right to use parts or
products of original or improved design in the repair or replacement. If Xantrex repairs or
replaces a product, its warranty continues for the remaining portion of the original
Warranty Period or 90 days fr om the date of the retur n shipment to the custom er,
whichever is greater. All replaced products and all part s removed from repair ed products
become the property of Xantrex.

Xantrex covers bot h p arts and labo r nec ess ary t o re pai r the pr oduct, an d ret urn shi pmen t to
the customer via a Xantrex-selected non-expedited surface freight within the contiguous
United States and Canada. Al aska and Hawaii are ex cluded. Contact Xan trex Customer
Servic e for details on fre ight policy for return shipments outside of the contiguous United
States and Canada.

How do you get service? If your product requires troubleshooting or warranty
service, contact your dealer.

If you are unable to contact your dealer, or the dealer is unable to provide service, contact
Xantrex dire c tly at:

Phone: [phone]
Fax: [phone]
Website: www.xantrex.com/support
Direct returns may be performed according to the Xant rex Return Material Authorization

Policy des cr ibed i n you r p roduct manu al . For s ome pr odu ct s, Xant r ex mai ntai ns a networ k
of regional Authorized Service Centers. Call Xantrex or check our website to see if your
product can be repaired at one of these facilities.

What proof of purchase is required? In any warranty claim, dated proof of purchase
must accompany the product and th e product must not have been disassembled o r
modifie d without prior written authorization by Xantrex.

Proof of pu rchase may be in any one of the following forms:

• The dated purchas e recei pt from the ori gi nal pu rchas e of the product at po int of sal e to
the end use r, or

• The dated dealer invoice or purchase receipt showing original equipment
manufacturer (OEM) status, or

• The dated invoice or purchase receipt show ing the product exchanged under warrant y

WA-1

Warranty and Return

What does this warranty not cover? This Limited Warranty does not cover normal
wear and te ar of t he produc t o r c osts rel ated to th e rem oval, i nstal la tion , o r tro ubl eshoot i ng
of the customer's electrical systems. This warranty does not apply to and Xantrex w ill not
be respon sible for any defect in or damage to:

a) the produ ct if it has been misuse d, neglected, improperly installed, physically

damaged or altered, either internally or externally, or damaged from impro per use or
use in an unsuitable environment;

b) the product if it has been subjected to fire, water, generalized corrosion, biological

infestat i ons, o r input vol tage th at crea te s oper at ing condi ti ons b eyon d t he maxim um or
minim um limits lis te d in th e X an tr e x pr o du c t sp ecificat ions incl u di ng hi gh in pu t v ol t­age from generators and ligh tning strikes;

c) the product if repairs have been done to it other than by Xant rex or its authorized ser-

vice centers (hereafter "ASCs");

d) the product if it is used as a component part of a product expr essly warranted by

another ma nufacturer;

e) the produc t if its or ig in al identi ficatio n (trade-mark, ser i a l number) mark in g s ha v e

been defaced, altered, or removed.

Disclaimer

Product

THIS LIMITED W ARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY
XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE
PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS,
GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR
IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT,
HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF
MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR
OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR
CONDITION OF QUALITY, MERCHANTABIL ITY OR FITNESS FOR A PARTICULAR
PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABIL ITY OR FITNESS FOR A
PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO
APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD
STIPULATED UNDER THIS LIMITED WARRANTY.

IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL
OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING
WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY
ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY
PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF
MISUSE OR ABUSE, OR THE INCORRECT INSTAL LATION, INTEGRATION OR
OPERATION OF THE PRODUCT.

Exclusions

If this product is a consumer product, federal law does not allow an exclusion of im plied
warranties. To the extent you are entitled to implied warranties under federal law, to the
extent permitted by applicable law they are limited to the duration of this Limited
Warranty. Some states and provinces do not allow limi tations or exclusi ons on implied

WA-2 975-0057-01-01

Warranty and Return

warranties or on the duration of an implied warranty or on the limitation or exclusion of
incidental or consequential damages, so the abo ve limitation(s) or exclusion(s) may not
apply to you. This Limited Warranty gives you specific legal right s. You ma y have other
rights w hich may vary from state to state or province to province.

