Owners Guide t 1-800-670-0707 (toll free in North America) 1-604-422-2777 (direct) f 1-604-420-2145 e CustomerService@xantrex.com www.xantrex.com XPower Powerpack 400 and 400 PLUS 975-0057-01-01 Printed in China 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 XpowerTM Powerpack 400 and 400 Plus Owner's Guide © April 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 April 2003 Revision 2 Part Number 975-0057-01-01 Contact Information Telephone: 1-800-670-0707 (toll free in North America) 1-604-422-2777 (direct) Fax: Email: Web: 1-604-420-2145 CustomerService@xantrex.com www.xantrex.com 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 Powerpack 400 and XPower Powerpack 400 Plus. 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. i About This Guide 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. References to XPower Powerpack In this guide, both the XPower Powerpack 400 and the XPower Powerpack 400 Plus (with the 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 or to the XPower Powerpack 400 Plus. Related Information You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com ii 975-0057-01-01 Important Safety Instructions The XPower Powerpack 400 and XPower Powerpack 400 Plus generate a type of AC power similar to a normal household wall outlet. Operating the XPower Powerpack 400 and XPower Powerpack 400 Plus incorrectly or misusing it may damage the equipment or create hazardous conditions for the user. Important: Before using your XPower Powerpack 400 and XPower Powerpack 400 Plus, be sure to read and save these safety instructions. Warnings and Cautions WARNING: Shock hazard. Keep Away from Children. The XPower Powerpack 400 and XPower Powerpack 400 Plus 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 400 and XPower Powerpack 400 Plus except to replace the internal battery. Have a qualified technician complete any service work. iii Important Safety Instructions CAUTION Do not connect any AC appliance with the neutral conductor connected to ground to the XPower Powerpack 400 and XPower Powerpack 400 Plus. CAUTION Do not expose the XPower Powerpack 400 and XPower Powerpack 400 Plus to temperatures over 104 °F (40 °C). - WARNING: Explosion hazard Do not use this product where there are flammable fumes or gases, such as in the bilge of a gasolinepowered 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 400 and XPower Powerpack 400 Plus, 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. iv 975-0057-01-01 Important Safety Instructions WARNING: Heated surface Ensure at least 2" (5 cm) air space is maintained on all sides of the XPower Powerpack 400 and XPower Powerpack 400 Plus. 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. 975-0057-01-01 v Important Safety Instructions 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 400 and XPower Powerpack 400 Plus to cool down for at least 3 minutes after each jumpstart. 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 - XPower Powerpack 400 Plus 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. vi 975-0057-01-01 Important Safety Instructions Precautions When Working With Batteries WARNING: Explosion and Fire Hazard 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. 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 a lead-acid battery. A lead-acid battery produces 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 a leadacid battery. 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. 975-0057-01-01 vii Important Safety Instructions 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. viii 975-0057-01-01 Important Safety Instructions Precautions for Using Rechargeable Appliances CAUTION The output of the inverter is non-sinusoidal. 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 and XPower Powerpack 400 Plus. Do not use the following with the XPower Powerpack 400 and XPower Powerpack 400 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 hand power tools. These affected chargers display a warning label stating that dangerous voltages are present at the battery terminals. Note: If you are unsure about using your rechargeable appliance with the XPower Powerpack 400 and XPower Powerpack 400 Plus, contact the equipment manufacturer to determine the rechargeable appliance's compatibility with the modified sinewave (non-sinusoidal) AC waveform. 975-0057-01-01 ix x Contents Important Safety Instructions Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii Precautions When Working With Batteries- - - - - - - - - - - - - - - vii Precautions for Using Rechargeable Appliances - - - - - - - - - - - ix 1 Introduction About the XPower Powerpack - - - - - - - - - - - - - - - - - - - - - Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - Automatic overload- - - - - - - - - - - - - - - - - - - - - - - - - - Overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Low Battery Protection - - - - - - - - - - - - - - - - - - - - - - - Jump-Start Cables Safety Feature - - - - - - - - - - - - - - - - 1­1 1­1 1­1 1­1 1­2 1­2 2 Features Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - XPower Powerpack Features - - - - - - - - - - - - - - - - - - - - - - Front Panel Detail - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Compressor (XPower Powerpack 400 Plus only) - - - Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2­1 2­2 2­2 2­5 2­6 2­7 2­8 xi 3 Operation Operating Conditions and Guidelines - - - - - - - - - - - - - - - - - 3­1 Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3­2 Using XPower Powerpack for the First Time - - - - - - - - - - - - 3­3 Recharging with the AC Charger - - - - - - - - - - - - - - - - - - - - 3­3 Using the light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3­4 Operating AC Appliances - - - - - - - - - - - - - - - - - - - - - - - - - 3­4 Understanding AC Appliances - - - - - - - - - - - - - - - - - - - 3­4 Run Time on Typical AC Appliances - - - - - - - - - - - 3­5 High Surge Appliances - - - - - - - - - - - - - - - - - - - - - 3­6 Trouble Appliances - - - - - - - - - - - - - - - - - - - - - - - 3­6 Operating Several Appliances at Once - - - - - - - - - - - 3­7 Operating an AC Appliance - - - - - - - - - - - - - - - - - - - - - 3­7 Operating 12 V DC Appliances - - - - - - - - - - - - - - - - - - - - - 3­8 Jump-Starting a Vehicle's Engine - - - - - - - - - - - - - - - - - - - -3­10 Using the Air Compressor: XPower Powerpack 400 Plus - - - -3­12 Over-Temperature Safety Protection - - - - - - - - - - - - - - -3­13 Inflating Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3­14 Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3­15 Connecting to an External Battery- - - - - - - - - - - - - - - - - - - -3­17 4 Maintenance Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - Recharging the XPower Powerpack Battery - - - - - - - - - - - - Recharging with the AC Charger- - - - - - - - - - - - - - - - - Recharging with ...