Xantrex TFB110 User manual
Smart choice for power
Installation Guide
Fuse Block
www.xantrex.com
TFB110/TFB110C
TFB200/TFB200C
TFB300/TFB300C
TFB350/TFB350C
TFB400/TFB400C
Installation Guide
2 ©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
About Xantrex
Xantrex Technology Inc., is a world-leading supplier of
advanced power electronics and controls with products
from 50 watt mobile units to 1 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
Trace and Xantrex are registered trademarks of Xantrex
International.
Notice of Copyright
Fuse Block Installation Guide ©June 2002 Xantrex
Technology Inc. All rights reserved.
Disclaimer
Since the use of this guide and the conditions or
methods of installation, operation, use and
maintenance of the unit are beyond the control of
Xantrex Technology Inc., the company does not assume
responsibility and expressly disclaims liability for loss,
damage, or expense arising out of or any way connected
with such installation, operation, use, or maintenance.
See pages 12 through 18 in this guide for specific
warranty information.
Date and Revision
June 2002, Revision A
Document Number
973-0019-01-02
Contact Information
Web: www.xantrex.com
Phone: 1.888.608.0721
Fax: 360.435.2229
©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
3
Table of Contents
About Xantrex .............................................................................................. 2
Trademarks ....................................................................................................... 2
Notice of Copyright .......................................................................................... 2
Disclaimer......................................................................................................... 2
Date and Revision ............................................................................................ 2
Document Number ........................................................................................... 2
Contact Information ........................................................................................ 2
Introduction ................................................................................................. 5
Tools/Materials Required .................................................................................. 5
Installation .................................................................................................... 6
Mounting.......................................................................................................... 6
Cable Installation into Fuse Block ................................................................... 7
For Fuse Blocks designed for Series-C Battery Cables .................................. 7
For Fuse Blocks designed for Ring-lugged Battery Cables ........................... 8
Wiring TFBs to the Battery, DC Disconnect, and Inverter ................................ 9
Care and Maintenance ............................................................................... 10
Fuse Replacement ........................................................................................... 10
Replacement Fuses ..................................................................................... 11
Limited Warranty ....................................................................................... 12
What does this warranty cover and how long does it last? .........................12
What will Xantrex do? ...................................................................................12
How do you get service? ................................................................................ 13
What does this warranty not cover? .............................................................14
DISCLAIMER ....................................................................................................15
Product....................................................................................................... 15
Exclusions ................................................................................................... 16
Information ................................................................................................ 16
WARNING: LIMITATIONS ON USE ................................................................ 17
Return Material Authorization Policy ........................................................... 17
Shipping Instructions ................................................................................. 18
If you are returning a product from outside of the USA or Canada..... 18
If you are returning a product to a Xantrex Authorized Service Center
(ASC) ................................................................................................... 18
Service Information.................................................................................... 19
Installation Guide
4 ©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
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
©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
5
Introduction
The Trace™ brand fuse block (TFB) protects the power
system’s DC wiring should an overcurrent condition
occur. The fuse block is placed between the battery’s
ungrounded conductor (usually the positive cable) and
the DC input terminal of the inverter.
The TFBs include a fast acting, current limiting class-T
fuse providing extremely fast protection when a short
circuit occurs. When the fuse is properly matched to the
system current, its time delay allows the inverter to
surge to full power without blowing the fuse. A plastic
cover prevents accidental short circuits to the fuse
terminals. Fuse sizes include 110, 200, 300, 350 and
400 amps.
There are two types of fuse blocks available. The
TFBxxxC fuse block has “set” screw lugs for cables with
no terminal connector’s on the ends (hereto referred to
as C-type battery cables). The TFBxxx fuse block has
stainless steel bolt connections for cables with ring
terminals (hereto referred to as ring-lugged battery
cables). Both fuse blocks include a black polycarbonate,
fiberglass reinforced base and a clear polycarbonate
snap-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 1
Fuse Block for C-type
Battery Cables (TFBxxxC)
Figure 1a
Fuse Block for Ring-lugged
Battery Cables (TFBxxx)
NOTE: These fuse
blocks meet the
National
Electrical Code
requirements for
overcurrent
protection.
Xantrex offers
the DC175 and
DC250 in an
enclosure for
applications
requiring NEC
compliance for
both overcurrent
protection and a
DC disconnect.
Installation Guide
6 ©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
Installation
Mounting
Locate the fuse block within 18 inches (45 cm) of the
battery. It should be placed in a location where it is
easily accessible should the fuse need replacing.
