973-0019-01-02 - Rev A - Fuse Block - Xantrex TFBs to the Battery, DC Disconnect, and Inverter...

Smart choice for power

Installation Guide

Fuse Block

www.xantrex.com

TFB110/TFB110CTFB200/TFB200CTFB300/TFB300CTFB350/TFB350CTFB400/TFB400C

Installation Guide

2 ©2002 Xantrex Technology Inc. All Rights ReservedP/N 973-0019-01-02 Rev A 06/2002

About Xantrex

Xantrex Technology Inc., is a world-leading supplier ofadvanced power electronics and controls with productsfrom 50 watt mobile units to 1 MW utility-scale systemsfor wind, solar, batteries, fuel cells, microturbines, andbackup power applications in both grid-connected andstand-alone systems. Xantrex products includeinverters, battery chargers, programmable powersupplies, and variable speed drives that convert, supply,control, clean, and distribute electrical power.

Trademarks

Trace and Xantrex are registered trademarks of XantrexInternational.

Notice of Copyright

Fuse Block Installation Guide ©June 2002 XantrexTechnology Inc. All rights reserved.

Disclaimer

Since the use of this guide and the conditions ormethods of installation, operation, use andmaintenance of the unit are beyond the control ofXantrex Technology Inc., the company does not assumeresponsibility and expressly disclaims liability for loss,damage, or expense arising out of or any way connectedwith such installation, operation, use, or maintenance.

See pages 12 through 18 in this guide for specificwarranty information.

Date and Revision

June 2002, Revision A

Document Number

973-0019-01-02

Contact Information

Web: www.xantrex.comPhone: 1.888.608.0721Fax: 360.435.2229

©2002 Xantrex Technology Inc. All Rights ReservedP/N 973-0019-01-02 Rev A 06/2002

3

Table of Contents

About Xantrex .............................................................................................. 2Trademarks ....................................................................................................... 2Notice of Copyright .......................................................................................... 2Disclaimer ......................................................................................................... 2Date and Revision ............................................................................................ 2Document Number ........................................................................................... 2Contact Information ........................................................................................ 2

Introduction ................................................................................................. 5Tools/Materials Required .................................................................................. 5

Installation .................................................................................................... 6Mounting .......................................................................................................... 6Cable Installation into Fuse Block ................................................................... 7

For Fuse Blocks designed for Series-C Battery Cables .................................. 7For Fuse Blocks designed for Ring-lugged Battery Cables ........................... 8

Wiring TFBs to the Battery, DC Disconnect, and Inverter ................................ 9

Care and Maintenance ............................................................................... 10Fuse Replacement ........................................................................................... 10

Replacement Fuses ..................................................................................... 11

Limited Warranty ....................................................................................... 12What does this warranty cover and how long does it last? ......................... 12What will Xantrex do? ................................................................................... 12How do you get service? ................................................................................ 13What does this warranty not cover? ............................................................. 14DISCLAIMER .................................................................................................... 15

Product ....................................................................................................... 15Exclusions ................................................................................................... 16Information ................................................................................................ 16WARNING: LIMITATIONS ON USE ................................................................ 17

Return Material Authorization Policy ........................................................... 17Shipping Instructions ................................................................................. 18

If you are returning a product from outside of the USA or Canada ..... 18If you are returning a product to a Xantrex Authorized Service Center

(ASC) ................................................................................................... 18

Service Information .................................................................................... 19

Installation Guide


List of Figures

Figure 1 Fuse Block for Type-C Battery Cables (TFBxxxC) ............................... 5

Figure 1a Fuse Block for Ring-lugged Battery Cables(TFBxxx) ........................ 5

Figure 2 Fuse Block Dimensional Drawing .................................................... 6

Figure 3 Installation for Type-C Battery Cables ............................................. 7

Figure 4 Installation for Ring-lugged Battery Cables ................................... 8

Figure 5 Wiring TFB’s to the Battery, DC Disconnect, and Inverter .............. 9

Figure 6 Remove the Two Nuts and Washers and Replace Fuse .................. 10

List of Tables

Table 1 Bolt and Nut Sizes ........................................................................... 6

Table 2 Replacement Fuses and Cable Sizes .............................................. 11


5

Introduction

The Trace™ brand fuse block (TFB) protects the powersystem’s DC wiring should an overcurrent conditionoccur. The fuse block is placed between the battery’sungrounded conductor (usually the positive cable) andthe DC input terminal of the inverter.

