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.
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.
Xpower™ Powerpack 400 and 400 Plus Owner’s Guide
© October 2005 Xantrex International. All rights reserved.
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.
October 2005 Revision B
975-0057-01-01
Phone: 1 360-925-5059
Fax:
1 360-925-5143
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.
Important: These notes describe an important action item
or an item that you must pay attention to.
i
About This Guide
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
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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.
CAUTION
Do not connect any AC appliance with the neutral conductor
connected to ground to the XPower Powerpack 400 and
XPower Powerpack 400 Plus.
iii
Important Safety Instructions
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 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 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.
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.
iv
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Important Safety Instructions
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 400 and XPower Powerpack 400 Plus
to cool down for at least 3 minutes after each jump-start.
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.
975-0057-01-01
v
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 lead-
acid 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.
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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.
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vii
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.
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Contents
Important Safety Instructions
Warnings and Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - iii
Precautions When Working With Batteries- - - - - - - - - - - - - - - vi
Precautions for Using Rechargeable Appliances - - - - - - - - - - viii
1
2
Introduction
About the XPower Powerpack - - - - - - - - - - - - - - - - - - - - - - 1–1
Comprehensive Protection - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Automatic overload- - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–1
Low Battery Protection - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Jump-Start Cables Safety Feature - - - - - - - - - - - - - - - - - 1–2
Features
Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–1
XPower Powerpack Features - - - - - - - - - - - - - - - - - - - - - - - 2–2
Front Panel Detail- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Air Compressor (XPower Powerpack 400 Plus only) - - - - 2–5
Left Side View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Storage Compartment - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
3
Operation
Operating Conditions and Guidelines - - - - - - - - - - - - - - - - - 3–1
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Using XPower Powerpack for the First Time - - - - - - - - - - - - 3–3
Recharging with the AC Charger - - - - - - - - - - - - - - - - - - - - 3–3
Using the light - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
ix
Operating AC Appliances - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Understanding AC Appliances - - - - - - - - - - - - - - - - - - - 3–5
Run Time on Typical AC Appliances - - - - - - - - - - - 3–5
High Surge Appliances - - - - - - - - - - - - - - - - - - - - - 3–6
Trouble Appliances - - - - - - - - - - - - - - - - - - - - - - - 3–6
Operating Several Appliances at Once - - - - - - - - - - - 3–7
Operating an AC Appliance - - - - - - - - - - - - - - - - - - - - - 3–7
Operating 12 V DC Appliances - - - - - - - - - - - - - - - - - - - - - 3–8
Jump-Starting a Vehicle’s Engine - - - - - - - - - - - - - - - - - - - -3–10
Using the Air Compressor: XPower Powerpack 400 Plus - - - -3–12
Over-Temperature Safety Protection - - - - - - - - - - - - - - -3–13
Inflating Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13
Inflating Small Sports Equipment - - - - - - - - - - - - - - - - -3–15
Connecting to an External Battery- - - - - - - - - - - - - - - - - - - -3–16
4
Maintenance
Battery Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–1
Recharging the XPower Powerpack Battery - - - - - - - - - - - - - 4–2
Recharging with the AC Charger- - - - - - - - - - - - - - - - - - 4–2
Recharging with the DC Charging Cable - - - - - - - - - - - - 4–3
Recharging with a Generator’s Regulated 12 V DC Outlet 4–6
Recharging From a Solar Panel- - - - - - - - - - - - - - - - - - - 4–7
Replacing the Internal Battery - - - - - - - - - - - - - - - - - - - - - - 4–7
Battery Life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Obtaining a Replacement Battery - - - - - - - - - - - - - - - - - 4–8
Replacing the Battery - - - - - - - - - - - - - - - - - - - - - - - - - 4–9
Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–11
Replacing the Incandescent Light - - - - - - - - - - - - - - - - - - - -4–11
Replacing the External Fuse- - - - - - - - - - - - - - - - - - - - - - - -4–12
x
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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–3
Warranty and Return - - - - - - - - - - - - - - - - - - - - - - - - WA–1
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xii
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 V
DC appliances whenever you need power for work or play, at
home or on the road.
XPower Powerpack:
•
•
•
•
Powers 115 V AC appliances
Powers 12 V DC appliances
Jump-starts vehicle engines
Provides lighting for emergency use
In addition, the XPower Powerpack 400 Plus:
•
Comes with a 250 psi air compressor for inflating tires
and small sports equipment.
Comprehensive Protection
Automatic overload
The XPower Powerpack has built-in protection against output
overload. If you connect to the AC Outlet(s) an appliance that
draws more than 320 W, or one which draws excessive surge
power, the power to the AC Outlet automatically shuts off.
Overheating
The XPower Powerpack is protected from overheating. If the
inverter exceeds a safe temperature, power to the AC Outlet
automatically shuts off.
1-1
Introduction
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 (11.0 V DC)
and the unit turns off at 10.5 V DC.
Jump-Start Cables Safety Feature
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.
1-2
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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.
Materials List
Your XPower Powerpack package includes these items:
p
p
p
p
p
p
XPower Powerpack 400 or XPower Powerpack 400 Plus
Owner’s Guide
AC Charger
DC Charging Cable
Jump-Start Cables
Accessory bag
The XPower Powerpack 400 Plus also includes:
p
p
two nozzle adaptors for the compressor
One sports needle adaptor for the compressor
If any of these materials are missing or are unsatisfactory in
any way, please contact Customer Service, see Appendix
WA.
2-1
Features
XPower Powerpack Features
Front Panel Detail
5
6
7
4
8
3
2
1
XPower Powerpack Features
1
DC Power Socket can:
•
•
Power 12 V DC auto, RV or marine appliances
Recharge XPower Powerpack from a 12 V outlet in a vehicle
using the DC Charging Cable.
2
3
2 AC Outlets are standard 3-prong outlets supplying 120 V AC
power for running an AC appliance.
AC Outlet ON/OFF switch illuminates when the switch is turned
on.
2-2
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XPower Powerpack Features
4
5
Digital Display displays the inverter’s Output Power in W and
Battery Charge status in % FULL.
Charging Status light illuminates when the XPower Powerpack
is in Charging Status mode (i.e. AC Charger is connected to the
inverter’s Charger Input Socket and plugged into the household
120 V AC outlet).
6
7
8
Battery Charge % light illuminates (green) when Battery Charge
information is displayed on the Digital Display.
