Xantrex Technology XW4024-120/240-60 manual

XW P ower System Installation Guide XW4024-120/240-60 XW4548-120/240-60 XW6048-120/240-60 XW P ower Distribution P anel XW System Control P anel XW Solar Charg e Controller XW Automatic Generator Start[...]

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XW Power System Installation Guide[...]

About Xantrex Xantrex T echnology Inc. is a world-leading supplier of advanced power electronics and cont rols with products from 50 watt mobile units to 2.5 MW utili ty-scale systems for wind, solar, batteries, fuel cells, micro turbines, and backup power applications in both grid-connected and stand-alone sy stems. Xantrex products include invert[...]

975-0239-01-01 iii About This Guide Purpose The purpose of this Installa tion Guide is to provide expl an ations and procedures for installing the XW Power System. Scope The Guide provides safety guidelines, deta iled planning and procedures for installing the XW Inverter/Charg er and related system components (the “XW Power System”). It does n[...]

About T his Guide iv 975-0239-01-01 Conventions Used The following conventions are used in this guide. Related Information Additional information abou t operating the XW Inverter/Char ger, see the XW Inverter/Charger Operatio n Guide (975-0240-01-01). For more information about re lated componen ts, refer to: • XW Power System Intallation Overvie[...]

975-0239-01-01 v Important Safety Instructions 1. Before using the inverter , r e ad all inst ructions and cautionary markings on the unit, the batteries, and all appr opriate sections of this manual. 2. Use of accessories not recommended or sold by Xantrex T echnology Inc. may result in a risk of fire, electric sh ock, or injury to persons. 3. The[...]

Important Safety Instructions vi 975-0239-01-01 Limitations on Use Explosive Gas Precautions 1. W o rking in the vicinity of lead acid ba tteries is dangerous. Batteries generate explosive gases during normal operation. Th erefore, you must read this guide and follow the instructions exactly before in stalling or using your inverter/char ger . 2. T[...]

975-0239-01-01 vii Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Limitations on Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi Explosive Gas Precautions - - - - - - - - - - - - - - - - -[...]

Contents viii 975-0239-01-01 Accessing the AC Terminal Block an d AC Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17 Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18 AC Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - - [...]

Contents 975-0239-01-01 ix 4 XW Solar Charge Controller Installation Installing the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Arra[...]

Contents x 975-0239-01-01 Appendix A Specifications Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2 XW Series Overload Capability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Output Power Versus Ambient Te[...]

975-0239-01-01 xi Figure 1-1 XW Power System Installation Diagram Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Figure 1-2 XW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 –3 Figure 1-3 XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - [...]

Fi g u r e s xii 975-0239-01-01 Figure 2-33 Functional Test for Multiple Inverters - Page 2 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–42 Figure 3-1 Network-Managed Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Figure 3-2 Xanbus Cable and RJ45 Conn ector Pin Numbers - - - - - [...]

975-0239-01-01 xiii Table 2-1 Mounting Plate Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Table 2-2 Recommend ed Battery Cable Size Versus Length - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Table 2-3 Battery Cable (in cond uit) to Maximum Breaker/Fu se Size - - - - - - - - - - -[...]

xiv[...]

1 Intr oduction Chapter 1, “Introduction” lists and describes the components and basic features of the XW Power System. F or this T opic See .... “System Overview” page 1–2 “System Components and Accessories” page 1–3[...]

Introduction 1–2 975-0239-01-01 System Overview The XW Power System consists of several devices, components, a nd optional accessories that, when installed together , crea te a re newable ener gy power system that can be customized to suit nearly any application—off grid, gri d tied, or backup. Up to three inverters can be installed in parallel[...]

System Components and Accessories 975-0239-01-01 1–3 System Components and Accessories XW Inverter/Charg er The XW Inverter/Charger i s a modular “build ing block” sine-wave in verter/charger that can be used for both resi den tial and commercial stand-alone, grid-backup, and grid-tie applications with battery energy storage. Th e XW Series i[...]

Introduction 1–4 975-0239-01-01 The XW Conduit Box comes in two piece s and mounts dire ctly to the bottom of the inverter/charger with keyhole slots an d screws. It is secured to the inverter by two #10-32 screws and is secured to the wall by two screws (not provided). Internal wire barriers (or raceways) are incl uded to keep communi cations wi[...]

System Components and Accessories 975-0239-01-01 1–5 XW Connection Kit for INV2 The XW Connection Kit for Inv2 (FGA # 865- 1020) is the extension kit required for connecting a second or third XW Inve rter/Charger in the same system. Figure 1-5 XW Connection Kit for INV2 XW Conduit Box XW Connection Kit includes: • XW Conduit Box with raceway ba[...]

Introduction 1–6 975-0239-01-01 XW Solar Charg e Controller The XW Solar Charge Controller (FGA # 865-103 0) is a 60 amp charge controller with integrated PVGFP and separate Battery T emperature Sensor . The XW Solar Charge Controller can be used with 12-, 24-, 36-, 48-, and 60 -volt DC battery systems. However , the XW Inverter/Char ger can only[...]

