Xantrex XPower Powerpack 400 Plus, 400 R User manual

by
XPower Powerpack
400 Plus and XPower
Powerpack 400 R
Owner’s Guide
975-0162-01-01_Rev-C.book Page i Friday, October 20, 2006 10:40 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 2.5 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 Powerpack 400 Plus and XPower Powerpack 400 R 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™ Powerpack 400 Plus and 400 R Owner’s Guide © August 2006 Xantrex
International. All rights reserved.
Exclusion for Documentation
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 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’S RISK; 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
August 2006 Revision C
Part Number
975-0162-01-01
Product Numbers
XPower Powerpack 400 Plus (FGA) 852-1900
XPower Powerpack 400 R (FGA) 852-1900-01
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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i
About This Guide
Purpose
The purpose of this Owner’s is to provide explanations and
procedures for installing, operating, maintaining, and
troubleshooting the XPower Powerpack 400 Plus and
XPower Powerpack 400 R.
The Guide provides safety guidelines, detailed planning and
setup information, as well as information about operating and
troubleshooting the unit.
Conventions Used
The following conventions are used in this guide.
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 product or to other equipment.
Important: These notes describe an important action item
or an item that you must pay attention to.
Note:These notes describe additional information which
may add to your understanding of how to use the product.
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About This Guide
ii 975-0162-01-01
References to XPower Powerpack
In this guide, both the XPower Powerpack 400 Plus and the
XPower Powerpack 400 R (with radio and air compressor)
are referred to as XPower Powerpack when the information
applies to both models. However, when the information is
specific to one model, then reference is made specifically to
the XPower Powerpack 400 Plus or to the XPower
Powerpack 400 R.
Related Information
You can find more information about Xantrex Technology
Inc. as well as its products and services at
www.xantrex.com.
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iii
Important Safety Instructions
The XPower Powerpack 400 Plus and XPower Powerpack
400 R generate a type of AC power similar to a normal
household wall outlet. Operating the XPower Powerpack
incorrectly or misusing it may damage the equipment or
create hazardous conditions for the user.
Warnings and Cautions
Important: Before using your XPower Powerpack 400 Plus and
XPower Powerpack 400 R, be sure to read and save these safety
instructions.
WARNING: Limitations on Use
The XPower Powerpack 400 Plus and XPower Powerpack
400 R are not intended for use in connection with life support
systems or other medical equipment or devices.
WARNING: Shock hazard. Keep away from
children.
The XPower Powerpack generates the same potentially lethal AC
power as a normal household wall outlet. Do not insert foreign
objects into the AC Outlet, the DC Power Socket, the Jump-Start
Cable Port, or the ventilation holes. Do not expose this product to
water, rain, snow, or spray.
Do not open the XPower Powerpack except to replace the internal
battery. Have a qualified technician complete any service work.
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Important Safety Instructions
iv 975-0162-01-01
Figure i Basic Safety
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Important Safety Instructions
975-0162-01-01 v
WARNING: Explosion hazard
Do not use this product where there are flammable fumes or gases,
such as in the bilge of a gasoline- powered boat, or near propane
tanks. Do not use this product in an enclosure containing
automotive-type lead acid batteries. These batteries, unlike the
sealed AGM battery in XPower Powerpack, vent explosive
hydrogen gas which can be ignited by sparks from electrical
connections.
When working on electrical equipment, always ensure someone is
nearby to help you in an emergency.
WARNING: Heated surface
Ensure at least 2" (5 cm) air space is maintained on all sides of the
XPower Powerpack. During operation, keep away from materials
that may be affected by high temperatures such as blankets, pillows
and sleeping bags.
WARNING: Fire hazard
Never allow jump-start cables’ red and black clamps to touch each
other or another common metal conductor. This could cause
damage to the unit and/or create a sparking/explosion hazard.
Always disconnect the jump-start cables from the unit after use and
clip the plastic guard over the jump-start cable port.
WARNING: Fire hazard
Jump-start cable clamps must be connected positive to positive (red
clamp to battery “+”) and negative to negative (black clamp to
battery “-”). A reverse polarity connection (positive to negative)
may cause damage to the unit and/or create a sparking/explosion
hazard.
