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- Owner's Manual
Xantrex XPower Powerpack 400 Plus, 400 R Owner's Manual
Summary of XPower Powerpack 400 Plus, 400 R
Page 1
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.
Page 2
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-a...
Page 3: About This Guide
I about this guide purpose the purpose of this owner’s is to provideexplanations 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...
Page 4: Related Information
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 specifi...
Page 5: Warnings and Cautions
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 a...
Page 6
Important safety instructions iv 975-0162-01-01 figure i basic safety 975-0162-01-01_rev-c.Book page iv friday, october 20, 2006 10:40 am.
Page 7: Warning: Explosion Hazard
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. ...
Page 8: Warning: Fire Hazard
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 smok...
Page 9
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 explosi...
Page 10: Appliances
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 batteri...
Page 11: Contents
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 p...
Page 12: Operation
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 - - - -...
Page 13: Maintenance
Contents 975-0162-01-01 xi 4 maintenance battery maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1 replacing the internal battery - - - - - - - - - - - - - - - - - - - - - - 4–2 battery life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 obtaining a repla...
Page 14
Xii 975-0162-01-01_rev-c.Book page xii friday, october 20, 2006 10:40 am.
Page 15: Figures
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 - - - - - - -...
Page 16
Xiv 975-0162-01-01_rev-c.Book page xiv friday, october 20, 2006 10:40 am.
Page 17: Introduction
1-1 1 introduction 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...
Page 18: Overheating
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 protecti...
Page 19: Features
2-1 2 features 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 unsatisf...
Page 20: Xpower Powerpack Features
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 975-0162-01-01_rev-c.Book page 2 friday, october 20, 2006 10:40 am.
Page 21
Xpower powerpack features 975-0162-01-01 2-3 see “control panel operation” on page 3–16 for detailed instructions on using the control panel. Feature description dc power socket can: • power 12 volt dc auto, rv, or marine appliances. • recharge xpower powerpack from a 12 v outlet in a vehicle using ...
Page 22: Storage Compartment
Features 2-4 975-0162-01-01 storage compartment figure 2-3 storage compartment feature description ac charger lets you recharge the xpower powerpack from a standard ac wall outlet and can only be used to recharge the internal battery of the xpower powerpack. The charger can be stored in ac charger c...
Page 23
Xpower powerpack features 975-0162-01-01 2-5 radio (xpower powerpack 400 r only) see “radio operation” on page 3–29 for detailed instructions for using the radio features. Figure 2-4 back panel radio enlargement feature description feature description fm antenna minutes set button frequency indicato...
Page 24: Air Compressor
Features 2-6 975-0162-01-01 air compressor figure 2-5 air compressor features feature description o n /o ff switch turns the compressor unit on and off. Pressure gauge shows the psi (lbs/in2) valve connector with connector hose nozzle adapters (one large and small nozzle adapter, 1 sports needle ada...
Page 25
Xpower powerpack features 975-0162-01-01 2-7 emergency light and jump-start port figure 2-6 emergency light and jump-start port feature description 5 w incandescent light illuminates for about 30 hours when the battery is fully charged. Light on / off switch (400 plus) light on / off /pulse switch (...
Page 26: Accessories
Features 2-8 975-0162-01-01 accessories figure 2-7 accessories and accessory bag feature description red emergency light cover lens stored in the rear compartment (xpower powerpack 400 r only). This cover can turn the 5 w incandescent light into a red “emergency” light when placed over the existing ...
Page 27: Operation
3-1 3 operation chapter 3 explains how to operate the xpower powerpack efficiently. This chapter covers: • choosing a location (page 3–2) • recharging the xpower powerpack (page 3–3) • operating ac appliances (page 3–11) • operating 12 volt dc appliances (page 3–14) • control panel operation (page 3...
Page 28: Choosing A Location
Operation 3-2 975-0162-01-01 choosing a location the xpower powerpack should be operated only in locations that meet the following requirements. Warning: fire or explosion the xpower powerpack contains components that tend to produce arcs or sparks. To prevent fire or explosion, do not operate the x...