System Components and Accessories 975-0239-01-01 1–7 XW Automatic Generator Start The XW Automatic Generator Start can automa tically activate a generator to provide an XW Series Inverter/Charger with power to re char ge depleted batteries or assist with heavy loads. The XW Automatic Generator S tart ad ds intelligence to power management and eli[...]

1–8[...]

2 Inverter/Char g er Installation Chapter 2, “Inverter/Charger Installation” describes how to mount and install the XW Inverter/Charger, and the XW Power Distribution Panel and XW Conduit Box. F or this T opic See.... “Pre-Installation” page 2–2 “Step 1: Installing th e Mounting Plate” page 2–4 “Step 2: Mounting the Inverter” pa[...]

Inverter/Charger Installation 2–2 975-0239-01-01 Pre-Installation Before installing the XW Invert er/Charger, read all inst ructio ns and cautionary mark ings located in this manual. Location The XW Inverter/Charger is certified for indo or (heated or unheated) installations only . Close to batte ry bank Locate the inverter as close to the batter[...]

Pre-Installation 975-0239-01-01 2–3 Clearance Requir ements Provide a minimum clearance of 6 inches (15 cm)—12 inches is preferred—around the top and 6 inches (15 cm) at the bottom of t he inverter for ve ntilation. There must be at least three feet of clearance in front of the inverter . Ensure that the ve nts are not obstructed with foreign[...]

Inverter/Charger Installation 2–4 975-0239-01-01 Step 1: Installing the Mounting Plate Each XW Inverter/Charger and XW Powe r Distribution Panel requires a separate mounting plate. This bracket is first attached to the wall, then the inverter/char g er or distribution panel is atta ched to the wall bracket. The wall bracket is attached to the wal[...]

Step 1: Installing the Mounting Plate 975-0239-01-01 2–5 Figure 2-3 Mounting the Brack et for the XW Inve rter/Charger or Distribution P anel Wall studs 16" on center behind wallboard Add ¾" plywood if additiona l support is needed. Side View 2 × 4 wall stud Wallboard Plywood (optional) mounting plate 60" (152.4 cm) from floor pu[...]

Inverter/Charger Installation 2–6 975-0239-01-01 Step 2: Mounting the Inverter Figure 2-4 Mounting the XW Inverter/Charger 2 Align the flange on the back of the XW Inverte r/Charger with the bottom edge of the mounting plate. Lower the flange on the inverter onto the mounting plate. CAUTION : Before releasing the full wei ght of t he unit, ensure[...]

Step 3: Mounting the XW P ower Di stribution P anel and XW Conduit Box 975-0239-01-01 2–7 Step 3: Mounting the XW P ower Distribution P anel and XW Conduit Box Mount the XW Distribution Panel on the m ounting bracket follo wing the same procedure in Step 2. When mounting the XW Conduit Box as shown in Figure 2-5, it is not necessary to attach the[...]

Inverter/Charger Installation 2–8 975-0239-01-01 Step 4: W iring the Inverter This section provides proced ures for making AC and DC connections between the XW Inverter/Charg er and the power distribu tion pane l using the cables that are pre-installed in the distribution panel. This s ection also assumes that the XW Conduit Box wa s installed in[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–9 Batteries See the F AQs section of the Xantrex W eb site for information on dete rmining batte ry bank requirements. Consider the following reco mmendations for battery use. • Use only the deep discharge t ypes for inverter applications. • Use the same battery type for all batteries in t he bank.[...]

Inverter/Charger Installation 2–10 975-0239-01-01 T erminal covers Color-coded snap-on DC terminal covers are provided to prevent accidental contact with the terminals. T erminal covers are required fo r all installations, even if a XW Conduit Box is used. It is also recommended that the shank of the ring te rminals (cable lugs) be covered with h[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–11 T orque V alues for the XW P ower Distribution P anel Inverter Grounding Backfeed Protection Requirements T able 2-7 T orque V alues for AC Disconnects and AC Break ers Wir e Size T orq ue V alue AWG I n- l b N - m 16–10 45 5 84 5 5 6–4 45 5 T able 2-8 T orque V alues for the Ground Bus , AC Ne [...]

Inverter/Charger Installation 2–12 975-0239-01-01 W iring the Inverter to the XW P ower Distribution P anel Grounding the DC System The inverter ’ s chassis ground bar (see Figure 2-7) is used to conn ect the chassis of the inverter to the DC grounding system. The terminal accepts wires from #14 A WG to #2 A WG . Important: If a XW Conduit Box [...]

Step 4: Wiring the Inverter 975-0239-01-01 2–13 Installing the Battery T emperature Sensor The Battery T emperature Sensor (BTS) port is for connecting to the Battery T emperature Sensor , which regulates battery charging based on battery temperature. Installing a sensor extends battery life by preventing overcharging in warm tempe ratures and un[...]