WARNING: Fire hazard
The jump-start feature is designed for short term operation only—
less than 4 seconds. Operating the jump-start feature for more than
4 seconds may cause damage to the unit. Allow the XPower
Powerpack to cool down for at least 3 minutes after each jump-
start.
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Important Safety Instructions
vi 975-0162-01-01
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 in vicinity of the
engine or batteries.
WARNING: Risk of explosion, fire or burns
The battery terminals exposed at the Jump-Start Cable Port have
enough energy present to cause a spark, creating an explosion
hazard, or to cause burns if a metal object contacts both terminals.
Always clip the plastic guard over the Port when not in use.
WARNING: Fire hazard
Do not leave the compressor unattended while operating. The
compressor is designed for short term operation only. Operation of
the compressor over an extended period of time will cause the
compressor unit to overheat and may cause damage. Allow the
compressor to cool down for 10 minutes after each 10 minutes of
continuous operation.
CAUTION
Do not connect any AC appliance with the neutral conductor
connected to ground to the XPower Powerpack.
CAUTION
Do not expose the XPower Powerpack to temperatures over 104 °F
(40 °C).
WARNING: Explosion and fire hazard
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Important Safety Instructions
975-0162-01-01 vii
4. Be careful not to drop a metal object on the battery or
allow a metal tool to simultaneously touch the positive
and negative cable ends or battery terminals. It might
spark or short-circuit the battery or other electrical parts
and cause an explosion.
5. Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with batteries.
Batteries produce a short-circuit current high enough to
weld a ring or other similar objects to metal, causing a
severe burn.
6. If you need to remove a battery, always remove the
positive terminal from the battery first. Make sure all
accessories are off so you don’t cause an arc.
7. Someone should be within range of your voice, or close
enough to come to your aid when you work near
batteries.
8. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, and eyes.
9. Wear complete eye protection and clothing protection.
Avoid touching your eyes while working near batteries.
10. If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid enters your
eyes, immediately flood them with running cold water for
at least twenty minutes and get medical attention
immediately.
11. Keep a supply of baking soda on hand in the area of the
batteries. Baking soda neutralizes lead-acid battery
electrolyte.
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Important Safety Instructions
viii 975-0162-01-01
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 rechargeable batteries can be damaged if
connected to the XPower Powerpack 400 Plus and XPower
Powerpack 400 R.
Do not use the following with the XPower Powerpack 400
Plus and XPower Powerpack 400 R:
• 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 hand power
tools. These affected chargers display a warning label
stating that dangerous voltages are present at the battery
terminals.
CAUTION
The output of the inverter is non-sinusoidal.
Note:If you are unsure about using your rechargeable appliance
with the XPower Powerpack, contact the equipment manufacturer
to determine the rechargeable appliance’s compatibility with the
modified sine wave (non-sinusoidal) AC waveform.
