HI400 Owner’s Guide
About Xantrex Xantrex Technology develops, manufactures, and markets advanced power electronic products. The company’s products convert raw electrical power from any source into high-quality power required by electronic and electrical equipment. Trademark Xantrex is a registered trademark of Xantrex Technology Inc. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.
Contents Important safety information General precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - vi Precautions when working with batteries - - - - - - - - - - - - - - - - - vii Precautions for using rechargeable appliances - - - - - - - - - - - - viii 1 Introduction Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 HI400 features - - - - - - - - - - - - - - - -
Contents Connecting the AC input cord - - - - - - - - - - - - - - - - - - - - - - - 22 Checks prior to initial power-up - - - - - - - - - - - - - - - - - - - - - 23 Starting up and testing your installation - - - - - - - - - - - - - - - - 23 3 Operation Operation features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inverter on and off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ground fault circuit interrupter (GFCI) protection - - - - - - - - Alternate AC source - - - - -
Contents Estimating battery requirements - - - - - - - - - - - - - - - - - - - - - - Battery sizing example- - - - - - - - - - - - - - - - - - - - - - - - - - - Battery sizing worksheet - - - - - - - - - - - - - - - - - - - - - - - - - Using multiple batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - Two batteries connected in parallel - - - - - - - - - - - - - - - - - - Two separate battery banks- - - - - - - - - - - - - - - - - - - - - - - - Battery tips - - - - - - - - - - - - - - - - - - -
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Important safety information Important: Before installing and using your HI400 Inverter, be sure to read and save these safety instructions. General precautions 1. Before installing and using the inverter, read all appropriate sections of this guide and any cautionary markings on the inverter and batteries. 2. Do not operate the inverter if it has received a sharp blow, been dropped, or otherwise damaged. If the unit is damaged, see “Service during warranty” on page 48 and “Returning a product” on page 49.
Explosive gas precautions Explosive gas precautions WARNING: Explosion hazard . 1. Batteries generate explosive gases during normal operation. Be sure you follow all relevant instructions exactly before installing or using your inverter. 2. This equipment contains components which 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.
Precautions when working with batteries Precautions when working with batteries WARNING: Explosion and fire hazards 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 near the engine or battery. 4. Use caution to reduce the risk of dropping a metal tool on the battery.
Precautions for using rechargeable appliances Precautions for using rechargeable appliances Most rechargeable battery-operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage charging out. Some chargers for rechargeable batteries can be damaged if connected to the HI400 Inverter.
Introduction Chapter 1 “Introduction” describes the main operating features of the HI400 Inverter.
Introduction Introduction The HI400 Inverter is a modified sine wave (MSW) inverter providing power for a variety of AC loads, such as TVs, VCRs, laptops, camcorders and other small AC devices. They are CSA certified for use in recreational vehicles. The HI400 is available in two versions: • “HI400 with hardwire” is designed for permanent hardwired installation. • “HI400 with hardwire and GFCI outlet” has a GFCI receptable on the front and a hardwire compartment.
Introduction • • This receptacle has a “ground fault circuit interrupter” to reduce shock hazards on loads connected to both the receptacle and hardwire outputs. Ignition lockout Ignition lockout prevents the inverter from operating while the engine is running. It allows the user to turn the inverter on and off remotely. Transfer switch Automatically connects the loads on the receptacle and hardwire outputs to the external AC source when one is available.
HI400 features HI400 features Figure 1 below, and Figure 2 opposite, show the front and back panels of the HI400. Table 1 and Table 2 list the respective panel parts. ➀➁ ➂ Figure 1 Table 1 4 ➃ ➄ ➅ Front Panel - “Hardwire with GFCI” version.
HI400 features ➀ ➁ Figure 2 p Table 2 ➂ ➃ ➄ ➅ Back panel Back panel features Feature Description ➀ ➁ ➂ ➃ ➄ ➅ Air vents Cable clamp Chassis grounding lug AC hardwiring compartment (with cover on) DC input terminals AC input cord 5
Materials list Materials list Your HI400 inverter package includes the items listed below: ❐ Inverter with hardwire (80-0401-12) or Inverter with hardwire and GFCI outlet (80-0400-12) ❐ Owner’s Guide 6
Installation Chapter 2 “Installation” provides complete information for installing the HI400 Inverter. Specifically, this section describes: • safety instructions and installation codes that must be observed during installation. • installation tools and materials. • appropriate locations and environments for mounting the inverter. • AC cabling, DC cabling, and ground information. • detailed installation procedures.