Output Power (W) light illuminates (green) when Output Power
information is displayed on the Digital Display.
Display Function button, when pressed, allows for reading Battery
Charge status on the Digital Display. Toggles Digital Display’s
power ON/OFF.
Not
Audible Alarm (inside the unit) sounds in the event of overheating
shown or low battery protection on inverter.
Control Panel Operation
Monitor total
AC power
consumed by
the
Inverter’s ON/OFF
switch is turned ON;
Output Power (W)
light illuminates
(green);
No action required.
The Digital Display
will show the AC
power drawn from the run time, press Display
inverter by the Function button to turn
In order to save the
battery power and
ensure longer inverter
applications
powered from AC charger is
applications powered off the Digital Display.
the
unplugged from the
from the Powerpack’s Press Display Function
Powerpack’s 2 wall AC outlet.
AC outlets
AC outlets.
button again to turn the
display On for AC
power reading.
975-0057-01-01
2-3
Features
Monitor
Battery
Charging
status
Inverter’s ON/OFF
switch is turned to
OFF;
No action required.
A flashing green
Recharging with the
supplied AC charger is
a true “plug-in-and-
forget” charging
All appliances must be Charging Status
disconnected from the light indicates that the method.
AC and DC power
outlets;
Powerpack’s battery
needs recharging and the AC charger
We recommend leaving
The ON/OFF switch
of the incandescent
light must be turned to
OFF;
that the AC charger is connected when the
charging the battery.
Powerpack is not in use
to permanently
A steady green
maintain the battery in
fully charged condition.
The AC charger must Charging Status
be plugged into the
Powerpack’s Charger
light indicates that the
Powerpack’s battery
Input Socket and also is fully charged and
in to a household AC
outlet.
the Powerpack is
ready for use.
Check Battery Inverter’s ON/OFF
Push and hold the
Display Function
button.
This function is
Charge status
switch is turned to
OFF;
disabled when the AC
charger is plugged in to
the Charger Input
All appliances must be
disconnected from the The green Battery
Socket, or when the
AC and DC power
outlets;
Charge (%) light will inverter main switch is
come on and the
ON.
The ON/OFF switch
of the incandescent
Digital Display will
show the remaining
For accurate Battery
Charge reading, allow
light must be turned to battery capacity in %. 15 minutes between
OFF;
charging/use and
The AC charger must
not be plugged into
the Powerpack’s
Charger Input Socket.
battery capacity check.
2-4
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XPower Powerpack Features
Air Compressor (XPower Powerpack 400 Plus only)
2
1
3
1
2
On/Off switch turns the compressor unit on and off.
2
Pressure gauge shows the PSI (lb./in )
3
Valve connector with connector hose
Nozzle Adaptor Compartment is integrated into AC charger compartment.
975-0057-01-01
2-5
Features
Left Side View
1
2
3
4
1
5 W incandescent light illuminates for about 30 hours when the
battery is fully charged.
2
3
Light On/Off Switch
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. The jump-start cable connection is designed
so that the cables cannot be inserted incorrectly into the Jump-Start
Cable Port.
4
Plastic Guard for covering jump-start cable port.
2-6
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XPower Powerpack Features
Storage Compartment
3
4
5
2
1
XPower Powerpack 400 Plus shown
1
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. Can be stored in AC
charger compartment.
2
3
Charger Input Socket for use with the AC Charger supplied (see
1).
External Replaceable Fuse is rated at 250 A, 32 V. Located
behind fuse cover.
4
5
Compressor Nozzle Adaptor Compartment
AC Charger Compartment may be used for storing the AC
Charger.
975-0057-01-01
2-7
Features
Accessories
1
2
3
1
2
Detachable heavy-duty jump-start cables
DC Charging Cable lets you recharge the XPower Powerpack
from a 12 V system in a car, SUV, RV or a boat. This can be stored
in the storage compartment.
3
Accessory bag
Not
Shown
Nozzle packet (XPower Powerpack 400 Plus only) contains 2
nozzle adaptors and sports needle adaptor, in the storage
compartment on the back of the unit.
2-8
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3
Operation
Chapter 3 explains how to operate the XPower Powerpack
efficiently. This chapter covers:
•
•
•
•
•
•
Recharging the XPower Powerpack for first time use
Using the built in light
Operating AC appliances and 12 V DC appliances
Jump-starting a vehicle’s engine
Connecting to an external battery for additional run time
Using the compressor on the XPower Powerpack 400
Plus.
Operating Conditions and Guidelines
CAUTION
Read all operating instructions before operating the XPower
Powerpack.
CAUTION
Do not use the XPower Powerpack to operate any AC
appliances or 12 V DC appliances while recharging with the
AC Charger.
The AC Charger may fail if AC appliances or 12 V DC
appliances are operated while the AC Charger is connected.
CAUTION
The XPower Powerpack is not intended for use as a UPS
(Uninterruptible Power Supply).
3-1
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.
The XPower Powerpack should be operated only in a location
that meets these requirements:
:
Do not allow water or other liquids to drop or splash on the
XPower Powerpack.
Ambient air temperature should be between 32 and 104ºF
(0 and 40ºC)—the cooler the better within this range.
Leave at least 2" (5 cm) clearance around the XPower
Powerpack for air flow. Ensure that the ventilation
openings are not obstructed.
Do not operate the unit in the same compartment as
batteries or in any compartment capable of storing
flammable liquids like gasoline.
Do not operate the unit where it will be exposed to battery
gases. These gases are very corrosive, and prolonged
exposure will damage the XPower Powerpack.
3-2
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Using XPower Powerpack for the First Time
Using XPower Powerpack for the First Time
n
Important: Prior to operating your AC appliance or 12 V
DC appliance, ensure that the battery of the XPower
Powerpack is fully charged. If the battery has been fully
discharged, recharging with the AC Charger may take up to
35 hours.
Recharging with the AC Charger
Note: The Battery Charge (%) reading on the digital
display is only accurate when the XPower Powerpack has
been disconnected from all appliances and all charging
sources for fifteen minutes.
Recharging with the AC Charger is a true “plug-in-and-
forget” charging method. We recommend leaving the AC
Charger connected when the XPower Powerpack is not in
use.
To recharge with the AC Charger:
1. Disconnect any 12 V DC appliances and turn the light
off.
2. Turn the AC Outlet On/Off switch to Off.
3. Plug the AC Charger into a standard AC wall outlet.
4. Insert the AC Charger cable end into the Charger Input
Socket located in the storage compartment of the unit.
