Xantrex AC to DC Converter XADC User's Manual
Contents
1. 25 Xantrex AC to DC Converter 26 Trademarks Xantrex AC to DC Converter 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 Notice of Copyright Xantrex AC to DC Converter Installation Instructions March 2007 Xantrex International All rights reserved Exclusion for Documentation 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 LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL 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 AND REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW XANTREX COM Date and Revision March 2007 Revision E Part Number 975 0301 01 01 Contact Information Telephone 1 360 925 5097 direct Fax 1 360 925 51432. Connecting the XADC and Panel Together To connect the XADC and panel together 1 Slide the XADC under the panel until the pilot pins on the mounting tabs on the top of the XADC slide in to the corresponding holes on the mounting clips on the bottom of the panel see Figure 12 2 Using the hardware provided in the panel hardware bag screw the panel to the XADC using the holes on the panel that have lined up with the holes on the top of the XADC mounting flange mounting clips T o XADC mounting tabs with pilot pins and panel T T t o I ir Figure 12 Connecting the XADC and Panel 975 0301 01 01 17 Xantrex AC to DC Converter Preparing the Mounting Location for the XADC and Panel To prepare the XADC and panel mounting location 1 Cut a mounting hole 12 in x 12 1 8 in 305 mm x 307 mm for the connected XADC and panel or follow the instructions in Preparing the Mounting Location for the XADC on page 13 for the XADC and cut a mounting hole 12 in x 8 in 305 mm x 203 mm for the panel or use an existing hole from a previous converter installation 2 Place the XADC and panel into the mounting hole and hold them against the mounting surface 3 Mark the positions of the mounting screws and then remove the XADC and panel from the mounting hole Connection Types for AC and DC Both the AC and DC busses use a screw in lug type of connection To perform connectio
3. e Connect the equipment into an outlet on a circuit different from that which the receiver is connected e Consult the dealer where the XADC was purchased or an experienced radio TV technician for help Xantrex AC to DC Converter Installation Main Components Figure 1 and Figure 2 show the main components of the XADC Figure 1 XADC External Components Item Description 1 AC wiring compartment 2 Intake and outflow vents do not obstruct 3 DC wiring compartment 4 Ground connection 2 possible connection locations 5 Mounting flanges 975 0301 01 01 AC DC Distribution Panel 975 0301 01 01 Figure 2 Item Installation Instructions i 7 XADC Internal Components Description AC wiring compartment hole Black AC line cable White AC neutral cable Green AC ground cable Grommet supplied Strain relief not supplied DC wiring compartment hole 1 2 in 3 8 in trade size with in knockout DC fuses OO CO WD NM BY WY N DC positive and negative connection lugs The XADC may be pre installed with an AC DC Distribution Panel The panel is available in two configurations which provides the approved wiring boxes for AC and DC conn
4. Preparing to Install To prepare the XADC for installation 1 Plan your wire routing to and from the AC input breaker and the DC battery using the wire lengths recommended in Table 2 on page 24 2 Attach the two mounting flanges to the XADC Tighten until the lock washer is flat plus turn Figure 7 Mounting Flanges 3 Remove the AC and DC wiring compartment panels by unscrewing the two screws in each of the panels see Figure 8 Figure 8 AC and DC Wiring Compartment Removal 12 975 0301 01 01 Installation Instructions Preparing the Mounting Location for the XADC To prepare the XADC mounting location 1 Place the XADC into the intended mounting position and hold it against the mounting surface 2 Mark the positions of the four side flange mounting screws and then remove the XADC 3 Drill pilot holes for the mounting screws in the marked positions Connecting the DC Battery 975 0301 01 01 When following the procedure see Table 2 on page 24 for wire lengths and Table 1 on page 24 for torque values A WARNING Shock hazard Ensure that the DC battery is physically disconnected or that the DC disconnect or breaker is open before attempting any installation Important Ensure that a main battery fuse is installed within 18 in 450 mm of the battery of a rating corresponding to the battery wire size gauge used Important Ensure that a suitable rated disconnect switch is installed be
