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.
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.
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. 975-0162-01-01...
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. Important: Before using your XPower Powerpack 400 Plus and XPower Powerpack 400 R, be sure to read and save these safety instructions.
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Important Safety Instructions Figure i Basic Safety 975-0162-01-01...
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Important Safety Instructions 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.
Important Safety Instructions 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.
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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.
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 Plus and XPower Powerpack 400 R.
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: •...
Introduction 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.
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 unsatisfactory in any way, please contact Customer Service, see Appendix Figure 2-1 Package Contents...
Features XPower Powerpack Features Front Panel DC Socket Cover Figure 2-2 Front Panel Enlargement Control Panel AC Outlet Cover 975-0162-01-01...
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Feature Description DC Power Socket can: • Power 12 volt DC auto, RV, or marine appliances. • Recharge using the DC Charging Cable. Two AC Outlets are standard 3-prong outlets supplying 120 Vac power for running AC appliances. AC Outlet Outlets.
Features 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 compartment or in the Accessory Bag.
Radio (XPower Powerpack 400 R only) See “Using the Radio: XPower Powerpack 400 R” on page 3–28. Figure 2-4 Back Panel Radio Enlargement Feature Description FM antenna Frequency indicator light Power O Time set button Tuning dial Hours set button See “Radio Operation”...
Features Air Compressor IMPORTANT: 250 psi Maximum. Nozzle Adapters: Figure 2-5 Air Compressor Features Feature Description Pressure gauge shows the PSI (lbs/in2) Valve connector with connector hose Nozzle Adapters (one Large and Small Nozzle adapter, 1 sports needle adapter) Small Nozzle Adapter Large Nozzle Adapter 1 Sports Needle Adapter switch turns the compressor unit on and off.
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 Light Jump-Start Cable Port supplies high power DC current. The cables connect to the Jump-Start Cable Port when jump-starting a vehicle’s battery or when connecting an external battery to the XPower Powerpack.
Features 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 clear lens.
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) •...
Operation Choosing a Location 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 XPower Powerpack in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment.
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 instructions will void the product warranty.
Operation 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 using this method can take approximately 35 hours assuming the battery is fully-discharged and that there is a full 120 volts of power at the AC wall outlet being used.
Ensure the Emergency Light Switch is in the position. (Center) Insert the AC Charging plug into the Charger Input Socket inside the Storage Compartment on the back of the unit. Figure 3-2 Charging with AC Power 975-0162-01-01 Recharging the XPower Powerpack Battery Ensure the AC Power Switch is in the O AC Charging...
Operation Charging with the DC-to-DC Accessory Cable WARNING: Fire and explosion hazard Do not use this recharging method if your vehicle has abnormally high voltage electrical systems that operate above 15 Vdc. This may lead to accumulations of hydrogen, causing exposure to fire and explosion hazard.
Insert one end of the DC Charging Cable into the DC Socket on the front unit. Ensure the vehicle’s engine is running and insert the other end of the DC Charging Cable into the 12 Vdc Accessory Socket in the vehicle. Figure 3-3 Charging with DC Power 975-0162-01-01 Recharging the XPower Powerpack Battery...
Operation Recharging with a Generator’s Regulated 12 Vdc Outlet WARNING: Fire and explosion hazard The generator output must be intended for battery charging and have an output of 15 volts or less. An unregulated output or one that exceeds 15 Vdc can damage the battery. This may lead to accumulations of hydrogen, causing exposure to fire and explosion hazard.
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 30 watts) maximum. Some panels may already come with the appropriate hardware.
Operation 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 battery. This kind of damage is not covered under the warranty.
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.
Operation Operating AC Appliances Figure 3-6 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.
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. Appliances such as televisions, computer monitors and appliances with motors consume much more power than their average rating when they are first switched on.
Operation 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 Powerpack will operate before recharging is required.
Operating DC Appliances 1. Check the State-of-charge to ensure the battery is fully charged. 2. To enable the low-battery alarm, open the AC Outlet cover and turn the power switch to ON. 3. Plug the DC appliance into the DC socket and turn the appliance on (if required).
Operation Control Panel Operation Front Figure 3-8 Using the Control Panel Required How to... Condition Monitor total Inverter’s AC power switch is turned consumed by Output Power (W) light illuminates applications (green); powered from AC charger is unplugged from the Powerpack’s wall AC outlet.
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Required How to... Condition Monitor Inverter’s Battery switch is turned to Charging status All appliances must be disconnected from the AC and DC power outlets; the incandescent light must be turned to The AC charger must be plugged into the Powerpack’s Charger Input Socket and also in to a household AC...
Operation 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 other or another common metal conductor.
Operation 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 switch (located beneath the light’s lens). The XPower Powerpack 400 R has a three-position /Pulse switch.
PULSE (XPower Powerpack 400 R only) Figure 3-11 Using the Emergency Light 975-0162-01-01 Using the Emergency Light Switch is in the CENTER position. Switch is in the FAR RIGHT position. Switch is in the FAR LEFT position. 3-21...
Operation 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 10 minutes after each 10 minutes of continuous operation.
Pressure Gauge Valve Connector Storage Figure 3-12 XPower Powerpack Air Compressor Thumb Latch OPEN Note Leave the thumb latch in the OPEN position for storing to relieve pressure on the internal mechanisms. Figure 3-13 Value Connector Usage 975-0162-01-01 Using the Air Compressor Hose Thumb Latch Switch...