Inverter/Charger Installation 2–14 975-0239-01-01 Making DC Connections This section describes how to make DC connec tions between the inverter/char ger and the power distribution panel (u sing the pre-insta lled DC cables in the distribution panel), between the distribution panel to the batteries (using battery cables provi ded by the installer?[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–15 CA UTION: Damage to Equipment Do not put anything betw een the battery cable lug and the te rminal surface. Ov erheating of the terminal may occur . Do not apply any type of antio xidant paste until after the batt ery cable wiring is tightened. The same applies for all DC connections. Do no t over-t[...]

Inverter/Charger Installation 2–16 975-0239-01-01 Making A C Connections This section describes how to make AC conn ections between the XW Inverter/Charger and the XW Power Distribution Panel (using th e pre-installed AC wiring in the XW Power Distribution Panel) and between the XW Powe r Distribution Panel and the AC distribution panel, or sub-p[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–17 Accessing the A C T erminal Block and AC Gr ound Bar All AC wiring connects to th e AC terminal block located on the left-hand side of the inverter beneath the AC access cover . Figure 2-13 AC T e r m i n al B l o ck xant rex Hybrid Inverter /Ch arger Grid (A C1) Gen ( A C 2) F aul t / Wa rnin g Equ[...]

Inverter/Charger Installation 2–18 975-0239-01-01 Grounding the A C System See T able 2-4 o n page 10 for torque values for the AC terminal and AC Ground bar . See Figure 2-8 on pa ge 2–1 1 for torque requir ements for the ground bar in the XW Power Distribution Panel. Important: Place the Neutral-to-ground b ond in a permanently instal led AC [...]

Step 4: Wiring the Inverter 975-0239-01-01 2–19 A C Wiring to the Inverter A C Distribution P anel An inverter AC distribution pan el (also known as a sub-pa nel or inverter load panel) an d AC conduit must be installed before AC wiring is connected to the inverter . Install the inverter AC distributio n panel and conduit as follows: 1. Determine[...]

Inverter/Charger Installation 2–20 975-0239-01-01 2. Connect the wires labelled “INV1 L1-GRID” and “INV1 L2-GRID” to the inverter . If the AC source will be the utility grid, connect to the GRID (AC1) terminals (L1-GRID, L2-GRID). If the system will be of f-grid and the only AC source will be a generator , these wires can be connecte d to[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–21 Wiring the XW Inverter/Char ger to a XW P ower Distribution P anel Figure 2-16 Wiring the Inverter to the XW Po wer Distribution P anel Actual wiring requirements may vary. Power Distribution bars in the XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–[...]

Inverter/Charger Installation 2–22 975-0239-01-01 Generator W iring to the XW Inverter/Char ger using a XW P ower Distribution P anel Figure 2-17 Generator Wiring Using a XW P ower Distribution P anel Actual wiring require ments may vary. CAUTION : Generators must be hard-wired to the XW Power Distribution Panel. In an off-gri d installati on (i.[...]

Step 4: Wiring the Inverter 975-0239-01-01 2–23 AU X Po r t The XW Series has a 12 Vdc auxiliary output that can be co nfigured to trigger in response to one of the followi ng battery conditions: • low battery voltage • high battery voltage • low battery temperature • high battery temperature • any device fault The auxiliary output can [...]

Inverter/Charger Installation 2–24 975-0239-01-01 A UX-RPO: User Remote P ower Off (RPO) Connecting JU-2 (AUX-RPO) and JU-3 (AUX-COM) termina ls together through an external switch (normal open contact) will pr ovide the system shut off function if the switch is closed. The external switch if pressed overrides the control provided from the front [...]

Basic Functional T est - Single Inverter 975-0239-01-01 2–25 Basic Functional T est - Single Inverter The following steps will comple te a basic functional test of the XW Inverter/Charger. If any test fails, please refer to th e T roubleshooting se ction in the XW Inverter/Charger Operation Guide for assistance. Confirm All Connections Once the A[...]

Inverter/Charger Installation 2–26 975-0239-01-01 Enable the Inverter By default, Invert Mode is enabled and the unit should star t inverting upon transitioning from Standby Mode. If Invert Mode is disa bled, the display will show (---) once out of St andby Mode. If the unit powers u p in Standb y Mode, prese the ON/OFF button momentarily to chan[...]

Basic Functional T est - Single Inverter 975-0239-01-01 2–27 A C V oltage Check T o perform an AC voltage check: 1. W ith the inverter on (INVER T [green, kW] LED on solid), verify the AC voltage at AC Loads block terminal L1-Load to N-Load. 2. V erify tha t neutral is bonded to ground in the system by measuring the hot and neutral voltages relat[...]

Inverter/Charger Installation 2–28 975-0239-01-01 Figure 2-23 Functional T est for Single Inverter Systems[...]

Step 5: Installing Additional Inverters 975-0239-01-01 2–29 Step 5: Installing Additional Inverters Installation Steps T o install multiple inverters: 1. Disconnect all power from the system. 2. Mount additional inverter(s). See “S tep 1: Installing the Mounting Plate” on page 2–4 and “S tep 2: Mounting the Inverter” o n page 2–6. 3. [...]

