XPower3000.
XPower3000.book Page ii Wednesday, December 10, 2003 6:52 AM About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems.
XPower3000.book Page iii Wednesday, December 10, 2003 6:52 AM About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the XPower Inverter 3000 Plus. Scope The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the inverter, as well as information about operating and troubleshooting the inverter.
XPower3000.book Page iv Wednesday, December 10, 2003 6:52 AM About This Guide 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 unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
XPower3000.book Page v Wednesday, December 10, 2003 6:52 AM Important Safety Instructions WARNING This chapter contains important safety and operating instructions. Read and keep this Owner’s Guide for future reference. 1. Before installing and using the XPower Inverter 3000 Plus, read all instructions and cautionary markings on the XPower Inverter 3000 Plus, the batteries, and all appropriate sections of this guide. 2. Do not expose the XPower Inverter 3000 Plus to rain, snow, spray, or bilge water.
XPower3000.book Page vi Wednesday, December 10, 2003 6:52 AM Safety Explosive gas precautions WARNING: Explosion hazard 1. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your XPower Inverter 3000 Plus. 2. This equipment contains components which tend to produce arcs or sparks.
XPower3000.book Page vii Wednesday, December 10, 2003 6:52 AM Safety 5. Remove all metal items, like rings, bracelets, and watches when working with lead-acid batteries. Lead-acid batteries produce a short circuit current high enough to weld metal to skin, causing a severe burn. 6. Have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery. 7. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 8.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM 1 Introduction The XPower Inverter 3000 Plus has been designed to give you quality power, ease of use, and reliability. Please take a few moments to read this chapter to familiarize yourself with the main performance features and protection features. Quality Power The XPower Inverter 3000 Plus is designed for use in recreational vehicles (RVs), light and heavy duty truck applications, and other invehicle applications.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Introduction Ease of Use Superior features and rugged durability have been combined with ease of use: • The inverter is compact, lightweight, and easy to install. • Loads can be powered directly from the AC outlets. • Easy-to-read indicators on the front panel let you monitor system performance at a glance.
XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM 2 Features Chapter 2, “Features” describes the main features of the XPower Inverter 3000 Plus. Familiarize yourself with them before installing and operating the inverter. Remote On/Off Switch The Remote On/Off switch can be plugged into the remote switch connector port on the front of the inverter. The remote switch lets you turn the inverter on and off from a convenient location up to 20 feet (6 m) away from the inverter.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Features AC Panel 6 7 5 4 3 2 8 1 9 10 11 12 Figure 2-2 AC Panel 2–2 Feature Description 1 On/Off Switch turns the inverter’s control circuit on and off. This switch is not a power disconnect switch. Disconnect AC and DC power before working on any circuits connected to the inverter. 2 Fault light (red): indicates the inverter has shut down due to inverter overload or over-temperature.
XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM AC Panel 975-0128-01-01 Feature Description 6 Status Display: Shows Voltage, Current or AC Power. VOLTAGE: Indicates battery power at the input terminal of the inverter in volts (V). CURRENT: Indicates current drawn from the battery by the inverter in amps (A). AC POWER: Indicates the output power from the inverter as a percentage of total available watts being utilized.
XPower3000.book Page 4 Wednesday, December 10, 2003 6:52 AM Features DC Panel 3 2 4 5 1 Figure 2-3 DC Panel 2–4 Feature Description 1 Chassis Ground Lug connects to vehicle chassis, DC grounding bus or to engine’s negative bus. 2 Ventilation Opening must not be obstructed for the proper operation of the inverter. When the inverter is mounted, the ventilation opening on the DC panel must not point up or down.
XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM 3 Installation Chapter 3, “Installation,” provides information on cables and fuses to help you plan for your installation and provide procedures for installing the inverter. Read the entire chapter before beginning the installation procedures so that you can plan an installation that is suited to your power needs.
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XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM Designing Your Installation Installation Codes Governing installation codes vary depending on the location and type of installation. Electrical installations must meet local and national wiring codes and should be performed by a qualified electrician. In residential applications, electrical codes do not allow permanent connection of AC distribution wiring to the inverter’s AC output receptacles.