Page 29: Battery
Recharging the xpower powerpack battery 975-0162-01-01 3-3 attention: charge before use charge thexpower powerpack for at least 48 hours immedi- ately after purchase. Recharge after each use and once every three months. See “recharging the xpower powerpack bat- tery”. Failure to follow these instruc...
Page 30
Operation 3-4 975-0162-01-01 charging with the ac charger using the ac charger is the simplest method for recharging the battery. While charging from an ac source, the charging status led on the control panel will flash. The led will illuminate steady when the battery has reached capacity. Charging ...
Page 31
Recharging the xpower powerpack battery 975-0162-01-01 3-5 figure 3-2 charging with ac power 1. Ensure the emergency light switch is in the o ff position. (center) ≈ 35 hours charge time (assuming the battery has been fully discharged). 2. Ensure the ac power switch is in the o ff position. 3. Inser...
Page 32
Operation 3-6 975-0162-01-01 charging with the dc-to-dc accessory cable the xpower powerpack comes with a dc charging cable to allow the unit to be charged from a dc source such as an automobile, rv, or boat. The dc charging input port is the dc socket on the front of the unit. The vehicle to be use...
Page 33
Recharging the xpower powerpack battery 975-0162-01-01 3-7 figure 3-3 charging with dc power 1. Insert one end of the dc charging cable into the dc socket on the front unit. Vehicle’s 12 vdc power socket 2. Ensure the vehicle’s engine is running and insert the other end of the dc charging cable into...
Page 34: Outlet
Operation 3-8 975-0162-01-01 recharging with a generator’s regulated 12 vdc outlet refer to the owner’s guide accompanying your generator for detailed instructions on connecting the generator to a unit like the xpower powerpack. You can recharge the battery of the xpower powerpack using a generator ...
Page 35
Recharging the xpower powerpack battery 975-0162-01-01 3-9 recharging from a solar panel small, unregulated 12-volt solar panels can be used to charge the xpower powerpack through the ac charger input socket on the back of the unit. The solar panels must be rated to produce a maximum of 2.5 amps (or...
Page 36: Checking The State-of-Charge
Operation 3-10 975-0162-01-01 checking the state-of-charge important: if using the dc-to-dc accessory cable socket to charge the unit using solar panels, the solar panel must be regulated. Solar panels can rest at up to 18 vdc with full sunlight when batteries are full. This can cause damage to the ...
Page 37: Ac Appliances
Ac appliances 975-0162-01-01 3-11 ac appliances the xpower powerpack has two ac power outlets for use with ac appliances. You can either plug the appliance directly into the ac outlet on the xpower powerpack or you can use an ac power bar to increase the number of outlets available. However, the com...
Page 38: Operating Ac Appliances
Operation 3-12 975-0162-01-01 operating ac appliances low-battery alarm while in use, when the battery reaches 11 vdc, the low-battery alarm will sound indicating that battery is low the unit is about to be shutdown to prevent battery damage. When the battery reaches 10.5 vdc, the unit will automati...
Page 39: Overload Protection
Ac appliances 975-0162-01-01 3-13 overload protection in the event of an overload (> 320 wac) or overheating, the xpower powerpack automatically shuts down. Remove the load. The unit should reset. High surge appliances the wattage rating of ac appliances is the average power used by the appliance. A...
Page 40: 12 Vdc Appliances
Operation 3-14 975-0162-01-01 12 vdc appliances the xpower powerpack can operate one 12 vdc auto, rv, marine, or other portable appliance that draws 12 amps or less from a 12 vdc power outlet or from a vehicle’s accessory socket. The fewer watts a 12 vdc appliance draws, the longer the xpower powerp...