The TFBs include a fast acting, current limiting class-Tfuse providing extremely fast protection when a shortcircuit occurs. When the fuse is properly matched to thesystem current, its time delay allows the inverter tosurge to full power without blowing the fuse. A plasticcover prevents accidental short circuits to the fuseterminals. Fuse sizes include 110, 200, 300, 350 and400 amps.

There are two types of fuse blocks available. TheTFBxxxC fuse block has “set” screw lugs for cables withno terminal connector’s on the ends (hereto referred toas C-type battery cables). The TFBxxx fuse block hasstainless steel bolt connections for cables with ringterminals (hereto referred to as ring-lugged batterycables). Both fuse blocks include a black polycarbonate,fiberglass reinforced base and a clear polycarbonatesnap-on cover.

Tools/Materials Required

• 4 screws (type depending on mounting material)• 5/16 inch allen wrench (for C-type fuse blocks only)• 9/16 inch socket for 3/8" hex nuts• 1/2 inch socket for 5/16" hex nuts• assorted screwdrivers• knife

Figure 1Fuse Block for C-type

Battery Cables (TFBxxxC)

Figure 1aFuse Block for Ring-lugged

Battery Cables (TFBxxx)

NOTE: These fuseblocks meet theNationalElectrical Coderequirements forovercurrentprotection.Xantrex offersthe DC175 andDC250 in anenclosure forapplicationsrequiring NECcompliance forboth overcurrentprotection and aDC disconnect.

Installation Guide


Installation

Mounting

Locate the fuse block within 18 inches (45 cm) of thebattery. It should be placed in a location where it iseasily accessible should the fuse need replacing.

1. Squeeze the clear plastic protective cover andremove it from the fuse block base.

2. Use the fuse block base as a template for location ofthe four mounting holes. The fuse block should bemounted to a secure surface. Allow at least 6 inches(15 cm) from the fuse contacts to allow for removalwithout shorting to a grounded object.

3. Use appropriate hardware (not supplied) to mountthe fuse block.

7.0" (177.8 cm)

6.250" (158.75 cm)

2.00"(50.6 cm)

X4 holes for #10 screws

1.32"(33.53 cm)A ABB

Figure 2Fuse Block Dimensional Drawing

(Not to scale)

Table 1Bolt and Nut Sizes

NOTE: It is notrecommended tolocate the fuseblock inside theenclosure withthe batterieswhere explosivegases may exist.

epyTkcolBesuF)tun/tlob(xxxBFT

)wercstes(CxxxBFT

eziSguL/tloB

A B

002,011BFT tunxehhtiwtlob81-8/3 tunxehhtiwtlob01-61/5

004,053,003BFT tunxehhtiwtlob81-8/3 tunxehhtiwtlob81-8/3

C002,C011BFT selbactuc0/2-4#rofsgul0/2# tunxehhtiwtlob01-61/5

C004,C053,C003BFT selbactucMCM052-4#rofsgulMCM052 tunxehhtiwtlob81-8/3


7

Installation (continued)

Cable Installation into Fuse Block

For Fuse Blocks designed for C-Type Battery Cables (TFBxxxC)

1. Strip back 1 inch (2.5 cm) of the insulation on thebattery cable.

2. Insert the cable into the terminal block (ensure allconductor strands are in the block)

See Figure 3.

3. Tighten the hex screws to 10-15 ft/lbs.

4. Repeat Steps 2 and 3 for the connection to the otherend of the fuse block.

Figure 3Installation for C-Type Battery Cables

Strippedback 1 inch

Installation Guide


Figure 4Installation for Ring-lugged Battery Cables


Cable Installation into Fuse Block (continued)

hex nut hex nutsplit-

washerssplit-

washers

Ring-lug onBattery Cables Ring-lug on

Battery Cables

For Fuse Blocks designed for Ring-lugged Battery Cables (TFBxxx)

A. If necessary, install the ring-lugs (not supplied) ontothe battery cables. Ensure the terminal connector’shave a 3/8" diameter opening for placement over thestud connector on the fuse block.