XPower3000.book Page 4 Wednesday, December 10, 2003 6:52 AM Installation Choosing an Appropriate Location WARNING The inverter contains components that tend to produce arcs or sparks. To prevent fire or explosion, do not install the inverter in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment. WARNING To reduce the risk of fire, do not cover or obstruct the ventilation openings.
XPower3000.book Page 5 Wednesday, December 10, 2003 6:52 AM Designing Your Installation Calculating Cable Sizes To operate safely and effectively, the XPower Inverter 3000 Plus needs proper cables and fuses. Because the XPower Inverter 3000 Plus has lowvoltage and high-current input, it is essential that you use low-resistance wiring between the battery and the inverter to deliver the maximum amount of usable energy to your load.
XPower3000.book Page 6 Wednesday, December 10, 2003 6:52 AM Installation Table 3-1 Recommended DC Input Wire Sizes & Lengths RV (Recreational Vehicle) Cable length: Battery to Inverter (one way) Minimum Cable Size Maximum Battery Fuse Size 5 feet (1.5 m) or less No. 4/0 AWG 450 Adc 10 feet (3 m) 350 MCM 450 Adc Note: Never use a cable longer than 10 feet (3 m). Appropriate size cable can be bought at a welding supply house.
XPower3000.book Page 7 Wednesday, December 10, 2003 6:52 AM Designing Your Installation Calculating Fuse/Circuit Breaker Size Because your batteries can provide thousands of amps of short-circuit current, you need fuses or circuit breakers that can safely withstand the short-circuit current that the batteries can produce. To select the correct fuse type and size: 1. Determine the total short-circuit current rating for your batteries.
XPower3000.book Page 8 Wednesday, December 10, 2003 6:52 AM Installation Installing the inverter Do not proceed with the installation of your inverter until you have read the section, “Designing Your Installation” on page 3–1. The more thorough your planning, the better your power needs will be met to achieve maximum performance from your inverter. Safety Instructions Before you start to install the inverter: • Review the “Important Safety Instructions” on page v.
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XPower3000.book Page 10 Wednesday, December 10, 2003 6:52 AM Installation Mounting the Inverter Do not mount the inverter under the hood of your vehicle. See “Choosing an Appropriate Location” on page 3–4. To mount the inverter: 1. Make sure the On/Off switch is in the Off position. 2. Select an appropriate mounting location and orientation. The inverter must be oriented in one of the following ways: • • • Horizontally on a vertical surface. (Do not mount with the fan pointing up or down.
XPower3000.book Page 11 Wednesday, December 10, 2003 6:52 AM Installing the inverter AC Connections You can plug your AC loads directly into the receptacles on the inverter front panel. Output power to each receptacle is limited by a circuit breaker to 1500 Watts (15 A). You may also make a permanent AC connection via the AC knockout. This connection must be made in accordance with applicable electrical codes.
XPower3000.book Page 12 Wednesday, December 10, 2003 6:52 AM Installation WARNING: Electrical Shock Hazard Never operate the inverter without properly connecting the chassis ground. An electrical shock hazard could result from improper grounding. Grounding Locations You must connect the chassis ground terminal to a grounding point. Follow the installation guidelines below. These guidelines assume you are using the code-compliant DC supply cable and fuse sizes indicated in this manual.
XPower3000.book Page 13 Wednesday, December 10, 2003 6:52 AM Connecting the DC Cables Connecting the DC Cables Do not remove the terminal nut Do not place anything between battery cable lug and terminal surface. Assemble exactly as shown. Copper Compression Lug Aluminum Box Lug Figure 3-5 DC cable lug examples Consult Figure 3-1, “Configuration for Normal Loads” on page 3–2, or Figure 3-2, “Configuration for Heavy Loads” on page 3–2 for additional details that are specific to your installation.