The green Charging Status light changes from flashing to
steady when charging is complete (about 35 hours if the
battery is completely discharged).
975-0057-01-01
3-3
Operation
Important: The 35 hour charging time for the XPower
Powerpack assumes that there is 120 V at the AC wall
outlet. If the voltage is less than 120 V AC, it may take more
than 35 hours to fully recharge the XPower Powerpack. If,
after 35 hours of charging, the green Charging Status light
is still flashing, continue to charge the unit for another 15
hours.
Important: If you keep the XPower Powerpack in storage,
the battery will discharge over time. Remember to recharge
the battery every three months to keep the XPower
Powerpack operational.
Note: Once fully charged, the charging current
automatically reduces to a maintenance charge mode, and
the XPower Powerpack may be left permanently connected
to the AC Charger.
Using the 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 ON/OFF switch is located beneath the
light. The light can be adjusted up and down by pushing
against the top or bottom of the rim around the lens.
3-4
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Operating AC Appliances
Operating AC Appliances
Understanding AC Appliances
AC appliances are rated by how much electrical power (in
watts) they consume. XPower Powerpack can power most
appliances within its continuous power rating (320 W, 2.7 A).
Some appliances may be difficult or impossible to operate
from the XPower Powerpack. They may have high surge
requirements or should not be run from the XPower
Powerpack. See “High Surge Appliances” on page 3–6 and
“Trouble Appliances” on page 3–6.
Run Time on Typical AC Appliances
Note: The fewer watts an AC appliance uses, the longer the
XPower Powerpack will operate before recharging is
required.
Typical AC appliances that can be used on the XPower
Powerpack are listed in Table 3-1.
Table 3-1 AC Appliances and Run Times
Cordless telephone (stand by)
Home security system
Clock radio
5
40
5
40
8
22
Portable stereo
10
14
20
25
40
60
190
17
Fluorescent work light
Fireplace fan
10
8
Laptop computer
Table lamp
6
3
Color TV – 13"
3/8 “ drill
2 h 30 min.
20 min.
a. Represents actual power consumption as measured on sample appliances.
b. Operating times assume a fully charged 20 Ah battery and may vary based
on model/brand of appliance.
975-0057-01-01
3-5
Operation
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.
Although XPower Powerpack can supply momentary surge
power up to 600 W, some appliances may exceed the
capabilities of the XPower Powerpack and trigger the
inverter’s safety overload shutdown circuit.
Trouble Appliances
t
CAUTION
The output of the Powerpack’s inverter is non-sinusoidal.
Some equipment may be damaged by the inverter’s modified
sine wave output (non-sinusoidal).
Some appliances, including the types listed below, may be
damaged if they are connected to the inverter:
•
•
•
Electronics that modulate RF (radio frequency) signals
on the AC line will not work and may be damaged.
Speed controllers found in some fans, power tools,
kitchen appliances, and other loads may be damaged.
Some chargers for small rechargeable batteries can be
damaged. See “Precautions for Using Rechargeable
Appliances” on page viii for details.
•
Metal halide arc (MHI) lights can be damaged.
Note: If you are unsure about powering any device with the
inverter, contact the manufacturer of the device.
3-6
975-0057-01-01
Operating AC Appliances
Operating Several Appliances at Once
You can run several AC appliances if the total rating of all the
appliances (in watts) does not exceed 320 W. You can run
appliances using an AC power bar.
Run time, however, will decrease accordingly with the
number of appliances being operated and the AC power being
consumed.
Operating an AC Appliance
Before operating your AC appliance, ensure that the battery
of the XPower Powerpack is fully charged. See “Recharging
with the AC Charger” on page 3–3 for details.
To operate an AC appliance:
1. Open the protective covering on the right side of the
XPower Powerpack. Turn the AC Outlet On/Off switch
to the On position.
The switch illuminates to indicate AC power is available
at the AC Outlets.
2. Plug the AC appliance into one of the AC Outlets and
turn the appliance on. XPower Powerpack will operate
most devices rated up to 320 W.
3. Recharge the XPower Powerpack as soon as possible
after each use.
When using the XPower Powerpack to operate an AC
appliance and the low battery warning sounds, the
warning gives you time to shut your AC appliance off
before loss of AC power.
If you ignore the warning, the XPower Powerpack
automatically turns off a few minutes later to prevent
battery damage.
In the event of an overload, low battery voltage or
overheating, the XPower Powerpack automatically shuts
down.
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3-7
Operation
Operating 12 V DC Appliances
The XPower Powerpack can operate 12 V DC auto, RV,
marine, or other portable appliances that draw 12 A or less
from a 12 V DC power outlet or from a vehicle’s lighter
socket.
CAUTION Equipment damage
The DC Power Socket does not automatically switch off
when the internal battery is discharged. To protect the
internal battery against damage resulting from total
discharge, We recommend that the AC Outlet On/Off switch
is turned On when using the XPower Powerpack to operate a
12 V DC appliance.
Having the AC Outlet On/Off switch turned On enables the
alarm to warn you when the 12 V DC appliance has nearly
depleted the internal battery.
Note: The fewer watts a 12 V DC appliance draws, the
longer the XPower Powerpack will operate before
recharging is required.
3-8
975-0057-01-01
Operating 12 V DC Appliances
Typical 12 V DC appliances that can be used on the XPower
Powerpack are listed in Table 3-2.
Table 3-2 12 V DC Appliances and Run Times
5 W incandescent light (built
into the unit)
5
6
30
30
c
Cellular telephone
Stereo/CD player
Portable Cooler
10
30
17
4
a. Represents actual power consumption as measured on sample appliances.
b. Operating times assume a fully charged 20 Ah battery and may vary based
on model or brand of appliance.
c. Represents talks time available from 10 recharge cycles.
To operate a 12 V DC appliance:
1. Open the protective cover on the left side of the XPower
Powerpack.
2. Plug the 12 V DC appliance into the DC power socket on
the left side of the unit, and turn the 12 V DC appliance
on (if required).
If the 12 V DC appliance draws more than 12 A (or has a
short-circuit defect), the internal circuit breaker of the
XPower Powerpack shuts off the power to the 12 V DC
appliance. If this occurs, unplug the 12 V DC appliance,
and the internal circuit breaker automatically resets after
a few seconds.
3. Fully recharge the XPower Powerpack as soon as
possible after each use.