1. Squeeze the clear plastic protective cover and
remove it from the fuse block base.
2. Use the fuse block base as a template for location of
the four mounting holes. The fuse block should be
mounted to a secure surface. Allow at least 6 inches
(15 cm) from the fuse contacts to allow for removal
without shorting to a grounded object.
3. Use appropriate hardware (not supplied) to mount
the 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)
AA
BB
Figure 2
Fuse Block Dimensional Drawing
(Not to scale)
Table 1
Bolt and Nut Sizes
NOTE: It is not
recommended to
locate the fuse
block inside the
enclosure with
the batteries
where explosive
gases may exist.
epyTkcolBesuF
)tun/tlob(xxxBFT
)wercstes(CxxxBFT
eziSguL/tloB
AB
002,011BFTtunxehhtiwtlob81-8/3tunxehhtiwtlob01-61/5
004,053,003BFTtunxehhtiwtlob81-8/3tunxehhtiwtlob81-8/3
C002,C011BFTselbactuc0/2-4#rofsgul0/2#tunxehhtiwtlob01-61/5
C004,C053,C003BFTselbactucMCM052-4#rofsgulMCM052tunxehhtiwtlob81-8/3
©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
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 the
battery cable.
2. Insert the cable into the terminal block (ensure all
conductor 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 other
end of the fuse block.
Figure 3
Installation for C-Type Battery Cables
Stripped
back 1 inch
Installation Guide
8 ©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
Figure 4
Installation for Ring-lugged Battery Cables
Installation (continued)
Cable Installation into Fuse Block (continued)
hex nut hex nut
split-
washers
split-
washers
Ring-lug on
Battery 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) onto
the battery cables. Ensure the terminal connector’s
have a 3/8" diameter opening for placement over the
stud connector on the fuse block.
1. Remove the 3/8" hex nut and split washers from the
fuse block.
2. Place the cable ring lugs over the 3/8-18 bolt on the
fuse block assembly and reinstall the split washer
and 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 other
end of the fuse block.
NOTE: Do not place
anything
between the
ring-lug on the
battery cable
and the terminal
surface.
Terminal surface Terminal surface
3/8-18
bolt
3/8-18
bolt
©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
9
Figure 5
Wiring TFBs to the Battery, DC Disconnect, and Inverter
Installation (continued)
Wiring TFBs to the Battery, DC Disconnect, and Inverter
+-
BATTERY
INVERTER
TFB FUSE BLOCK FOR
C-TYPE
BATTERY CABLES
FUSE CL ASS T
300AMP
*DC
DISCONNECT
*DC DISCONNECT MAY NOT
BE REQUIRED IN ALL
APPLICATIONS
+-
BATTERY
TFB FUSE BLOCK
FOR RING-LUGGED
BATTERY CABLES
INVERTER
FUSE C LAS S T
300 AMP
*DC
DISCONNECT
*DC DISCONNECT MAY NOT
BE REQUIRED IN ALL
APPLICATIONS
Installation Guide
10 ©2002 Xantrex Technology Inc. All Rights Reserved
P/N 973-0019-01-02 Rev A 06/2002
Fuse Replacement
Before replacing the fuse, determine and correct the
cause of the overcurrent condition.
1. Use a hex socket and remove the two nuts (and split
washers) securing the fuse. Note the hardware
installed and the order of how it is stacked. This is
important to prevent excess heat which can cause
the fuse to open again.
2. Remove the open fuse and replace it with a known
good one.
3. Reinstall the hardware as it was originally stacked on
the fuse.
4. Tighten the hex nuts securing the fuse to
10-15 ft/lbs.
5. Double-check the battery cable connections and
verify all connections are properly tightened .
Figure 6
Remove the Two Nuts and Washers and Replace Fuse
Care and Maintenance
WARNING:
BEFORE
REPLACING
THE FUSE,
DISCONNECT ALL
POWER SOURCES
AND TURN OFF
ALL LOADS.
NOTE: If the system
also contains a
DC disconnect,
switch it to OFF
before replacing
the fuse.
NOTE: Fuses are NOT
covered under the
limited warranty.
FUSE CLASS T
300 AMP FUSE CLASS T
300 AMP
bolt
split-washer
hex nut
fuse
bolt
split-washer
hex nut
bolt
split-washer
hex nut
fuse
bolt
split-washer
hex nut
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9
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