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ix
Contents
Important Safety Instructions
Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii
Precautions When Working With Batteries- - - - - - - - - - - - - - - vi
Precautions for Using Rechargeable Appliances - - - - - - - - - - viii
1 Introduction
About the XPower Powerpack - - - - - - - - - - - - - - - - - - - - - - 1–1
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Automatic Overload - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Low Battery Protection - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Jump-Start Cables Safety Fuse - - - - - - - - - - - - - - - - - - - 1–2
2 Features
Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
XPower Powerpack Features - - - - - - - - - - - - - - - - - - - - - - - 2–2
Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Radio (XPower Powerpack 400 R only) - - - - - - - - - - - - - 2–5
Air Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Emergency Light and Jump-Start Port - - - - - - - - - - - - - - 2–7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
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Contents
x 975-0162-01-01
3 Operation
Operating Conditions and Guidelines - - - - - - - - - - - - - - - - - 3–1
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Recharging the XPower Powerpack Battery - - - - - - - - - - - - - 3–3
Charging with the AC Charger - - - - - - - - - - - - - - - - - - - 3–4
Charging with the DC-to-DC Accessory Cable - - - - - - - - 3–6
Recharging with a Generator’s Regulated 12 Vdc Outlet- - 3–8
Recharging From a Solar Panel - - - - - - - - - - - - - - - - - - - 3–9
Checking the State-of-Charge - - - - - - - - - - - - - - - - - - - -3–10
AC Appliances- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11
Operating AC Appliances - - - - - - - - - - - - - - - - - - - - - -3–12
Low-Battery Alarm - - - - - - - - - - - - - - - - - - - - - - -3–12
Overload Protection - - - - - - - - - - - - - - - - - - - - - - -3–13
High Surge Appliances - - - - - - - - - - - - - - - - - - - - -3–13
Trouble Appliances - - - - - - - - - - - - - - - - - - - - - - -3–13
12 Vdc Appliances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14
Operating DC Appliances - - - - - - - - - - - - - - - - - - - - - -3–15
Overload Protection - - - - - - - - - - - - - - - - - - - - - - -3–15
Low-Battery Alarm - - - - - - - - - - - - - - - - - - - - - - -3–15
Control Panel Operation - - - - - - - - - - - - - - - - - - - - - - - - - -3–16
Jump-Starting a Vehicle’s Engine - - - - - - - - - - - - - - - - - - - -3–18
Using the Emergency Light - - - - - - - - - - - - - - - - - - - - - - - -3–20
Using the Air Compressor - - - - - - - - - - - - - - - - - - - - - - - - -3–22
Over-Temperature Safety Protection - - - - - - - - - - - - - - -3–24
Inflating Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–25
Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3–27
Using the Radio: XPower Powerpack 400 R - - - - - - - - - - - - -3–28
Power Draw- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–28
Listening to the AM Band - - - - - - - - - - - - - - - - - - - - - -3–28
Radio Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–28
Radio Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–29
Connecting to an External Battery- - - - - - - - - - - - - - - - - - - -3–30
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Contents
975-0162-01-01 xi
4 Maintenance
Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Replacing the Internal Battery - - - - - - - - - - - - - - - - - - - - - - 4–2
Battery Life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Obtaining a Replacement Battery - - - - - - - - - - - - - - - - - 4–3
Battery Replacement Procedure - - - - - - - - - - - - - - - - - - 4–4
Replacing the Incandescent Light - - - - - - - - - - - - - - - - - - - - 4–5
Replacing the External Fuse- - - - - - - - - - - - - - - - - - - - - - - - 4–6
Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
5 Troubleshooting
Common Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - 5–1
Television Interference - - - - - - - - - - - - - - - - - - - - - - - - 5–1
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - 5–2
A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4
Warranty and Return - - - - - - - - - - - - - - - - - - - - - - - - WA–1
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xiii
Figures
Figure 2-1 Package Contents - - - - - - - - - - - - - - - - - - - - - - - - 2–1
Figure 2-2 Front Panel Enlargement - - - - - - - - - - - - - - - - - - - 2–2
Figure 2-3 Storage Compartment - - - - - - - - - - - - - - - - - - - - - 2–4
Figure 2-4 Back Panel Radio Enlargement - - - - - - - - - - - - - - - 2–5
Figure 2-5 Air Compressor Features - - - - - - - - - - - - - - - - - - - 2–6
Figure 2-6 Emergency Light and Jump-start Port- - - - - - - - - - - 2–7
