Xantrex XPower 1000 User manual

by
XPower Inverter 1000
Owner’s Guide

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells,
microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and variable speed drives
that convert, supply, control, clean, and distribute electrical power.
Trademarks
XPower is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex
International.
Other trademarks, registered trademarks, and product names are the property of their respective owners
and are used herein for identification purposes only.
Notice of Copyright
XPower Inverter 1000 Owner’s Guide © December 2003 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
December 2003 Revision A
Part Number
975-0127-01-01
Contact Information
Telephone: [phone] (toll free North America)
1 360 925 5097 (direct)
Fax: [phone] (toll free North America)
1 360 925 5143 (direct)
Email: [email protected]
Web: www.xantrex.com

iii
About This Guide
Purpose
The purpose of this Owner’s Guide is to provide explanations and
procedures for installing, operating, maintaining, and troubleshooting the
XPower Inverter 1000.
Scope
The Guide provides safety guidelines, detailed planning and setup
information, procedures for installing the inverter, as well as information
about operating and troubleshooting the unit. It does not provide details
about particular brands of batteries. You need to consult individual battery
manufacturers for this information.
Audience
The Guide is intended for anyone who needs to install and operate the
XPower Inverter 1000.

About This Guide
iv 975-0127-01-01
Conventions Used
The following conventions are used in this guide.
Related Information
You can find more information about Xantrex Technology Inc. as well as
its products and services at www.xantrex.com
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 unit or
other equipment.
Important: These notes describe things which are important for you to know, but
not as serious as a caution or warning.

v
Important Safety Instructions
1. Before installing and using the XPower Inverter 1000, read all
instructions and cautionary markings on the XPower Inverter 1000,
the batteries, and all appropriate sections of this guide.
2. Do not expose the XPower Inverter 1000 to rain, snow, spray, or bilge
water. To reduce risk of fire hazard, do not cover or obstruct the
ventilation openings. Do not install the XPower Inverter 1000 in a
zero-clearance compartment. Overheating may result.
3. Use only attachments recommended or sold by the manufacturer.
Doing otherwise may result in a risk of fire, electric shock, or injury
to persons.
4. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition and that wire is not undersized. Do not
operate the XPower Inverter 1000 with damaged or substandard
wiring.
5. Do not operate the XPower Inverter 1000 if it has received a sharp
blow, been dropped, or otherwise damaged in any way. If the XPower
Inverter 1000 is damaged, see the Warranty section.
6. Do not disassemble the XPower Inverter 1000. It contains no user-
serviceable parts. See Warranty for instructions on obtaining service.
Attempting to service the XPower Inverter 1000 yourself may result
in a risk of electrical shock or fire. Internal capacitors remain charged
after all power is disconnected.
7. To reduce the risk of electrical shock, disconnect both AC and DC
power from the XPower Inverter 1000 before attempting any
maintenance or cleaning or working on any circuits connected to the
XPower Inverter 1000. Turning off controls will not reduce this risk.
8. The XPower Inverter 1000 must be provided with an equipment-
grounding conductor connected to the AC input ground.
WARNING
This chapter contains important safety and operating instructions. Read and keep
this Owner’s Guide for future reference.

Safety
vi 975-0127-01-01
Explosive gas precautions
1. Working in the vicinity of lead-acid batteries is dangerous. Batteries
generate explosive gases during normal operation. Therefore, you
must read this guide and follow the instructions exactly before
installing or using your XPower Inverter 1000.
2. This equipment contains componentnts which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower
Inverter 1000 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.
3. To reduce the risk of battery explosion, follow these instructions and
those published by the battery manufacturer and the manufacturer of
the equipment in which the battery is installed.
WARNING: Explosion hazard

Safety
975-0127-01-01 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 batteries.
4. Use caution to reduce the risk or 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 all metal items, like rings, bracelets, and watches when
working with lead-acid battereis. Lead-acid batteries produce a short
circuit current high enough to weld metal to skin, causing a severe
burn.
6. Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
7. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
8. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
9. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.
10. If you need to remove a battery, always remove the ground terminal
from the battery first. Make sure all accessories are off so you don’t
cause a spark.
WARNING: Explosion or fire hazard

Safety
viii 975-0127-01-01
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 output.
Some chargers for small rechargeable batteries can be damaged if
connected to the XPower Inverter 1000. Do not use the following with the
XPower Inverter 1000:
• 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 power hand tools. These
affected chargers display a warning label stating that dangerous
voltages are present at the battery terminals.
If you are unsure about using your rechargeable appliance with the
XPower Inverter 1000, contact the equipment manufacturer to determine
the rechargeable appliance’s compatibility with the modifed sinewave
(non-sinusoidal) AC waveform.
CAUTION: Equipment damage
The output of the inverter is non-sinusoidal.