Warning: Limitations On Use

Please refer to your product manual for limitation s on uses of the product.

SPECIFICAL LY, PLEASE NOTE TH AT THE XPOWER POWERPACK 400 AND XPOWER

OWERPACK 400 PLUS SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT

P

SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING THE
GENERALITY OF THE FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR
WARRANTIES REGARDING THE USE OF THE XANTREX

AND XPOWER POWERPAC K 400 PLUS IN CONNECTION WITH LIFE SUPPORT SYSTEMS

OR OTHER MEDICAL EQUIPMENT OR DEVICES.

Please note that the XPower Powerpack 400 and XPower Powerpa ck 400 Plus is not
intended for use as an uninterruptible power supply and Xantrex make s no w arranty or
representation in connection with any use of the product for such purposes.

XPOWER POWERPACK 400

Return Material Authorization Policy

Before returning a product dir ectly to Xantrex you must obtain a Return Material
Authori zati on ( RMA) num ber a nd t he c orrec t f actor y "S hip To" address. Products must also
be shippe d prepaid. Product shi pm ents will be refuse d and returned at your expense if they
are unauthorized, returned without an RMA number cl early marked on the outside of the
shipping box, if they are shipp ed collect, or if they are shipped to the wrong location.

When you contact Xantrex to obtain service, plea se have your instruction manual ready f or
reference and be prepared to supply:

• The serial number of your product

• Information about the installation and use of the unit

• Information about the failure and/or reason for the return

• A copy of your dated proo f of purchase

Record the s e de ta ils in “Information About Your System” on page WA-4.

Return Procedure

1. Package the unit safely, preferably using the original box and packing materials. Please
ensure that your produ ct is sh ipp ed f ully in sured in the orig ina l pac kagi ng or equ iva lent .
This warranty will not apply where the product is damaged due to improper packaging.

2. Include the following:

• The RMA number supplied by Xantrex Technology Inc. clearly marked on the

outside of the box.

• A return address wh ere the unit can be shipped. Post offic e boxes are not

acceptable.

• A contact telephone number where you can be reached during work hours.

• A brief description of the problem.

3. Ship the unit prepaid to the address provided by your Xantrex customer service
representative.

975-0057-01-01 WA-3

Warranty and Return

If you ar e returning a product from outside of the USA or C anada In addition to the
above, you M UST in clude r et urn fr ei ght fun ds a nd ar e ful ly r espons ib le for al l docum ents ,
duties, tariffs, and deposits.

If you are returning a product to a Xantrex Authorized Service Center (ASC) A
Xantrex return material authorization (RMA) number is not required. However, you must
contac t the ASC prior to returni ng the product or presenting the unit to verify any return
procedu res that may apply to that particular facility.

Out of Warranty Servi c e

If the war ranty period for your XPower Powerpack 400 and XPower Powerp ack 400 Plus
has expi red, if the uni t was d amage d by misu se o r inco rr ec t inst all ati on , if o ther c ondi t ions
of the warr anty have not been met, or if no dated proof of purchase is av ailable, your unit
may be serviced or replaced for a flat fee.

To return your XPower Powerpack 400 and XPower Powerpack 400 Plus for out of
warranty service, contact Xantrex Custom er Service for a Return Material Au thorization
(RMA) numbe r and follow the other steps outlined in “Return Procedure” on page WA-3.

Payment opt ions such as credit card or money order will be explai ned by the Customer
Service Representative. In cases where the minimum flat fee do es not apply , as with
incomplete units or units with excessive damage, an additional fee will be charged. If
applicable, you will be contacted by Customer Service once your unit has been rec eived.

Inform at ion About Your System

As soon as you op en your XPower Powerpack 400 and XPower Powerpack 4 00 Plus
package, record the following information and be sure to keep your proof of purchase.

p Serial Number
p Purchased From
p Pu rchase Date

If you need to contact Customer Service, please record the following details before
calling. This informatio n will help our representatives give you better service.

_______________________________
_______________________________
_______________________________

p Warning, Error or Panel Fault

Message

_______________________________

p Appliances operating when

problem occur r ed

p Description of problem

______________________________________________________________
______________________________________________________________

WA-4 975-0057-01-01

_______________________________
_______________________________