Xantrex HI400 User manual

HI400
Owner’s Guide
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About Xantrex
Xantrex Technology develops, manufactures, and markets advanced power
electronic products. The company’s products convert raw electrical power from
any source into high-quality power required by electronic and electrical
equipment.
Trademark
Xantrex is a registered trademark of Xantrex Technology Inc.
Other trademarks, registered trademarks, and product names are the property of
their respective owners and are used herein for identification purposes only.
Notice of Copyright
HI400 Owner’s Guide © January 2002 Xantrex International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX
TECHNOLOGY INC. (“XANTREX”):
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR
SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN
ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE,
WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH
MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY
SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
January 2002, Revision 2
Part Number
445-0151-01-01
Contact Information
Web: www.xantrex.com
Email: [e-mail]
Phone: [phone]
Fax: [phone]
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i
Important safety information
General precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v
Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
Precautions when working with batteries- - - - - - - - - - - - - - - - - vii
Precautions for using rechargeable appliances - - - - - - - - - - - - viii
1Introduction
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
HI400 features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Materials list- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
2 Installation
Preparing for installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Installation codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Installation tools and materials - - - - - - - - - - - - - - - - - - - - - - - 9
Installation features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Installing the HI400 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Designing your installation- - - - - - - - - - - - - - - - - - - - - - - - - 11
Choosing a location- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Mounting your inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
Permanently connecting (hardwiring) the AC output- - - - - - - - 17
Installing the ignition lockout wiring - - - - - - - - - - - - - - - - - - 18
Connecting the DC cables - - - - - - - - - - - - - - - - - - - - - - - - - 19
Connecting the battery to the DC input- - - - - - - - - - - - - - - - - 20
Connecting the DC ground - - - - - - - - - - - - - - - - - - - - - - - - - 21
Contents
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Contents
ii
Connecting the AC input cord- - - - - - - - - - - - - - - - - - - - - - - 22
Checks prior to initial power-up - - - - - - - - - - - - - - - - - - - - - 23
Starting up and testing your installation - - - - - - - - - - - - - - - - 23
3Operation
Operation features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
Inverter on and off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
Ground fault circuit interrupter (GFCI) protection - - - - - - - - - 26
Alternate AC source - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Ignition lockout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Low battery condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
Inverter loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Operating several loads at once - - - - - - - - - - - - - - - - - - - - - - 28
Problem loads- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Turning the inverter off between charges - - - - - - - - - - - - - - - 29
Battery charging frequency- - - - - - - - - - - - - - - - - - - - - - - - - 29
4 Maintenance and Troubleshooting
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
Common problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
Buzz in audio equipment - - - - - - - - - - - - - - - - - - - - - - - - - - 32
Television interference- - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
Troubleshooting reference- - - - - - - - - - - - - - - - - - - - - - - - - - - 33
ASpecifications
Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
BBattery Types and Sizes
Battery types- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
Automotive starting batteries - - - - - - - - - - - - - - - - - - - - - - - 38
Deep-cycle lead-acid batteries- - - - - - - - - - - - - - - - - - - - - - - 38
Battery size- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39
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Contents
iii
Estimating battery requirements- - - - - - - - - - - - - - - - - - - - - - - 40
Battery sizing example- - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
Battery sizing worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - 42
Using multiple batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
Two batteries connected in parallel - - - - - - - - - - - - - - - - - - - 43
Two separate battery banks- - - - - - - - - - - - - - - - - - - - - - - - - 43
Battery tips- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
CWarranty and Product Information
Warranty information- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
Returning a product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
Out-of-warranty service - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
Contacting Xantrex Customer Service- - - - - - - - - - - - - - - - - - - 51
Other Xantrex products- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
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iv
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v
Important safety information
General precautions
1. Before installing and using the inverter, read all
appropriate sections of this guide and any cautionary
markings on the inverter and batteries.
2. Do not operate the inverter if it has received a sharp blow,
been dropped, or otherwise damaged. If the unit is
damaged, see “Service during warranty” on page 48 and
“Returning a product” on page 49.
3. Do not disassemble the inverter; it contains no user
serviceable parts. Attempting to service the unit yourself
could cause electrical shock or fire. Internal capacitors
remain charged after all power is disconnected. See
“Warranty information” on page 48 for instructions on
obtaining service.
