XP250 INSTALLATION AND OPERATION MANUAL
7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100
817.595.4969 voice, 817.595.1290 fax
800.886.4683 toll free
website www.exeltech.com
Manufacturer of UL Listed Products
XP250 INSTALLATION AND OPERATION MANUAL
Copyright © 2001 Exeltech Inc. All rights reserved. This Document may not be
copied, photocopied, reproduced, translated or converted to any electronic or
machine-readable form in whole or in part without prior written approval of
Exeltech, Inc.
Acknowledgments
Project Management: Ben Baker and John Goetz
Writing: Gary Chemelewski and David Bond
Copy Editing: Ben Baker
Art, Photography and Layout: John Goetz
May 2002
Exeltech
7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100
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XP250 INSTALLATION AND OPERATION MANUAL
Table of Contents
Introduction 1.0
page 3
Standard Features 2.0
page 5
Installation 3.0
page 7
Operation 4.0
page 10
Appendix A
page 11
Appendix B
page 12
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XP250 INSTALLATION AND OPERATION MANUAL
Introduction
1.0
Thank you for purchasing the finest sine-wave inverter in the power
conversion industry. Exeltech's journey to excellence includes the
first affordable sine-wave inverter, first modular inverter system, first
N+1 redundant inverter system, and the cleanest sine-wave output
in the industry.
Exeltech strives to manufacture products of the
highe st pos sible qua lity and is ded icated
to 100 % customer
satisfaction. Proudly built in the USA with American parts, Exeltech
is committed to TL 9000 standards and beyond, adding people and
procedur es cont inual ly to further improve qual ity and cust omer
service.
We welcome you as a customer to the Exeltech family.
.
Congratulations!
Exeltech’s XP series inverters provide the cleanest, best regulated sine-wave
output over the widest DC input of any inverter on the market today.
They are extremely low in total harmonic distortion; specified to 2%, and
typically better than 1.5%. Total harmonic distortion is typically 0.8 to
0.9%. Remaining distortion is a result of residual switching noise,
which amounts to a very clean 25 KHZ sine-wave superimposed on
the fundamental output. No significant harmonics of 25 KHZ exist.
This spectral purity will exist over the inverter's entire operating
envelope, including non-linear and reactive loads. As long as peak
output current remains less than 300% of rated current, total harmonic
distortion will remain within the 2% spec. Peak current capability of the
inverter is key to understanding it's operational envelope. As long as
the inverter is supplying less than this amount, it will function properly
.
and operate virtually any load.
Many inverters are rated in Volt-Amps (VA), as opposed to Watts.
This is in an attempt to make an inverter or UPS (Uninterruptible
Power Supply) appear larger than it really is. The only fair way to
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XP250 INSTALLATION AND OPERATION MANUAL
specify these products is in Watts (W), which is power the inverter
can actually deliver. If Exeltech inverters were specified in VA, Our
1100 Watt inverter could be rated at 1375 VA at .8 power factor,
1570 VA at .7 pf, or an incredible 2200 VA at .5 pf. It is confusing to
specify a product in VA because the power factor must also be
specified. Exeltech's XP-Series inverters can output their full rated
.
power continuously up to 30o C (86o F).
The inverter can maintain a spectrally pure output with any load due
to a specially designed non-linear control loop in the primary DC-to
-DC converter. This circuitry is one of three circuits that protect the
.
inverter from any overload condition.
.
XP-250
These inverters are capable of exceeding their rated power by 10%
for a limited time. The inverter's capability at this level is primarily
dependant upon temperature. If output power is exceeded, output
voltage is reduced to a level that will provide the inverter's rated
power to the load by clipping tops of the waveform. The inverter can
operate safely in this mode indefinitely. Should the overload condition
clear, the inverter will again provide the cleanest sine-wave in the
industry.
.
Page 4
XP250 INSTALLATION AND OPERATION MANUAL
Standard Features
2.0
DC INPUTS: A two-pole connector is provided under the rear
cover. The rear cover must also be removed to access this
connector. Use Appendix "A" to choose the appropriate gauge
wire for your specific model. A 2 pole female connector is provided.
"REMOTE" CONNECTION: is on the six-pole, plug-in connector,
.
located under the rear cover.
AC OUTPUTS: has one NEMA-15 outlet (standard wall receptacle),
located on the front panel. Additionally; may be hard-wired to
appliance / load using connections furnished on the six-pole, plug
.
-in connector, located under rear cover.
230 VAC: inverters have an IEC-320 receptacle located on the
.
front panel.
COOLING: convection cooled.
.
DC POWER ON LED: located on the front panel, will be "ON" when
.
inverter is powered up and DC power is available.
LOW BATT / THERM BUZZER: produces an audible alarm if DC
input voltage falls to a level within 2% to 4% of the low limit of
.
inverter, or, if there is an over temperature condition.
ON/OFF SWITCH: located on front panel; turns the inverter on and
.
off.