As the DC power socket is internally wired directly to the
internal battery, extended operation of a 12 V DC
appliance may result in excessive battery discharge. See
Caution for “Equipment damage” on page 3–8.
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3-9
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 V starting battery using the plied
Jump-Start Cables.
WARNING: Fire hazard
Never allow 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 clamps for the unit after use and clip
the plastic guard over the jump-start cable port.
WARNING: Fire hazard
Jump-start cable clamps’ connection to the vehicle’s battery
terminals must be 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: 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.
Important: Closely follow these instructions for jump-
starting your vehicle as they may be different from the
instructions supplied with other jump-start products or
jump-start cables.
3-10
975-0057-01-01
Jump-Starting a Vehicle’s Engine
To jump-start a vehicle or boat engine:
1. Turn off the vehicle or boat ignition and all accessories.
2. Engage the park or emergency brake and place the
transmission in park for an automatic or neutral for a
manual.
3. If jump-starting a boat engine, purge the engine
compartment and bilge of all fumes before jump-starting.
4. Connect the cables to the Jump-Start Cable Port on the
left side of the XPower Powerpack.
5. Position the XPower Powerpack on a flat, stable surface
near the battery and away from all moving parts of the
engine.
6. Connect the red positive (+) clip of the cables to the
positive (+) terminal of the engine battery.
The battery’s positive terminal is usually larger in
diameter than the negative terminal. In most vehicles, the
battery’s positive terminal has a red wire connected to it.
7. Connect the black negative (–) clip of the cables to the
engine block, cylinder head, or other stationary heavy
metal part of the motor, or to the negative (–) battery
terminal.
Before starting the engine, make sure the XPower
Powerpack and the cables are clear of belts and fans. Do
not crank the engine for more than 4 seconds.
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.
8. Remove the red positive (+) clip and then the black
negative (–) clip from the vehicle’s battery terminal.
9. Remove the cables from the Jump-Start Cable Port.
975-0057-01-01
3-11
Operation
Important: Recharge the XPower Powerpack as soon as
possible after each use. See “Recharging the XPower
Powerpack Battery” on page 4–2.
Using the Air Compressor: XPower
Powerpack 400 Plus
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.
WARNING: Fire Hazard
Do not leave the compressor unattended while in operation.
Keep out of reach of children.
WARNING: Risk of personal injury or
damage to equipment
Never leave the compressor unattended while in operation.
The compressor is capable of inflating to 250 PSI. Do not
exceed the recommended pressure of either the compressor or
the object being inflated. If either recommended pressure is
exceeded, an explosion may result.
3-12
975-0057-01-01
Using the Air Compressor: XPower Powerpack 400 Plus
Over-Temperature Safety Protection
It is recommended that you follow the warnings and turn the
compressor off for 10 minutes after every 10 minutes of
operation. However, the XPower Powerpack 400 Plus is
equipped with an over-temperature safety protection feature
that automatically turns the compressor off if it begins to
overheat. Once the compressor cools down to its normal
operating temperature it will automatically turn on again and
continue inflating. You should turn the compressor off at the
power switch if this safety feature engages, and allow the
compressor to cool for 15 minutes before re-starting.
WARNING: Risk of personal injury or
damage to equipment
Never leave the compressor unattended once it has switched
itself off due to overheating. It will turn on again and continue
inflating when its internal temperature drops.
Turn the compressor off at the power switch after each use or
any time the compressor turns off automatically.
Inflating Tires
Table 3-3 Pressure Specifications for Common Items
520-13
26
26
30
24
Football
13
9
A-78-14
E78-14
H-78-14
Basketball
Volleyball
5
Lawn Tractor Tire
22
HR-78-15
28
27-1 ¼
20-1 ½
85
40
975-0057-01-01
3-13
Operation
Note: The information in the table is for reference only.
For precise pressure specifications, refer to the information
supplied with the article to be inflated.
CAUTION
If the pressure gauge on the compressor indicates more than
twice the recommended pressure for the object you are
inflating, and you have only started to inflate the object, the
valve connector is incorrectly connected to the valve stem.
This may damage the XPower Powerpack 400 Plus. Remove
and reattach the valve connector to the valve stem.
To inflate your vehicle, motorcycle, or bicycle tires:
1. Place the valve connector securely on the tire valve stem,
push it as far as possible to allow normal airflow, and
close the thumb latch. If necessary, use a supplied nozzle
adapter.
2. Turn the compressor on, and inflate your tire to the
recommended pressure. Use Table: Pressure
Specifications for Common Items as a guide only.
3. Turn the compressor off after appropriate pressure is
reached.
4. Open the thumb latch and remove the valve connector
from the valve stem.
5. Check air pressure with a pressure gauge.
Note: Leave the thumb latch in the open position for
storing to relieve pressure on the internal mechanisms.
3-14
975-0057-01-01
Using the Air Compressor: XPower Powerpack 400 Plus
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. These types of products require
extended inflating times which may damage the compressor.
To inflate small sports equipment:
1. Place the valve connector fully on or into the valve
receptacle on the item. Go to Step 4.
OR
If necessary, use a supplied nozzle adaptor.
2. Choose the appropriate nozzle adaptor, insert the nozzle
adaptor into the valve stem and close the thumb latch.
3. Insert nozzle adaptor into the valve receptacle of the
item.
4. Turn the compressor on and inflate to appropriate
pressure.
WARNING: Fire Hazard
Allow the compressor to cool down for 10 minutes after each
10 minutes of continuous operation.
5. Turn the compressor off before removing nozzle adaptor
from valve stem.
6. Remove nozzle adaptor from valve connector and store
in storage compartment.
Note: Leave the thumb latch in the open position for
storing to relieve pressure on the internal mechanism.
975-0057-01-01
3-15
Operation
Connecting to an External Battery
You can extend battery operating times by connecting the
XPower Powerpack to a larger external battery.
For example, an external 60 Ah battery gives approximately
four times the operating time of the XPower Powerpack
internal 20 Ah battery.
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: Acid spills
Use a sealed, non-spillable battery for indoor use. Common
auto and marine batteries are not suitable for indoor use
unless their fumes are vented outdoors. Common auto and
marine batteries contain acid, which is hazardous if spilled.
Wear eye protection and protective clothing when connecting
the XPower Powerpack to an external battery.
3-16
975-0057-01-01
Connecting 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-Start Cable Port on the
left side of the XPower Powerpack.