Inverter/Charger Installation 2–30 975-0239-01-01 P arts List for Dual-Inverter Configur ations Installing an additional inverter using th e power dist ribution panel requires an XW Connection Kit (part nu mber 856-1020), which contai ns the following compon ents: • XW Conduit Box • Three 60 amp, 120/240 V AC, 2-pole, Square-D T ype QOU, DIN-[...]

Step 5: Installing Additional Inverters 975-0239-01-01 2–31 Figure 2-24 DC Connections to Dual Inverters Torque connections to the inverter DC terminals to 10-15 ft/lbs. Actual cable requirements may vary. AC Breakers shown in this illustration represent the breaker arrangement for a single AC source. Torque connections to th e battery terminals [...]

Inverter/Charger Installation 2–32 975-0239-01-01 A C Wiring for a Dual-Inverter System 1. Disconnect the AC wires (from the utility grid or generator and to the sub-panel) and remove the factory-installed distribution ba rs connected to top and bottom terminals on the AC breakers. 2. Remove bypa ss interlock bracke t. 3. Disconnect INV1 AC LOAD [...]

Step 5: Installing Additional Inverters 975-0239-01-01 2–33 Figure 2-26 AC Wiring for Dual-Inverter Systems Power Distribution bars in the XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–11 for torque requirements.[...]

Inverter/Charger Installation 2–34 975-0239-01-01 P arts List for a T riple-Inverter Configuration ❐ 1 x XW Power Distribution Panel (PDP) and Accessory kit (mounts to first unit). ❐ 1 x 865-1020 PDP ex tension kit for second unit. The following items are required for the third inverter (furthest from PDP) and should be sourced and prepared p[...]

Step 5: Installing Additional Inverters 975-0239-01-01 2–35 6. Connect positive battery cable for first invert er (supplied with PDP) to top terminal on first DC disconnect/breaker . 7. Connect positive battery cable for second inverter (supplied in 865-1020) to top terminal on second DC disconnect/breaker . 8. Connect positive battery cabl e for[...]

Inverter/Charger Installation 2–36 975-0239-01-01 A C Wiring for a T riple-Inverter System 1. Prepare power distribution bars (supplied in 865-1020) by cutting away one of the four tabs, only three tabs per power distribution bar are required in a three inverter system. A total of 6 distributio n bars should be prepared. 2. Mount the nine breaker[...]

Step 5: Installing Additional Inverters 975-0239-01-01 2–37 Figure 2-29 T riple-Inverte r AC Bre ak er Arrangement and Wiri ng Enlargement w ith a Single AC Input Source Figure 2-30 Wiring an External Bypass Sw itch for a T riple-Inverter Configuration TO AC 1 O R A C 2 ON I NV 3 TO A C 1 OR A C 2 ON IN V 2 FR OM AC L O AD ON IN V3 INV 1 IN ( GRI[...]

Inverter/Charger Installation 2–38 975-0239-01-01 Xanbus and A C Sync Cable A Xanbus and AC sync cable is required fo r multi-unit installation. The AC sync cable connects each inverter , and provide s the necessary communication and control between multiple units. Install these cables, routing it through the XW Conduit Box raceway , prior to mak[...]

Basic Functional T est - Multiple Inverters 975-0239-01-01 2–39 Basic Functional T est - Multiple Inverter s The following steps will complete a basic functional test of multiple XW Inverter/ Chargers. If any test fails, please refer to the T roubleshooting section in the XW Inverter/ Charger Op eration Guide for assistance. T o perform a functio[...]

Inverter/Charger Installation 2–40 975-0239-01-01 12. Confirm Master inverter di splays “0.00” and Slave(s) di splays “---” on their front panels. 13. Check for faults. If fault condition(s) ex ist, correct and restart Functional T est. 14. Check voltage at AC LOAD terminals of the Master Inverter . 15. Switch the AC Load bre akers ON. 16[...]

Basic Functional T est - Multiple Inverters 975-0239-01-01 2–41 Figure 2-32 Functional T est for Multiple Inverters - P age 1 of 2[...]

Inverter/Charger Installation 2–42 975-0239-01-01 Figure 2-33 Functional T est for Multiple Inverters - P a ge 2 of 2[...]

3 Xanbus Network Installation Chapter 3, “Xanbus Network Installation” provides detailed information for planning and installing the components necessary for network communication on a Xanbus system. F or this T opic See.... “Xanbus-enabled Devices” page 3–2 “The Xanbus System” page 3–2 “Installing the Network” page 3–7[...]

Xanbus Network Installation 3–2 975-0239-01-01 Xanbus-enabled Devices The Xanbus™-enabled designation means that the product works on a Xanbus network. Xanbus-enabled products are: • Easy to use. The Xanbus network simplifies operation and automates ro utine tasks. • Reliable. Software control eliminat es errors due to analog signalling. ?[...]

T he Xanbus System 975-0239-01-01 3–3 Network Components A Xanbus network consists of the following components: • Xanbus-enabled devices—these include th e XW System Control Panel, the XW Inverter/Charger, XW Aut omatic Generator Start, and XW Char ge Controller . The maximum number of Xanbus devices conn ected to a single Xanbus network shou[...]