OVER VOLTAGE PROTECTION: If input voltage to the inverter
exceeds set limits, the inverter will immediately shut off without
warning. When input voltage returns to normal range, the inverter will
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XP250 INSTALLATION AND OPERATION MANUAL
immediately restart. Since high over voltages tend to have very
fast edges, the inverter must shut down quickly to protect itself.
This kind of fault usually occurs if the battery is suddenly
disconnected from the system and the battery charger continues to
supply current. When battery voltage falls to within 2% to 4% of low
line voltage, the LOW BATT / THERM buzzer will sound. If the
condition continues without reducing load to the inverter or adding
charge to the battery, the inverter will shut off. When voltage rises to
approximately 95% of nominal battery voltage, the inverter will turn
back on and the alarm condition will clear. The inverter can be
manually reset by cycling the on/off switch. This will reset the
protection circuitry and turn the inverter on at any voltage above
.
minimum voltage.
OVER TEMPERATURE PROTECTION:
The inverter is also
protected against overheating. It will provide its full rated output
up to the temperature listed in the specification sheet. If it is
subjected to higher ambient temperatures, or air circulation is
blocked, the inverter may overheat. If the LOWBATT/ THERM
buzzer sounds, immediate action is required or the inverter will shut
down. Either reduce load, or provide more cooling in the immediate
environment. If no action is taken, the inverter will likely shut down
within 2 minutes. When the inverter shuts down, the alarm condition
will persist. Since the inverter has eliminated its load, it will cool fairly
quickly. It will automatically restart when it has cooled sufficiently, and
the LOW BATT/THERM alarm will clear. If the internal temperature is
.
over 105C a warning buzz 5 C before shut off.
If rated output power is exceeded, output voltage is reduced to a
level that will provide the inverter's rated power to the load by
clipping tops of the waveform. The inverter can operate safely in this
mode indefinitely. The overpower protection circuit will recover
.
instantly when the overpower condition clears.
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XP250 INSTALLATION AND OPERATION MANUAL
Installation
3.0
CAUTION: It is essential to read and understand all Warnings,
Cautions, and Notes before any connections are made to the Unit
or System. If further assistance is needed call (817)595-4969 and
.
ask for Customer Service.
WARNING: The inverter is designed to operate from a battery.
Performance cannot be guaranteed, and damage can result when a
.
charger or power supply is used without a battery in the circuit.
WARNING: The AC neutral lead is internally bonded to chassis;
chassis must be bonded to earth ground through the external
ground connector located on the unit. The negative or positive
terminal of the battery (DC source) must be bonded to earth ground;
it is recommended that it be to the same earth ground used for AC
.
ground. Refer to the figure below for wiring illustration.
(A)
A) Positive earth ground
B) Negative Earth Ground
+
*Note: Ground either “A” or “B”
NOT BOTH.
Battery
Inverter
-
+
-
(B)
CAUTION: Before any connections are made to the unit or system,
be sure to disconnect the battery terminals. Always disconnect the
grounded battery terminal first. When re-connecting, connect
ungrounded terminal first, and grounded terminal last.
.
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XP250 INSTALLATION AND OPERATION MANUAL
CAUTION: Polarity of leads is critical to avoid damage to the unit or
system. Check batteries and battery cables for correct polarity and
.
voltage.
CAUTION: Observe all National and Local Electric Codes when
.
connecting AC Power Connections.
.
INSTALLATION (Location)
Mounting location is critical to performance and life span of the
inverter. Heat and moisture are the two worst enemies of any
electronic device. Therefore, when choosing a mounting location,
consider the following requirements listed in order of importance:
1. Inverter must be sheltered from the elements. Select a clean, dry
.
location.
2. Inverter requires adequate ventilation for cooling. With proper
cooling, the inverter will operate efficiently and meet its published
ratings. All models can be mounted in several positions. Best
position, vertical. Second best, vertical with inverter front facing up.
.
.
Third, horizontal.
The XP-250 will perform best when mounted vertically.
This will allow warm air to rise through
vent holes on top, drawing cool air through vent holes on the bottom.
3. Inverter should be mounted as close to the battery as possible.
Shorter wire has less resistance, which translates to increased
.
efficiencies.
.
INSTALLATION (Wiring)
An in line fuse is recommended to protect the battery and wiring to
the inverter. This fuse should be located very close to the battery
positive (+) terminal. To select appropriate size fuse, consult the
.
"Rated and Peak Current" table in Appendix "A”.
XP-250: a two-pole connector is provided under the rear cover. The
rear cover must also be removed to access this connector (see
Appendix "B"). Use Appendix "A" to choose the appropriate gauge
wire for your specific model. A 2 pole female connector is provided..
1. Disconnect the grounded (-) terminal of battery and make sure
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XP250 INSTALLATION AND OPERATION MANUAL
the charger and inverter are off.
.
2. Make DC input connections to the inverter as illustrated in
Appendix "B". Attach DC wires to the 2 pole female connector.
