Xantrex XPower 5000 User manual

by
This guide for use by qualified installers only
XPower Inverter 5000
Installation Guide

This guide for use by qualified installers only
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products ranging from small mobile units to 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 5000 Installation Guide © September 2008 Xantrex International. All rights reserved.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREXTM”)
(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 LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER
SPECIAL, 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’SRISK; AND
(C)REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH
STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT
BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE
VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
September 2008 Revision C
Document Part Number
975-0411-01-01
Product Part Number
813-5000
Contact Information
Telephone: [phone] (toll free North America)
1 408 987 6030 (direct)
Fax: [phone] (toll free North America)
Email: [email protected]
Web: www.xantrex.com

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About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and
procedures for installing the XPower Inverter 5000.
Scope
The Guide provides safety guidelines and procedures for installing the
inverter. It does not provide details about particular brands of batteries.
You must consult individual battery manufacturers for this information.
Refer to Xpower Inverter 5000 Owner’s Guide (doc. part number: 975-
0376-01-01) for operational instructions.
Audience
The Guide is intended for qualified installers including licensed
technicians and electricians. It is intended for installers with knowledge
and experience in installing electrical equipment, knowledge of the
applicable installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards.
Organization
This Guide is organized into two chapters and one appendix.
Chapter 1 describes the standard features of the XPower Inverter 5000, as
well as its protection features. It also provides information on the different
parts of the XPower Inverter 5000.
Chapter 2 describes installation procedures including planning, wiring,
and mounting the XPower Inverter 5000.
Appendix A contains physical and electrical specifications of the XPower
Inverter 5000.

About This Guide
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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 they are not as serious as a caution or warning.

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Important Safety Instructions
IMPORTANT: Read and save this Installation Guide for
future reference.
This chapter contains important safety instructions for the XPower
Inverter 5000.
1. Before installing and using the XPower Inverter 5000, read all
instructions and cautionary markings on or provided with the XPower
Inverter 5000, the batteries, and all appropriate sections of this guide.
2. Do not expose the XPower Inverter 5000 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 5000 in a
zero-clearance compartment. Overheating may result.
3. To avoid a risk of fire and electric shock, make sure that existing
wiring is in good condition, adequately rated, and not undersized. Do
not operate the XPower Inverter 5000 with damaged or substandard
wiring.
4. Do not install or operate the XPower Inverter 5000 if it has received a
sharp blow, been dropped, or otherwise damaged in any way. If the
XPower Inverter 5000 is damaged, see the Warranty section.
5. Do not disassemble the XPower Inverter 5000. It contains no user-
serviceable parts. See Warranty for instructions on obtaining service.
Attempting to service the XPower Inverter 5000 yourself may result
in a risk of electrical shock or fire. Internal capacitors remain charged
after all power is disconnected.
WARNING: Shock, fire, and heat hazard. Risk of
injury to persons.

Safety
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6. To reduce the risk of electrical shock, disconnect DC power from the
XPower Inverter 5000 before attempting any maintenance or cleaning
or working on any circuits connected to the XPower Inverter 5000.
Turning off controls will not reduce this risk.
7. The XPower Inverter 5000 must be provided with equipment-
grounding conductors connected to the vehicle chassis as described in
“Chassis Ground Wire Sizing” on page 2–8 and “Output Conductor
Selection for Hardwire Installation” on page 2–8.
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 to
reduce the risk of battery explosion.
2. 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 5000.
3. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower
Inverter 5000 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.
4. Make sure the area around the battery is well ventilated.
5. Never smoke or allow a spark or flame near the engine or batteries.
6. 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.
7. 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
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8. 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.
9. Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
10. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
11. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near batteries.
12. 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.
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 5000. Do not use the following with the
XPower Inverter 5000:
• 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.
WARNING: Risk of personal injury due to burns or
battery acid
CAUTION: Risk of equipment damage
The output of the XPower Inverter 5000 is not sinusoidal and may not be
compatible with all loads. Follow the recommendations below.