5. WY DC positive lug battery DC negative lug battery p j DC battery fuses bottom four locations not included N DC positive cable to XADC positive j 05 DC negative cable to XADC negative a P Mounting flange Xantrex AC to DC Converter Installation Codes Governing installation codes vary depending on the specific location and application of the installation It is the installer s responsibility to ensure that all applicable installation requirements are met Some examples include the following e The U S National Electrical Code NEC e The Canadian Electrical Code CEC e The U S Code of Federal Regulations CFRs e Canadian Standards Association CSA and the RV Industry Association RVIA for installations in RVs Installation Tools and Materials 10 You will need the following items to install the XADC and panel O 2 Phillips screwdriver for removal of AC and DC wiring compartment panels O Torque screwdriver 20 50 in lb range with flat head socket insert optional robertson for AC and DC bus bars O Pliers for strain relief installation Ol 4x 6 or 8 pan head round head or washer head screws suitable for mounting the standalone XADC unit onto particleboard or wood and the equivalent screwdriver or 6 x 6 or 8 pan head round head or washer head screws suitable for mounting the attached XADC and AC DC Distribution Panel insta
6. gasoline powered machinery fuel tanks as well as joints fittings or other connections between components of a fuel system Precautions When Working With Batteries A WARNING Explosion or fire hazard 10 11 Make sure the area around the battery is well ventilated Never smoke or allow a spark or flame near the engine or batteries Use caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion 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 Have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching your eyes while working near batteries If battery acid contacts skin or clothing wash immediately with soap and water If acid enters your eye immediately flood it with running cold water for at least twenty minutes and get medical attention immediately If you need to remove a battery always remove the ground terminal from the battery first Make sure all accessories are off so you don t cause a spark 975 0301 01 01 Instal
7. load to the front AC bus on the panel marked Equipment Grounding Terminal Important Make a note of which AC load has been connected to which breaker using the provided label on the panel to the side of the breakers Use pencil in case the circuit is changed in the future Terminal AC input nnokous Ss f AC line connection to breaker 1 30A Main AC input and AC loads ground connection to Equipment Grounding d panel or breaker 4 5 50A panel AC loads hot to any breaker except reserved AC line breaker Main AC input and AC loads neutral connection to AC Neutral Terminal Figure 17 XADC AC Connections Mounting the XADC and Panel when Connected 975 0301 01 01 To mount the XADC and panel when connected l 2 Slide the complete unit into the mounting cutout Fasten the complete unit into the cutout and secure using 6 x 6 or 8 pan head round head or washer head screws suitable for mounting the unit onto particleboard or wood Install the XADC faceplate and tighten the four screws do not overtighten as this may cause stripping of the screw threads Install the DC fuse cover Install the panel faceplate and tighten the center screw do not overtigh
8. specifications for the above breakers the gauge of wire used must be selected based on 75 C ratings from your local electrical code Wiring with temperature ratings higher than 75 C may be used however the gauge must align with that of 75 C wire 4 Connect the AC input ground bare copper cable from the AC input source to the front AC bus on the panel marked Equipment Grounding Terminal 5 Connect the AC input neutral white cable from the AC input source to the rear AC bus on the panel marked AC Neutral Terminal 6 Connect the AC line black cable to the top breaker 30A panel or breaker 4 5 50A panel See Figure 4 on page 8 Important Main AC line must go into breaker location 1 top breaker for the 30A panel and into