XPower3000.book Page 14 Wednesday, December 10, 2003 6:52 AM Installation 4. Install a fuse and disconnect switch or breaker between the inverter and the battery. Ensure that the disconnect switch or breaker is turned off before installing. They must be installed in the positive side of the DC circuit, as close as possible to the battery. This protects your battery and wiring in case of accidental shorting. See “Calculating Fuse/Circuit Breaker Size” on page 3–7. 5.
XPower3000.book Page 15 Wednesday, December 10, 2003 6:52 AM Connecting the DC Cables 6. Connect one connector on the negative cable to the negative terminal on the DC end. Before proceeding, check that cable polarity is correct, and then connect the other end of the cable to the NEGATIVE (–) terminal on the battery. This is the last cable connection you make. If the disconnect switch or breaker is not turned off, a spark is normal when the connection is made.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM 4 Operation Chapter 4 explains how to operate the inverter efficiently and effectively.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Operation Turning the Inverter Off Between Charges The inverter draws less than 600 mA from the battery with the On/Off switch turned on and no load connected, but left in this state the inverter will eventually discharge the battery. To prevent unnecessary battery discharge, turn the inverter off when you are not using it.
XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM Operating Limits Operating Limits Power Output The XPower Inverter 3000 Plus can deliver up to 2500 W continuous and up to 3000 W for five minutes. The wattage rating applies to resistive loads such as incandescent lights. Input Voltage The allowable inverter input (battery) voltage ranges are shown in the following table: 975-0128-01-01 Operating Condition Voltage Range Comment Normal 10.5–15 V Optimum Performance 12.0–13.
XPower3000.book Page 4 Wednesday, December 10, 2003 6:52 AM Operation Inverter Loads The inverter will operate most AC loads within its power rating of 2500 W. However, some appliances and equipment may be difficult to operate, and other appliances may actually be damaged if you try to operate them with the inverter. Please read “High Surge Loads” and “Trouble Loads” carefully.
XPower3000.book Page 5 Wednesday, December 10, 2003 6:52 AM Routine Maintenance Routine Maintenance Minimal maintenance is required to keep your inverter operating properly. Periodically you should: • Clean the exterior of the inverter with a damp cloth to prevent the accumulation of dust and dirt. • Ensure that the DC cables are secure and fasteners are tight. • Make sure ventilation openings on the AC and DC panels of the inverter are not clogged.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM 5 Troubleshooting Chapter 5 will help you identify the source of most problems that can occur with the inverter. If you have a problem with the inverter, please review this chapter before contacting place of purchase. If you are unable to solve a problem and need to contact place of purchase, record the information in the form “Information About Your System” on page WA–6.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Troubleshooting Troubleshooting Reference WARNING: Electrical shock and burn hazard Do not disassemble the inverter. It does not contain any user-serviceable parts. Attempting to service the inverter yourself could result in an electrical shock or burn. Table 5-1 # 1 Troubleshooting Reference Error/Warning Code on Display Problem Possible Cause Solution AL1: Flashing Alarm: Beeping Low DC input terminal voltage.
XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM Troubleshooting Reference Table 5-1 # Troubleshooting Reference Error/Warning Code on Display Problem Possible Cause Solution 5 E03: Flashing Inverter is in Load applied is above Reduce the load if continuous Fault LED: Flashing overload shutdown. the continuous operation operation is required. Alarm: Beeping limit. 6 Inverter is in AL2 warning code is See solution under error # “2” E04: Flashing in this table.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM A Specifications Appendix A contains electrical performance and physical specifications for the inverter. Electrical Performance Output power at 25ºC (77ºF) ambient temperature and 12 V dc input: • Maximum continuous output power 2500 W • 5 minute rating 3000 W Output voltage 115 V AC RMS ± 5 % Output waveform Modified sine wave Output frequency 60 Hz ± 4 Hz Input voltage 10.5–15.0 VDC Low battery alarm 11.0 V Low battery cutout 10.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM B Battery Types The information in Appendix B will help you to select, connect, and maintain batteries that are most appropriate for your application. The batteries that you use strongly affect the performance of the XPower 3000. It is important to connect the inverter to the correct size and type of battery.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Battery Types A battery isolator is a solid-state electronic circuit that allows equipment to be operated from an auxiliary battery without danger of discharging the vehicle’s starting battery. During vehicle operation, the battery isolator automatically directs the charge from the alternator to the battery requiring the charge.
XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM Estimating Battery Requirements This same battery can deliver a higher or lower current for less or more time, limited approximately by the 100 Ah figure (for example, 50 A for 2 hours, or 200 A for 1/2 hour), but usually the capacity figure given is only accurate at the specified rate (20 hours).
XPower3000.book Page 4 Wednesday, December 10, 2003 6:52 AM Battery Types Battery Sizing Example This battery sizing example illustrates a typical calculation, assuming an opportunity to charge the batteries every three days.
XPower3000.book Page 5 Wednesday, December 10, 2003 6:52 AM Estimating Battery Requirements Battery Sizing Worksheet Use the following worksheet to calculate your battery needs. To ensure sufficient battery capacity, be generous when estimating the operating time per day for each of the loads you will run.
XPower3000.book Page 6 Wednesday, December 10, 2003 6:52 AM Battery Types Using Multiple Batteries As your power requirements increase, you may need to use more than one battery to obtain sufficient capacity. Read “Two Batteries Connected In Parallel” and “Two Separate Battery Banks” to determine whether two batteries or two battery banks are more appropriate for your applications.
XPower3000.book Page 7 Wednesday, December 10, 2003 6:52 AM Battery Tips Battery Tips WARNING Review “Precautions When Working With Batteries” on page vi before you work with the batteries in your system. Explosive/ Corrosive Gases Temperature Sensitivity Lead-acid batteries may emit hydrogen gases, oxygen, and sulfuric acid fumes when recharging. To reduce the risk of explosion: • • Vent the battery compartment to prevent the accumulation of gases.
XPower3000.book Page 8 Wednesday, December 10, 2003 6:52 AM Battery Types Battery Connections Connections to battery posts must be made with permanent connectors that provide a reliable, low-resistance connection. Do not use alligator clips. Clean the connections regularly and prevent corrosion by using a protective spray coating or Vaseline. Battery State of Charge You can measure battery state of charge with a hydrometer or approximate state of charge with a voltmeter.
XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM C Alternators and Charging Systems A good charging system is important for the health of your batteries. Poor recharging methods can quickly damage batteries. Appendix C provides guidelines for recharging batteries from an alternator, from AC power, and from alternate energy sources. Charging System Requirements Your charging system should be capable of delivering a charging current equal to 25% of the amp-hour capacity of your battery.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Alternators and Charging Systems Charging With an Engine Alternator Read the following information to determine whether your vehicle’s standard alternator will be adequate by itself, whether you should install an alternator controller, or whether you need a high-output alternator.
XPower3000.book Page 3 Wednesday, December 10, 2003 6:52 AM Charging From AC Power Charging From AC Power When recharging from AC power, use a good quality charger or RV converter that meets the requirements outlined in “Charging System Requirements” on page C–1. Do not use chargers intended for occasional recharging of automotive starting batteries. These chargers are not intended for continuous use.
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XPower3000.book Page 1 Wednesday, December 10, 2003 6:52 AM Warranty and Product Information 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 Inverter 3000 Plus. This warranty period lasts for 12 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.
XPower3000.book Page 2 Wednesday, December 10, 2003 6:52 AM Warranty and Product Information 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.
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XPower3000.book Page 4 Wednesday, December 10, 2003 6:52 AM Warranty and Product Information 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.
XPower3000.book Page 5 Wednesday, December 10, 2003 6:52 AM Out of Warranty Service If the warranty period for your XPower Inverter 3000 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 inverter may be serviced or replaced for a flat fee.
XPower3000.book Page 6 Wednesday, December 10, 2003 6:52 AM Warranty and Product Information Information About Your System As soon as you open your XPower Inverter 3000 Plus package, record the following information and be sure to keep your proof of purchase.