Xantrex Technology TV Converter Box XADC User Manual

XADC  
Xantrex AC to DC Converter  
Installation Instructions  
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 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  
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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. 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.  
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  
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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.  
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 gasoline-  
powered 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.  
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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.  
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  
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Xantrex AC to DC Converter  
Installation  
Main Components  
Figure 1 and Figure 2 show the main components of the XADC.  
4
3
2
1
5
Figure 1 XADC External Components  
Item  
Description  
1
2
3
4
5
AC wiring compartment  
Intake and outflow vents (do not obstruct)  
DC wiring compartment  
Ground connection (2 possible connection locations)  
Mounting flanges  
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Installation Instructions  
5
4
3
2
6
7
POS NEG  
(+) (-)  
1
8
9
Figure 2 XADC Internal Components  
Item  
Description  
1
2
3
4
5
6
7
8
9
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 ½ in. - 3/8 in. trade size (with ¾ in. knockout)  
DC fuses  
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.  
Important: The XADC P30 and XADC P50 panels are not intended for use with rigid  
conduit systems.  
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Xantrex AC to DC Converter  
6
7
1
5
2
8
9
3
4
Figure 3 AC/DC Distribution Panel Components  
Item  
Description  
1
2
3
4
5
6
7
8
9
DC fuse/AC breaker access panel (swings open with thumb latch)  
Removable DC fuse access panel with DC circuit designation label.  
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  
AC breaker knockouts  
30 Amp Panel Diagram  
50 Amp Panel Diagram  
Figure 4 30A and 50A Panel Connection Diagrams  
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975-0301-01-01  
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Installation Instructions  
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5
4
7
8
9
3
10  
2
11  
12  
1
13  
14  
Figure 5 AC/DC Distribution Panel and XADC Internal Components  
Item  
1
Description  
Equipment Grounding Terminal bus (front)  
AC Neutral Terminal bus (rear)  
2
3
AC wiring knockouts (½ in. - 3/8 in. trade size - and ¾ 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 (½ in. - 3/8 in. trade size - and ¾ in. nested) (7 positions)  
DC negative bus  
4
5
6
7
8
9
DC positive lug (battery)  
10  
11  
12  
13  
14  
DC negative lug (battery)  
DC battery fuses (bottom four locations - not included).  
DC positive cable (to XADC positive (+))  
DC negative cable (to XADC negative (-))  
Mounting flange  
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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. Code of Federal Regulations (CFRs)  
Canadian Standards Association (CSA) and the RV Industry Association  
(RVIA) for installations in RVs  
Installation Tools and Materials  
You will need the following items to install the XADC and panel:  
#2 Phillips screwdriver for removal of AC and DC wiring compartment panels  
Torque screwdriver (20 – 50 in-lb range) with flat head socket insert (optional  
robertson for AC and DC bus bars)  
Pliers for strain relief installation  
4 × #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 × #6 or #8 pan head, round head or washer head screws  
suitable for mounting the attached XADC and AC/DC Distribution Panel  
installation and the equivalent screwdriver  
All strain reliefs must be UL/CSA approved ½ in. or ¾ 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)  
Four DC battery fuses and up to 11 additional DC load fuses  
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.  
XADC converter  
Xantrex AC to DC Converter Owner’s Manual (Part #: 975-0305-01-01)  
Xantrex AC to DC Converter Installation Instructions (Part #: 975-0301-01-01)  
The following items are shipped with the AC/DC Distribution Panel.  
AC/DC Distribution Panel  
AC/DC Distribution Panel Safety Instructions sheet  
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975-0301-01-01  
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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.  
Cool  
While the unit will safely operate at ambient air temperatures between 14 ºF and 86 ºF  
(-10 ºC and 30 ºC) and will operate de-rated between 86 ºF and 140ºF (30 ºC and 60 ºC)  
— the cooler the better within this range. At ambients in excess of 140ºF (60ºC) the  
XADC may shut down.  