breaker location 4 and 5 for the 50A panel where breakers 4 and 5 must employ a ganging mechanism Bus bars have a protective tab to prevent non certified breakers from being installed 975 0301 01 01 AC Loads Installation Instructions To install the AC loads 1 Route the AC load cables through the knockouts in the back of the panel 2 Install breaker s for your AC loads See the documentation for your breaker to determine how it installs 3 Connect the hot lead black from each AC load to a breaker Connect the neutral lead white from each AC load to the rear AC bus on the panel marked AC Neutral Terminal 5 Connect the ground lead green or bare from each AC
9. C and will operate de rated between 86 F and 140 F 30 C and 60 C the cooler the better within this range At ambients in excess of 140 F 60 C the XADC may shut down Allow at least 18 inches 45 7 cm of clearance at the front of the XADC for air flow Ensure that the ventilation openings are not obstructed Do not install the XADC or panel in the same compartment as batteries or in any compartment capable of storing flammable liquids like gasoline Do not mount the XADC or panel where it will be exposed to gases produced by batteries Battery gases are corrosive and prolonged exposure to battery gases will damage them The XADC may be mounted in 3 orientations e horizontally on a flat surface e vertically on a wall with fan vent facing left e vertically on a wall with fan vent facing right Non Approved Mounting Orientation Non Approved Mounting Orientation Wall Mount Fan Up or Down Ceiling Mount Approved Mounting Orientation Desktop Mount Approved Mounting Orientation Wall Mount Fan Left or Right Figure 6 Installation Configurations 11 Xantrex AC to DC Converter Installing the XADC stand alone unit Follow the procedures in the order given 1 Preparing to Install 2 Preparing the Mounting Location for the XADC 3 Connecting the DC Battery 4 Connecting the AC Input 5 Mounting the XADC
10. DC if it has received a sharp blow been dropped or otherwise damaged in any way If the XADC is damaged see the Warranty section 5 Do not disassemble the XADC It contains no user serviceable parts and attempting to service the XADC will void your warranty See Warranty for instructions on obtaining service Attempting to service the XADC yourself may result in a risk of electrical shock or fire as the XADC remains charged after all power is disconnected 6 To reduce the risk of electrical shock disconnect both AC and DC power from the XADC before attempting any maintenance or cleaning or working on any circuits connected to the XADC 7 Never place the charger directly above or below the battery being charged gases or fluids from the battery will corrode and damage the charger Locate the charger as far away from the battery as the DC cables permit Xantrex AC to DC Converter Explosive Gas Precautions ie WARNING Explosion hazard Working in the vicinity of batteries may be dangerous Batteries generate explosive gases during normal operation therefore you must read this guide and follow the instructions exactly before installing or using your XADC This equipment contains components which tend to produce arcs or sparks To prevent fire or explosion do not install the XADC in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing
11. Recommended minimum DC wire gauge Recommended maximum 2 way DC cable length XADC 40 8 AWG 20 ft 610 cm XADC 60 6 AWG 20 ft 610 cm XADC 80 4 AWG 20 ft 610 cm a Run lengths over 20 ft 610 cm are not recommended Using larger run lengths or smaller gauge wires than recom mended will result in decreased charge load output performance as well as additional heating and interference effects 24 975 0301 01 01 Specifications Installation Instructions All specifications are subject to change without notice Additional specifications are available in the Xantrex AC to DC Converter Owner s Manual Part 975 0305 01 01 Electrical Performance AC Input XADC 40 XADC 60 XADC 80 Input current at rated output 6 Aac 9 Aac 12 Aac Nominal input voltage 120 Vac 60 Hz Frequency 50 70 Hz DC Output XADC 40 XADC 60 XADC 80 Recommended maximum battery bank size 220 Ah 220 Ah 400 Ah Output current 40 Adc 60 Adc 80 Adc Mechanical Specifications Physical Specifications XADC 40 XADC 60 XADC 80 Weight 7 9 Ib 8 2 Ib 8 3 Ib 3 6 kg 3 7 kg 3 8 kg Operating temperature range 14 F 86 F 10 C 30 C de rated 86 F 140 F 30 C 60 C gt 140 F 60 C unit may shut down Length 11 13 16 in 300 0 mm Width 7 1 8 in 180 0 mm Height 4 3 4 in 120 0 mm 975 0301 01 01
