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