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
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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975-0301-01-01
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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975-0301-01-01
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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Installation Instructions
6
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
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
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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
975-0301-01-01
21
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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975-0301-01-01
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.
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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.
24
975-0301-01-01
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 USER’S 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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975-0301-01-01
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