1. Remove the 3/8" hex nut and split washers from thefuse block.

2. Place the cable ring lugs over the 3/8-18 bolt on thefuse block assembly and reinstall the split washerand hex nut.

See Figure 4.

3. Tighten the hex nuts to 10-15 ft/lbs.

4. Repeat Steps 2, 3, and 4 for connection to the otherend of the fuse block.

NOTE: Do not placeanythingbetween thering-lug on thebattery cableand the terminalsurface.

Terminal surface Terminal surface

3/8-18bolt

3/8-18bolt


9

Figure 5Wiring TFBs to the Battery, DC Disconnect, and Inverter


Wiring TFBs to the Battery, DC Disconnect, and Inverter

+ -BATTERY

INVERTER

TFB FUSE BLOCK FORC-TYPE

BATTERY CABLES

FU

SE

CL

AS

S T

30

0 A

MP

*DCDISCONNECT

*DC DISCONNECT MAY NOTBE REQUIRED IN ALL

APPLICATIONS

+ -BATTERY

TFB FUSE BLOCKFOR RING-LUGGEDBATTERY CABLES

INVERTER

FUS

E C

LAS

S T

300

AM

P

*DCDISCONNECT

*DC DISCONNECT MAY NOTBE REQUIRED IN ALL

APPLICATIONS

Installation Guide


Fuse Replacement

Before replacing the fuse, determine and correct thecause of the overcurrent condition.

1. Use a hex socket and remove the two nuts (and splitwashers) securing the fuse. Note the hardwareinstalled and the order of how it is stacked. This isimportant to prevent excess heat which can causethe fuse to open again.

2. Remove the open fuse and replace it with a knowngood one.

3. Reinstall the hardware as it was originally stacked onthe fuse.

4. Tighten the hex nuts securing the fuse to10-15 ft/lbs.

5. Double-check the battery cable connections andverify all connections are properly tightened .

Figure 6Remove the Two Nuts and Washers and Replace Fuse

Care and Maintenance

WARNING:BEFOREREPLACINGTHE FUSE,DISCONNECT ALLPOWER SOURCESAND TURN OFFALL LOADS.

NOTE: If the systemalso contains aDC disconnect,switch it to OFFbefore replacingthe fuse.

NOTE: Fuses are NOTcovered under thelimited warranty.

FUS

E C

LAS

S T

300

AM

PF

US

E C

LAS

S T

300

AM

P

bolt

split-washer

hex nutfuse

bolt

split-washer

hex nut

bolt

split-washer

hex nutfuse

bolt

split-washer

hex nut


11

Replacement Fuses

Replacement fuses are available from XantrexTechnology Inc. These fuses fit either the TFBxxx orTFBxxxC models (of the same rating only).

See Table 2 for part numbers for replacement fuses.

Care and Maintenance (continued)

WARNING:REPLACE FUSEWITH ONLY THESAME TYPE(CLASS T) ANDRATING(AMPERAGE/VOLTAGE).

NOTE: The temperaturerating of thecable sizesspecified inTable 2 are 75 °Cin free-air basedon an ambient airtemperature of30 °C (86 °F).

Table 2Replacement Fuses and Cable Sizes

#BFT egarepmAtnemecalpeR

esuFeziSelbaC

C011FBT/011BFT spma011 011FT mm2.12/GWA4# 2

C002FBT/002BFT spma002 002FT mm4.76/GWA0/2# 2

C003FBT/003BFT spma003 003FT mm701/GWA0/4# 2



Installation Guide


Limited Warranty

What does this warranty cover and how long does it last?

This Limited Warranty is provided by XantrexTechnology, Inc. (“Xantrex”) and covers defects inworkmanship and materials in your Fuse Block. Thiswarranty lasts for a Warranty Period of two years fromthe date of purchase at point of sale to you, the originalend user customer.

What will Xantrex do?

Xantrex will, at its option, repair or replace the defectiveproduct free of charge, provided that you notify Xantrexof the product defect within the Warranty Period, andprovided that Xantrex through inspection establishesthe existence of such a defect and that it is covered bythis Limited Warranty.