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Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1Quality Power- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Ease of Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
AC Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
DC Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Remote Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
2Designing Your Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
Installation Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Calculating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Choosing an Effective Charging System - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Choosing an Appropriate Location and Mounting Orientation - - - - - - - - - - - - - 2–4
Selecting Cable Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
DC Input Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Selecting a DC Input Fuse or Circuit Breaker - - - - - - - - - - - - - - - - - - - - - 2–7
Chassis Ground Wire Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Output Conductor Selection for Hardwire Installation - - - - - - - - - - - - - - - 2–8
Installing the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Overview of Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Installing the Remote On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Connecting the Chassis Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Connecting the AC Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Connecting the DC Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Contents

x

1–1
This guide for use by qualified installers only
1Introduction
The XPower Inverter 5000 is 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 5000 is designed for use in recreational vehicles
(RVs), light and heavy duty truck applications, and other in-vehicle
applications.
• The inverter provides up to 4000 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 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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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 (part number: 100-0830-01-01) lets you
control the inverter from a convenient location—up to 10 feet (3 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 will limit battery
discharge.
High battery voltage shutdown Shuts the inverter down automatically
if the input voltage rises to 15.5 V or more.
Overload and short-circuit shutdown Shuts the inverter down
automatically if a short-circuit is detected in the load 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.
Back-EMF (backfeed) protection Shuts the inverter down
automatically if a motor that is connected to the AC outlet overloads or if
an AC source is connected to the AC outlet.
GFCI-protected outlets Provides standard ground fault detection and
protection to prevent severe or fatal electric shocks.
DC terminal over temperature protection Monitors the DC terminals
to prevent inverter or cable overheating due to loose connections or
undersized DC cables.

Features
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Features
Chapter 1, “Introduction” describes the main features of the XPower
Inverter 5000. Familiarize yourself with them before installing and
operating the inverter.
AC Panel
Figure 1-1 AC Panel
REMOTE
SWITCH DISPLAY
FUNCTION
VOLTAG E
CURRENT
AC POWER
V
A
kW
POWER FAULT
INVERTER
5000
20A 20A
5
6
8
10
1
234
7
9
11
12

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Feature Description
1On/Off Switch turns the inverter’s control circuit on and off. This
switch is not a power disconnect switch. Disconnect DC power
before working on any circuits connected to the inverter.
2Fault light (red): indicates the inverter has shut down due to
inverter overload, over-temperature, under voltage, over voltage, AC
output short circuit, or AC back-EMF (backfeed) protection
shutdown.
3Power light (green): indicates the inverter is operating.
4Status indicator lights: VOLTAGE, CURRENT, AC POWER
When lit, each light indicates which status is being displayed.
5Status Display: Shows Voltage, Current or AC Power.
VOLTAGE: Indicates battery voltage 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 being drawn from the
inverter in utilized kilowatts (kW).
6Display Function Button Press this to display battery voltage,
battery current and AC output power.
7Remote On/Off Switch Connector Port: For connecting the
Remote On/Off Switch. The remote switch and a 10-foot
communications cable is included with the inverter.
8Two duplex GFCIs: Each GFCI has two three-prong AC outlets and
is connected in series with a 20 A circuit protector.
9Two 20 A circuit protectors
10 Mounting Flanges (front and rear) allow you to mount the inverter
permanently.
11 Ventilation Openings must not be obstructed for the proper
operation of the inverter. Refer to “Choosing an Appropriate
Location and Mounting Orientation” on page 2–4 for installation
clearances and orientation.
12 AC Knockout with strain-relief clamp: For hardwiring the inverter
and securing the cables.

Features
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DC Panel
Figure 1-2 DC Panel
Feature Description
1Chassis Ground Lug connects to vehicle chassis.
2Ventilation Opening and Fan Assembly must not be obstructed for
the proper operation of the inverter. Refer to “Choosing an
Appropriate Location and Mounting Orientation” on page 2–4 for
installation clearances and orientation.
3Negative (–) DC Input Terminal connects to one end of the
negative battery cable. The other end of the negative battery cable is
connected to the negative terminal of the battery.
4Positive (+) DC Input Terminal connects to one end of the positive
battery cable. The other end of the positive battery cable is
connected to the positive terminal of the battery.
5Serial number of your inverter.
DANGER: Thisunitemployscompo-
nentsthattendtoproducearcsor sparks.
Riskoffireandexplosion– Do notinstall
near batteries, in machinery space, or
area in which ignition-protected
equipmentis required. Shock Hazard–
Do not open.No serviceable parts inside.
INPUT: 12 Vdc (nominal),
520 A (5 min. max.) / 415 A (cont.)
OUTPUT: 120 Vac / 60 Hz
5 kW / 41 A (5 min max.)
4 kW / 33 A (continuous)
CHASSIS GND
Serial No.
BATTERY
NEG.
BATTERY
POS.
WARNING: Shock,energy,andfirehazards. Readmanualbeforeinstallingor using.Topreventfire,donotcoveror
obstructventilationopenings. Do not mount in zero-clearancecompartment. Overheatingmay result. Do not expose to rain or
spray. UseGroundFaultCircuitInterruptersonlyasspecifiedin themanualssuppliedwiththisunit. Othertypesmayfailtooperate
when connected to this unit.Ensure proper grounding.Total harmonic distortion is 38%;maximum single harmonic is 32%.
Patents Pending
Designed in Canada by
Xantrex / Assembled in China
1
2
3
4
5

