Xantrex Technology Power Supply 40 A XADC 40 User Manual

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40 A (XADC-40)  
60 A (XADC-60)  
80 A (XADC-80)  
Owners Guide  
Xantrex AC to DC  
Converter  
Manual Type  
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Xantrex AC to DC  
Converter  
Owners Guide  
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About Xantrex  
Xantrex Technology Inc. is a world-leading supplier of advanced power  
electronics and controls with products from 50 watt mobile units to one MW  
utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and  
backup power applications in both grid-connected and stand-alone systems.  
Xantrex products include inverters, battery chargers, programmable power  
supplies, and variable speed drives that convert, supply, control, clean, and  
distribute electrical power.  
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 Owner’s Guide© 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 D  
Part Number  
975-0305-01-01  
Contact Information  
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About This Guide  
Purpose  
The purpose of this Owner’s Guide is to provide explanations  
and procedures for operating and troubleshooting the Xantrex  
AC to DC Converter (XADC).  
Scope  
The Guide provides information about operating and  
troubleshooting the unit.  
Audience  
The Guide is intended for anyone who needs to operate and  
troubleshoot the XADC.  
Organization  
This Guide is organized into two chapters and one appendix:  
Features: Chapter 1 introduces the Xantrex AC to DC  
Converter, shows where the major components are and lists  
the special features.  
Operation and Troubleshooting: Chapter 2 describes how to  
operate the XADC and common situations or problems that  
may arise and possible solutions.  
Specifications: Appendix A contains electrical performance  
and physical specifications for the XADC.  
iii  
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About This Guide  
Conventions Used  
The following conventions are used in this guide.  
WARNING  
Warnings identify conditions or practices that could result in  
personal injury or loss of life.  
CAUTION  
Cautions identify conditions or practices that could result in  
damage to the unit or to other equipment.  
Important: These notes describe an important action item or  
an item that you must pay attention to.  
This Guide contains information for three versions of the  
Xantrex AC to DC Converter.  
The 40 Amp 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.  
Related Information  
You can find more information about Xantrex Technology  
Inc. as well as its products and services at www.xantrex.com  
iv  
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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 chapter contains important safety and operating  
instructions. Read and keep this Owner’s Guide for future  
reference.  
1. Before 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. 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 it 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.  
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Safety  
Precautions When Working With Batteries  
WARNING: Explosion or fire hazard  
1. Follow all instructions published by the battery  
manufacturer and the manufacturer of the equipment in  
which the battery is installed. 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  
using your XADC.  
2. Make sure the area around the battery is well ventilated.  
3. Never smoke or allow a spark or flame near the engine or  
batteries.  
4. 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.  
5. 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.  
6. Have someone within range of your voice or close  
enough to come to your aid when you work near a lead-  
acid battery.  
7. Have plenty of fresh water and soap nearby in case  
battery acid contacts skin, clothing, or eyes.  
8. Wear complete eye protection and clothing protection.  
Avoid touching your eyes while working near batteries.  
9. 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.  
vi  
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Safety  
10. 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.  
11. 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.  
12. 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  
975-0305-01-01  
vii  
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Contents  
Important Safety Instructions- - - - - - - - - - - - - - - - - - - - v  
1
Features  
Introduction- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1  
Special Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1  
Main Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2  
Optional AC/DC Distribution Panel- - - - - - - - - - - - - - - - - - 2  
2
Operation and Troubleshooting  
Switching the XADC On and Off - - - - - - - - - - - - - - - - - - - - - - 5  
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5  
Troubleshooting Reference - - - - - - - - - - - - - - - - - - - - - - - - - - 6  
A
Specifications  
Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - 7  
Electrical Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7  
Warranty and Return Information - - - - - - - - - - - - - - - - 8  
viii  
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Features  
1
Introduction  
The Xantrex AC to DC Converter (XADC) is a family of  
converter/chargers, consisting of 40A (XADC-40), 60A  
(XADC-60), and 80A (XADC-80) units. All XADC units  
will accept a broad range of 120 Vac input power and convert  
it into a 3-step DC charge algorithm designed for use with  
12Vdc battery systems and/or to power DC loads. The  
XADC can operate from generator power and potentially  
poor quality campground power. The XADC is available as  
either a standalone product or integrated with an optional  
AC/DC Distribution Panel.  
Special Features  
The XADC has many convenient features:  
Current limiting, over-temperature protection, input  
under-voltage protection and input over-voltage  
protection to give you worry-free, safe operation  
Three stage, power factor corrected, charging means  
more AC power is available to run other appliances  
Ability to recharge completely “dead” batteries (0 Volts)  
Both input and output ventilation on one side for  
maximum flexibility in installation  
Optional AC/DC Distribution Panel for ease of  
installation and maintenance  
Ultra-quiet fan operation  
Battery reverse polarity protection to prevent damage to  
the unit in the event of a reverse polarity connection  
1
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Main Components  
Figure 1-1 shows the main components of the XADC.  
2
4
3
1
5
Figure 1-1 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 locations)  
Mounting flanges  
Optional 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.  