2. Connect the red positive (+) clip of the cables to the red
positive (+) terminal of the external battery.
3. Connect the black negative (–) clip of the cables to the
black negative (–) terminal of the external battery.
WARNING: Sparking and Explosion
Do not remove the cables from the Jump-Start Cable Port
when the positive and negative clamps are connected to the
terminals of the external battery.
To disconnect the cables from an external battery and
from the XPower Powerpack:
1. To disconnect the XPower Powerpack from the external
battery when the external battery is discharged or no
longer needed, remove the red positive (+) clip, and then
remove the black negative (–) clip.
2. Remove the cables from the Jump-Start Cable Port.
3. Recharge the XPower Powerpack as soon as possible
after use.
CAUTION
Do not recharge the XPower Powerpack when an external
battery is connected. The AC charger may be damaged.
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3-17
3-18
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 a damp cloth to remove the
accumulated dust and dirt.
WARNING: Shock hazard
Disconnect all sources of AC power and DC power before
performing any type of maintenance.
Battery Maintenance
All rechargeable batteries gradually discharge when left
standing, and you need to recharge them periodically to
maintain maximum battery capacity. The AC Charger
supplied with the XPower Powerpack is designed to regulate
the charging process, ensuring that the battery is always fully
charged but never overcharged. To ensure safe recharging
and maximum battery life, recharge the XPower Powerpack
only with the supplied charger or approved battery chargers.
s.
CAUTION
Due to inherent self-discharge, lead acid batteries must be
charged at least every 3 months, especially in a warm
environment. Leaving a battery in a discharged state, or not
recharging every 3 months, may result in permanent battery
damage and poor jump-start performance.
4-1
Maintenance
CAUTION
Do not attempt to recharge the XPower Powerpack battery if
it is frozen. Gradually warm the frozen battery to 32 °F (0 °C)
before recharging.
Recharging the XPower PowerpackBattery
To check the battery’s charge level, press the Display
Function button.
Note: Battery Charge (%) status is only accurate when
the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.
You can recharge the battery using:
•
•
the fully automatic “plug-in-and-forget” AC Charger.
the DC Charging Cable to recharge from your vehicle as
you drive.
•
•
a generator equipped with a regulated 12 V battery
charging outlet.
a solar panel.
Recharging with the AC Charger
Recharging with the AC Charger is a true “plug-in-and-
forget” charging method.
CAUTION
Do not operate AC or DC appliances while the XPower
Powerpack is being recharged with the AC Charger.
The AC Charger may be permanently damaged if AC
appliances or 12 V DC appliances are operated while the AC
Charger is connected.
4-2
975-0057-01-01
Recharging the XPower Powerpack Battery
To recharge with the AC Charger:
1. Disconnect any 12 V DC appliance and turn the light
switch to Off.
2. Turn the AC Outlet On/Off switch to Off.
3. Plug the AC Charger into a standard AC wall outlet.
4. Insert the AC Charger cable end into the Charger Input
Socket located in the charger storage compartment.
5. While the XPower Powerpack is recharging, the green
Charging Status light is flashing. If the battery is
completely discharged, a typical recharge may take up to
35 hours. When fully charged, the green Charging
Status light changes to steady and the XPower
Powerpack is ready to use.
Important: The 35-hour charging time for the XPower
Powerpack assumes that there is 120 V at the AC wall
outlet. If the voltage is less than 120 V AC, it may take more
than 35 hours to fully recharge the XPower Powerpack. If,
after 35 hours of charging, the green Charging Status light
is still flashing and not steady, continue to charge the unit
for another 15 hours.
Once the battery is fully charged, the charging voltage
and current automatically reduces to a maintenance level
and the XPower Powerpack may be left permanently
connected to the AC Charger. If your utility power is
interrupted, the charging process automatically restarts
when power returns.
Recharging with the DC Charging Cable
Using the DC Charging Cable, the XPower Powerpack can
be recharged while you drive your vehicle.
Important: Although the charge regulation circuitry in the
XPower Powerpack does not operate with this charging
method, most vehicle voltage regulators will ensure that the
XPower Powerpack is not overcharged.
975-0057-01-01
4-3
Maintenance
WARNING: Fire and Explosion Hazard
Do not use this recharging method if your vehicle has
abnormally high voltage electrical systems that operate above
15 V DC. This may lead to accumulations of hydrogen,
causing exposure to fire and explosion hazard.
CAUTION
Do not operate AC or DC appliances while the XPower
Powerpack is being recharged with the DC Charging Cable
from your vehicle.
To recharge the XPower Powerpack while you drive using
the DC Charging Cable:
1. While the vehicle engine is running, plug one end of the
DC Charging Cable into the DC Power Socket of the
XPower Powerpack.
2. Plug the opposite end of the DC Charging Cable into the
vehicle’s lighter socket or 12 V accessory outlet.
3. Once the XPower Powerpack is fully charged or if your
vehicle’s engine is not running, disconnect the DC
Charging Cable from both sockets.
Most of the XPower Powerpack’s capacity will be
restored in four hours while the vehicle engine is
running.
Note: The green Charging Status light will not illuminate
when the XPower Powerpack is recharged through the DC
Charging Cable.
Note: Battery Charge (%) indicator is only accurate when
the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.
4-4
975-0057-01-01
Recharging the XPower Powerpack Battery
Important: Do not leave the XPower Powerpack
permanently connected to the vehicle’s lighter socket or
12 V accessory outlet.
975-0057-01-01
4-5
Maintenance
Recharging with a Generator’s Regulated 12 V DC
Outlet
WARNING: Fire and Explosion Hazard
The generator output must be intended for battery charging
and have an output of 15 V or less. An unregulated output or
one that exceeds 15 V DC can damage the battery.
This may lead to accumulations of hydrogen, causing
exposure to fire and explosion hazard.
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 in several ways:
•
Using the AC Charger to recharge the XPower
Powerpack from a generator is possible, but would
require extended generator running time.
•
Using a generator which has an auxiliary regulated 12 V
DC output designed for charging 12 V batteries. Most
generators are equipped with them. Use this power
source for faster charging.
•
Using a generator with a regulated 12 V DC lighter
socket. Follow the connection instructions in
“Recharging with the DC Charging Cable” on page 4–3.
Most of the XPower Powerpack’s battery capacity will be
recharged in a few hours.