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Remote Switch
Figure 1-3 Remote Switch
Feature Description
1Remote On/Off Switch turns the inverter’s control circuit on and
off. This switch is not a power disconnect switch. Disconnect DC
power before working on any circuits connected to the inverter.
2Communications Cable is 10 feet (3 m) long. This cable can be
replaced and/or extended with a standard telephone cable up to a
maximum total length of 25 feet (7.5 m).
12

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2Installation
Chapter 2, “Installation,” provides information on cables and fuses to help
you plan for your installation, and it provides 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 must 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 must:
• Be aware of installation codes
• Calculate your battery requirements
• Choose an effective charging system
• Choose an appropriate location and mounting orientation
• Calculate the cable size for your inverter
• Select the correct fuses or circuit breakers
Study Figures “Configuration for Normal Loads” on page 2–2 and
“Configuration for Heavy Loads” on page 2–2 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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Figure 2-1 Configuration for Normal Loads
Figure 2-2 Configuration for Heavy Loads
5000
5000

Designing Your Installation
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Installation Codes
Governing installation codes vary depending on the location and type of
installation. Electrical installations must meet local and/or national wiring
codes and should be performed by a qualified electrician.
An example of a national wiring code is the US National Electrical Code
(NEC, NFPA70) article 551 governing electrical installations in RVs. In
other geographical regions or for other applications, other codes will
apply. It is the installer's responsibility to identify and apply all
applicable codes.
Calculating Battery Requirements
Battery type and battery size strongly affect the performance of the
inverter. Therefore, you must identify the type of loads your inverter will
be powering, and how much you will be using them between charges.
Once you know how much power you will be using, you can determine
how much battery capacity you need. We recommend that you purchase
as much battery capacity as possible.
For information on calculating battery capacity, go to www.xantrex.com,
click Support, select the Xpower Inverters product, and then click Go.
Under Calculators & Problem Solvers, click Battery Calculator.
Choosing an Effective Charging System
The charging system must be appropriate for your particular installation.
A well-designed charging system ensures that power is available when
you need it and that your batteries remain in top condition. Inadequate
charging will degrade system performance, and the wrong type of charger
will reduce battery life.
For information about choosing an effective battery charging system, go
to www.xantrex.com, click Support, select the Xpower Battery
Chargers product, and then click Go. Under Tech Notes & How-To's,
click Selecting the Right Battery Charger.
NOTE: If the main charging source will be the vehicle's alternator, then
its voltage and current ratings must be appropriate for the size and type of
battery that is selected.
CAUTION: Equipment damage
The inverter must only be connected to a 12 V battery system. It will not operate
if connected to a 6 V battery and will be damaged if connected to a 24 V battery.

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Choosing an Appropriate Location and Mounting Orientation
Appropriate
Location The inverter must only be installed in a location that is:
:
WARNING: Fire or explosion hazard
The inverter contains components which tend to produce arcs or sparks. To
prevent fire or explosion, do not install the XPower Inverter 5000 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: Fire hazard
To reduce the risk of fire, do not cover or obstruct the ventilation openings. Do
not install the inverter in a zero-clearance compartment. Overheating may result.
Dry Do not allow water or other liquids to drop or splash on it.
Cool Ambient air temperature should be between 0 and 40ºC
(32 and 105ºF)—the cooler the better within this range.
Ventilated Allow at least 3" (76 mm) of clearance around the inverter
for air flow. Ensure that the ventilation openings on each
end of the inverter are not obstructed.
Safe Do not install the inverter in the same compartment as
batteries or in any compartment capable of storing
flammable liquids like gasoline.
Close to
battery Do not use excessive DC cable lengths: they increase wire resistance which leads to voltage drop and heating.
Consequently, it reduces available power and run-time.
Longer AC wires are preferable to longer DC wires: voltage
drop is less of an issue and the cost is lower.
Protected
from battery
gases
Do not mount the inverter where it will be exposed to gases
produced by batteries. Battery gases are corrosive, and
prolonged exposure to battery gases will damage the
inverter.