3. (Optional) Using 12-18 AWG wire, make Remote On/Off
connection from the rear panel terminal labeled "REMOTE" to one
pole of a small toggle switch. Then from the other pole of toggle
.
switch, make a connection to battery negative (-).
4. Make sure the toggle switch is off.
.
Note: in order for the Remote On/Off switch to operate inverter,
.
On/Off switch on the front panel must be off.
5. If the appliance / load will be hard-wired to the inverter instead of
or in addition to the outlets provided on the front panel, see
.
Appendix "B".
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XP250 INSTALLATION AND OPERATION MANUAL
Operation
4.0
.
TURN ON INVERTER:
XP-250: Turn inverter on using toggle switch on front panel, or the
"REMOTE" switch if installed. LED next to the switch will illuminate,
.
indicating the inverter is operational.
Note: If using "REMOTE" switch, the front panel switch must be
off. (If either switch is "on", the inverter will turn on. Both switches
.
must be off for the inverter to turn off.)
TURN ON APPLIANCE/LOAD:
.
1. Check Input Power Requirements of the appliance. Make sure
that it is less than Rated Output Power of the inverter. If more than
one appliance will be run simultaneously, the sum of their Input
Power Requirements must be less than Rated Output Power of the
.
inverter.
2. If appliance/load has been hard-wired to the barrier terminal strip
as illustrated in Appendix "B", then turn appliance on. Otherwise;
3. Plug the appliance into the receptacle provided on front panel,
.
then turn appliance on.
Note: It is recommend that the inverter be turned ON before the
.
appliance/load.
Page 10
XP250 INSTALLATION AND OPERATION MANUAL
APPENDIX A
Input Power Requirements:
MODEL
NORMAL
VDC
(TYPICAL)
MINIMUM VDC
CUT-OFF / ALARM
(TYPICAL)
MAXIMUM
VDC
(TYPICAL)
XP-250 / 12VDC
13.8 VDC
10.4 / 10.6 VDC
16.5 VDC
24.5 A
27.8 A
XP-250 / 24VDC
27.6 VDC
19 / 21 VDC
33 VDC
12.3 A
14 A
XP-250 / 48VDC
55.2 VDC
41.5 / 42.5 VDC
62 VDC
6.1 A
6.9 A
XP-250 / 66VDC
75.9 VDC
57.5 / 58.5 VDC
91 VDC
4.5 A
5A
XP-250 / 108VDC
124.0 VDC
94 / 95 VDC
149 VDC
2.7 A
3A
RATED
PEAK
CURRENT CURRENT
Recommended Input Wire Sizes (For Variable Distances from the Battery):
MODEL
LESS THAN 5’
LESS THAN 10’
LESS THAN 15’
LESS THAN 20’
XP-250 / 12VDC
8 AWG
4 AWG
4 AWG
2 AWG
XP-250 / 24VDC
12 AWG
10 AWG
8 AWG
6 AWG
XP-250 / 48VDC
18 AWG
16 AWG
14 AWG
14 AWG
XP-250 / 66VDC
18 AWG
18 AWG
16 AWG
16 AWG
XP-250 / 108VDC
18 AWG
18 AWG
18 AWG
18 AWG
.786”
0
XP-250 Mechanical Specifications:
0
.250”
4.977”
5.227”
.218” SLOT 4 PLACES”
TOP
2.770”
0
SIDE
FRONT
Page 11
10.768”
10.096”
10.596”
Note: The table specifies standard wire sizes (not smaller than 18 AWG) that will provide less than a
2% voltage drop at Low-line Input voltage and Rated Output Power.
XP250 INSTALLATION AND OPERATION MANUAL
APPENDIX B
Note: Use Rated Current and voltage in Appendix "A" to select an
appropriate Toggle Switch or Relay for your specific model inverter.
XP-250 with DC Toggle Switch:
Battery
DC Toggle Switch
(See Appendix A)
+
.
-
Inverter
+
.
XP-250 with DC Relay:
Normally Open
Contacts
Battery
DC Toggle Switch
(Low Current)
-
Relay Coil
Relay
+
Inverter
+
.
INSTALLATION
CAUTION: Be sure to disconnect all DC power to installation wiring.
Be sure to disconnect batteries and chargers. Make all connections
.
to the inverter BEFORE connecting DC power to the battery.
Insert 2 pole female connector
after attaching DC wires.
Follow correct Polarity!
REMOTE
LINE
NEUT
CHASSIS
XP-250 Rear View (AC/DC Connections):
BAT (+) BAT (-)
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XP250 INSTALLATION AND OPERATION MANUAL
Made in the USA
9 3 1 - X2 1 M* - * 0 G
Document subject to change without notice.
931-X21M*-*0G
MAY 24, 2006.
7317 Jack Newell Blvd North
Fort Worth, Texas 76118-7100
817.595.4969 voice, 817.595.1290 fax
800.886.4683 toll free
website www.exeltech.com