Page 41: Operating Dc Appliances
12 vdc appliances 975-0162-01-01 3-15 operating dc appliances overload protection if the 12 vdc appliance draws more than 12 amps (or has a short-circuit defect), the internal circuit breaker of the xpower powerpack shuts off the power to the 12 vdc appliance. If this occurs, unplug the 12 vdc appli...
Page 42: Control Panel Operation
Operation 3-16 975-0162-01-01 control panel operation figure 3-8 using the control panel how to... Required condition required action note monitor total ac power consumed by the applications powered from the powerpack’s two ac outlets inverter’s on / off switch is turned on ; output power (w) light ...
Page 43
Control panel operation 975-0162-01-01 3-17 monitor battery charging status inverter’s on / off switch is turned to off ; all appliances must be disconnected from the ac and dc power outlets; the on / off switch of the incandescent light must be turned to off ; the ac charger must be plugged into th...
Page 44: Warning: Fire Hazard
Operation 3-18 975-0162-01-01 jump-starting a vehicle’s engine you can use the xpower powerpack to jump-start a vehicle or boat engine that has a 12-volt starting battery using the jump-start cables supplied with the unit. Warning: fire hazard never allow cables’ red and black clamps to touch each o...
Page 45
Jump-starting a vehicle’s engine 975-0162-01-01 3-19 to jump-start a vehicle or boat engine: figure 3-9 using the jump-start cables 975-0162-01-01_rev-c.Book page 19 friday, october 20, 2006 10:40 am.
Page 46: Using The Emergency Light
Operation 3-20 975-0162-01-01 using the emergency light the xpower powerpack has a built-in incandescent light which will operate for about 30 hours before the unit needs to be recharged. The xpower powerpack 400 plus has a two-position off / on switch (located beneath the light’s lens). The xpower ...
Page 47
Using the emergency light 975-0162-01-01 3-21 figure 3-11 using the emergency light off o n /o ff switch is in the center position. On pulse (xpower powerpack 400 r only) o n /o ff switch is in the far right position. O n /o ff switch is in the far left position. 975-0162-01-01_rev-c.Book page 21 fr...
Page 48: Using The Air Compressor
Operation 3-22 975-0162-01-01 using the air compressor warning: fire hazard the compressor is designed for short term operation only. Operating the compressor over an extended period of time will cause the compressor unit to overheat, which could lead to fire. Allow the compressor to cool down for 1...
Page 49
Using the air compressor 975-0162-01-01 3-23 figure 3-12 xpower powerpack air compressor figure 3-13 value connector usage valve connector storage valve connector hose thumb latch pressure gauge o n /o ff switch sports ball needle large adapter small adapter thumb latch open thumb latch closed note ...
Page 50
Operation 3-24 975-0162-01-01 over-temperature safety protection the xpower powerpack is equipped with an over-temperature safety protection feature that automatically turns the compressor off if it begins to exceed a safe operating temperature. Once the compressor cools down to its normal operating...
Page 51: Inflating Tires
Using the air compressor 975-0162-01-01 3-25 if the xpower powerpack shuts off due to an over-temperature condition, turn off the power switch and allow the compressor to cool for 15 minutes before re-starting. Inflating tires the information in table 3-3 is for reference only. For precise pressure ...
Page 52
Operation 3-26 975-0162-01-01 to inflate your vehicle, motorcycle, or bicycle tires: figure 3-15 inflating tires 1. Locate value connector. Remove from storage and uncoil hose. Install a nozzle adapter if necessary. 2. Remove valve stem cap from tire to be inflated. 3. Place valve connector firmly a...
Page 53: Caution
Using the air compressor 975-0162-01-01 3-27 inflating small sports equipment you can use the compressor to inflate small sports equipment such as balls (soccer balls and footballs). To inflate small sports equipment: caution the xpower powerpack cannot be used to inflate large capacity inflatables ...
Page 54: Power Draw
Operation 3-28 975-0162-01-01 using the radio: xpower powerpack 400 r power draw the am/fm radio on the back panel is powered by the internal battery in the xpower powerpack 400 r. When turned on, the radio draws 30 ma, allowing you to use the radio for more than one month when the xpower powerpack ...
