Xantrex XPower 500 User manual

by
XPower Inverter 500
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 500 Owner’s Guide © September 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
September 2003 Revision B
Part Number
975-0094-01-01
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: [e-mail]
Web: www.xantrex.com

iii
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Important Safety Information . . . . . . . . . . . . . . . . . . 2
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . 2
3. XPower 500 Inverter Features . . . . . . . . . . . . . . . . . . 6
AC Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Connecting the XPower 500 . . . . . . . . . . . . . . . . . . . . 9
Choosing a Location . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fastening the Inverter to a Mounting Surface . . . . . . . 9
Connecting the XPower 500 to DC Power . . . . . . . . 10
Using the Battery Clip Wire Assembly . . . . . . . . . . 12
Hardwiring the Inverter to the Battery . . . . . . . . . . 14
Disconnecting the Battery . . . . . . . . . . . . . . . . . . . . . 16
Replacing the In-Line Fuse . . . . . . . . . . . . . . . . . . . . 16
5. Operating the XPower 500 . . . . . . . . . . . . . . . . . . . . 17
Operating Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interference With Electronic Equipment. . . . . . . . . 19
6. Battery Operating Time . . . . . . . . . . . . . . . . . . . . . . 20
7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Regulatory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10. Other Xantrex Products . . . . . . . . . . . . . . . . . . . . . 32
Table of Contents

iv

1
1 Introduction
Thank you for purchasing the Xantrex XPower Inverter 500.
The XPower 500 is part of a family of advanced, high-
performance power inverters from Xantrex, the leader in the
field of high-frequency inverter design.
Connected directly to a 12 volt battery, the XPower 500
efficiently and reliably powers a wide variety of household
AC products, such as TVs and VCRs, laptop computers,
camcorder and cell phone chargers, compact fluorescent
lights, soldering irons, and small power tools.
The XPower 500 uses reliable solid state power electronics
for years of safe, trouble-free operation and includes
automatic safety monitoring circuitry to protect it from
inadvertent overload conditions.
Read this guide before connecting or using the XPower 500,
and save it for future reference. The main topics in the guide
are:
• Safety information (page 2)
• XPower 500 features (page 6)
• Instructions for connecting the inverter (page 10)
• Operating guidelines (page 17)
• Troubleshooting information (page 21)
• Specifications (page 24)
• Warranty and service information (page 26)

2
2 Important Safety Information
If the XPower 500 is connected or used incorrectly,
hazardous conditions may be created. Read and save this
safety information, and pay special attention to all Caution
and Warning statements in the guide and on the inverter
itself. Warnings and Cautions are indicated by this symbol:
•Warning statements identify conditions that could
result in personal injury or loss of life.
•Caution statements identify conditions or practices that
could result in damage to the XPower 500 or other
equipment.
Warnings and Cautions
WARNING: Shock hazard
The XPower 500 generates the same potentially lethal AC
power as a household wall outlet. Do not insert foreign
objects in the inverter’s AC outlet or any other openings in
the inverter. Do not open the inverter. Have a qualified
individual complete any service work.
WARNING: Shock hazard
Do not expose the XPower 500 to water, rain, snow, or
spray.

3
WARNING: Risk of fire or explosion
The XPower 500 contains components that 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.
WARNING: Fire hazard
To reduce the risk of fire, do not cover or obstruct the
ventilation openings. Do not install the XPower 500 in a
zero-clearance compartment. Overheating may result.
WARNING: Shock and fire hazard
During installation route all cable/wiring away from sharp
edges and hot surfaces of the engine compartment or
vehicle.

4
CAUTION: Risk of damage to equipment
The XPower 500 is designed to be directly connected to
standard electrical and electronic equipment in the manner
described in this guide. Do not connect it to household or
RV AC distribution wiring. Do not connect it to any AC
load circuit in which the neutral conductor is connected to
ground (earth) or to the negative of the DC (battery)
source.
CAUTION: Risk of damage to the XPower
500
Reverse battery polarity (negative connected to positive;
positive connected to negative) will damage the XPower
500, and it will require servicing. Damage caused by
reverse polarity is not covered by your warranty.

5
CAUTION: Risk of damage to rechargeable
appliances.
The output of the XPower 500 is non-sinusoidal. Certain
battery chargers can be damaged if they are connected to
the XPower 500. Two particular types of equipment are
prone to this problem:
• Small battery-operated appliances such as
rechargeable flashlights, shavers, and night lights that
can be plugged directly into an AC receptacle to
recharge.
• Certain battery chargers for battery packs used in hand
power tools. These chargers have a warning label
stating that dangerous voltages are present at the
charger battery terminals.
Do not use the XPower 500 with the type of appliances
just described.
CAUTION: Risk of damage due to high
temperatures.
Do not use the XPower 500 in temperatures over 40° C
(105° F). Overheating may result.