Note: Battery Charge (%) indicator is only accurate when
the XPower Powerpack has been disconnected from all
appliances and all charging sources for fifteen minutes.
4-6
975-0057-01-01
Replacing the Internal Battery
Recharging From a Solar Panel
Small, unregulated 12 V solar panels rated to produce a
maximum of 2.5 A (or 30 W) can be used to charge the
XPower Powerpack through the Charger Input Socket.
You will need to purchase a standard 5.5 mm OD x 2.5 mm
(0.217” x 0.10”) ID DC Coaxial (barrel type) connector to
mate with the Charger Input Socket.
To recharge with a solar panel:
1. Connect the solar panel’s red positive (+) wire to the
coaxial plug’s inner contact.
2. Connect the solar panel’s black negative (–) wire to the
plug’s outer contact.
Once the connector is inserted into the Charger Input
Socket and the solar panel is placed in the sun, the
XPower Powerpack charges automatically just as with
the AC Charger. See “Recharging with the AC Charger”
on page 4–2.
It takes about ten hours in direct sunlight to recharge the
XPower Powerpack from a 2.5 A solar panel.
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.
Important: Recharge the XPower Powerpack fully at least
every three months if it is placed in storage or in a vehicle
trunk. Store in a location that maintains a temperature range
between 32 and 86 °F (0 and 30°C).
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4-7
Maintenance
CAUTION
Discharging the internal battery below 10.0 V will damage
the battery and shorten its life.
Obtaining a Replacement Battery
Replacement batteries are available from stores that
specialize in and have a selection of lead acid, AGM
(Absorbed Glass Mat) batteries.
Refer to Table 4-1 for a listing of batteries approved for use
with the XPower Powerpack:
Table 4-1 Approved Replacement Batteries
Panasonic
Panasonic:
#LC–X1220P
(12 V 20 Ah)
Tel: 1-800-833-9626
Digi-Key
Tel: 1-800-344-4539
EnerSys
EnerSys
#NPX–80
(12 V 20 Ah)
Tel: 1-800-962-1287 (Eastern US)
Tel: 1-800-423-4667 (Western US)
4-8
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Replacing the Internal Battery
Replacing the Battery
WARNING: Shock or Electrical Hazard
Read this entire section before disassembling the unit.
Before attempting to replace the internal battery, make sure
you:
•
•
•
Disconnect any charging cables, 12 V DC appliances,
and AC appliances from the XPower Powerpack.
Turn off the AC Outlet On/Off switch and turn off the
light switch.
Remove the jump-start cables.
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. Reverse polarity will damage the
XPower Powerpack and could cause serious injury.
To replace the battery:
1. Place the XPower Powerpack upright on a stable, level
surface.
2. On the XPower Powerpack, unscrew the four fasteners
on the battery cover. Place the fasteners in the cover for
safe keeping.
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4-9
Maintenance
Fasteners
3. Disconnect the wires on the battery only.
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. Securely fasten the bolt and washer that holds the red
positive (+) cable to the positive (+) battery terminal and
the black negative (–) cable to the negative (–) battery
terminal.
6. Do not overtighten the bolt. Consult the battery
manufacturer for torque specifications.
7. On the XPower Powerpack, replace the battery cover and
the four fasteners.
8. Dispose of the old battery in an environmentally
responsible manner.
4-10
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Recycling
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.
Do not dispose of the old internal battery with common
household waste. Please ask your local authorities about
recycling services that are available in your area.
Replacing the Incandescent Light
To replace a light bulb:
1. Turn the light switch off.
2. Unscrew the cover and lens.
3. Gently grasp the bulb and pull to remove the light
reflector assembly and the bulb.
4. While holding the light reflector assembly, gently
unscrew the black knob at the back of the assembly.
5. Remove the old bulb and insert a replacement bulb of the
same type and rating into the light reflector assembly.
6. Holding the light reflector assembly, gently screw the
black knob on to the back of the assembly.
7. Reattach the lens and cover.
975-0057-01-01
4-11
Maintenance
Replacing the External Fuse
The replacement fuse must be rated at 250 A, 32 V DC. See
page 2–7 for a diagram. To replace the external fuse:
1. Remove the fuse cover.
2. Unscrew the two bolts on the fuse.
3. Replace the fuse. Ensure that the replacement fuse is
rated at 250 A, 32 V DC and is of the same type.
4. Tighten the fuse with the two bolts.
5. Replace the fuse cover.
4-12
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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” on page WA–4 and then contact your dealer.
Common Problems
Buzz in Audio Equipment
Some inexpensive stereo systems have inadequate internal
power-supply filtering and may buzz slightly when powered
by the XPower Powerpack. The best solution to eliminate the
buzzing is to use an audio system with a good quality filter.
Television Interference
The XPower Powerpack is shielded to minimize interference
with TV signals. If TV signals are weak, you may see
interference in the form of lines scrolling across the TV
screen. Try one of the following suggestions to minimize or
eliminate the interference:
•
•
•
•
Use an extension cord to increase the distance between
the XPower Powerpack and the TV, antenna, and cables.
Adjust the orientation of the XPower Powerpack,
television, antenna, and cables.
Maximize TV signal strength by using a better antenna.
Use a shielded antenna cable where possible.
Try a different TV. Different models vary considerably in
their susceptibility to interference.
5-1
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.
Table 5-1 Troubleshooting reference
AC appliance AC appliance rated
Use an AC appliance with a power
more than 320 W, the rating less than 320 W.
safety overload has
will not
operate;
audible alarm tripped.
is not
sounding.
AC appliance is rated AC appliance may exceed the
less than 320 W, high XPower Powerpack’s surge
starting surge has
tripped the safety
overload.
capability. Use an AC appliance with
a starting surge within the XPower
Powerpack surge rating.
AC appliance Battery has discharged Turn the AC Outlet On/Off switch
will not
operate;
to 10.5 V.
off and recharge the XPower
Powerpack.
audible alarm
is sounding.
Inverter has
Turn the AC Outlet On/Off switch
overheated due to poor off and allow the XPower
ventilation or
excessively warm
environmental
conditions.
Powerpack to cool for 15 minutes or
more. Clear blocked fan opening or
remove objects covering the unit,
then restart the XPower Powerpack.
Move to a cooler environment.
5-2
975-0057-01-01
Troubleshooting Reference
Table 5-1 Troubleshooting reference
Overload
shutdown
Appliance power
Unplug the appliance and confirm
that the appliance’s power
requirement is 320 W or less before
attempting to restart the appliance.
requirements exceed
the capability of the
XPower Powerpack.