4. To reduce the risk of electrical shock, disconnect both
AC and DC power from the inverter before working on
any circuits connected to the inverter. Turning off the
front panel On/Off Switch will not reduce this risk.
5. Protect the inverter from rain, snow, spray, and bilge
water.
6. To reduce the risk of overheating or fire, keep the
ventilation openings clear, and do not install the inverter
in a zero-clearance compartment.
Important: Before installing and using your HI400
Inverter, be sure to read and save these safety instructions.
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Explosive gas precautions
vi
Explosive gas precautions
1. Batteries generate explosive gases during normal
operation. Be sure you follow all relevant instructions
exactly before installing or using your inverter.
2. This equipment contains components which tend to
produce arcs or sparks. To prevent fire or explosion, do
not install the inverter in compartments containing
batteries or flammable materials or in locations that
require ignition-protected equipment. This includes any
space containing gasoline-powered machinery, fuel
tanks, as well as joints, fittings, or other connections
between components of the fuel system.
WARNING: Explosion hazard
.
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Precautions when working with batteries
vii
Precautions when working with batteries
1. Follow all instructions published by the battery
manufacturer and the manufacturer of the equipment in
which the battery is installed.
2. Make sure the area around the battery is well ventilated.
3. Never smoke or allow a spark or flame near the engine or
battery.
4. Use caution to reduce the risk of dropping a metal tool on
the battery. It could spark or short circuit the battery or
other electrical parts and could cause an explosion.
5. Remove metal items like rings, bracelets, and watches
when working with lead-acid batteries. These batteries
produce a short-circuit current high enough to weld a ring
or the like to metal and cause a severe burn.
6. If you need to remove a battery, always remove the
positive terminal from the battery first. Make sure all
accessories are off so you don’t cause an arc.
WARNING: Explosion and fire hazards
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Precautions for using rechargeable appliances
viii
Precautions for using rechargeable
appliances
Most rechargeable battery-operated equipment uses a
separate charger or transformer that is plugged into an AC
receptacle and produces a low voltage charging out.
Some chargers for rechargeable batteries can be damaged if
connected to the HI400 Inverter.
Do not use the following with the HI400 Inverter:
• Small battery-operated appliances like flashlights, razors,
and night lights that can be plugged directly into an AC
receptacle to recharge.
• Some chargers for battery packs used in hand power
tools. These affected chargers display a warning label
stating that dangerous voltages are present at the battery
terminals.
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1
Introduction
Chapter 1 “Introduction” describes the main
operating features of the HI400 Inverter.
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Introduction
2
Introduction
The HI400 Inverter is a modified sine wave (MSW) inverter
providing power for a variety of AC loads, such as TVs,
VCRs, laptops, camcorders and other small AC devices.
They are CSA certified for use in recreational vehicles.
The HI400 is available in two versions:
• “HI400 with hardwire” is designed for permanent
hardwired installation.
• “HI400 with hardwire and GFCI outlet” has a GFCI
receptable on the front and a hardwire compartment. It
provides easy access for plugging a load directly into the
output of the unit. The hardwire compartment allows the
unit to be installed permanently.
HI400 offers the following inverter features:
• Ability to run many of the entertainment loads that you
use at home.
You can operate TVs, stereos, VCRs, computers and
even small battery chargers. You can run multiple loads
up to 400 watts in total.
• Surge capability
HI400 will surge up to 550 watts peak.
• Low voltage shutdown
The inverter shuts off when your batteries discharge to
less than 10 volts.
When the battery voltage recharges to above 12.5 volts,
the inverter automatically restarts. This feature prevents
the inverter from draining the batteries if it is left on
without a load.
• Ground fault circuit interrupter (GFCI)
As well as providing for permanent hardwire installation,
the GFCI model provides a receptacle for plugging in a
load.
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Introduction
3
This receptacle has a “ground fault circuit interrupter” to
reduce shock hazards on loads connected to both the
receptacle and hardwire outputs.
• Ignition lockout
Ignition lockout prevents the inverter from operating
while the engine is running. It allows the user to turn the
inverter on and off remotely.