Xanbus Network Installation 3–4 975-0239-01-01 • Network terminators (Figure 3-3)—th e Xanbus network must be properly terminated at each end with male or female networ k terminators to ensu re the communication signal quality on the network. If the network is not properly terminated, signal quality is degraded and performanc e on the network[...]

T he Xanbus System 975-0239-01-01 3–5 Ordering Network Components T able 3-2 provides a partial list of network components and part numbers. Ready-made cables are available in standard lengths from 3 feet to 75 feet. For the most up-to-date list, call an authorized Xantrex dealer or visit the Outlet Store at www .xantrex.com . Network Layouts Xan[...]

Xanbus Network Installation 3–6 975-0239-01-01 Daisy Chain Layout In a daisy chain layout, each device on the network is linked with separ ate lengths of Xanbus cable, as shown in Figure 3-6. This layout d oes not require network connectors. As in the multi-drop backbone layout, tw o terminators are required to ensure the communication signal qua[...]

Installing the Network 975-0239-01-01 3–7 Installing the Network Before Y ou Begin the Installation • Read the entire section before installing th e network. It’ s im po rtant to plan the installation from beginning to end. • Assemble all the tools and materials required for the installation. Installation T ools and Materials T ools The fol[...]

Xanbus Network Installation 3–8 975-0239-01-01 The total length of the network, includin g all connected Xa nbus-ena bled devices and the XW Series, cannot exceed 13 0 feet (40 m). See T able 3-3. Mounting a Network Connector T o mount a network connector: 1. Select an appropriate location with th e connector in the recommended mounting orientati[...]

Installing the Network 975-0239-01-01 3–9 Installing Xanbus-Enabled Devices If you are installing a Xanbus-e nabled device on an exis ting Xanbus System, put the system in Standby mode using the System Settings menu on the XW System Control Panel. T o install the Xanbus-enabled devic es: 1. Determine and prepare the location for each device. Refe[...]

Xanbus Network Installation 3–10 975-0239-01-01 Completing the Daisy Chain Layout T o complete the d aisy chain layout: ◆ Insert a male terminator into the o pen network port of the Xanb us-enabled devic e at each end of the network. See Figure 3-9. Figure 3-9 Completing a Daisy-Chain Layout CA UTION: Unp redicta ble device behavior After conne[...]

4 XW Solar Char ge Contr oller Installation Chapter 4, “XW Solar Charge Controll er Installation” describes how to mount and connect the XW Charge Cont roller as part of the XW System. F or this T opic See.... “PV Array Requirements” page 4–2 “Mounting” page 4–3 “Grounding” page 4–8 “W iring” page 4–9 “Commissioning”[...]

XW Solar Charge Controller Installation 4–2 975-0239-01-01 Installing the Charg e Controller This chapter describes installing the XW So lar Charge Controller with the XW Power System, including the power distribution panel. For stand-alone installation, see the XW Solar Charge Controller Owner’ s Guide. PV Array Requir ements Each Charge Contr[...]

Mounting 975-0239-01-01 4–3 MPPT V oltag e Range The XW Solar Charge Contro ller maximum pow er point tracking algorithm maximizes the output power of PV arrays as lon g as the oper ating voltage is wit hin the MPP T operational window . Ensure that the PV array used in the system operate s within the MPP T operational window . Effect s of array [...]

XW Solar Charge Controller Installation 4–4 975-0239-01-01 If using “sealed” batteries, the controller can be mounted in the same enclosure as long as it is adequately ventilated. For optimal and safe operation, ensure ther e is adequate clearance around the XW Solar Char ge Controller. See T able 4-2. If cleara nces are reduced below these m[...]

Mounting 975-0239-01-01 4–5 Removing the W iring T erminals Cover Before mounting, you must remove the wi ring terminals cover to access the mounting holes and the w iring terminals. The wiring terminals cover is secured with two Phillips #8-32 × 2 ½-inch screws on the front cover of the unit. See Figure 4-2. Removing Knockouts Six dual and two[...]

XW Solar Charge Controller Installation 4–6 975-0239-01-01 Mounting the Controller The XW Solar Charge Controller can be mounted to either the side or the top of the power distribution panel. The power distrib ution panel has keyhole slots and screw holes for side mounting, and two pairs of conduit hole s for top mounting the XW Solar Char ge Con[...]

Mounting 975-0239-01-01 4–7 5. Insert two screws in the two mounting holes provided to secure the unit to the wall. 6. Provide strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires. Figure 4-5 Mounting the XW Sola r Charge Controller xantr ex S ola r Cha rg e Contr ol l e r Secure with[...]

XW Solar Charge Controller Installation 4–8 975-0239-01-01 Grounding The XW Solar Char ge Controller is designed to work only with negative-grounded electrical systems. Ground ing for both PV an d battery circuits is provided inside the wiring compartment. Ea ch ground connection ca n accommodate up to #6 A WG wire size. A fuse rated at 1 A, 600 [...]

Wiring 975-0239-01-01 4–9 Wi r i n g DC T erminal Connector Locations T erminal connectors for DC wiring are located inside the wiring compartment. The labels above the DC wiring terminals and inside the wiring compartmen t identify all the connection points. See Figure 4-7. Wir e Size and Over -current Protection Requir ements The wiring, over-c[...]