12. Smart choice for power xantrex Xantrex AC to DC Converter Installation Instructions XADC 975 0301 01 01 Revision E About These Installation Instructions 2 Important Safety Instructions 3 Installation 6 Main Components 6 AC DC Distribution Panel 7 Installation Codes 10 Installation Tools and Materials 10 Choosing a Location 11 Installing the XADC stand alone unit 12 Preparing to Install 12 Preparing the Mounting Location for the XADC 13 Connecting the DC Battery 13 Connecting the AC Input 14 Mounting the XADC 15 Installing XADC with the AC DC Distribution Panel 15 Configurations 15 Preparing to Install 15 Connecting the XADC and Panel Together 17 Preparing the Mounting Location for the XADC and Panel 18 Connection Types for AC and DC 18 Connecting the DC to the Panel 18 Connecting the Panel to the XADC DC Side 20 Connecting
13. ation Instructions To mount the XADC using the mounting plates 1 2 Align the XADC with the 4 previously marked mounting positions Fasten the XADC using 4 x 6 or 8 pan head round head or washer head screws suitable for mounting unit onto particleboard or wood Tighten until the unit is secure to the mounting surface Installing XADC with the AC DC Distribution Panel Follow this procedure if you are planning to install the XADC with the optional AC DC Distribution Panel called panel for the purposes of these instructions Configurations Preparing to Install 975 0301 01 01 Follow the procedures in the order given oe rnNt nn FY DN Preparing to Install Connecting the XADC and Panel Together Preparing the Mounting Location for the XADC and Panel Connecting the DC to the Panel Connecting the Panel to the XADC DC Side Connecting the Panel to the XADC AC Side Connecting the AC to the Panel Mounting the XADC and Panel Remotely Mounting the XADC and Panel when Connected The XADC and panel may either be connected together and mounted in a single mounting hole or they may be mounted in separate mounting positions Important If you intend to mount the XADC and panel remotely remember that twice the distance between the XADC and the panel is to be calculated as part of the DC cable run length as recommended in Table 2 on page 24 To prepare the panel fo
14. direct Email customerservice xantrex com Web www xantrex com 975 0301 01 01
15. ections 30A Part Number 810 0030 00 XADC P30 eight output breakers 50A Part Number 810 0050 00 XADC P50 10 output breakers In each configuration there are also 11 unassigned DC fuses and four reserved fuses for the battery connections Figure 3 and Figure 5 show the main components of the XADC with AC DC Distribution Panel Important The XADC P30 and XADC P50 panels are not intended for use with rigid conduit systems Xantrex AC to DC Converter Ty i Figure 3 AC DC Distribution Panel Components Item Description 1 DC fuse AC breaker access panel swings open with thumb latch 2 Removable DC fuse access panel with DC circuit designation label 3 Removable AC DC Distribution Panel faceplate service technician only Removable faceplate for XADC converter service technician only Screw for removing panel faceplate service technician only AC breakers not included Screw for removing DC fuse access panel Fuse puller Co N A a A AC breaker knockouts esesen ge yeewewe we Line 1 i en Branch 4 Position i linet i O 1 Outputs o Upper Line Main Inpute inei Busbar i Line 1 5 Position Ma
16. ections Connecting the AC Input When following the procedure see Table 1 on page 24 for torque values A WARNING Shock hazard Ensure that the AC disconnect or breaker is open on the AC line before attempting any installation To connect the AC input 1 Route AC wires through the AC wiring compartment hole 2 If you plan to use the in knockout for the AC wiring remove the outer knockout 3 Connect the XADC ground green cable to the incoming ground It is recommended that you use marrettes for this as they have built in insulation 4 Connect the XADC AC neutral white cable to the incoming neutral It is recommended that you use marrettes for this as they have built in insulation 5 Connect the XADC AC line black cable to the incoming line It is recommended that you use marrettes for this as they have built in insulation Reattach the AC wiring compartment panel Reconnect the AC by closing or engaging the main AC disconnect breaker Grommet AC ground green neutral o 0000000000 white and line black PERE Y OROKCROROROROKONOROKOM 0 0 0 0 0 0 0 0 0 0 0 C 00000000000 0 0 0 0 0 0 0 0 0 0 0 C lo 200202020020 0200c iri T 0220090005000000 AC wiring 002020209020002090200 0 070 P55 O Og R OE compartment hole 2026902000002090 0595032525252959 F 000a 0000A aA Figure 10 XADC AC Connections 14 975 0301 01 01 Mounting the XADC Install
