ExelTech XP250 User manual

7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100
817.595.4969 voice, 817.595.1290 fax
800.886.4683 toll free
website www.exeltech.com
XP250 INSTALLATION AND OPERATION MANUAL
Manufacturer of UL Listed Products

XP250 INSTALLATION AND OPERATION MANUAL
Page 1
Copyright © 2001 Exeltech Inc. All rights reserved. This Document may not be
copied, photocopied, reproduced, translated or converted to any electronic or
machine-readable form in whole or in part without prior written approval of
Exeltech, Inc.
Acknowledgments
Project Management: Ben Baker and John Goetz
Writing: Gary Chemelewski and David Bond
Copy Editing: Ben Baker
Art, Photography and Layout: John Goetz
May 2002
Exeltech
7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100

XP250 INSTALLATION AND OPERATION MANUAL
Page 2
Introduction 1.0
Standard Features 2.0
Installation 3.0
Operation 4.0
Appendix A
Appendix B
page 3
page 5
page 7
page 10
page 11
page 12
Table of Contents

XP250 INSTALLATION AND OPERATION MANUAL
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Thank you for purchasing the finest sine-wave inverter in the power
conversion industry. Exeltech's journey to excellence includes the
first affordable sine-wave inverter, first modular inverter system, first
N+1 redundant inverter system, and the cleanest sine-wave output
in the industry. Exeltech strives to manufacture products of the
highest possible quality and is dedicated to 100% customer
satisfaction. Proudly built in the USA with American parts, Exeltech
is committed to TL 9000 standards and beyond, adding people and
procedur es continually to further improve quality and customer
service. We welcome you as a customer to the Exeltech family.
Congratulations!
Exeltech’s XP series inverters provide the cleanest, best regulated sine-wave
output over the widest DC input of any inverter on the market today.
They are extremely low in total harmonic distortion; specified to 2%, and
typically better than 1.5%. Total harmonic distortion is typically 0.8 to
0.9%. Remaining distortion is a result of residual switching noise,
which amounts to a very clean 25 KHZ sine-wave superimposed on
the fundamental output. No significant harmonics of 25 KHZ exist.
This spectral purity will exist over the inverter's entire operating
envelope, including non-linear and reactive loads. As long as peak
output current remains less than 300% of rated current, total harmonic
distortion will remain within the 2% spec. Peak current capability of the
inverter is key to understanding it's operational envelope. As long as
the inverter is supplying less than this amount, it will function properly
and operate virtually any load.
Many inverters are rated in Volt-Amps (VA), as opposed to Watts.
This is in an attempt to make an inverter or UPS (Uninterruptible
Power Supply) appear larger than it really is. The only fair way to
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Introduction
1.0

XP250 INSTALLATION AND OPERATION MANUAL
Page 4
specify these products is in Watts (W), which is power the inverter
can actually deliver. If Exeltech inverters were specified in VA, Our
1100 Watt inverter could be rated at 1375 VA at .8 power factor,
1570 VA at .7 pf, or an incredible 2200 VA at .5 pf. It is confusing to
specify a product in VA because the power factor must also be
specified. Exeltech's XP-Series inverters can output their full rated
o o
power continuously up to 30 C (86 F).
The inverter can maintain a spectrally pure output with any load due
to a specially designed non-linear control loop in the primary DC-to
-DC converter. This circuitry is one of three circuits that protect the
inverter from any overload condition.
These inverters are capable of exceeding their rated power by 10%
for a limited time. The inverter's capability at this level is primarily
dependant upon temperature. If output power is exceeded, output
voltage is reduced to a level that will provide the inverter's rated
power to the load by clipping tops of the waveform. The inverter can
operate safely in this mode indefinitely. Should the overload condition
clear, the inverter will again provide the cleanest sine-wave in the
industry.
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XP-250

XP250 INSTALLATION AND OPERATION MANUAL
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DC INPUTS:
"REMOTE" CONNECTION:
AC OUTPUTS:
230 VAC: IEC-320
COOLING:
DC POWER ON LED:
LOW BATT / THERM BUZZER:
ON/OFF SWITCH:
OVER VOLTAGE PROTECTION:
A two-pole connector is provided under the rear
cover. The rear cover must also be removed to access this
connector. Use Appendix "A" to choose the appropriate gauge
wire for your specific model. A 2 pole female connector is provided.
is on the six-pole, plug-in connector,
located under the rear cover.
has one NEMA-15 outlet (standard wall receptacle),
located on the front panel. Additionally; may be hard-wired to
appliance / load using connections furnished on the six-pole, plug
-in connector, located under rear cover.
inverters have an receptacle located on the
front panel.
convection cooled.
located on the front panel, will be "ON" when
inverter is powered up and DC power is available.
produces an audible alarm if DC
input voltage falls to a level within 2% to 4% of the low limit of
inverter, or, if there is an over temperature condition.
located on front panel; turns the inverter on and
off.
If input voltage to the inverter
exceeds set limits, the inverter will immediately shut off without
warning. When input voltage returns to normal range, the inverter will
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Standard Features
2.0