Xantrex will, at its option, use new and/or reconditionedparts in performing warranty repair and buildingreplacement products. Xantrex reserves the right to useparts or products of original or improved design in therepair or replacement. If Xantrex repairs or replaces aproduct, its warranty continues for the remainingportion of the original Warranty Period or 90 days fromthe date of the return shipment to the customer,whichever is greater. All replaced products and all partsremoved from repaired products become the propertyof Xantrex.

Xantrex covers both parts and labor necessary to repairthe product, and return shipment to the customer via aXantrex-selected non-expedited surface freight withinthe contiguous United States and Canada. Alaska andHawaii are excluded. Contact Xantrex Customer Servicefor details on freight policy for return shipments outsideof the contiguous United States and Canada.



13

Limited Warranty (continued)

How do you get service?

If your product requires troubleshooting or warrantyservice, contact your merchant. If you are unable tocontact your merchant, or the merchant is unable toprovide service, contact Xantrex directly at:

Phone: 360.435.8826Fax: 360.474.0616Email: [email protected]

Direct returns may be performed according to theXantrex Return Material Authorization Policy describedin your product manual. For some products, Xantrexmaintains a network of regional Authorized ServiceCenters. Call Xantrex or check our website to see if yourproduct can be repaired at one of these facilities.

In any warranty claim, dated proof of purchase mustaccompany the product and the product must not havebeen disassembled or modified without prior writtenauthorization by Xantrex.

Proof of purchase may be in any one of the followingforms:

• the dated purchase receipt from the original purchaseof the product at point of sale to the end user, or

• the dated dealer invoice or purchase receipt showingoriginal equipment manufacturer (OEM) status, or

• the dated invoice or purchase receipt showing theproduct exchanged under warranty.

Installation Guide


What does this warranty not cover?

This Limited Warranty does not cover normal wear andtear of the product or costs related to the removal,installation, or troubleshooting of the customer’selectrical systems. This warranty does not apply to andXantrex will not be responsible for any defect in ordamage to:

a) the product if it has been misused, neglected,improperly installed, physically damaged or altered,either internally or externally, or damaged fromimproper use or use in an unsuitable environment;

b) the product if it has been subjected to fire, water,generalized corrosion, biological infestations, orinput voltage that creates operating conditionsbeyond the maximum or minimum limits listed inthe Xantrex product specifications including highinput voltage from generators and lightning strikes;

c) the product if repairs have been done to it other thanby Xantrex or its authorized service centers(hereafter “ASCs”);

d) the product if it is used as a component part of aproduct expressly warranted by anothermanufacturer;

e) the product if its original identification (trademark,serial number) markings have been defaced,altered, or removed.




15

DISCLAIMER

Product

THIS LIMITED WARRANTY IS THE SOLE ANDEXCLUSIVE WARRANTY PROVIDED BY XANTREX INCONNECTION WITH YOUR XANTREX PRODUCT ANDIS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHERWARRANTIES, CONDITIONS, GUARANTEES,REPRESENTATIONS, OBLIGATIONS AND LIABILITIES,EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE INCONNECTION WITH THE PRODUCT, HOWEVERARISING (WHETHER BY CONTRACT, TORT,NEGLIGENCE, PRINCIPLES OF MANUFACTURER’SLIABILITY, OPERATION OF LAW, CONDUCT,STATEMENT OR OTHERWISE), INCLUDING WITHOUTRESTRICTION ANY IMPLIED WARRANTY ORCONDITION OF QUALITY, MERCHANTABILITY ORFITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIEDWARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE TO THE EXTENT REQUIREDUNDER APPLICABLE LAW TO APPLY TO THEPRODUCT SHALL BE LIMITED IN DURATION TO THEPERIOD STIPULATED UNDER THIS LIMITEDWARRANTY.

IN NO EVENT WILL XANTREX BE LIABLE FOR ANYSPECIAL, DIRECT, INDIRECT, INCIDENTAL ORCONSEQUENTIAL DAMAGES, LOSSES, COSTS OREXPENSES HOWEVER ARISING WHETHER INCONTRACT OR TORT INCLUDING WITHOUTRESTRICTION ANY ECONOMIC LOSSES OF ANY KIND,ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONALINJURY, ANY DAMAGE OR INJURY ARISING FROM ORAS A RESULT OF MISUSE OR ABUSE, OR THEINCORRECT INSTALLATION, INTEGRATION OROPERATION OF THE PRODUCT.


