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