2
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Main Components  
1
2
3
4
5
6
7
8
9
Figure 1-2 AC/DC Distribution Panel Components  
Item  
Description  
1
DC fuse/AC breaker access panel (swings open with  
thumb latch)  
2
3
Removable DC fuse access panel with DC circuit  
designation label.  
Removable AC/DC Distribution Panel faceplate  
(service technician only)  
4
5
AC breakers (not included)  
Screw for removing AC/DC panel faceplate (service  
technician only)  
6
7
8
9
Screw for removing DC fuse access panel  
Fuse puller  
AC breaker knockouts  
Removable faceplate for XADC converter (service  
technician only)  
975-0305-01-01  
3
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4
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Operation and  
Troubleshooting  
2
Switching the XADC On and Off  
The XADC is always On when AC voltage is applied. To  
switch the XADC Off, disconnect the AC input voltage by  
turning the AC breaker off.  
Maintenance  
It may be necessary to replace the DC fuses in the XADC.  
Fuses for XADC should be:  
XADC-40  
XADC-60  
XADC-80  
a
a
a
2 × 30 A  
3 × 30 A  
4 × 30 A  
a.Littelfuse Type 257 or equivalent  
If the optional AC/DC Distribution Panel is installed, it may  
be necessary to replace the AC breakers and DC fuses.  
Fuses for DC loads should be:  
Littelfuse Type 257 or equivalent and the maximum allowed  
fuse for the DC loads is 20 A.  
Breakers for the AC side should be:  
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.  
5
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Troubleshooting Reference  
WARNING: Electric shock hazard  
Do not remove the cover of the XADC or disassemble the XADC.  
The XADC does not contain any internal user-serviceable parts and  
attempting to service the unit yourself could result in electrical  
shock or burn and will also void your warranty.  
Table 2-1 Troubleshooting reference  
Problem  
Possible Cause  
Solution  
XADC will  
not run  
Cables are loose  
Check DC and AC connections  
Output fuses are  
damaged or not  
installed  
Check output fuses  
AC input breaker open Check AC input breaker  
Short circuit in one or Remove load fuses one by one until  
more of the load  
circuits  
XADC output voltage recovers,  
re-install load fuses one by one to  
find faulty load circuit(s)  
Internal temperature  
too hot  
Check that the XADC has sufficient  
ventilation. Allow the XADC to cool  
down and restart.  
Something may be  
preventing the fan  
from turning. The unit  
has a safety shutoff in  
this situation.  
Ensure that nothing is obstructing  
the fan operation.  
6
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Specifications  
A
Specifications are subject to change without notice.  
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)  
Electrical Performance  
AC Input  
XADC-40 XADC-60 XADC-80  
Input current (at rated output)  
Nominal input voltage  
6 Aac  
9 Aac  
120 Vac, 60 Hz  
108 Vac – 130 Vac  
90 Vac  
12 Aac  
Normal operating input voltage  
Min. operating input voltage  
Max. operating input voltage  
Power factor (rated output, nominal input)  
Safe (non-operating) input voltage range  
Frequency  
140 Vac  
0.95  
0 – 150 Vrms  
50 – 70 Hz  
7
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DC Output  
XADC-40 XADC-60 XADC-80  
Recommended battery bank size  
Output current  
220 Ah  
40 Adc  
44A  
220 Ah  
60 Adc  
64 A  
400 Ah  
80 Adc  
84 A  
Current limit (maximum)  
Nominal output voltage  
13.5 Vdc (float charge)  
14.2 Vdc (bulk/absorption charge)  
Min. output voltage  
0 V  
a
1.5% at terminals of XADC  
Load regulation  
b
1.5%  
Line regulation  
No load voltage accuracy  
Efficiency at nominal output  
Battery draw when turned off  
0.1 Vdc  
85%  
< 2 mA  
a.Load regulation is the converter's ability to maintain a constant output voltage as the load  
current changes.  
b. Line regulation is the converter's ability to maintain a constant output voltage as the line  
(input) voltage changes.  
Warranty and Return Information  
If your vehicle is within its factory warranty period:  
The warranty for this product is covered under your vehicle's express warranty, please  
contact your vehicle manufacturer's owner services department for technical support and  
warranty service.  
If your vehicle is out of its factory warranty period:  
If the warranty period for your Xantrex AC to DC Converter has expired, if the unit was  
damaged by misuse or incorrect installation, if other conditions of the warranty have not  
been met, or if no dated proof of purchase is available, your unit may be serviced or  
replaced for a flat fee.  
To return your Xantrex AC to DC Converter for out of warranty service, contact Xantrex  
Customer Service at 1-360-925-5097 for a Return Material Authorization (RMA) number.  
Payment options such as credit card or money order will be explained by the Customer  
Service Representative. In cases where the minimum flat fee does not apply, as with  
incomplete units or units with excessive damage, an additional fee will be charged. If  
applicable, you will be contacted by Customer Service once your unit has been received.  
8
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Xantrex Technology Inc.  
Printed in China  
975-0305-01-01  
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