Xantrex Technology XADC User Manual

Xantrex AC to DC Converter

XADC

Installation Instructions

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 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

975-0301-01-01 Revision E

Xantrex AC to DC Converter

About These Installation Instructions

Purpose

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.

Audience

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

W arnings 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 Xantrex 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.

2 975-0301-01-01

Important Safety Instructions

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 XADC if it has received a sharp blow, been dropped, or
otherwise damaged in any way. If the XADC is damaged, see the Warranty
section.

Installation Instructions

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

975-0301-01-01 3

Xantrex AC to DC Converter

Explosive Gas Precautions

WARNING: Explosion hazard

1. Working in the vicinity of batteries may be dangerous. Batteries generate
explosive gases during normal operation, therefore, yo u must read this guide
and follow the instructions exactly before installing or using your XADC.

2. 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 gasoline­powered machinery , fuel tanks, as well as joints, fittings, or other connections
between components of a fuel system.

Precautions When Working With Batteries

WARNING: Explosion or fire hazard

3. Make sure the area around the battery is well ventilated.

4. Never smoke or allow a spark or flame near the engine or batteries.

5. 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.

6. 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.

7. Have someone within range of your voice or close enough to come to your aid
when you work near a lead-acid battery.

8. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.

9. Wear complete eye protection and clothing protection. Avoid touching your
eyes while working near batteries.

10. 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.

11. 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.

4 975-0301-01-01

12. Use the XADC for char ging 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

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:

• Reorient or relocate the receiving antenna

• Increase the separation between the equipment and the receiver

• Connect the equipment into an outlet on a circuit different from that which the
receiver is connected

• Consult the dealer where the XADC was purchased or an experienced radio/
TV technician for help

Installation Instructions

975-0301-01-01 5

Xantrex AC to DC Converter

Installation

Main Components

Figure 1 and Figure 2 show the main components of the XADC.

2

3

1

5

Figure 1

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

XADC External Components

4

6 975-0301-01-01

Installation Instructions

5

4
3

6

2

POS

NEG

(+)

1

(-)

7

8

9

Figure 2

Item Description

1 AC wiring compartment hole
2 Black AC line cable
3 White AC neutral cable
4 Green AC ground cable
5 Grommet (supplied)
6 Strain relief (not supplied)
7 DC wiring compartment hole ½ in. - 3/8 in. trade size (with ¾ in. knockout)
8DC fuses
9 DC positive (+) and negative (-) connection lugs

AC/DC Distribution Panel

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 connections:
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.

XADC Internal Components

Important:

conduit systems.

975-0301-01-01 7

The XADC P30 and XADC P50 panels are not intended for use with rigid

Xantrex AC to DC Converter

1

5

2

3

4

Figure 3

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)
4 Removable faceplate for XADC converter (service technician only)
5 Screw for removing panel faceplate (service technician only)

AC/DC Distribution Panel Components

6

7

8
9

6 AC breakers (not included)
7 Screw for removing DC fuse access panel
8 Fuse puller
9 AC breaker knockouts

30 Amp Panel Diagram

Figure 4

30A and 50A Panel Connection Diagrams

50 Amp Panel Diagram

8 975-0301-01-01