Ventilated  
Safe  
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.  
Protected from Do not mount the XADC or panel where it will be exposed to gases produced by batteries.  
battery gases  
Battery gases are corrosive, and prolonged exposure to battery gases will damage them.  
The XADC may be mounted in 3 orientations:  
horizontally on a flat surface  
vertically on a wall with fan vent facing left  
vertically on a wall with fan vent facing right  
Non-Approved Mounting Orientation  
Wall Mount (Fan Up or Down)  
Non-Approved Mounting Orientation  
Ceiling Mount  
Approved Mounting Orientation  
Desktop Mount  
Approved Mounting Orientation  
Wall Mount (Fan Left or Right)  
Figure 6 Installation Configurations  
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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. Tighten until the lock washer  
is flat plus ¼ 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  
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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.  
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 between 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 ¾ 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 ½ 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.  
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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. Route AC wires through the AC wiring compartment hole.  
2. If you plan to use the ¾ 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.  
6. Reattach the AC wiring compartment panel.  
7. Reconnect the AC by closing or engaging the main AC disconnect breaker.  
Grommet  
AC ground (green), neutral  
(white) and line (black)  
AC wiring  
compartment hole  
Figure 10 XADC AC Connections  
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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.  
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).  
Follow the procedures in the order given:  
1. “Preparing to Install”  
2. “Connecting the XADC and Panel Together”  
3. “Preparing the Mounting Location for the XADC and Panel”  
4. “Connecting the DC to the Panel”  
5. “Connecting the Panel to the XADC DC Side”  
6. “Connecting the Panel to the XADC AC Side”  
7. “Connecting the AC to the Panel”  
8. “Mounting the XADC and Panel Remotely”  
9. “Mounting the XADC and Panel when Connected”  
Configurations  
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.  
Preparing to Install  
To prepare the panel for installation:  
1. Open the door on the panel and remove the center screw.  
2. Remove the panel faceplate.  
3. Remove the correct number of AC and DC knockouts for your installation  
from the back of the panel.  
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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.  
6. 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.  
2. Install a UL/CSA approved strain relief on both the AC and DC wiring  
compartment holes.  
3. 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 information.  
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. × 12 1/8 in. – 30.5 cm ×  
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  
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.  
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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  
mountingflange(keepthe  
left or right flange and  
mounting hardware for  
the bottom flange)  
Add this mounting flange  
Remove this side  
mounting flange  
(using one of the removed  
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.  
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.  
XADC mounting tabs  
with pilot pins and panel  
mounting clips  
Figure 12 Connecting the XADC and Panel  
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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. 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 connections 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  
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.  
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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.  
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.  
Remove these  
three screws  
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.  
DC Knockouts  
DC fuses  
Negative DC bus  
Positive DC bus  
Negative DC  
battery lug  
Positive DC  
battery lug  
Figure 14 Connecting DC to the Panel  
975-0301-01-01  
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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. 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.  
DC positive and  
negative cable  
DC wiring  
compartment hole  
Negative DC connection  
lug screw  
Positive DC connection  
lug screw  
Figure 15 Connecting Panel to XADC DC Side  
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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. 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.  
3. Connect the AC ground (green) cable from the XADC to the front AC bus on  
the panel, marked “Equipment Grounding Terminal”.  
4. Connect the neutral (white) cable from the XADC to the rear AC bus on the  
panel, marked “AC Neutral Terminal”.  
5. 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  
XADC AC ground  
4+5 (50A panel)  
connection to  
Equipment  
Grounding Terminal  
XADC AC cables to  
any breaker except  
XADC AC neutral  
reserved AC line  
connection to AC  
breaker  
Neutral Terminal  
AC wiring  
compartment hole  
Figure 16 Connecting Panel to XADC AC Side  
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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. 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 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.  
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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. Connect the ground lead (green or bare) from each AC 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.  