Figure 2-7 Accessories and Accessory Bag - - - - - - - - - - - - - - 2–8
Figure 3-1 Ventilation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Figure 3-2 Charging with AC Power - - - - - - - - - - - - - - - - - - - 3–5
Figure 3-3 Charging with DC Power - - - - - - - - - - - - - - - - - - - 3–7
Figure 3-4 Charging with a Solar Panel - - - - - - - - - - - - - - - - - 3–9
Figure 3-5 Checking the State-of-Charge - - - - - - - - - - - - - - - -3–10
Figure 3-6 Operating AC Appliances- - - - - - - - - - - - - - - - - - -3–12
Figure 3-7 Operating AC Appliances- - - - - - - - - - - - - - - - - - -3–15
Figure 3-8 Using the Control Panel - - - - - - - - - - - - - - - - - - - -3–16
Figure 3-9 Using the Jump-start Cables - - - - - - - - - - - - - - - - -3–19
Figure 3-10 Emergency Light - - - - - - - - - - - - - - - - - - - - - - - -3–20
Figure 3-11 Using the Emergency Light - - - - - - - - - - - - - - - - -3–21
Figure 3-12 XPower Powerpack Air Compressor - - - - - - - - - - -3–23
Figure 3-13 Value Connector Usage - - - - - - - - - - - - - - - - - - - -3–23
Figure 3-14 Nozzle Adapter Usage - - - - - - - - - - - - - - - - - - - - -3–24
Figure 3-15 Inflating tires - - - - - - - - - - - - - - - - - - - - - - - - - - -3–26
Figure 3-16 Inflating Small Sports Equipment - - - - - - - - - - - - -3–27
Figure 3-17 Radio Features - - - - - - - - - - - - - - - - - - - - - - - - - -3–28
Figure 3-18 Basic Jump-start Cable Safety- - - - - - - - - - - - - - - -3–31
Figure 3-19 Connecting the XPower Powerpack to an External Battery
3–32
Figure 4-1 Accessing the Internal Battery for Replacement- - - - 4–4
Figure 4-2 Replacing the Fuse - - - - - - - - - - - - - - - - - - - - - - - 4–6
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xiv
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1-1
1Introduction
About the XPower Powerpack
Easy-to-use and designed for years of reliable service, the
XPower Powerpack can run many AC appliances and 12 volt
DC appliances whenever you need power for work or play, at
home or on the road.
XPower Powerpack:
• Powers 115 volt AC appliances
• Powers 12 volt DC appliances
• Jump-starts vehicle engines
• Provides lighting for emergency use
• Inflates tires and small sports equipment with a 250 psi
air compressor.
In addition, the XPower Powerpack 400 R comes with:
• An AM/FM radio with digital alarm clock.
Comprehensive Protection
Automatic Overload
The XPower Powerpack has built-in protection against output
overload. If you connect an appliance that draws more than
320 W to the AC Outlet(s), or one which draws excessive
surge power, the power to the AC Outlet automatically shuts
off. The unit will reset automatically after the loads are
removed and the unit cools down.
The DC Socket is protected by a thermal switch that monitors
the temperature of the socket. If an overload condition occurs
while using the DC Socket, the excessive temperature will
shut down the power to the Socket.
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Introduction
1-2 975-0162-01-01
Overheating
The XPower Powerpack is protected from overheating. If the
inverter exceeds a safe temperature, power to the AC Outlet
and DC Socket automatically shuts off. It will reset
automatically after the unit cools down.
Low Battery Protection
Low battery protection protects the internal battery from
excessive discharge and possible damage. When the AC
Outlet ON/OFF switch is turned on, an audible alarm alerts you
when the internal battery is nearly discharged (11.0Vdc) and
the unit turns off at 10.5 Vdc.
Jump-Start Cables Safety Fuse
The XPower Powerpack comes with a user-replaceable
250 A fuse to protect the unit and vehicle battery from
damage through reverse polarity and short-circuit conditions.
CAUTION
When using only the DC Socket to power your loads, be sure to
turn the AC Outlet ON/OFF switch to ON. This ensures that the
Low Battery Alarm will sound and will alert you to a low battery
condition. Failure to turn the AC Outlet ON/OFF Switch to ON
when using the DC Socket can allow the unit to be over-discharged
which can destroy the battery. Over-discharging the battery in this
manner will void the unit’s warranty.
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2-1
2Features
Chapter 2 describes the main features of the XPower
Powerpack. We recommend that you familiarize yourself
with these features before operating the unit.
Contents
Your XPower Powerpack package includes the items shown
in Figure 2-1.
If any of these materials are missing or are unsatisfactory in
any way, please contact Customer Service, see Appendix
WA .
Figure 2-1 Package Contents
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Features
2-2 975-0162-01-01
XPower Powerpack Features
Front Panel
Figure 2-2 Front Panel Enlargement
1
2
3
4
5
6
7
8
Control Panel
DC Socket
Cover
AC Outlet
Cover
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