XW Solar Charge Controller Installation 4–10 975-0239-01-01 Battery Circuit The DC-rated fuse or circuit breaker between the battery and the XW Solar Charge Controller must have a maximum size of 1.25 × 60 A (the maximum current rating of the XW Solar Char ge Controller). Th at is, the fuse or circuit brea ker must be rated equal to o r above 75[...]

Wiring 975-0239-01-01 4–11 T able 4-4 One-W ay Wire Dis tance and Wi re Size for a 24 Vdc System Maximum one-way wi re distance for a < 3% voltage drop assuming 60 Adc charging current F or 24 Vdc systems Distance in feet (meters) Distance in feet (meters) a a.These wire sizes are not approved by UL to be installed in th e controller, bu t may[...]

XW Solar Charge Controller Installation 4–12 975-0239-01-01 Connecting the XW Solar Charg e Cont roller to the Distribution P anel T o connect the XW Solar Charge Controller: 1. Connect the PV array’ s positive (+) output to the PV array disconnect. 2. Route another (+) cable from the other end of the PV disconnect to the terminal marked PV + i[...]

Wiring 975-0239-01-01 4–13 Figure 4-8 Connecting Solar DC Sources in the P ower Distribution P anel Actual wiring require ments may vary.[...]

XW Solar Charge Controller Installation 4–14 975-0239-01-01 Commissioning During commissioning, the XW Solar Char ge Controller prompts the installer to enter important system informatio n such as the nominal batter y voltage, battery type, and battery bank capacity . Ensure the system info rmation is available pr ior to commissioning. If a XW Sy[...]

Commissioning 975-0239-01-01 4–15 3. From the Select Device menu on the SCP , select a XW Solar Char ge Controller (each unit should appear as “MPP T60 00” where th e 60 stands for 60A, and the 00 is its device number). 4. On the MPP T Setup menu, ensure the Advanced Settin gs item is displayed. If Advanced Settings are not displayed (and Ba [...]

XW Solar Charge Controller Installation 4–16 975-0239-01-01 3. On the Advanced Settings me nu, select Copy From, then select the XW Solar Charge Controller you want to copy from. Y ou should select the unit with the device nu mber that matches the firs t unit you configured. 4. Press Enter . The settings are automatically copied from the selected[...]

5 XW System Accessories Installation Chapter 5, “XW System Accessories In stallation” describes how to mount and install the XW System Control Pa nel and the Automatic Generator S tart. F or this T opic See.... “The XW System Control Panel” page 5–2 “The XW Automatic Generator S tart” page 5–7[...]

XW System Accessories Installation 5–2 975-0239-01-01 The XW System Control P anel The XW Series Inverter/Charger can be cont rolled remotely by co nnecting a XW System Control Panel. The XW System Control Panel is optional for single in verter systems. The XW System Control Panel is re quired for configuring systems with multiple inverters. The [...]

T he XW System Control P anel 975-0239-01-01 5–3 Materials and T ools Required Y ou will need these materials and to ols to complete the installation: ❐ Mounting template sticker (supplied) ❐ Mounting plate (supplied) ❐ mounting plate (supplied) ❐ Four #6 screws (supplied) ❐ T wo #8 screws (supplied) ❐ Cable clamps or hardware fastene[...]

XW System Accessories Installation 5–4 975-0239-01-01 4. Secure the mounting plate by tightening th e two screws to rotate the tabs to the horizontal position (see Figure 5-3) and pull the tabs tight against the inner surface of the wall. Be careful not to overtig hten the screws and damage the wall. 5. Connect the network cable(s) (and terminato[...]

T he XW System Control P anel 975-0239-01-01 5–5 6. Place the unit into the mounting plate and secure it with four #6 screws. 7. Peel off the protective plastic coatin g coveri ng the screen and indicator ligh t. T o flush mount the XW System Control Panel with no mountin g plate: 1. Peel the backing from the supplied mountin g template sticker a[...]

XW System Accessories Installation 5–6 975-0239-01-01 4. Connect the network cable(s) (and terminator if necessary) to either input on the back of the XW System Control Panel. See Figure 5-4. Connect a network terminator to the XW System Control Panel if it is the last device at the end of a series-type network layout. 5. Place the unit in the op[...]

T he XW Automati c Generator S tart 975-0239-01-01 5–7 V erifying the Installation If network power (from an inverter/charger) is present, the back light will come on and the XW System Control Panel will show the star tup screen (see the XW Inverter/Charger Operation Guide), then show the System Home screen. The XW Automatic Generator Start Some [...]

XW System Accessories Installation 5–8 975-0239-01-01 ❐ #16 or #18 A WG wire (see “Wire Size and Length” on page 5–1 1) ❐ Xantrex network cables or equivalent (Category 5) ❐ Network terminators (if required) ❐ Phillips screwdriver ❐ W ire cutters and wire strippers Choosing a Location The XW Automatic Generator S tart should be in[...]