Preparing for installation Preparing for installation Prior to beginning your installation, review the “Important Safety Instructions” on page v, and read the entire “Installation” section so you can plan your installation from beginning to end. WARNING: Electrical shock and fire hazards Xantrex recommends all wiring be done by qualified personnel. Disconnect all AC and DC power sources to prevent accidental shock.
Preparing for installation Installation tools and materials You will need the following tools and materials to install the inverter: ❐ #2 Phillips screwdriver ❐ Wire stripper ❐ 4 mounting screws or bolts and appropriate tools ❐ 3/8” wide slot screwdriver for DC input and chassis ground terminals ❐ 3-conductor (2-conductor-plus-ground cable) AC output cable sized appropriately for load according to applicable installation code(s). In the NEC, CEC and RV applications, this is No. 14 AWG.
Preparing for installation Installation features Figure 3 and Table 3 below, list the installation features of your HI400 inverter.
Installing the HI400 Installing the HI400 Overview This section provides detailed installation information.
Installing the HI400 Note: Throughout this manual, the term “shorepower” refers to AC input power from a utility grid, generator, or other source.
Installing the HI400 AC output neutral bonding The neutral conductor of the inverter’s AC output circuit is automatically connected (“bonded”) to the safety ground whenever the inverter is running and AC utility shorepower is not present. When AC shorepower is present, this connection is automatically lifted, as that same bonding connection will be present in the AC shorepower source.
Installing the HI400 DC cabling This includes the DC cables between the battery, the DC disconnect and over-current protection device, and the inverter. For copper cable rated 60 °C, 75 °C, or 90 °C, the minimum size cable allowed in NEC, CEC, or RV installations is No. 8 AWG (assuming a 40 Adc fuse or breaker is used). Batteries Every HI400 inverter requires a 12 V deep-cycle battery or group of batteries to provide the DC current that the inverter converts to AC.
Installing the HI400 Table 4 Tested GFCI models Manufacturer Model number Leviton 6599 Pass & Seymour 1591 Hubbell GF 5252GYA Choosing a location WARNING: Risk of fire or explosion This equipment contains components that tend to produce arcs or sparks. To reduce the risk of fire or explosion, do not install this equipment in compartments containing batteries or flammable materials, or in locations that require ignition-protected equipment.
Installing the HI400 Ventilated See the warning on page 15. Allow at least 5 inches of clearance on each size of the inverter for air flow. Do not allow the ventilation openings on the unit to become obstructed. Make sure the compartment in which the inverter is installed allows airflow through the compartment. Safe See the warning on page 15. Do not install the inverter in the same compartment as batteries or in any compartment capable of storing flammable liquids like gasoline.
Installing the HI400 Permanently connecting (hardwiring) the AC output WARNING: Fire, shock, and energy hazards Make sure wiring is disconnected from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes. Do not connect the output leads of the inverter to any incoming AC source. To hardwire the AC output connections: 1. Remove the AC hardwire compartment cover.
Installing the HI400 5. Connect the black and white (line and neutral) wires from the AC cable to the black and white wires located in the HI400 hardwire compartment. Be sure to connect black to black and white to white. Check to make sure the wires are making a good connection, and secure the twist-on wire connectors with electrical tape. 6. Connect the ground wire (bare or green) from the AC cable to the green-headed screw on the back wall of the hardwire compartment.
Installing the HI400 2. Route the lockout signal wire through the cable clamp and into the hardwire compartment. 3. Strip approximately ½ inch off the insulation of the red ignition lockout wire and the lockout signal wire (if using the twist-on wire connectors provided). If you are providing your own connectors, follow the manufacturer’s recommendations regarding strip length and use of the connectors. 4.
Installing the HI400 Follow the procedures given below to connect the battery to the DC input terminals. The cables should be as short as possible and large enough to handle the required current, in accordance with the electrical codes or regulations applicable to your installation. As noted above, the recommended cable size is No. 8 AWG for compliance with NEC, CEC, and RV codes (assuming a 40 amp DC fuse).
Installing the HI400 7. Insert the other end of the negative (–) cable into the negative (–) terminal on the HI400 and tighten the terminal screw. Ensure all strands of wire are inside the connector (no stray strands). The terminal manufacturer’s recommended tightening torque is 21 inch-pounds. 8. Attach the positive (+) cable to the breaker or fuse and disconnect combination installed on the battery positive (+) terminal in step 5. Tighten the connection according to the manufacturer’s recommendations. 9.
Installing the HI400 In an RV or vehicle installation, this will usually be the vehicle chassis or a dedicated DC ground bus. Connecting the AC input cord WARNING: Shock hazard Connect the AC input cord only to a properly grounded standard 120 Vac, 15 A receptacle. If the correct type of receptacle is not available, have an electrician install one.