XP250 INSTALLATION AND OPERATION MANUAL
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immediately restart. Since high over voltages tend to have very
fast edges, the inverter must shut down quickly to protect itself.
This kind of fault usually occurs if the battery is suddenly
disconnected from the system and the battery charger continues to
supply current. When battery voltage falls to within 2% to 4% of low
line voltage, the LOW BATT / THERM buzzer will sound. If the
condition continues without reducing load to the inverter or adding
charge to the battery, the inverter will shut off. When voltage rises to
approximately 95% of nominal battery voltage, the inverter will turn
back on and the alarm condition will clear. The inverter can be
manually reset by cycling the on/off switch. This will reset the
protection circuitry and turn the inverter on at any voltage above
minimum voltage.
The inverter is also
protected against overheating. It will provide its full rated output
up to the temperature listed in the specification sheet. If it is
subjected to higher ambient temperatures, or air circulation is
blocked, the inverter may overheat. If the LOWBATT/ THERM
buzzer sounds, immediate action is required or the inverter will shut
down. Either reduce load, or provide more cooling in the immediate
environment. If no action is taken, the inverter will likely shut down
within 2 minutes. When the inverter shuts down, the alarm condition
will persist. Since the inverter has eliminated its load, it will cool fairly
quickly. It will automatically restart when it has cooled sufficiently, and
the LOW BATT/THERM alarm will clear. If the internal temperature is
over 105C a warning buzz 5 C before shut off.
If rated output power is exceeded, output voltage is reduced to a
level that will provide the inverter's rated power to the load by
clipping tops of the waveform. The inverter can operate safely in this
mode indefinitely. The overpower protection circuit will recover
instantly when the overpower condition clears.
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OVER TEMPERATURE PROTECTION:

CAUTION:
WARNING:
WARNING:
CAUTION:
It is essential to read and understand all Warnings,
Cautions, and Notes before any connections are made to the Unit
or System. If further assistance is needed call [phone] and
ask for Customer Service.
The inverter is designed to operate from a battery.
Performance cannot be guaranteed, and damage can result when a
charger or power supply is used without a battery in the circuit.
The AC neutral lead is internally bonded to chassis;
chassis must be bonded to earth ground through the external
ground connector located on the unit. The negative or positive
terminal of the battery (DC source) must be bonded to earth ground;
it is recommended that it be to the same earth ground used for AC
ground. Refer to the figure below for wiring illustration.
Before any connections are made to the unit or system,
be sure to disconnect the battery terminals. Always disconnect the
grounded battery terminal first. When re-connecting, connect
ungrounded terminal first, and grounded terminal last.
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XP250 INSTALLATION AND OPERATION MANUAL
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Installation
3.0
Battery
Inverter
+
--
+
(A)
(B)
A) Positive earth ground
B) Negative Earth Ground
*Note: Ground either “A” or “B”
NOT BOTH.

XP250 INSTALLATION AND OPERATION MANUAL
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CAUTION:
CAUTION:
INSTALLATION (Location)
1.
2.
INSTALLATION (Wiring)
1.
Polarity of leads is critical to avoid damage to the unit or
system. Check batteries and battery cables for correct polarity and
voltage.
Observe all National and Local Electric Codes when
connecting AC Power Connections.
Mounting location is critical to performance and life span of the
inverter. Heat and moisture are the two worst enemies of any
electronic device. Therefore, when choosing a mounting location,
consider the following requirements listed in order of importance:
Inverter must be sheltered from the elements. Select a clean, dry
location.
Inverter requires adequate ventilation for cooling. With proper
cooling, the inverter will operate efficiently and meet its published
ratings. All models can be mounted in several positions. Best
position, vertical. Second best, vertical with inverter front facing up.
Third, horizontal.
The XP-250 will perform best when mounted vertically.
T h i s w i l l a l l o w w a r m a i r t o r i s e t h r o u g h
vent holes on top, drawing cool air through vent holes on the bottom.
Inverter should be mounted as close to the battery as possible.
Shorter wire has less resistance, which translates to increased
efficiencies.
An in line fuse is recommended to protect the battery and wiring to
the inverter. This fuse should be located very close to the battery
positive (+) terminal. To select appropriate size fuse, consult the
"Rated and Peak Current" table in Appendix "A”.
XP-250: a two-pole connector is provided under the rear cover. The
rear cover must also be removed to access this connector (see
Appendix "B"). Use Appendix "A" to choose the appropriate gauge
wire for your specific model. A 2 pole female connector is provided.
Disconnect the grounded (-) terminal of battery and make sure
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3.