17. ex AC to DC Converter will be referred to as the XADC 40 when it is being referenced individually The 60 Amp Xantrex AC to DC Converter will be referred to as the XADC 60 when it is being referenced individually The 80 Amp Xantrex AC to DC Converter will be referred to as the XADC 80 when it is being referenced individually When the Xantrex XADC 40 XADC 60 and XADC 80 are being referenced together they will be referred to as the XADC 975 0301 01 01 Installation Instructions Important Safety Instructions 975 0301 01 01 WARNING Limitations on Use The Xantrex AC to DC Converter is not intended for use in connection with life support systems or other medical equipment or devices WARNING This section contains important safety and operating instructions Read and keep these Installation Instructions for future reference 1 Before installing and using the XADC read all instructions and cautionary markings on the XADC the batteries and all appropriate sections of this guide 2 Do not expose the XADC to rain snow spray or water To reduce risk of fire hazard do not cover or obstruct the ventilation openings Do not install the XADC in a zero clearance compartment Overheating may result 3 To avoid a risk of fire and electric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the XADC with damaged or substandard wiring 4 Do not operate the XA
18. in Input Branch Busbar l Outputs P 3 Position SS O O see eee Lower Line 30 Amp Panel Diagram K _Busbar _ 50 Amp Panel Diagram Figure 4 30A and 50A Panel Connection Diagrams 8 975 0301 01 01 975 0301 01 01 Figure 5 Item Installation Instructions gt ol fo QW Th 1 k Na e i A Vay U L TN 1 Hl teal tes Uy i W a i FY Ww O 1e OOOO DOOO SOO000 0 B sso ono I oso on JEE CS ial z D oe AC DC Distribution Panel and XADC Internal Components Description Equipment Grounding Terminal bus front AC Neutral Terminal bus rear AC wiring knockouts 1 2 in 3 8 in trade size and 34 in nested 7 positions AC breakers not included 50 A panel shown fully populated DC branch circuit fuses not included maximum 20 amps per branch DC positive terminal strip 11 positions DC wiring knockouts 1 2 in 3 8 in trade size and 3 4 in nested 7 positions DC negative bus OO CO NIA MN A WY
19. lation Instructions 12 Use the XADC for charging a lead acid battery only Do not use the XADC to charge nickel cadmium or dry cell batteries commonly used with home appliances and electronic equipment These batteries may burst and cause injury to persons and damage to property 13 Never attempt to charge a frozen battery Charging a battery when its temperature is below 32 F 0 C is inefficient and ineffective If possible warm the battery above 32 F 0 C before charging FCC Information to the User 975 0301 01 01 This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction guide may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment on and off the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and the receiver
20. llation and the equivalent screwdriver O All strain reliefs must be UL CSA approved in or in trade size strain relief One strain relief for DC wires for standalone XADC Four strain reliefs for separated mounting Up to 14 additional strain reliefs as required for full AC and DC circuit population dependent on wire sizing O Four DC battery fuses and up to 11 additional DC load fuses O One breaker for installing the XADC one AC breaker for installing the panel and up to six additional AC load breakers The following items are shipped with the XADC e XADC converter e Xantrex AC to DC Converter Owner s Manual Part 975 0305 01 01 e Xantrex AC to DC Converter Installation Instructions Part 975 0301 01 01 The following items are shipped with the AC DC Distribution Panel e AC DC Distribution Panel e AC DC Distribution Panel Safety Instructions sheet 975 0301 01 01 Installation Instructions e XADC converter faceplate and mounting hardware e Plastic bag containing two mounting tabs and related hardware one top mounting flange and related hardware Choosing a Location Dry Cool Ventilated Safe Protected from battery gases 975 0301 01 01 The XADC and AC DC Distribution Panel must only be installed in a location that is Do not allow water or other liquids to drop or splash on the XADC While the unit will safely operate at ambient air temperatures between 14 F and 86 F 10 C and 30