6
3 XPower 500 Inverter Features
This section describes the main features of the XPower 500.
Figure 1 shows the inverter’s AC panel.
Figure 1 AC Panel on the XPower 500 (European AC Outlet)
➀ AC Outlet An AC outlet is located on one end of the
inverter. It allows you to plug in a 230 volt AC product with
a power consumption of 500 watts or less when the inverter
is connected to a 12 volt battery.
The AC outlet on your inverter may be different from the
one shown here. For all available outlets, see Figure 2,
Figure 3, and Figure 4, on page 8.
➁ On/Standby Switch The two positions on the On/
Standby switch are: = Standby and = On.
①②③
④
➄

7
When the inverter is connected to a DC power source and
the On/Standby switch is on, AC power is available at the
outlet.
➂ Power Light The green PWR light is on all the time
when the On/Standby switch is on.
➃ Fault Light The red light indicates that the
inverter has shut down because of low or high battery
voltage, AC overload, or excessively high temperatures.
➄ Mounting Flanges Mounting flanges on the AC and
DC ends allow you to mount the inverter permanently. For
additional information, see “Fastening the Inverter to a
Mounting Surface” on page 9.
Audible Alarm An audible alarm warns you of a high
temperature shutdown or of an impending low voltage
shutdown.
Fan The fan (see Figure 5) turns on when an AC load of
100 watts or higher is plugged in.

8
AC Outlets
Depending on your geographic location, your XPower 500
will have one of the following AC outlets.
Figure 2 European AC Outlet
Figure 3 British AC Outlet
Figure 4 Australian and New Zealand AC Outlet

9
4 Connecting the XPower 500
This section explains how to connect the XPower 500.
Choosing a Location
For the best performance, choose a location that is:
•Dry Do not expose the inverter to water drip or spray.
•Cool Operate the inverter in ambient temperatures
between 0° C and 40° C (32° F and 100° F). Keep it
away from heating vents and direct sunlight.
•Well ventilated For proper cooling, allow at least 5 cm
(2 in.) of clearance around the inverter.
•Clean and free of dust and dirt Choose a location
that is free of any debris that could get into the inverter.
•Protected from battery gases Do not mount the
inverter where it will be exposed to battery gases. These
are very corrosive and will damage the inverter.
Fastening the Inverter to a Mounting
Surface
For temporary or portable use, place the inverter on a flat
surface like a table or the floor of your vehicle.
For a permanent installation, use four screws to attach the
inverter’s mounting flanges to an appropriate surface.
Note: Local and national electrical codes that apply to your
installation may require that you permanently mount the inverter if
you make permanent electrical connections and may disallow
permanent mounting if you make a temporary electrical
connection.

10
Connecting the XPower 500 to DC Power
WARNING: Corrosive materials and energy
hazard
To reduce the risk of irritation and burns, wear protective
eyewear and clothing when you work with batteries.
Take special care to ensure that metal tools or personal
objects like rings or watches do not contact the battery
terminals.
CAUTION: Risk of damage to the XPower
500
The XPower 500 must only be operated with a nominal 12
volt battery. The inverter will not operate with a lower
voltage battery. A higher voltage battery will damage the
inverter.
CAUTION: Damage to the XPower 500
Reversing the positive and negative battery cables will
damage the inverter and will void your warranty.
When you connect the inverter to the battery, double check
the connections. The red wire must be connected to the red
(+) terminal on the inverter and the positive (+) terminal
on the battery. The black wire must be connected to the
black (–) terminal on the inverter and the negative (–)
terminal on the battery.