Installing the HI400 Checks prior to initial power-up Before powering up your inverter, ensure these conditions are met: ❐ On/Off power switch is in the off position. ❐ Positive (+) battery cable is connected to the positive (+) battery terminal. ❐ Negative (–) battery cable is connected to the negative (–) battery terminal. ❐ Battery voltage is within the proper range for this unit (10.0 – 15.0 Vdc). ❐ DC Fuse is intact (not blown).
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Operation Chapter 3 “Operation” explains how to operate the HI400 Inverter.
Operation features Operation features CAUTION Read all operating instructions before operating the HI400. Inverter on and off The On/Off power switch on the front panel turns the HI400 inverter on or off: • • In the On position, the green inverter On LED indicator illuminates and the unit begins inverting if AC shorepower is not present. The HI400 is now operational and you can apply a load requiring less than 400 watts.
Operation features Monthly testing Once a month, with either AC shorepower or inverter power present, press the test button on the GFCI receptacle. The reset button should pop out. Push it to reset the GFCI, and continue normal operation. This should be completed on a monthly basis. If the reset button does not pop out, the GFCI may have failed. Disconnect AC and DC power to the unit and have a qualified service person look at it.
Inverter loads Inverter loads The HI400 will operate most AC loads within its power rating (400 watts/3.3 amps). Typical loads that can be used on the HI400 are as follows: • • • • • • Laptops Small TVs Handheld computing devices VCRs Camcorders Other light duty AC devices Operating several loads at once If you are going to operate several loads from the HI400, turn them on separately after you have turned the inverter on.
Inverter loads • Some chargers for battery packs used in power hand tools. These affected chargers display a warning label stating that dangerous voltages are present at the battery terminals. If you are unsure about powering any load with the HI400, contact the appliance manufacturer. Turning the inverter off between charges When the power switch is on but no power is being supplied to a load, the inverter idles and draws less than 400 mΑ from the battery.
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Maintenance and Troubleshooting Chapter 4 “Maintenance and Troubleshooting” will help you identify common problems that can occur with the HI400 Inverter. Read this chapter before calling Xantrex Customer Service. If you cannot solve the problem, record the information asked for on page 51. This will help our Customer Service Representatives to assist you better.
Maintenance Maintenance WARNING: Shock hazard Disconnect all sources of AC and DC power before doing any routine maintenance. Minimal maintenance is required to keep your HI400 operating properly. Periodically you should • clean the exterior of the unit with a damp cloth to prevent the accumulation of dust and dirt. • ensure the DC cables are secure at both the HI400 and the battery.
Troubleshooting reference • • • Adjust the orientation of the HI400, 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.
Troubleshooting reference Table 5 Troubleshooting reference Problem Possible Cause Solution Electronic shutdown (No LED illuminated) High battery voltage, overload, short circuit Turn power switch off. Disconnect all loads and then turn power switch on No AC output (No LED illuminated) Output circuit breaker or tripped GFCI Check the circuit breaker and GFCI. Push in the GFCI button to reset. High battery Wait for battery voltage to drop. Reset the inverter. Check battery fuse.
Specifications Appendix A “Specifications” contains electrical and physical specifications for the HI400 Inverter.
Electrical Electrical Output power • continuous • surge capacity 400 W 550 W Output voltage 120 Vac RMS ±5% Output frequency 60 Hz nominal Output wave form Modified sine wave Transfer switch 4 Amp AC High battery shutdown 15.0 V Low battery shutdown 10.0 V Efficiency Approximately 80-90% No load current draw (switch on) Less than 400mA Physical Length 9.7 inches (24.6 cm) Width 6.5 inches (16.5 cm) Height 3.5 inches (8.9 cm) Weight 4 lb (1.
Battery Types and Sizes Appendix B contains “Battery Types and Sizes.” The batteries you use strongly affect the performance of the HI400 Inverter. It is important to connect the inverter to the correct size and type of battery. The information in this appendix will help you select, connect, and maintain batteries that are most appropriate for your application.
Battery types Battery types Automotive starting batteries The lead-acid battery you are most familiar with is probably the starting battery in your automobile. An automotive starting battery is designed to deliver a large amount of current for a short period of time (so it can start your engine). Only a small portion of the battery’s capacity is used when starting the engine and it is quickly recharged by the running engine.