T he XW Automati c Generator S tart 975-0239-01-01 5–9 Installing the XW Auto matic Generator Start Installation Overview Installing the XW Automatic Generato r Start involves the following steps: 1. Mounting the unit. 2. Connecting the wiring harn ess to: • the generator (page 5–12) • thermostats (optional) (page 5–13 ) • external shut[...]

XW System Accessories Installation 5–10 975-0239-01-01 Mounting the Unit The XW Automatic Generator S tart is to be mounted vertically on a wall with the connectors facing downwards. T o mount the XW Automatic Generator S tart: 1. Hold the unit flush and sq uare against the wall, panel, or horizontal surface. • If the mounting surface requires [...]

T he XW Automati c Generator S tart 975-0239-01-01 5–11 The wires on the wiring harness can be extend ed to meet installatio n requirements. When extending the wire harness, ensure that the extension wires are the same color as the wires on the harness. T o install the XW Automatic Generator S tart using the wiring harness: 1. Connect each wire o[...]

XW System Accessories Installation 5–12 975-0239-01-01 Connecting the Generator T o connect the XW Automati c Generator Start to a generator , you must identify the start wiring configuration of the ge nerator you want to use. Generators must be auto-start capable, and generators equipped with remote operation connections are ideal. If the genera[...]

T he XW Automati c Generator S tart 975-0239-01-01 5–13 This section describes the generator configura tions and provides di agrams for connecting the wiring harness to the generator ’ s start wiring. Connecting the Ther mostats (optional) W ires 1, 2, 3, and 4 on the wiring harness ca n be connected to two thermostats. W ires 1 (yellow) and 2 [...]

XW System Accessories Installation 5–14 975-0239-01-01 Connecting an External Manu al ON/OFF Switch (optional) The external manual ON/OFF inputs (wire s 7 an d 8 on the wiring harness) are intended for wiring to one or more remote ON/OFF switches for star ting and stopping the genera tor manually . The oth er contact of the switch should be conne[...]

T he XW Automati c Generator S tart 975-0239-01-01 5–15 Connecting an External ON/OFF LED W ires 9 (White/Blue) and 1 1 (Black) on the wi ring harness can be connected to an LED or other light to accompany a remo te external ON/OFF switch. Th is light turns on when the generator run signal is active to visually indicate that the generator is runn[...]

XW System Accessories Installation 5–16 975-0239-01-01 Connecting the Wiring Harness to the XW Automatic Gener ator Start After all the external connectio ns have been wired to the wiring harness, the connector on the wiring harness must be plugged into th e 20-contact co nnector on the XW Automatic Generator Start. T o connect the wiring harness[...]

T he XW Automati c Generator S tart 975-0239-01-01 5–17 Connecting the XW Automatic Gene r ator Start to the Xanbus Network T o connect the XW Automatic Generator S tart to the Xanbus netwo rk, plug a Category 5 network cable into one o f the network ports on t he bottom panel of the XW Automatic Generator Start. Connect the other end of that sam[...]

XW System Accessories Installation 5–18 975-0239-01-01 V erifying P ower Is A vailable When the XW Automatic Generator S tart h as been installed properly , the Power and Network indicator lights illuminate. If one or both lights are out, check the netw ork connections and ensure the network power supply is on. Figure 5-13 V erifying P ower is Av[...]

A Specifications Appendix A, “Specifications” provide s the electrical and environmental specifications for the XW Series.[...]

Specifications A–2 975-0239-01-01 Electrical Specifications T able A-1 XW P o wer System Electric al Specific ations Model XW6048-120 /240-60 XW4548-120/2 40-60 XW4024-120/240-60 Continuous Outpu t Power 6,000 W 4,500 W 4,000 W Surge Rating (10 seconds) 12,000 W 9,000 W 8,000 W Surge Current L-n: 105 A rms (7 sec) L-L: 52.5 A rms (7 sec) L-n: 75 [...]

Electrical Specifications 975-0239-01-01 A–3 XW Series Overload Capability Loads presented to the inverter are seldom co nstant. T ypically , lar ge loads are operated for only short periods of time. In order to prov ide the maximum utility , Xantrex inverters are allowed to operate at power levels that exc eed their continuous power ratings. Thi[...]

Specifications A–4 975-0239-01-01 Output P ower V ersus Ambient T emperature When the internal temperature of the X W Series exceeds its ra ted range, the unit reduce s it ener gy output to ensure maximu m co mponent ratings are not exceeded. XW Series Efficiency Inverting Efficiency (T ypical) Figure A-2 Output P ower V ersus Ambient T emperatur[...]

Mechanical Specifications 975-0239-01-01 A–5 Charging Efficiency (T ypical) Sell Mode Efficiency (T ypical) Mechanical Specifications T able A-2 XW P ower System Mechanical Specifications Model XW6048-120/2 40-60 XW4548-120/240-60 XW4024-12 0/240-60 Supported Battery T ypes Flooded (default), Gel, AGM, Custom Battery bank size 100–2000 Ah Non V[...]