11
You can make a temporary or a permanent connection
between the inverter and the 12 volt DC power source.
• Use the battery clip wire assembly to make a temporary
connection (page 12).
• Hardwire the inverter to the battery to make a
permanent connection (page 14).
Refer to Figure 5 and Figure 6 when you connect the
inverter.
Figure 5 DC Panel on the XPower 500
①
②
③
①Fan ②Red (positive +) terminal ③ Black (negative –)
terminal

12
Using the Battery Clip Wire Assembly
WARNING: Corrosive materials and energy
hazard
To reduce the risk of irritation and burns, wear protective
eyewear and clothing when you work with batteries.
Take special care to ensure that metal tools or personal
objects like rings or watches do not contact the battery
terminals.
WARNING: Fire hazard
The wires in most 12 volt sockets or power outlets are not
large enough for loads greater than 150 watts: they will
overheat and present a fire hazard.
For loads greater than 150 watts, connect the inverter
directly to the battery and use appropriately sized wires
like those in the battery clip wire assembly provided with
the inverter.
CAUTION: Risk of damage to the XPower
500.
Reversing the positive and negative battery cables will
damage the inverter and void your warranty.
When you connect the inverter to the battery, double check
the connections. The red wire must be connected to the red
(+) terminal on the inverter and the positive (+) terminal
on the battery. The black wire must be connected to the
black (–) terminal on the inverter and the negative (–)
terminal on the battery.

13
To connect the inverter to a 12 volt battery using the battery
clip wire assembly:
1. Remove the nuts from the DC terminals on the inverter.
2. Place the red ring connector on the red (positive +) DC
terminal, and then screw the red nut on until it is snug.
Do not over tighten.
3. Attach the red clip to the red (positive +) battery
terminal.
4. Attach the black clip to the black (negative –) battery
terminal.
5. Place the black ring connector on the black (negative –)
DC terminal, and then screw the black nut on until it is
snug. Do not over tighten.
Note: A spark may occur when you make this
connection. This is normal.
6. Check that both clips are securely connected to the
battery terminals. A loose connection will cause
excessive voltage drop and may cause the cables to
overheat. This could result in equipment damage or fire.
7. Turn on the On/Standby switch. The green PWR light
comes on, and AC power is available at the outlet.

14
Hardwiring the Inverter to the Battery
A hardwired installation is illustrated in Figure 6.
Figure 6 Hardwiring the XPower 500 to a 12 Volt Battery
WARNING: Shock and fire hazard
Use a qualified installer to perform a hardwired
installation.
➂
②
①
④
➄
⑥
–
+
① XPower 500 ② 8.4mm
2
(8 AWG) red wire from the
positive inverter terminal to the positive battery terminal (via
the fuse and switch)
➂ 80 amp automotive fuse ④ 12 volt,
80 amp disconnect switch
➄ 12 volt battery ⑥ 8.4mm
2
(8 AWG) black wire from the negative inverter terminal to
the negative battery terminal.

15
To hardwire the inverter to a 12 volt battery:
1. Cut the clips off the cable clip wire assembly.
2. Using 8.4mm2(8 AWG) wire or heavier, extend the
power cord if you need to, to a maximum total length of
2 meters (6.5 feet) including the existing XPower 500
power cord length. Solder all connections and make
sure they are properly insulated by using electrical tape
or heat shrinkable tubing.
3. Install an 80 amp automotive fuse and a switch rated at
80 amps in the positive (red) wire, close to the end that
will attach to the battery. See Figure 6. The switch lets
you disconnect the DC power if you need to replace the
in-line fuse. Solder and insulate the connections as
detailed in Step 2 above.
4. Turn off the in-line switch.
5. Solder or crimp heavy-duty terminals to the battery end
of the positive and negative wires. Use terminals that
mate properly with the battery terminals or existing
battery cable clamps.
CAUTION: Damage to the XPower 500
Reversing the positive and negative battery cables will
damage the inverter and will void your warranty.
Before connecting the inverter to the battery, double check
the connections: the red wire must be connected to the red
terminal on the inverter and the positive (+) terminal on
the battery; the black wire must be connected to the black
terminal on the inverter and the negative (–) terminal on
the battery

16
6. Remove the nuts from the DC terminals on the inverter.
7. Place the red ring connector on the red (positive +) DC
terminal on the inverter, and then screw the red nut on
until it is snug. Do not over tighten.
8. Fasten the positive terminal (red wire) to the positive
battery post.
9. Fasten the negative terminal (black wire) to the
negative battery post.
10. Place the black ring connector on the black (negative –)
DC terminal on the inverter, and then screw the black
nut on until it is snug. Do not over tighten.
11. Turn on the in-line switch.
12. Turn on the inverter’s On/Standby switch. The green
PWR light comes on, and AC power is available at the
outlet.
Disconnecting the Battery
• Before you disconnect the battery, turn off the AC load,
and then turn off the in-line switch.
Replacing the In-Line Fuse
• If you need to replace the in-line fuse (Figure 6), turn
off the in-line switch to disconnect the DC power.