21. mation Make the following changes to the XADC if you intend to connect the XADC and panel and mount them in a single mounting hole 12 in x 12 1 8 in 30 5 cm x 30 7 cm 1 Remove the four screws from the XADC faceplate and remove the faceplate 2 Remove the two side mounting flanges and keep them for re use 3 Take one of the mounting flanges from the mounting hardware bag in the 16 panel shipping box see Figure 11 and screw it to the top of the XADC The mounting flange screw holes will line up with the corresponding pilot holes in the XADC 975 0301 01 01 Installation Instructions Add these two mounting tabs from the panel hardware bag Add this mounting flange ss from the panel hardware w a bag Remove this side n i mounting flange keep the left or right flange and mounting hardware for the bottom flange Add this mounting flange emove this side using one of the removed mounting flange side mounting flanges and the associated hardware Figure 11 Mounting Flanges for Installation 4 Take one of the side mounting flanges that you removed in step 2 above and screw it to the bottom of the XADC The mounting flange screw holes will align with the two pilot holes in the XADC 5 Take the two small mounting tabs with pilot pin attached from the mounting hardware bag in the panel shipping box and screw them to the top of the XADC behind the AC and DC wiring compartment holes see Figure 11
22. ns with the screw in type lug 1 Ensure the screw is loosened 2 Slide the cable into the hole behind the screw 3 Tighten the screw see Table 1 on page 24 for torque values Connecting the DC to the Panel 18 See Connection Types for AC and DC on page 18 for information on the connections used on the busses When following the procedure see Table 2 on page 24 for wire lengths and battery DC fuse ratings and Table 1 on page 24 for torque values WARNING Shock hazard Ensure that the DC battery is physically disconnected or that the DC disconnect or breaker is open before attempting any installation To connect the DC loads See Figure 14 for additional information 1 Install a UL CSA approved strain relief on the incoming negative black cables and incoming positive red cables Tighten the clamping ring but not the clamp screws on the strain relief Important Multiple cables can be placed into a strain relief Check the strain relief manufacturer s datasheet for maximum number of cables allowed 2 Route the incoming negative black cables and incoming positive red cables through the knockouts in the back of the panel 975 0301 01 01 Installation Instructions 3 Connect the incoming negative black cable from each of the loads to the negative DC bus 4 Connect the incoming positive red cable from each of the loads to the positive DC bus 5 Install fuses for the DC l
23. oads and the DC battery The bottom four DC fuses are for the battery Fuses for DC loads should be Littelfuse Type 257 or equivalent and the maximum allowed fuse for the DC loads is 20 A Important You may remove the PCB with the positive DC bus and fuse holders by removing the three screws for ease of connection Keep the screws for reconnecting the PCB See Figure 13 3 O000000000 Cor wun wU Remove these three screws S i Figure 13 DC PCB Removal 6 Connect the incoming negative black cable from the battery to the negative DC battery lug 7 Connect the incoming positive red cable from the battery to the positive DC battery lug 8 Tighten the clamp screws on the strain relief to secure the DC wires J S a DC Knockouts gt Fh o o e coro DC fuses p RO D f 4 nn Negative DC bus TNL dla Positive DC bus 000000000 Cz T N CG LI a JOI 0 egative DC battery lug H SZ 7 rN 60000 S T S N I SPSOOOC N o o YZ Positive DC battery lug ha 5 Figure 14 Connecting DC to the Panel 975 0301 01 01 19 Xantrex AC to DC Converter Connecting the Panel to the XADC DC Side When following the p