Operation Ready to use Figure 3-14 Nozzle Adapter Usage 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 temperature it will automatically turn on again and continue inflating.
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 specifications, refer to the information supplied with the article to be inflated.
Operation To inflate your vehicle, motorcycle, or bicycle tires: 1. Locate Value Connector. Remove from storage and uncoil hose. Install a nozzle adapter if necessary. 3. Place Valve Connector firmly and completely over valve stem on the tire. 4. Press the Thumb Latch toward the hose until it locks into place. 5.
Inflating Small Sports Equipment You can use the compressor to inflate small sports equipment such as balls (soccer balls and footballs). CAUTION The XPower Powerpack cannot be used to inflate large capacity inflatables such as float tubes, large air mattresses, and inflatable boats.
Operation 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 400 R is fully charged.
Radio Operation Required How to... Condition Listen to the radio Set the clock Turn off the radio to show the time. Set the alarm Turn off the radio to show the time. Use the Set the alarm clock alarm, turn off radio to show time.
Operation 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 Ah battery.
Do NOT reverse the polarity of the battery! Do NOT allow the clamps on the Jump-start cable touch each other when connected to the XPower Powerpack.! Figure 3-18 Basic Jump-start Cable Safety 975-0162-01-01 Connecting to an External Battery Only connect to a 12 Vdc Battery.
Operation 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 3-32 To connect the XPower Powerpack to an external battery using the jump-start cables: 1. Connect the cables to the Jump-Start Cable Port on the left side of the XPower Powerpack.
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 a damp cloth to remove the accumulated dust and dirt.
Maintenance Replacing the Internal Battery WARNING: Shock or electrical hazard Read this entire section before disassembling the unit. WARNING If you do not know how to safely remove and install batteries, have this task performed by a qualified service technician. WARNING: Fire hazard When installing the replacement battery, make sure the battery polarity is correct.
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 are standard sizes used for a variety of applications (not just the Powerpack), so you may rest assured that the battery will continue to be widely available many years into the future.
Maintenance 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 light switch. • Remove the jump-start cables. Figure 4-1 Accessing the Internal Battery for Replacement To replace the battery: 1.
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 negative (–) internal cable. 5.
Maintenance 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: AC Charging Input Socket Fuse Cover Unscrew these two bolts to remove the fuse.
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 exposed to the environment, the old internal battery should be recycled or safely disposed of at your local recycling depot.
Specifications Chapter A, “Specifications” includes the electrical, mechanical, and environmental specifications for the XPower Powerpack. Electrical Specifications 12 V DC Section Internal battery type Internal battery voltage (nominal) Internal battery capacity (minimum) Internal battery CCA rating DC Power Socket (maximum continuous load) Built-in incandescent light (replaceable) Jump-start cable port Jump-start fuse (external—user replaceable,...
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Specifications AC Power Section Output power • Continuous output power • Five minute AC output power • AC output surge capacity Output voltage Output frequency Output wave form No load current draw Input voltage range Low battery alarm Low battery shutdown High battery voltage shutdown Over temperature shutdown Overload shutdown...
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Air Compressor Pressure Radio (XPower Powerpack 400 R only) AM Frequency FM Frequency Accessories Jump-start cables (replacement part # 449-0207-01-01) DC-to-DC charge cable (replacement part # 449-0187-01-01) AC Charger input cable (replacement part # 074-1004) Nozzle adaptor (for air compressor, (replacement part # 160-0015-01-01) Incandescent Light Bulb 975-0162-01-01...
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”...
Troubleshooting 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 parts and attempting to service the unit yourself could result in electrical shock or burn.
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Table 5-1 Troubleshooting reference Problem Possible Cause Over- Inverter has temperature overheated due to poor shutdown ventilation or excessively warm environmental conditions. Alarm sounds Internal battery is nearly discharged. (11.0 V). If you ignore this warning, the XPower Powerpack automatically switches off when the battery reaches 10.5 V.
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Troubleshooting Table 5-1 Troubleshooting reference Problem Possible Cause Run time is Internal battery is not less than fully charged. expected. AC appliance power consumption is higher than expected. Charging No AC power at the Status light is AC wall outlet. when AC Charger is AC Charger is faulty.
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Table 5-1 Troubleshooting reference Problem Possible Cause Green The voltage at the AC Charging wall outlet is less than Status light is 120 Vac. still flashing and hasn’t Internal battery is changed to permanently damaged. steady after 50 hours of charging.
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Troubleshooting Table 5-1 Troubleshooting reference Problem Possible Cause The battery External fuse (250 A) clamps of the is blown. jump-start cables measure zero volts. The light does Light bulb has burnt not turn on. out. The AM radio The XPower does not work Powerpack AC outlets or buzzes...
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 date of purchase at the point of sale to you, the original end user customer.
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Warranty and Return 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 not be responsible for any defect in or damage to: a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either internally or externally, or damaged from improper use or...
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 of this Limited Warranty. Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.
This warranty will not apply where the product is damaged due to improper packaging. 2. Include the following: • The RMA number supplied by Xantrex Technology Inc. clearly marked on the outside of the box. • A return address where the unit can be shipped. Post office boxes are not acceptable.
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. ❐ Serial Number ❐ Purchased From ❐ Purchase Date If you need to contact Customer Service, please record the following details before calling.