Page 55: Radio Operation
Using the radio: xpower powerpack 400 r 975-0162-01-01 3-29 radio operation how to... Required condition required action note listen to the radio press the am band button or the fm band button . To turn off the radio, press the power off button . When radio is on, the station frequency is displayed....
Page 56: Warning: Acid Spills
Operation 3-30 975-0162-01-01 connecting to an external battery you can extend battery operating times by connecting the xpower powerpack to a larger external 12 vdc battery. For example, an external 60 ah battery gives approximately four times the operating time of the xpower powerpack internal 20 ...
Page 57
Connecting to an external battery 975-0162-01-01 3-31 figure 3-18 basic jump-start cable safety do not reverse the polarity of the battery! Only connect to a 12 vdc battery. Do not allow the clamps on the jump-start cable touch each other when connected to the xpower powerpack.! 975-0162-01-01_rev-c...
Page 58
Operation 3-32 975-0162-01-01 to connect the xpower powerpack to an external battery using the jump-start cables: figure 3-19 connecting the xpower powerpack to an external battery to connect the xpower powerpack to an external battery using the jump-start cables: 1. Connect the cables to the jump-s...
Page 59: Maintenance
4-1 4 maintenance chapter 4 provides information on maintaining your internal battery, recharging options for the internal battery, and replacing user-replaceable parts. Routine maintenance is required to keep your xpower powerpack operating properly. Occasionally clean the exterior of the unit with...
Page 60: Battery Life
Maintenance 4-2 975-0162-01-01 replacing the internal battery battery life the high quality battery used in the xpower powerpack will serve as a reliable power source for years when properly maintained. To maximize battery life, it is important to recharge the xpower powerpack battery after each use...
Page 61
Replacing the internal battery 975-0162-01-01 4-3 obtaining a replacement battery when the battery reaches the end of its service life, you may purchase a replacement through an industrial battery supplier. The supplier should specialize in deep-cycle batteries. The recommended replacement batteries...
Page 62
Maintenance 4-4 975-0162-01-01 battery replacement procedure before attempting to replace the internal battery, make sure you: • disconnect any charging cables, 12 volt dc appliances, and ac appliances from the xpower powerpack. • turn off the ac outlet on / off switch and turn off the light switch....
Page 63
Replacing the incandescent light 975-0162-01-01 4-5 4. After removing the old battery, position the new battery close to the back of the xpower powerpack. Make sure the positive battery terminal is next to the red positive (+) internal cable and the black negative terminal is next to the black negat...
Page 64: Replacing The External Fuse
Maintenance 4-6 975-0162-01-01 replacing the external fuse the replacement fuse must be rated at 250 a, 32 vdc. (mega fuse - 2 11/16" x 3/4" holes: 2" on center. Max. 32-volt dc) to replace the external fuse: figure 4-2 replacing the fuse 1. Locate the fuse cover inside the storage compartment of xp...
Page 65: Recycling
Recycling 975-0162-01-01 4-7 recycling the xpower powerpack is designed to provide years of service. However, when the internal battery reaches the end of its service life, you will need to replace it as described in your manual. Because the internal battery contains lead, which can be hazardous if ...
Page 66
Maintenance 4-8 975-0162-01-01 975-0162-01-01_rev-c.Book page 8 friday, october 20, 2006 10:40 am.
Page 67: Specifications
A-1 a specifications chapter a, “specifications” includes the electrical, mechanical, and environmental specifications for the xpower powerpack. Electrical specifications \ 12 v dc section internal battery type sealed, agm (absorbed glass mat) lead acid internal battery voltage (nominal) 12 vdc inte...
Page 68
Specifications a-2 975-0162-01-01 ac power section output power • continuous output power • five minute ac output power • ac output surge capacity 320 w 400 w 600 w output voltage 115 ± 10 vac rms output frequency 60 hz ± 4 hz output wave form modified sinewave no load current draw input voltage ran...