AC input knockouts  
AC line connection  
to breaker 1 (30A  
Main AC input and AC loads  
panel) or breaker  
ground connection to  
4+5 (50A panel)  
Equipment Grounding  
Terminal  
AC loads “hot” to  
any breaker except  
reserved AC line  
Main AC input and AC  
breaker  
loadsneutralconnection  
to AC Neutral Terminal  
Figure 17 XADC AC Connections  
Mounting the XADC and Panel when Connected  
To mount the XADC and panel when connected:  
1. Slide the complete unit into the mounting cutout.  
2. Fasten the complete unit into the cutout and secure using 6 × #6 or #8 pan  
head, round head or washer head screws suitable for mounting the unit onto  
particleboard or wood.  
3. Install the XADC faceplate and tighten the four screws (do not overtighten as  
this may cause stripping of the screw threads).  
4. Install the DC fuse cover.  
5. Install the panel faceplate and tighten the center screw (do not overtighten as  
this may cause stripping of the screw threads).  
6. Close the hinged door.  
975-0301-01-01  
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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. 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  
DC (+) Battery Terminal Lug  
12 in-lbs (12-14 AWG)  
30 in-lbs (2 AWG)  
28 in-lbs (4-6 AWG)  
25 in-lbs (8 AWG)  
25 in-lbs (10-14 AWG)  
DC (-) Ground Terminal Lug  
30 in-lbs (2 AWG)  
28 in-lbs (4-6 AWG)  
25 in-lbs (8 AWG)  
25 in-lbs (10-14 AWG)  
DC (-) Ground Terminal Bus  
Line/Load Terminals  
35 in-lbs (4-6 AWG)  
25 in-lbs (8 AWG)  
20 in-lbs (10-14 AWG)  
See Circuit Breaker  
AC Neutral/Ground Terminal Bus(s) 35 in-lbs (4-6 AWG)  
25 in-lbs (8 AWG)  
20 in-lbs (10-14 AWG)  
Ground Terminal  
45 in-lbs (6 AWG)  
40 in-lbs (8 AWG)  
35 in-lbs (10-14 AWG)  
Table 2 DC Wire Size (to battery bank)  
Recommended minimum Recommended maximum 2-way  
a
Converter model  
XADC-40  
DC wire gauge  
DC cable length  
20 ft (610 cm)  
20 ft (610 cm)  
20 ft (610 cm)  
8 AWG  
XADC-60  
6 AWG  
XADC-80  
4 AWG  
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.  
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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 #: 975-  
0305-01-01).  
Electrical Performance  
AC Input  
XADC-40 XADC-60 XADC-80  
Input current (at rated output)  
Nominal input voltage  
Frequency  
6 Aac  
9 Aac  
12 Aac  
120 Vac, 60 Hz  
50 – 70 Hz  
DC Output  
XADC-40 XADC-60 XADC-80  
Recommended maximum battery bank size 220 Ah  
220 Ah  
60 Adc  
400 Ah  
80 Adc  
Output current  
40 Adc  
Mechanical Specifications  
Physical Specifications  
XADC-40  
XADC-60  
XADC-80  
Weight  
7.9 lb  
8.2 lb  
8.3 lb  
(3.6 kg)  
(3.7 kg)  
(3.8 kg)  
Operating temperature range  
14 ºF – 86 ºF (-10 ºC – 30 ºC)  
de-rated 86 ºF – 140ºF (30 ºC – 60 ºC)  
> 140ºF (60 ºC) unit may shut down  
Length  
Width  
Height  
11 13/16 in. (300.0 mm)  
7 1/8 in. (180.0 mm)  
4 3/4 in. (120.0 mm)  
975-0301-01-01  
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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.  
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 USERS RISK; AND  
(C) 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:  
Fax:  
1 360 925 5097 (direct)  
1 360 925 5143 (direct)  
Email:  
Web:  
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