24. r installation 1 2 3 Open the door on the panel and remove the center screw Remove the panel faceplate Remove the correct number of AC and DC knockouts for your installation from the back of the panel 15 Xantrex AC to DC Converter 4 AC breaker positions 1 and 2 have been removed from the removable faceplate on the panel Remove extra positions from the panel by twisting the knockouts back and forth Any knockouts that have been accidentally removed can be replaced with one of the following parts ITE Gould QF 3 or Cutler Hammer Bryant Westinghouse FB 1B If you intend to mount the XADC and panel remotely install a UL CSA approved strain relief on both of the bottom AC and DC wiring compartment holes If you intend to mount the XADC and panel remotely you may need to increase the length and gauge of the DC cables from the panel to the XADC see Configurations on page 15 To prepare the XADC for remote installation Make the following changes to the XADC if you intend to mount the XADC and panel remotely 1 Remove the plastic wire protection grommets from the AC and DC wiring compartment holes Install a UL CSA approved strain relief on both the AC and DC wiring compartment holes You may need to increase the length of the AC cables from the XADC to the panel use a minimum of 14 AWG wire for any such extensions To prepare the XADC for connected installation See Figure 11 for additional infor
25. re 16 Connecting Panel to XADC AC Side 975 0301 01 01 21 Xantrex AC to DC Converter Connecting the AC to the Panel 22 See Connection Types for AC and DC on page 18 if you are not familiar with the connections used on the breakers When following the procedure see Table 2 on page 24 for wire lengths and Table 1 on page 24 for torque values See Figure 4 on page 8 for panel electrical connection diagrams WARNING Shock hazard Ensure that the AC disconnect or breaker is open on the AC line before attempting any installation To connect the AC input 1 Install a UL CSA approved strain relief on the AC input cables 2 Route the AC input cables through the knockouts in the back of the panel 3 Install breaker s for your AC input source See the documentation for your breaker to determine how it installs CAUTION Breakers can be damaged if forced onto the AC stab lok bus bar Breakers should slide easily into position without excess force Important The following breakers are suitable for each circuit MAIN Cutler Hammer Bryant Westinghouse Type BR Series and ITE Gould QP Series The maximum current rating for the main breaker is not to exceed the rating of the panelboard BRANCH Cutler Hammer Bryant Westinghouse Type BR BD Series and ITE Gould QP QT Series The maximum current rating for the branch breaker is not to exceed 20A WIRE GAUGE In order to remain within the manufacturer s
26. rocedure see Table 2 on page 24 for wire lengths and Table 1 on page 24 for torque values To connect the panel to the XADC DC side 1 Remove the DC wiring compartment panel on the XADC see Figure 8 2 Loosen the positive and negative screws on the DC connection lugs see Figure 15 3 Route the large positive red cable and negative black cable from the panel through the DC wiring compartment hole to the XADC 4 Make the DC ground connections to the ground lug on the right hand side or the top of the XADC see Figure 10 5 Slide the negative black cable into the XADC negative DC connection lug and tighten the DC negative screw 6 Slide the positive red cable into the XADC positive DC connection lug and tighten the DC positive screw EA 3 3 N I y WY OOOO LJ b 33 33 YZ l 1a Sze r y N WNION DC positive and negative cable rey a3 33 000000000 DC wiring compartment hole ate YE rE XN Te ee Negative DC connection lug screw Positive DC connection lug screw Figure 15 Connecting Panel to XADC DC Side 20 975 0301 01 01 Installation Instructions Connecting the Panel to the XADC AC Side When following the procedure see Table 2 on page 24 for wire length