XP250 INSTALLATION AND OPERATION MANUAL
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the charger and inverter are off.
Make DC input connections to the inverter as illustrated in
Appendix "B". Attach DC wires to the 2 pole female connector.
(Optional) Using 12-18 AWG wire, make Remote On/Off
connection from the rear panel terminal labeled "REMOTE" to one
pole of a small toggle switch. Then from the other pole of toggle
switch, make a connection to battery negative (-).
Make sure the toggle switch is off.
in order for the Remote On/Off switch to operate inverter,
On/Off switch on the front panel must be off.
If the appliance / load will be hard-wired to the inverter instead of
or in addition to the outlets provided on the front panel, see
Appendix "B".
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2.
3.
4.
Note:
5.

XP250 INSTALLATION AND OPERATION MANUAL
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TURN ON INVERTER:
XP-250:
Note:
TURN ON APPLIANCE/LOAD:
1.
2.
3.
Note:
Turn inverter on using toggle switch on front panel, or the
"REMOTE" switch if installed. LED next to the switch will illuminate,
indicating the inverter is operational.
If using "REMOTE" switch, the front panel switch must be
off. (If either switch is "on", the inverter will turn on. Both switches
must be off for the inverter to turn off.)
Check Input Power Requirements of the appliance. Make sure
that it is less than Rated Output Power of the inverter. If more than
one appliance will be run simultaneously, the sum of their Input
Power Requirements must be less than Rated Output Power of the
inverter.
If appliance/load has been hard-wired to the barrier terminal strip
as illustrated in Appendix "B", then turn appliance on. Otherwise;
Plug the appliance into the receptacle provided on front panel,
then turn appliance on.
It is recommend that the inverter be turned ON before the
appliance/load.
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Operation
4.0

XP250 INSTALLATION AND OPERATION MANUAL
Page 11
APPENDIX A
XP-250 / 12VDC 13.8 VDC 10.4 / 10.6 VDC 16.5 VDC 24.5 A 27.8 A
XP-250 / 24VDC 27.6 VDC 19 / 21 VDC 33 VDC 12.3 A 14 A
XP-250 / 48VDC 55.2 VDC 41.5 / 42.5 VDC 62 VDC 6.1 A 6.9 A
XP-250 / 66VDC 75.9 VDC 57.5 / 58.5 VDC 91 VDC 4.5 A 5 A
XP-250 / 108VDC 124.0 VDC 94 / 95 VDC 149 VDC 2.7 A 3 A
MODEL NORMAL
VDC
(TYPICAL)
MINIMUM VDC
CUT-OFF / ALARM
(TYPICAL)
MAXIMUM
VDC
(TYPICAL) RATED
CURRENT PEAK CURRENT
XP-250 / 12VDC
MODEL
Input Power Requirements:
Recommended Input Wire Sizes (For Variable Distances from the Battery):
8 AWG
LESS THAN 5’
4 AWG
LESS THAN 10’
4 AWG
LESS THAN 15’
2 AWG
LESS THAN 20’
XP-250 / 24VDC 12 AWG 10 AWG 8 AWG 6 AWG
XP-250 / 48VDC 18 AWG 16 AWG 14 AWG 14 AWG
XP-250 / 66VDC 18 AWG 18 AWG 16 AWG 16 AWG
XP-250 / 108VDC 18 AWG 18 AWG 18 AWG 18 AWG
Note: The table specifies standard wire sizes (not smaller than 18 AWG) that will provide less than a
2% voltage drop at Low-line Input voltage and Rated Output Power.
XP-250 Mechanical Specifications:
”10.768”10.596”10.096
.786” 0
0
.250”
4.977”
5.227” .218” SLOT 4 PLACES”
0
2.770”
TOP
FRONT SIDE

XP250 INSTALLATION AND OPERATION MANUAL
Page 12
Note:
XP-250 with DC Toggle Switch:
XP-250 with DC Relay:
INSTALLATION
CAUTION:
Use Rated Current and voltage in Appendix "A" to select an
appropriate Toggle Switch or Relay for your specific model inverter.
Be sure to disconnect all DC power to installation wiring.
Be sure to disconnect batteries and chargers. Make all connections
to the inverter BEFORE connecting DC power to the battery.
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Inverter
Battery DC Toggle Switch
(See Appendix A)
+
-
+
-
Normally Open
Contacts
Inverter
Battery
+
-
+
-
Relay Coil
Relay
DC Toggle Switch
(Low Current)
APPENDIX B
XP-250 Rear View (AC/DC Connections):
BAT (+) BAT (-)
CHASSIS LINE NEUT REMOTE
Insert 2 pole female connector
after attaching DC wires.
Follow correct Polarity!

XP250 INSTALLATION AND OPERATION MANUAL
Document subject to change without notice.
931-X21M*-*0G
MAY 24, 2006.
7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100
817.595.4969 voice, 817.595.1290 fax
800.886.4683 toll free
website www.exeltech.com
Made in the USA
9 3 1 - X2 1 M* - * 0 G