975-0127-01-01 ix
Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1 Introduction
Quality Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
2 Features
Materials List- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
AC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
DC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
3 Installation
Designing Your Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1
Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Choosing an Appropriate Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Calculating Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Calculating Size of DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Calculating Size of Chassis Ground Cable - - - - - - - - - - - - - - - - - - - - - - - 3–7
Calculating Fuse/Circuit Breaker Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Installing the XPower 1000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Grounding Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Chassis Ground Screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Contents

x
4 Operation
Turning the Inverter On and Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Turning the Inverter Off Between Charges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Operating Limits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Power Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Input Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Inverter Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
High Surge Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Trouble Loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Routine Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
XPower 1000 unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
5 Troubleshooting
Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
A Specifications
Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
Mounting Templates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
B Battery Types
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–1
Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–1
Deep-Cycle Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Battery Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4
Battery Sizing Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4
Battery Sizing Worksheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5
Using Multiple Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6
Two Batteries Connected In Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6
Two Separate Battery Banks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6

Contents
975-0127-01-01 xi
Battery Tips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
C Alternators and Charging Systems
Charging System Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–1
Charging With an Engine Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Using a Standard Vehicle Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Using an Alternator Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Using a High-Output Alternator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Charging From AC Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3
Charging From Alternative Energy Sources - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3
Warranty and Return Information - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

xii

1–1
1Introduction
Congratulations on your purchase of the XPower Inverter 1000! The
XPower Inverter 1000 has been designed to give you quality power, ease
of use, and reliability.
Please take a few moments to read this chapter to familiarize yourself
with the main performance features and protection features of the XPower
1000.
Quality Power
The XPower 1000 is a quality inverter designed for recreational vehicle
(RV) and truck applications.
• The XPower 1000 provides up to 1000 watts of continuous power. It
is designed to handle loads such as 600 watt microwaves, TVs,
VCRs, and midsized power tools.
• The XPower 1000’s high surge capability lets you handle many hard-
to-start loads, including large TVs and small refrigerators.
• The XPower 1000’s low standby battery demand means you don’t
have to worry about excessive drain on your battery if you leave the
inverter on for a few days. When the XPower 1000 is on but no power
is being supplied to a load, the inverter draws less than 300 mA from
the battery.
• The cooling fan in the inverter is thermally activated and comes on
when the XPower 1000 becomes warm. The fan turns off
automatically after the inverter has cooled.

Introduction
1–2 975-0127-01-01
Ease of Use
Superior features and rugged durability have been combined with ease of
use:
• The XPower 1000 is compact, light weight, and easy to install.
• Loads can be powered directly from the AC outlets.
Comprehensive Protection
The XPower 1000 is equipped with numerous protection features to
guarantee safe and trouble-free operation:
Low battery alarm Alerts you if the battery has become discharged to
11.0 V or lower.
Low battery voltage shutdown Shuts the XPower 1000 down
automatically if the battery voltage drops below 10.5 volts. This feature
protects the battery from being completely discharged.
High battery voltage shutdown Shuts the XPower 1000 down
automatically if the input voltage rises to 15 volts or more.
Overload shutdown Shuts the XPower 1000 down automatically if a
short circuit is detected in the circuitry connected to the inverter’s output,
or if the loads connected to the inverter exceed the inverter’s operating
limits.
Over temperature shutdown Shuts the XPower 1000 down
automatically if its internal temperature rises above an unacceptable level.

2–1
2Features
Chapter 2 describes the main features of the XPower 1000.
Xantrex recommends that you familiarize yourself with them before
installing and operating the inverter.
Materials List
Your XPower 1000 package includes:
• One XPower 1000 inverter
• Two M6 lock washers (on the DC input cable terminals)
• Two M6 nuts (on the DC input cable terminals)
• Owner’s Guide
If any of these materials are missing or are unsatisfactory in any way,
please contact Customer Service. Contact infomation is available on
page WA–1.
As soon as you unpack your inverter, be sure to record the product
information in the form on page WA–6.

Features
2–2 975-0127-01-01
AC Panel
Figure 2-1 AC Panel
Feature Description
1On/Off Switch turns the inverter’s control circuit on and off. This
switch is not a power disconnect switch. Disconnect AC and DC
power before working on any circuits connected to the inverter.
2Power light is a green light indicating the On/Off Switch is on and
AC voltage is present at the inverter’s AC outlets.
3Fault light is a red light indicating the inverter has shut down due to
low or high battery voltage, unit overload, or over temperature.
43-Prong AC Outlets:
XPower 1000 delivers a combined total of 1000 watts of continuous
AC power across two outlets.
5Ventilation Opening must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation opening must not point up or down.
6Mounting Flange allows you to mount the inverter permanently.
1
3
2
4
6
1
5

DC Panel
975-0127-01-01 2–3
DC Panel
Figure 2-2 DC Panel
Feature Description
1Chassis Ground Screw connects to vehicle chassis, DC grounding
bus or to engine’s negative bus.
2Positive DC Cabling Terminal always connects to the cable
connected to the positive terminal of the battery.
3Negative DC Cabling Terminal always connects to the cable
connected to the negative terminal of the battery.
4Ventilation Opening must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation opening must not point up or down.
5Serial number of your unit
6Mounting Flange allows you to mount the inverter permanently.
4
1
2
3
5
6

2–4

3–1
3Installation
Chapter 3 provides information on cables and fuses to help you plan for
your installation and provide procedures for installing the XPower 1000.
Xantrex highly recommends that you read the entire chapter before
beginning the installation procedures so that you can plan an installation
that is suited to your power needs.
Designing Your Installation
Before doing anything else, you need to determine how you are going to
use your XPower 1000, and then design a power system that will give you
maximum performance. The more thorough your planning, the better
your power needs will be met. In particular, you will need to:
• Be aware of installation codes
• Calculate your battery requirements
• Choose an effective charging system
• Choose an appropriate location
• Calculate the cable size for your XPower 1000
• Select the correct fuses or circuit breakers
Study Figure 3-1, “Configuration for Normal Loads” on page 3–2 and
Figure 3-2, “Configuration for Heavy Loads” on page 3–3 for an example
of a setup for normal or heavy loads in a vehicle. When you have decided
upon your configuration, then you can calculate battery requirements.