Installation Guide



Exclusions

If this product is a consumer product, federal law doesnot allow an exclusion of implied warranties. To theextent you are entitled to implied warranties underfederal law, to the extent permitted by applicable lawthey are limited to the duration of this Limited Warranty.Some states and provinces do not allow limitations orexclusions on implied warranties or on the duration of animplied warranty or on the limitation or exclusion ofincidental or consequential damages, so the abovelimitation(s) or exclusion(s) may not apply to you. ThisLimited Warranty gives you specific legal rights. You mayhave other rights which may vary from state to state orprovince to province.

Information

WITHOUT LIMITING THE GENERALITY OF THEFOREGOING, UNLESS SPECIFICALLY AGREED TO BY ITIN WRITING, XANTREX

(a) MAKES NO WARRANTY AS TO THE ACCURACY,SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OROTHER INFORMATION PROVIDED IN MANUALS OROTHER DOCUMENTATION PROVIDED BY IT INCONNECTION WITH THE PRODUCT; AND

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FORLOSSES, DAMAGES, COSTS OR EXPENSES, WHETHERSPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL ORINCIDENTAL, WHICH MIGHT ARISE OUT OF THE USEOF SUCH INFORMATION.

THE USE OF ANY SUCH INFORMATION WILL BEENTIRELY AT THE USER’S RISK.


17


WARNING: LIMITATIONS ON USE

The Fuse Block is not intended for use in connectionwith life support systems and Xantrex makes nowarranty or representation in connection with any use ofthe product for such purposes.

Xantrex Technology, Inc.8999 Nelson WayBurnaby, British ColumbiaCanadaV5A 4B5

Return Material Authorization Policy

Before returning a product directly to Xantrex you mustobtain a Return Material Authorization (RMA) numberand the correct factory “Ship To” address. Productsmust also be shipped prepaid. Product shipments willbe refused and returned at your expense if they areunauthorized, returned without an RMA number clearlymarked on the outside of the shipping box, if they areshipped collect, or if they are shipped to the wronglocation.

When you contact Xantrex to obtain service, please haveyour instruction manual ready for reference and beprepared to supply:

• The part number of your product

• Information about the installation and use of the unit

• Information about the failure and/or reason for thereturn

• A copy of your dated proof of purchase

NOTE: DO NOT RETURNPRODUCTS TOTHIS ADDRESS.Please call yourXantrex CustomerService Repre-sentative forreturn mailinginstructions.

Installation Guide



Shipping Instructions

1. Package the unit safely, preferably using the originalbox and packing materials. Please ensure that yourproduct is shipped fully insured in the originalpackaging or equivalent. This warranty will not applywhere the product is damaged due to improperpackaging.

2. Include the following:

• the RMA number supplied by XantrexTechnology Inc clearly marked on the outsideof the box,

• a return address where the unit can be shipped(post office boxes are not acceptable),

• a contact telephone number where you can bereached during work hours, and

• a brief description of the problem.

3. Ship the unit prepaid to the address provided byyour Xantrex customer service representative.

If you are returning a product from outside of the USA or Canada

In addition to the above, you MUST include returnfreight funds and are fully responsible for alldocuments, duties, tariffs, and deposits.

If you are returning a product to a Xantrex Authorized Service Center (ASC)

A Xantrex return material authorization (RMA) numberis not required. However, you must contact the ASC priorto returning the product or presenting the unit to verifyany return procedures that may apply to that particularfacility.


19

Service Information

Part Number:

Purchase Date:

Problem:

Include a telephone number where you can be reachedduring business hours and a complete return shippingaddress (P.O. Box numbers are not acceptable).

Name:

Address:

City:

State / Province:

Zip / Postal Code:

Country:

Phone:

FAX:

Email Address:

Xantrex Technology Inc.1 888 608 0721 Phone1 360 435 2229 Faxwww.xantrex.com

Printed in the USA973-0019-01-02 Rev A 06/2002

Installation Guide

973-0019-01-02 - Rev A - Fuse Block - Xantrex TFBs to the Battery, DC Disconnect, and Inverter...

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