Xantrex XPower 3000 User manual

by
XPower Inverter 3000 Plus
Owner’s Guide
XPower3000.book Page i Wednesday, December 10, 2003 6:52 AM

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 3000 Plus 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
975-0128-01-01
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
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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 3000 Plus.
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 inverter. 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 3000 Plus.
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About This Guide
iv 975-0128-01-01
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.
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v
Important Safety Instructions
1. Before installing and using the XPower Inverter 3000 Plus, read all
instructions and cautionary markings on the XPower Inverter 3000
Plus, the batteries, and all appropriate sections of this guide.
2. Do not expose the XPower Inverter 3000 Plus 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 3000 Plus 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 3000 Plus with damaged or substandard
wiring.
5. Do not operate the XPower Inverter 3000 Plus if it has received a
sharp blow, been dropped, or otherwise damaged in any way. If the
XPower Inverter 3000 Plus is damaged, see the Warranty section.
6. Do not disassemble the XPower Inverter 3000 Plus. It contains no
user-serviceable parts. See Warranty for instructions on obtaining
service. Attempting to service the XPower Inverter 3000 Plus
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 3000 Plus before attempting any
maintenance or cleaning or working on any circuits connected to the
XPower Inverter 3000 Plus. Turning off controls will not reduce this
risk.
8. The XPower Inverter 3000 Plus 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.
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Safety
vi 975-0128-01-01
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 3000 Plus.
2. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower
Inverter 3000 Plus 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.
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.
WARNING: Explosion hazard
WARNING: Explosion or fire hazard
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Safety
975-0128-01-01 vii
5. Remove all metal items, like rings, bracelets, and watches when
working with lead-acid batteries. 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 ar off so you don’t
cause a spark.
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 3000 Plus. Do not use the following
with the XPower Inverter 3000 Plus:
• 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.
CAUTION: Equipment damage
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viii
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975-0128-01-01 ix
Important Safety Instructions
Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
Precautions for Using Rechargeable Appliances - - - - - - - - - - - - - - - - - - - - - - - - - -vii
1 Introduction
Quality Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
2 Features
Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
Dimensions of Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
AC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
DC Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
3 Installation
Designing Your Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–1
Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Choosing an Appropriate Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Calculating Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Calculating Size of DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Calculating Size of Chassis Ground Cable - - - - - - - - - - - - - - - - - - - - - - - 3–6
Calculating Fuse/Circuit Breaker Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Installing the inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Contents
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Contents
x 975-0128-01-01
Installing the Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10
AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Grounding Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Chassis Ground Lug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
DC Disconnects and Over-Current Devices - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
4 Operation
Turning the Inverter On and Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Turning the Inverter Off Between Charges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Display Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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
Recharging Your Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
5 Troubleshooting
Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
A Specifications
Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
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Contents
975-0128-01-01 xi
B Battery Types
Battery Types- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1
Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1
Deep-Cycle Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1
Battery Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3
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
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 Product Information - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1
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xii
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1–1
1Introduction
The XPower Inverter 3000 Plus 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.
Quality Power
The XPower Inverter 3000 Plus is designed for use in recreational
vehicles (RVs), light and heavy duty truck applications, and other in-
vehicle applications.
• The inverter provides up to 2500 W of continuous power. It is
designed to handle loads such as microwaves, refrigerators, freezers,
circular saws, and small air compressors.
• The inverter’s high surge capability lets you handle many hard-to-
start loads, including large TVs, refrigerators, and freezers.
• The inverter’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 inverter is on but no power is being
supplied to a load, the inverter draws less than 600 mA from the
battery.
• The cooling fan in the inverter is thermally activated and comes on
when the inverter becomes warm. The fan turns off automatically
after the inverter has cooled.
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Introduction
1–2 975-0128-01-01
Ease of Use
Superior features and rugged durability have been combined with ease of
use:
• The inverter is compact, lightweight, and easy to install.
• Loads can be powered directly from the AC outlets.
• Easy-to-read indicators on the front panel let you monitor system
performance at a glance.
• Remote On/Off switch lets you control the inverter from a convenient
location—up to 20 feet (6 m) away—while the inverter itself is
mounted out of sight.
Comprehensive Protection
The inverter 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 inverter down automatically
if the battery voltage drops below 10.5 V. This feature protects the battery
from being completely discharged.
High battery voltage shutdown Shuts the inverter down automatically
if the input voltage rises to 15 V or more.
Overload shutdown Shuts the inverter 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 inverter down automatically if
its internal temperature rises above an acceptable level.
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2–1
2Features
Chapter 2, “Features” describes the main features of the XPower Inverter
3000 Plus. Familiarize yourself with them before installing and operating
the inverter.
Remote On/Off Switch
The Remote On/Off switch can be plugged into the remote switch
connector port on the front of the inverter. The remote switch lets you turn
the inverter on and off from a convenient location up to 20 feet (6 m)
away from the inverter.
Dimensions of Remote On/Off Switch
Figure 2-1 XPower Remote On/Off Switch
Length 2" (5.05 cm)
Width 2½" (6.40 cm)
Depth 1" (2.54 cm)
Cable Length 20'(6 m)
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Features
2–2 975-0128-01-01
AC Panel
Figure 2-2 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.
2Fault light (red): indicates the inverter has shut down due to
inverter overload or over-temperature.
3Power light (green): indicates the inverter is operating.
4Display Function Button Press this to display battery voltage,
battery current and AC output power.
5Status indicator lights: VOLTAGE, CURRENT, AC POWER
When lit, each light indicates which status is being displayed.
3
75
8
9
10
4
11 12
1
56
2
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AC Panel
975-0128-01-01 2–3
6Status Display: Shows Voltage, Current or AC Power.
VOLTAGE: Indicates battery power at the input terminal of the
inverter in volts (V).
CURRENT: Indicates current drawn from the battery by the inverter
in amps (A).
AC POWER: Indicates the output power from the inverter as a
percentage of total available watts being utilized.
7Two 15 A Breakers
83-Prong AC Outlets: Each outlet is protected by a 15-amp breaker.
9AC Knockout: For hardwiring the inverter.
10 Remote On/Off Connector Port: For connecting the Remote On/
Off Switch.
11 Mounting Flanges (front and rear) allow you to mount the inverter
permanently.
12 Ventilation Openings must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation opening on the DC panel must not point up or down.
Feature Description
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Features
2–4 975-0128-01-01
DC Panel
Figure 2-3 DC Panel
Feature Description
1Chassis Ground Lug connects to vehicle chassis, DC grounding
bus or to engine’s negative bus.
2Ventilation Opening must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation opening on the DC panel must not point up or down.
3Negative DC Cabling Terminal always connects to the cable
connected to the negative terminal of the battery.
4Positive DC Cabling Terminal always connects to the cable
connected to the positive terminal of the battery.
5Serial number of your inverter.
1
2
3
4
5
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3–1
3Installation
Chapter 3, “Installation,” provides information on cables and fuses to help
you plan for your installation and provide procedures for installing the
inverter.
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 inverter, 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 inverter
• Select the correct fuses or circuit breakers
Study Figures “Configuration for Normal Loads” on page 3–2 and
“Configuration for Heavy Loads” on page 3–2 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.
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Installation
3–2 975-0128-01-01
Figure 3-1 Configuration for Normal Loads
Figure 3-2 Configuration for Heavy Loads
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