• Transfer switch
Automatically connects the loads on the receptacle and
hardwire outputs to the external AC source when one is
available. Upon disconnection, or loss of the external AC
source, the transfer switch automatically transfers the
load circuits over to inverter power.
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HI400 features
4
HI400 features
Figure 1 below, and Figure 2 opposite, show the front and
back panels of the HI400. Table 1 and Table 2 list the
respective panel parts.
Figure 1 Front Panel - “Hardwire with GFCI” version.
Table 1 Front panel features
Feature Description
➀Fan vents
➁Output circuit protector
➂ON/OFF power switch
➃Dual AC receptacle (on the GFCI outlet and hardwire
version only)
➄GFCI test and reset buttons (on the GFCI outlet and
hardwire version only)
➅“On inverter” and “low battery status” LEDs
➂➃➄➅
➀➁
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HI400 features
5
Figure 2 Back panel
pTable 2 Back panel features
Feature Description
➀Air vents
➁Cable clamp
➂Chassis grounding lug
➃AC hardwiring compartment (with cover on)
➄DC input terminals
➅AC input cord
➀➁➂➃➄➅
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Materials list
6
Materials list
Your HI400 inverter package includes the items listed below:
❐Inverter with hardwire (80-0401-12) or
Inverter with hardwire and GFCI outlet (80-0400-12)
❐Owner’s Guide
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7
Installation
Chapter 2 “Installation” provides complete
information for installing the HI400 Inverter.
Specifically, this section describes:
• safety instructions and installation codes
that must be observed during installation.
• installation tools and materials.
• appropriate locations and environments
for mounting the inverter.
• AC cabling, DC cabling, and ground
information.
• detailed installation procedures.
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Preparing for installation
8
Preparing for installation
Prior to beginning your installation, review the “Important
Safety Instructions” on page v, and read the entire
“Installation” section so you can plan your installation from
beginning to end.
Installation codes
Applicable installation codes vary depending on the specific
location and application of the installation. Some examples
are:
• The U.S. National Electrical Code (NEC)
• The Canadian Electrical Code (NEC)
• NEC, Canadian Standards Association (CSA), and RV
Industry Association (RVIA) requirements for
installation in RVs.
It is the installer’s responsibility to determine which codes
apply, and to ensure that all applicable installation
requirements are met.
WARNING: Electrical shock and fire
hazards
Xantrex recommends all wiring be done by qualified
personnel. Disconnect all AC and DC power sources to
prevent accidental shock. Disable and secure all AC and
DC disconnect devices and automatic generator starting
devices.
It is the installer’s responsibility to ensure compliance
with all applicable installation codes and regulations.
CAUTION
Be sure to read all instructions before installing and
operating this inverter.
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Preparing for installation
9
Installation tools and materials
You will need the following tools and materials to install the
inverter:
❐#2 Phillips screwdriver
❐Wire stripper
❐4 mounting screws or bolts and appropriate tools
❐3/8” wide slot screwdriver for DC input and chassis
ground terminals
❐3-conductor (2-conductor-plus-ground cable) AC output
cable sized appropriately for load according to applicable
installation code(s). In the NEC, CEC and RV
applications, this is No. 14 AWG.
❐Crimp connectors and appropriate crimping tool for AC
output wiring and ignition lockout wiring (if twist-on
wire connectors are not appropriate for your installation).
❐DC cable, sized appropriately for load per the applicable
installation code(s). In NEC, CEC and RV applications,
this is No. 8 AWG if copper conductors rated 60 °C –
90 °C are used.
❐Terminals for connecting the DC cables to the battery, as
well as appropriate tools for those terminals (for
example, crimping tool, hex-key, etc.).
❐AC and DC disconnects and over-current protective
devices.
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Preparing for installation
10
Installation features
Figure 3 and Table 3 below, list the installation features of
your HI400 inverter.
Figure 3 Installation features: back view
Table 3 Installation features: back view
Feature Description
➀DC input terminals
➁Cable clamp
➂Chassis grounding lug
➃AC Hardwire compartment
➄Ground screw for AC output ground
➅Ignition lockout wire (red)
➆AC output wiring (black, white)
➇AC input cord
➈Wire connectors (3)
➀
➇
➈
➆
➁➂➃➅
➄
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