Over-
Inverter has
Turn off the AC Outlet On/Off
temperature
shutdown
overheated due to poor switch, and let the XPower
ventilation or
excessively warm
environmental
conditions.
Powerpack cool down.
Alarm sounds Internal battery is
nearly discharged.
(11.0 V).
Turn the AC outlet ON/OFF switch
OFF and recharge the XPower
Powerpack.
If you ignore this
warning, the XPower
Powerpack
automatically switches
off when the battery
reaches 10.5 V.
Measured AC Use of an
output voltage average-reading, AC
The modified sinewave (MSW)
output of the XPower Powerpack
requires a true RMS reading meter,
such as the Fluke 87 series, for
accurate measurement.
is too low.
voltmeter to read
output voltage.
Battery is almost fully Press Display Function button to
discharged.
verify battery status and recharge the
XPower Powerpack as necessary.
“Battery Charge %” reading on the
digital display is only accurate when
the XPower Powerpack has been
disconnected from all appliances and
all charging sources for fifteen
minutes.
975-0057-01-01
5-3
Troubleshooting
Table 5-1 Troubleshooting reference
Run time is
less than
Internal battery is not Recharge using the AC Charger,
fully charged.
until green Charging Status light is
expected.
steady.
AC appliance power
Check AC appliance power or
consumption is higher wattage rating (or current draw for
than expected.
12 V DC appliances) and compare
with Table 3-1 on page 3–5 and
Table 3-2 on page 3–9.
Charging
Status light is AC wall outlet.
No AC power at the
Ensure power is available at the AC
wall outlet.
Off when AC
Charger is
connected
AC Charger is faulty. Replace the AC Charger.
Green
Charging
Status light is display is only
flashing
(indicating
recharging)
and Battery
Charge (%)
does not turn
on.
Battery Charge (%)
reading on digital
Unplug the charging sources and any
appliances and let the XPower
Powerpack rest for 15 minutes to
obtain an accurate reading.
accurate when the
XPower Powerpack
has been disconnected
from all appliances
and all charging
sources for fifteen
minutes.
Green
Charging
The voltage at the AC Use AC wall outlet that supplies 120
wall outlet is less than V AC.
Status light is 120 V AC.
still flashing
and hasn’t
changed to
steady after 50
hours of
Internal battery is
permanently damaged.
Replace the battery.
charging.
5-4
975-0057-01-01
Troubleshooting Reference
Table 5-1 Troubleshooting reference
The
compressor
runs but won’t placed on the valve
The valve connector
may not be securely
Check that the valve connector is
securely placed on the valve stem
before closing the thumb latch.
inflate
stem.
(XPower
Powerpack
400 Plus only). inflated may have a
leak.
The item being
Check that the item being inflated
has no leaks.
Check the compressor hose for any
breaks or leaks at connections.
The
The compressor may
Turn off the compressor and let it
compressor
runs slowly
(XPower
Powerpack
have overheated from cool down.
excessive use.
Battery voltage is too Check the condition of the internal
400 Plus only). low.
battery. The battery may need to be
recharged or replaced.
The engine
being jump-
XPower Powerpack
battery is not fully
Recharge the XPower Powerpack
battery.
started will not charged.
start.
The engine condition Have the engine serviced.
is poor.
External fuse (250 A) Replace 250 A, 32 V fuse with same
is blown.
type and ratings.
The engine start
capacity exceeds the
XPower Powerpack
jump-start capability.
975-0057-01-01
5-5
Troubleshooting
Table 5-1 Troubleshooting reference
The battery
clamps of the
jump-start
External fuse (250 A) Replace 250 A, 32 V fuse with same
is blown.
type and ratings.
cables measure
zero volts.
The light does Light bulb has burnt
not turn on. out.
Remove lens cover and replace bulb
with one of the same type and rating.
5-6
975-0057-01-01
A
Specifications
Electrical Specifications
\
Internal battery type
sealed, AGM (Absorbed
Glass Mat) lead acid
Internal battery voltage (nominal)
Internal battery capacity (minimum)
Internal battery CCA rating
12 V DC
20 Ah
200 CCA
DC Power Socket (maximum continuous load)
Built-in incandescent light (replaceable)
Jump-start cable port
12 A with automatic reset
5 W bulb
50 A
Jump-start fuse (external - user replaceable)
250 A
A-1
Specifications
Output power
•
•
•
Continuous output power
Five minute AC output power
AC output surge capacity
320 W
400 W
600 W
Output voltage
115 ± 10 V AC RMS
60 Hz ± 4 Hz
Output frequency
Output wave form
modified sinewave
<0.20 A DC
No load current draw
Input voltage range
10.5 to 15.0 V DC
11.0 V DC
Low battery alarm
Low battery shutdown
High battery voltage shutdown
Over temperature shutdown
Overload shutdown
10.5 V DC
Yes, automatic reset
Yes, automatic reset
Yes, automatic reset
Yes, automatic reset
2 x 25 A or 1 x 50 A
AC output short circuit protection
Fuse (internal)
Operating temperature range
32 – 104 ºF
(0 – 40 ºC)
Storage temperature range
32 – 86ºF
(0 – 30 ºC)
AC Charger bulk charging current
Peak charging voltage (nominal)
Charge restart voltage (nominal)
750 mA
14.2 V
12.9 V
1 mA
Float charge after full charge is completed
(nominal)
AC Charger input socket maximum current
2.5 A
A-2
975-0057-01-01
Physical Specifications
an
2
Pressure
250 PSI (lb./in )
Jump-start cables
24" (0.61 m), 4 AWG wire
with black and red battery
clamps
DC charge cable
AC Charger input
39" (1 m) 18 AWG with male
to male lighter plugs
120 ± 10 V AC, 60 Hz
two nozzle adaptors
Nozzle adaptor (for air compressor on the
XPower Powerpack 400 Plus only)
one sports needle adaptor
Physical Specifications
Depth
Width
Height
Weight
8" (20.3 cm)
8" (20.3 cm)
16" (40.6 cm)
9 ½" (24.1 cm)
21.8 lb. (9.9 kg)
16" (40.8 cm)
9 ½" (24.1 cm)
23 lb. (10.5 kg)
Important: All specifications are subject to change without
notice.