Battery size Battery size CAUTION The HI400 must only be connected to batteries with a nominal output voltage of 12 volts. The HI400 will not operate from a 6 volt battery and will be damaged if connected to a 24 volt battery. Battery size or capacity is as important as the battery type for efficient operation of your loads. Xantrex recommends that you purchase as much battery capacity as possible. A number of different standards are used to rate battery energy storage capacity.
Estimating battery requirements To calculate the battery capacity you require, read “Estimating battery requirements” and “Battery sizing example” on page B–41, and then complete the “Battery sizing worksheet” on page B–42. Estimating battery requirements To determine how much battery capacity you need: 1. Determine how many watts are consumed by each appliance you will operate from the HI400. You can normally find this on a label on the product.
Estimating battery requirements Battery sizing example This battery sizing example illustrates a typical calculation, assuming an opportunity to charge the batteries every three days.
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 your loads.
Using multiple batteries 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. Two batteries connected in parallel Two identical batteries can be connected (positive (+) to positive and negative (–) to negative) in a parallel system.
Battery tips Battery tips Note: Review “Precautions when working with batteries” on page vii, before working with the batteries in your system. WARNING: Explosive/corrosive gases Lead-acid batteries may emit hydrogen, oxygen, and sulphuric acid fumes when recharging. To reduce the risk of explosion: • Vent the battery compartment to prevent the accumulation of gases. • Do not install electronic or electrical equipment in the battery compartment.
Battery tips Do not leave batteries in a discharged state for more than a day or two. They will undergo a chemical process (sulfation) that can permanently damage the battery. As well, batteries self-discharge over a period of three to six months, so they should be recharged periodically even if they are not being used. Discharged batteries If your batteries are not the “maintenancefree” type, check the electrolyte level at least once a month. Excessive fluid loss is a sign of overcharging.
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Warranty and Product Information Appendix C “Product and System Information” contains the warranty and return information for the HI400 Inverter.
Warranty information Warranty information Xantrex manufactures its products from parts and components that are new or equivalent to new, in accordance with industry standard practices. This warranty covers any defects in workmanship or materials. What does this warranty cover? How long does the coverage last? This warranty lasts for one (1) year from the date of purchase. Implied warranties of merchantability and fitness for a particular purpose are limited to one year from date of purchase.
Returning a product service, please return it to the place of purchase along with a copy of your dated proof of purchase. If you are unable to contact your merchant, or the merchant is unable to provide service, contact Xantrex directly: Web: www.xantrex.com Email: techhelp@xantrex.com Phone: 800-446-6180 (toll free) Fax: 360-925-5143 Returning a product You must obtain a Return Material Authorization (RMA) number from Xantrex before returning a product directly to Xantrex.
Out-of-warranty service 8. Ship the inverter to the address provided in Step 1, freight prepaid. Xantrex recommends that you obtain proof of delivery. How other laws apply This warranty gives you specific legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.
Contacting Xantrex Customer Service Contacting Xantrex Customer Service If none of the troubleshooting suggestions work, you will need to call Xantrex Customer Service. If possible, note the circumstances surrounding the failure below. This will assist the service technician in diagnosing the problem quickly.
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Index A AC disconnects 11 AC input cord 22, 23 AC load circuit 13 AC output cable, 3-conductor 9 AC shorepower 11 Ah. See amp-hour capacity.
Index D DC cable 9 DC circuit breaker 21 DC distribution panel 20 DC ground bus (dedicated) 21 DC grounding point 21 DC input terminals 19 DC input wiring 20 depth of discharge (DOD) 41 disconnect switch 21 E electrical code requirements 12 electrolyte level 45 explosive gases vi F features back panel 5 front panel 4 ground fault circuit interrupter (GFCI) 2 ignition lockout 3 low voltage shutdown 2 multiple loads 2 surge capability 2 transfer switch 3 flanges 16 H hydrometer 45 I ignition lockout wire
Index batteries 14 DC cabling 14 DC disconnects and over-current devices 13 mounting inverter 16 L lockout signal wire 18 M malfunction 22 materials list 6 mounting screws 9 MSW (modified sine wave) 2 N neutral conductor 13 No. 14 AWG 9, 17 No. 18 AWG 18 No.
Index S W safety information v serial number 49 starting batteries 39 state of charge 45 warranty 48 Canadian customers, for 50 contacting Xantrex customer service 51 legal rights under warranty 50 length of coverage 48 not covered under warranty 48 out-of-warranty service 50 returning a product 49 service during warranty 48 what does it cover 48 what will Xantrex do 48 wide slot screwdriver 9 wire stripper 9 T tools and materials 9 transfer feature 23 troubleshooting 33 buzz in audio equipment 32 comm
