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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

Xantrex AC to DC Converter

Installation Instructions

XADC

975-0301-01-01 Revision E

Summary of content (26 pages)

PAGE 1
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 Installa
PAGE 2
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.
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Installation Instructions 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.
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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, you 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.
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Installation 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.
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Xantrex AC to DC Converter Installation Main Components Figure 1 and Figure 2 show the main components of the XADC.
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Installation Instructions 5 4 3 2 6 7 1 POS (+) NEG (-) 8 9 Figure 2 XADC Internal Components 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.
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Xantrex AC to DC Converter 6 1 5 7 2 8 3 9 4 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.
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Installation Instructions 4 5 6 7 8 9 3 10 2 11 1 12 13 14 Figure 5 AC/DC Distribution Panel and XADC Internal Components 975-0301-01-01 Item Description 1 Equipment Grounding Terminal bus (front) 2 AC Neutral Terminal bus (rear) 3 AC wiring knockouts (½ in. - 3/8 in. trade size - and ¾ in.
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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: • • • • The U.S. National Electrical Code (NEC) The Canadian Electrical Code (CEC) The U.S.
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Installation Instructions • • XADC converter faceplate and mounting hardware Plastic bag containing two mounting tabs and related hardware, one top mounting flange and related hardware Choosing a Location The XADC and AC/DC Distribution Panel must only be installed in a location that is: Dry Do not allow water or other liquids to drop or splash on the XADC.
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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” 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.
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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 When following the procedure, see Table 2 on page 24 for wire lengths and Table 1 on page 24 for torque values.
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Xantrex AC to DC Converter Strain relief Ground lug (option 1) DC wiring knockout Ground lug (option 2) POS (+) NEG (-) Negative DC connection lug screw Positive DC connection lug screw Figure 9 XADC DC Connections Connecting the AC Input When following the procedure, see Table 1 on page 24 for torque values. 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.
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Installation Instructions Mounting the XADC To mount the XADC using the mounting plates: 1. Align the XADC with the 4 previously marked mounting positions. 2. Fasten the XADC using 4 × #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.
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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. 5. 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.
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Installation Instructions Add these two mounting tabs (from the panel hardware bag) Add this mounting flange (from the panel hardware bag) Remove this side mounting flange (keep the left or right flange and mounting hardware for the bottom flange) Add this mounting flange (using one of the removed side mounting flanges and the associated hardware) Remove this side mounting flange Figure 11 Mounting Flanges for Installation 4.
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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. × 12 1/8 in. – 305 mm × 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. × 8 in. – 305 mm × 203 mm) for the panel, or use an existing hole from a previous converter installation. 2.
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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 loads 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.
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Xantrex AC to DC Converter Connecting the Panel to the XADC DC Side When following the procedure, 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.
PAGE 21
Installation Instructions Connecting the Panel to the XADC AC Side 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. Refer to local electrical codes for wire gauge sizes. To connect the panel to the XADC AC side: 1. Remove the AC wiring compartment panel on the XADC (see Figure 8). 2.
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Xantrex AC to DC Converter Connecting the AC to the Panel 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.
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Installation Instructions AC Loads 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. 4. Connect the neutral lead (white) from each AC load to the rear AC bus on the panel, marked “AC Neutral Terminal”. 5.
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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. × 8 in. – 305 mm × 203 mm). 2. Fasten the panel to the mounting surface using 6 × #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). 4. Install the DC fuse cover. 5.
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Installation Instructions Specifications All specifications are subject to change without notice. Additional specifications are available in the Xantrex AC to DC Converter Owner’s Manual (Part #: 9750305-01-01).
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Xantrex AC to DC Converter 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.