975-0057-01-01
A-3
A-4
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 and XPower Powerpack 400 Plus. This warranty period lasts for
6 months from the date of purchase at the point of sale to you, the original end user
customer. You require proof of purchase to make warranty claims.
What will Xantrex do? Xantrex will, at its option, repair or replace the defective
product free of charge, provided that you notify Xantrex of the product defect within the
Warranty Period, and provided that Xantrex through inspection establishes the existence
of such a defect and that it is covered by this Limited Warranty.
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty
repair and building replacement products. Xantrex reserves the right to use parts or
products of original or improved design in the repair or replacement. If Xantrex repairs or
replaces a product, its warranty continues for the remaining portion of the original
Warranty Period or 90 days from the date of the return shipment to the customer,
whichever is greater. All replaced products and all parts removed from repaired products
become the property of Xantrex.
Xantrex covers both parts and labor necessary to repair the product, and return shipment to
the customer via a Xantrex-selected non-expedited surface freight within the contiguous
United States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer
Service for details on freight policy for return shipments outside of the contiguous United
States and Canada.
How do you get service? If your product requires troubleshooting or warranty
service, contact your dealer.
If you are unable to contact your dealer, or the dealer is unable to provide service, contact
Xantrex directly at:
Phone:
Fax:
1 360-925-5059
1 360-925-5143
Website:
Direct returns may be performed according to the Xantrex Return Material Authorization
Policy described in your product manual. For some products, Xantrex maintains a network
of regional Authorized Service Centers. Call Xantrex or check our website to see if your
product can be repaired at one of these facilities.
What proof of purchase is required? In any warranty claim, dated proof of purchase
must accompany the product and the product must not have been disassembled or
modified without prior written authorization by Xantrex.
Proof of purchase may be in any one of the following forms:
•
•
•
The dated purchase receipt from the original purchase of the product at point of sale to
the end user, or
The dated dealer invoice or purchase receipt showing original equipment
manufacturer (OEM) status, or
The dated invoice or purchase receipt showing the product exchanged under warranty
WA-1
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
use in an unsuitable environment;
b) the product if it has been subjected to fire, water, generalized corrosion, biological
infestations, or input voltage that creates operating conditions beyond the maximum or
minimum limits listed in the Xantrex product specifications including high input volt-
age from generators and lightning strikes;
c) the product if repairs have been done to it other than by Xantrex or its authorized ser-
vice centers (hereafter "ASCs");
d) the product if it is used as a component part of a product expressly warranted by
another manufacturer;
e) the product if its original identification (trade-mark, serial number) markings have
been defaced, altered, or removed.
Disclaimer
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY
XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE
PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS,
GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR
IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT,
HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF
MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR
OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR
CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO
APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD
STIPULATED UNDER THIS LIMITED WARRANTY.
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL
OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING
WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY
ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY
PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF
MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR
OPERATION OF THE PRODUCT.
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
WA-2
975-0057-01-01
Warranty and Return
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 Limited Warranty gives you specific legal rights. You may have other
rights which may vary from state to state or province to province.
Warning: Limitations On Use
Please refer to your product manual for limitations on uses of the product.
SPECIFICALLY, PLEASE NOTE THAT THE XPOWER POWERPACK 400 AND XPOWER
POWERPACK 400 PLUS SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT
SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING THE
GENERALITY OF THE FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR
WARRANTIES REGARDING THE USE OF THE XANTREX XPOWER POWERPACK 400
AND XPOWER POWERPACK 400 PLUS IN CONNECTION WITH LIFE SUPPORT SYSTEMS
OR OTHER MEDICAL EQUIPMENT OR DEVICES.
Please note that the XPower Powerpack 400 and XPower Powerpack 400 Plus is not
intended for use as an uninterruptible power supply and Xantrex makes no warranty or
representation in connection with any use of the product for such purposes.
Return Material Authorization Policy
Before returning a product directly to Xantrex you must obtain a Return Material
Authorization (RMA) number and the correct factory "Ship To" address. Products must also
be shipped prepaid. Product shipments will be refused and returned at your expense if they
are unauthorized, returned without an RMA number clearly marked on the outside of the
shipping box, if they are shipped collect, or if they are shipped to the wrong location.
When you contact Xantrex to obtain service, please have your instruction manual ready for
reference and be prepared to supply:
•
•
•
•
The serial number of your product
Information about the installation and use of the unit
Information about the failure and/or reason for the return
A copy of your dated proof of purchase
Record these details in “Information About Your System” on page WA-4.
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 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.
A contact telephone number where you can be reached during work hours.
A brief description of the problem.
•
•
•
3. Ship the unit prepaid to the address provided by your Xantrex customer service
representative.
975-0057-01-01
WA-3
Warranty and Return
If you are returning a product from outside of the USA or Canada In addition to the
above, you MUST include return freight funds and are fully responsible for all documents,
duties, tariffs, and deposits.
If you are returning a product to a Xantrex Authorized Service Center (ASC) A
Xantrex return material authorization (RMA) number is not required. However, you must
contact the ASC prior to returning the product or presenting the unit to verify any return
procedures that may apply to that particular facility.
Out of Warranty Service
If the warranty period for your XPower Powerpack 400 and XPower Powerpack 400 Plus
has expired, if the unit was damaged by misuse or incorrect installation, if other conditions
of the warranty have not been met, or if no dated proof of purchase is available, your unit
may be serviced or replaced for a flat fee.
To return your XPower Powerpack 400 and XPower Powerpack 400 Plus for out of
warranty service, contact Xantrex Customer Service for a Return Material Authorization
(RMA) number and follow the other steps outlined in “Return Procedure” on page WA-3.
Payment options such as credit card or money order will be explained by the Customer
Service Representative. In cases where the minimum flat fee does not apply, as with
incomplete units or units with excessive damage, an additional fee will be charged. If
applicable, you will be contacted by Customer Service once your unit has been received.
Information About Your System
As soon as you open your XPower Powerpack 400 and XPower Powerpack 400 Plus
package, record the following information and be sure to keep your proof of purchase.
_______________________________
_______________________________
_______________________________
p
p
p
Serial Number
Purchased From
Purchase Date
If you need to contact Customer Service, please record the following details before
calling. This information will help our representatives give you better service.
p
p
p
Warning, Error or Panel Fault
Message
_______________________________
Appliances operating when
problem occurred
_______________________________
_______________________________
Description of problem
______________________________________________________________
______________________________________________________________
WA-4
975-0057-01-01
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