Specifications A–6 975-0239-01-01 Accessories System Network Xanbus (publ ish-subscribe ne twork, no need for hubs or special cards) Emissions FCC Class B Regulatory approvals UL 1741 1st Edition: 2005 V ersion, CSA 107.1-01 Enclosure T ype NEMA T ype 1 - Indoor (sensitive electronic components sealed inside enclosure) Rated T emperature Range (m[...]

B W iring Diagrams Appendix B, “W iring Diagrams” illustrate the most basic configurations and are for reference only . Specific in stallations may require additional equipment to meet nationa l or local electric code s. Ensure all safety requirements are st rictly followed. For ...... See.... “Single-Inverter System (Backup only)” page B?[...]

B–2[...]

Wiring Diagrams 975-0239-01-01 B-3 Single-Inverter System (Backup only) Figure B-1 Single-Inverter System (Backup only)[...]

Wiring Diagram B-4 975-0239-01-01 Single-Inverter System Renewable Energy (Solar) Figure B-2 Single-Inverter System Re new able Energy (Solar)[...]

Wiring Diagrams 975-0239-01-01 B-5 Single-Inverter System Renewable Energy (W ind or Hydro) Figure B-3 Single-Inverter Syst em Renewable Energy (Wind or Hydro)[...]

Wiring Diagram B-6 975-0239-01-01 Dual-Inverter System Renewable Energy (Solar) Figure B-4 Dual-Inverter System Renewable Energy (Solar)[...]

Wiring Diagrams 975-0239-01-01 B-7 Dual-Inverter System Renewable Energy (W ind or Hydro) Figure B-5 Dual-Inverter System Renewa ble Energy (Wind or Hydro)[...]

Wiring Diagram B-8 975-0239-01-01[...]

C Alternate System Configur ations Appendix C, “Alternate System Confi gurations” provides wiring diagrams for inverter/charger installations th at do not require use of the power distribution panel a nd the XW Conduit Box.[...]

Alternate System Configu rations C–2 975-0239-01-01 DC Grounding for Single-Inverter Systems See T able 2-4, “T orque V alues for AC W iri ng (AC T erminals and Ground Bar),” on page 10. See T able 2-5, “T orque V alues for th e Chassis Ground Lug ,” on page 10. See T able 2-6, “T orque V alues for the In verter Battery T erminals,” o[...]

Battery Connections for Single Inve rter Systems 975-0239-01-01 C–3 Battery Connections for Single Inverter Systems Figure C-2 DC Connections to a Single Inverter Torque connections to the inverter DC terminals to 10- 15 ft./lbs. Torque connections to the battery terminals per battery manufacturer’ s recommendations. This illustrates an example[...]

Alternate System Configu rations C–4 975-0239-01-01 A C Grounding for Single-Inverter Systems Figure C-3 Grounding the AC System This illustrates an example only. Ac tua l ground requireme nts may vary.[...]

AC Output Wiring to the Inverter AC Distribution P anel 975-0239-01-01 C–5 A C Output Wiring to the Inverter A C Distribution P anel Figure C-4 AC Output Wiring to the Inverter AC Distribution P anel Actual wiring require ments may vary.[...]

Alternate System Configu rations C–6 975-0239-01-01 Generator W iring to the Inverter W ARNING: Shock Hazard Before making any electrical conn ections, ensure both the AC and DC disconnect devices are in the OPEN (disconnect) position. Important: If the load is too big for the inverter to operate from battery power , do not install the load in th[...]

Utility Wiring to the Inverter Input 975-0239-01-01 C–7 Utility W iring to the Inverter Input CA UTION: Damage to Equipment The inverter ’ s AC LOAD terminals must never be wired to any AC sour ce such as a generator output or utility panel. This wi ll cause severe da mage to the inverter w hich is not covered under warranty . Figure C-6 Utilit[...]

Alternate System Configu rations C–8 975-0239-01-01 W ind or Hydro DC Sour ces Figure C-7 Connecting Wind or Hydro DC Sources Actual wiring requirements may vary.[...]

Index 975-0239-01-01 IX–1 A AC Connections 2–16 AC sync cable 2–38 AC T erminal Block 2–17 Additional Inverters 2–29 Automatic Generator Start 1–7, 5–7 AUX Port 2–23 AUX Port T erminal Assignments 2– 24 AUX+12V V oltage Su pply 2–23 AUX-RPO User Remote Power Off 2–24 B B+ wires 5–12 battery bank requirements 2–9 battery ca[...]

Index IX–2 975-0239-01-01 T thermostat connecting 5–13 inputs and returns 5–1 1, 5–13 U User Line W iring 2–24 V verifying network power 5–7, 5–18 W web site i–iv Wi n d C–8 W ire Size and Over -current Protection Requirem ents 4–9 Wi r i n g 4–9 W iring the Inverter 2–8 X Xantrex web site iv, i–iv XW Inverter/Charger 1–[...]

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Xantrex Technology Inc. 800 670 0707 Tel Toll Free in North America 360 925 5097 Tel direct 800 994 7828 Fax Toll Free in North America 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.com 975-0239-01-01 Printed in China[...]