Page 69
Electrical specifications 975-0162-01-01 a-3 air compressor pressure 250 psi (lb./in 2 ) radio (xpower powerpack 400 r only) am frequency 526–1606 khz fm frequency 87-109 mhz accessories jump-start cables (replacement part # 449-0207-01-01) 24" (0.61 m), 4 awg wire with black and red battery clamps ...
Page 70: Physical Specifications
Specifications a-4 975-0162-01-01 physical specifications physical specifications xpower powerpack 400 plus xpower powerpack 400 r depth 8" (20.3 cm) 8" (20.3 cm) width 16" (40.8 cm) 16" (40.8 cm) height 9 ½" (24.1 cm) 9 ½" (24.1 cm) weight 21.8 lb. (9.9 kg) 23 lb. (10.5 kg) important: all specifica...
Page 71: Troubleshooting
5-1 5 troubleshooting troubleshooting will help you identify the common problems than can occur with the xpower powerpack. Read this chapter before calling customer service. If you cannot solve the problem with the xpower powerpack, record the information asked for on “information about your system”...
Page 72: Troubleshooting Reference
Troubleshooting 5-2 975-0162-01-01 troubleshooting reference warning: electric shock hazard do not remove the cover of the xpower powerpack or disassemble the xpower powerpack except to replace the internal battery or 250 a fuse. The xpower powerpack does not contain any internal user-serviceable pa...
Page 73
Troubleshooting reference 975-0162-01-01 5-3 over- temperature shutdown inverter has overheated due to poor ventilation or excessively warm environmental conditions. Turn off the ac outlet on / off switch and let the xpower powerpack cool down. Disconnect the 12vdc appliance and let the xpower power...
Page 74
Troubleshooting 5-4 975-0162-01-01 run time is less than expected. Internal battery is not fully charged. Ac appliance power consumption is higher than expected. Recharge using the ac charger, until green charging status light is steady. Check ac appliance power or wattage rating (or current draw fo...
Page 75
Troubleshooting reference 975-0162-01-01 5-5 green charging status light is still flashing and hasn’t changed to steady after 50 hours of charging. The voltage at the ac wall outlet is less than 120 vac. Internal battery is permanently damaged. Use ac wall outlet that supplies 120 vac. Replace the b...
Page 76
Troubleshooting 5-6 975-0162-01-01 the battery clamps of the jump-start cables measure zero volts. External fuse (250 a) is blown. Replace 250 a, 32 v fuse with same type and ratings. See “replacing the external fuse” on page 4–6. The light does not turn on. Light bulb has burnt out. Remove lens cov...
Page 77: Warranty and Return
Wa-1 warranty and return warranty what does this warranty cover? This limited warranty is provided by xantrex technology inc. ("xantrex") and covers defects in workmanship and materials in your xpower powerpack 400 plus and xpower powerpack 400 r. This warranty period lasts for 6 months from the dat...
Page 78: Disclaimer
Warranty and return wa-2 975-0162-01-01 what does this warranty not cover? This limited warranty does not cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This warranty does not apply to and xantrex will...
Page 79: Exclusions
Warranty and return 975-0162-01-01 wa-3 exclusions if this product is a consumer product, federal law does not allow an exclusion of implied warranties. To the extent you are entitled to implied warranties under federal law, to the extent permitted by applicable law they are limited to the duration ...
Page 80: Return Procedure
Warranty and return wa-4 975-0162-01-01 return procedure 1. Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged du...
Page 81
Warranty and return 975-0162-01-01 wa-5 information about your system as soon as you open your xpower powerpack 400 plus and xpower powerpack 400 r package, record the following information and be sure to keep your proof of purchase. If you need to contact customer service, please record the followi...
Page 82
Wa-6 975-0162-01-01_rev-c.Book page 6 friday, october 20, 2006 10:40 am.