XPower 1500 User manual

by
XPower Inverter 1500
Owner's Guide
975-0166-01-01 REV. B Printed in China
t 1-800-394-0440 (toll free in North America)
1-360-925-5097 (direct)
f 1-800-994-7828 (toll free in North America)
1-360-925-5143 (direct)
e [email protected]
www.xantrex.com
ARTWORK NO. 975-0166-01-01 REV. B 2004-07-02

by
XPower Inverter 1500
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 1500 Owner’s Guide © July 2004 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
July 2004 Revision B
Part Number
975-0166-01-01
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: customerser[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 1500.
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 1500.

About This Guide
iv 975-0166-01-01
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 that 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 1500, read all
instructions and cautionary markings on the XPower 1500, the
batteries, and all appropriate sections of this guide.
2. Do not expose the XPower 1500 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 1500 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 1500 with damaged or substandard wiring.
5. Do not operate the XPower 1500 if it has received a sharp blow, been
dropped, or otherwise damaged in any way. If the XPower 1500 is
damaged, see the Warranty section.
6. Do not disassemble the XPower 1500. It contains no user-serviceable
parts. See Warranty for instructions on obtaining service. Attempting
to service the XPower 1500 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 1500 before attempting any maintenance or
cleaning or working on any circuits connected to the XPower 1500.
Turning off controls will not reduce this risk.
8. The XPower 1500 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 975-0166-01-01
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 1500.
2. This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not install the XPower 1500
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
975-0166-01-01 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 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 are off so you don’t
cause a spark.
WARNING: Explosion or fire hazard

Safety
viii 975-0166-01-01
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 1500. Do not use the following with the
XPower Inverter 1500:
• 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 1500, contact the equipment manufacturer to determine the
rechargeable appliance’s compatibility with the modified sinewave (non-
sinusoidal) AC waveform.
CAUTION: Equipment damage
The output of the inverter is non-sinusoidal.
CAUTION: Equipment damage
Do not connect live AC power to the XPower inverter’s AC outlets. The inverter
will be damaged even if it is switched OFF.
Do not connect any AC load that has its neutral conductor connected to ground to
the XPower inverter.

975-0166-01-01 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 1500 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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

x
4 Operation
Turning the Inverter On and Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Operating Several Loads at Once - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Turning the Inverter Off Between Uses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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
XPower 1500 unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
5 Troubleshooting
Common Problems- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Buzz in Audio Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Television Reception - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
A Specifications
Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–1
Dimensions for Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
B Battery Types
Battery Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1
Automotive Starting Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–1
Deep-Cycle Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Battery Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2
Estimating Battery Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4
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

Contents
975-0166-01-01 xi
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 Return Information - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1
Direct to place of purchase - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–4
Direct to Xantrex - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–4

xii

1–1
1Introduction
Congratulations on your purchase of the XPower Inverter 1500! The
XPower 1500 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 themain performance features and protection features of the XPower
1500.
Quality Power
The XPower 1500 is a quality inverter designed for recreational vehicle
(RV) and truck applications.
• The XPower 1500 provides up to 1500 watts of continuous power. It
is designed to handle loads such as 1000-watt microwaves, TVs,
VCRs, and midsized power tools.
• The XPower 1500’s high surge capability (3000 W) lets you handle
many hard-to-start loads, including large TVs and small refrigerators.
• The XPower 1500’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 XPower 1500 is on but no power
is being supplied to a load, the inverter draws less than 300 mA from
the battery.
• The cooling fan in the inverter is thermally activated and comes on
when the XPower 1500 becomes warm. The fan turns off
automatically after the inverter has cooled.

Introduction
1–2 975-0166-01-01
Ease of Use
Superior features and rugged durability have been combined with ease of
use:
• The XPower 1500 is compact, light weight, and easy to install.
• Loads can be powered directly from the AC outlets.
Comprehensive Protection
The XPower 1500 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 XPower 1500 down
automatically if the battery voltage drops below 10.5 volts. This feature
protects the battery from being completely discharged. The unit will
automatically restart when the battery voltage rises to 12.0 volts or more.
High battery voltage shutdown Shuts the XPower 1500 down
automatically if the input voltage rises to 15 volts or more. To restart the
unit manually, turn the unit’s main ON/OFF switch to OFF and then to
ON.
Overload shutdown Shuts the XPower 1500 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. To restart the unit manually, turn the unit’s main ON/OFF switch to
OFF and then to ON.
Over temperature shutdown Shuts the XPower 1500 down
automatically if its internal temperature rises above an unacceptable level.
To restart the unit manually, turn the unit’s main ON/OFF switch to OFF
and then to ON.

2–1
2Features
Chapter 2 describes the main features of the XPower 1500.
Xantrex recommends that you familiarize yourself with them before
installing and operating the inverter.
Materials List
Your XPower 1500 package includes:
• One XPower 1500
• Two 5/16" lock washers (on the DC input cable terminals)
• Two 5/16" nuts (on the DC input cable terminals)
• One 4' connector cable assembly with ring terminals (4 AWG)
• Owner’s Guide
If any of these materials are missing or are unsatisfactory in any way,
please contact Customer Service. Contact information is available on
page WA–1.
As soon as you unpack your inverter, be sure to record the product
information in the form on page WA–6.

Features
2–2 975-0166-01-01
AC Panel
Figure 2-1 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.
2Power light is a green light indicating the On/Off Switch is on and
AC voltage is present at the inverter’s AC outlets.
3 Fault light is a red light indicating the inverter has shut down due to
low or high battery voltage, unit overload, or over temperature.
43-Prong AC Outlets:
XPower 1500 delivers a combined total of 1500 watts of continuous
AC power across two outlets.
5Ventilation Openings must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation openings must not point up or down.
6Mounting Flange allows you to mount the inverter permanently.
1
3
2
4
6
1
5

DC Panel
975-0166-01-01 2–3
DC Panel
l
Figure 2-2 DC Panel
Feature Description
1Chassis Ground Screw connects to vehicle chassis, DC grounding
bus or to engine’s negative bus.
2Positive DC Cabling Terminal always connects to the cable
connected to the positive terminal of the battery.
3Negative DC Cabling Terminal always connects to the cable
connected to the negative terminal of the battery.
4Ventilation Opening must not be obstructed for the proper
operation of the inverter. When the inverter is mounted, the
ventilation opening must not point up or down.
5Serial number of your unit (on center flange).
6Mounting Flange allows you to mount the inverter permanently.
4
1
2
3
5
6

2–4

3–1
3Installation
Chapter 3 provides information on cables and fuses to help you plan for
your installation and provide procedures for installing the XPower 1500.
Xantrex highly recommends that you 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 XPower 1500, 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 XPower 1500
• Select the correct fuses or circuit breakers
Study Figure 3-1, “Configuration for Normal Loads” on page 3–2 and
Figure 3-2, “Configuration for Heavy Loads” on page 3–3 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.