27. s and Table 1 on page 24 for torque values See Figure 4 on page 8 for panel electrical connection diagrams Refer to local electrical codes for wire gauge sizes To connect the panel to the XADC AC side 1 2 Remove the AC wiring compartment panel on the XADC see Figure 8 Route the all AC cables from the XADC through the AC wiring compartment hole in the top of the XADC Ensure factory installed grommet is still present Connect the AC ground green cable from the XADC to the front AC bus on the panel marked Equipment Grounding Terminal Connect the neutral white cable from the XADC to the rear AC bus on the panel marked AC Neutral Terminal Connect the AC line black cable from the XADC to the any breaker on the panel that is not reserved for the AC main line Tighten as per the manufacturer s recommended torque rating usually located on the side of breakers AC line connection to breaker 1 30A panel or breaker 4 5 50A panel XADC AC ground connection to Equipment Grounding Terminal ADC AC cables to any breaker except reserved AC line breaker XADC AC neutral connection to AC Neutral Terminal AC wiring compartment hole Figu
28. ten as this may cause stripping of the screw threads Close the hinged door 23 Xantrex AC to DC Converter Mounting the XADC and Panel Remotely To mount the XADC and panel remotely 1 Slide the panel into the mounting cutout 12 in x 8 in 305 mm x 203 mm 2 Fasten the panel to the mounting surface using 6 x 6 or 8 pan head round head or washer head screws suitable for mounting the panel onto particleboard or wood 3 Install the panel faceplate and tighten the center screw do not overtighten as this may cause stripping of the screw threads Install the DC fuse cover Follow the instructions in Mounting the XADC on page 15 to mount the XADC DC Wire Size and Torque Values Table 1 Torque Requirements Connection Torque Value DC Load Output Terminal 12 in lbs 12 14 AWG DC Battery Terminal Lug 30 in Ibs 2 AWG 28 in Ibs 4 6 AWG 25 in Ibs 8 AWG 25 in Ibs 10 14 AWG DC Ground Terminal Lug 30 in Ibs 2 AWG 28 in Ibs 4 6 AWG 25 in Ibs 8 AWG 25 in Ibs 10 14 AWG DC Ground Terminal Bus 35 in lbs 4 6 AWG 25 in Ibs 8 AWG 20 in Ibs 10 14 AWG Line Load Terminals See Circuit Breaker AC Neutral Ground Terminal Bus s 35 in lbs 4 6 AWG 25 in Ibs 8 AWG 20 in Ibs 10 14 AWG Ground Terminal 45 in Ibs 6 AWG 40 in Ibs 8 AWG 35 in Ibs 10 14 AWG Table 2 DC Wire Size to battery bank Converter model
29. the Panel to the XADC AC Side 21 Connecting the AC to the Panel 22 Mounting the XADC and Panel when Connected 23 Mounting the XADC and Panel Remotely 24 DC Wire Size and Torque Values 24 Specifications 25 Electrical Performance 25 Mechanical Specifications 25 Xantrex AC to DC Converter About These Installation Instructions Purpose Audience The purpose of these Installation Instructions is to provide explanations and procedures for installing the Xantrex AC to DC Converter XADC The Installation Instructions provide safety guidelines and procedures for installing the XADC These Installation Instructions are intended for qualified installers who need to be certified technicians or electricians Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions or practices 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 to other equipment Important These notes describe an important action item or an item that you must pay attention to This Guide contains information for three versions of the Xantrex AC to DC Converter The 40 Amp Xantr
30. tween the main battery fuse and the battery To connect the DC 1 Loosen the positive and negative screws on the DC connection lugs see Figure 9 2 If you plan to use the 3 4 in knockout for the DC wiring remove the outer knockout 3 Install a UL CSA approved strain relief on the incoming DC cables Tighten the clamping ring but not the clamp screws on the strain relief 4 Route the incoming cables through the DC wiring compartment knockout in the top of the XADC 5 Remove in 12 mm of insulation from the ends of the incoming cables 6 Make the DC ground connections to either of the ground lugs shown in Figure 9 7 Slide the incoming negative black cable into the XADC negative DC connection lug Tighten the DC negative screw 8 Slide the incoming positive red cable into the XADC positive DC connection lug Tighten the DC positive screw 9 Tighten the clamp screws on the strain relief to secure the DC wires 10 Reattach the DC wiring compartment panel 11 Reconnect vehicle battery connections 13 Xantrex AC to DC Converter Ground lug CL_i strain relief option 1 option Wn LDC wiring knockout iil woe lug option 2 D POS NEG H 9 B Negative DC connection ele lug screw i Z Positive DC connection lug screw vuvvvvvvvvvuy Figure 9 XADC DC Conn
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