Xantrex XW4024-120/240-60 Installation Manual
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Xantrex XW4024-120/240-60 Installation Manual

Xw power system
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Summary of Contents for Xantrex XW4024-120/240-60

  • Page 1: Installation Guide

    XW4024-120/240-60 XW4548-120/240-60 XW6048-120/240-60 Installation Guide ™ Power System XW Power Distribution Panel XW System Control Panel XW Solar Charge Controller XW Automatic Generator Start...
  • Page 3 ® XW Power System Installation Guide...
  • Page 4 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 Copyright © 2008 Xantrex Technology Inc. No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of: Xantrex Technology Inc.

  • Page 5: About This Guide

    About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the XW Power System. Scope The Guide provides safety guidelines, detailed planning and procedures for installing the XW Inverter/Charger and related system components (the “XW Power System”).

  • Page 6: Conventions Used

    XW Automatic Generator Start Owner’s Guide (975-0307-01-01) These guides are available at www.xantrex.com. Printed copies should be included with the components. For more information about Xantrex Technology, Inc. as well as its products and services visit www.xantrex.com. 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 7: Important Safety Instructions

    1. Before using the inverter, read all instructions and cautionary markings on the unit, the batteries, and all appropriate sections of this manual. 2. Use of accessories not recommended or sold by Xantrex Technology Inc. may result in a risk of fire, electric shock, or injury to persons.

  • Page 8: Explosive Gas Precautions

    Single-phase Operation Only CAUTION The XW4024-120/240-60, XW4548-120/240-60 and XW6048-120/240-60 series of Inverter/Chargers are designed and tested for operation with single phase, three wire (120V/240V) AC sources and should not be connected to a three phase AC source.

  • Page 9: Table Of Contents

    Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Introduction System Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 System Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2...
  • Page 10 Contents AUX Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24 AUX+12V Voltage Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24 AUX-RPO: User Remote Power Off (RPO) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25 User Line Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25...
  • Page 11 Contents Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8 Internal Ground Fault Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8 Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays - - - - - - - - - - - - 4–9 Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10...
  • Page 12 Contents Charging Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6 Charging Power Factor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6 Grid-tie Sell Mode Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7 Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7...
  • Page 13 Figures Figure 1-1 XW Power System Installation Diagram Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Figure 1-2 XW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-3...
  • Page 14 Figures Figure 3-1 Network-Managed Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Figure 3-2 Xanbus Cable, RJ45 Connector Pin Numbers and Network Terminators - - - - - - - - - - - - - - - - 3–3 Figure 3-3...
  • Page 15 Tables Table 2-1 Mounting Plate Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Table 2-2 Recommended Battery Cable Size Versus Length- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Table 2-3...

  • Page 17: Introduction

    Introduction Chapter 1, “Introduction” lists and describes the components and basic features of the XW Power System. For this Topic See..“System Overview” page 1–2 “System Components and Accessories” page 1–3 This manual for use by qualified personnel only...

  • Page 18: System Overview

    120/240-volt, 3-wire, single-phase systems allowing for increased capacity. CAUTION The XW4024-120/240-60, XW4548-120/240-60 and XW6048-120/240-60 series of Inverter/Chargers are designed and tested for operation with single phase, three wire (120V/240V) AC sources and should not be connected to a three phase AC source.

  • Page 19: System Components And Accessories

    System Components and Accessories System Components and Accessories XW Inverter/Charger The XW Inverter/Charger is a modular “building block” sine-wave inverter/charger that can be used for both residential and commercial stand-alone, grid-backup, and grid-tie applications with battery energy storage. The XW Series is a self-contained DC to AC inverter, battery charger, and AC transfer switch.

  • Page 20: Xw Power Distribution Panel Panel And Xw Conduit Box

    Introduction Internal wire barriers (or raceways) are included to keep communications wires separate from AC and DC power wires. The XW Conduit Box also includes multiple cable strap points. XW Power Distribution Panel Panel and XW Conduit Box The XW Power Distribution Panel (FGA: 865-1015) includes a mounting plate and XW Conduit Box.

  • Page 21: Xw Connection Kit For Inv2

    System Components and Accessories 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 Inverter/Charger in the same system. XW Connection Kit includes: • XW Conduit Box with raceway barriers and cable strap connections points, •...

  • Page 22: Xw Solar Charge Controller

    Introduction XW Solar Charge Controller The XW Solar Charge Controller (FGA # 865-1030) is a 60 amp charge controller with integrated PVGFP and separate Battery Temperature Sensor. The XW Solar Charge Controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems. However, the XW Inverter/Charger can only work at 24 or 48 volts depending on the model.

  • Page 23: Xw Automatic Generator Start

    System Components and Accessories XW Automatic Generator Start The XW Automatic Generator Start can automatically activate a generator to provide an XW Series Inverter/Charger with power to recharge depleted batteries or assist with heavy loads. The XW Automatic Generator Start adds intelligence to power management and eliminates time spent monitoring batteries and inverter loads.
  • Page 24 1–8...

  • Page 25: Inverter/Charger Installation

    Inverter/Charger 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. For this Topic See..“Pre-Installation” page 2–2 “Step 1: Installing the Mounting Plate” page 2–4 “Step 2: Mounting the Inverter”...

  • Page 26: Pre-Installation

    Inverter/Charger Installation Pre-Installation Before installing the XW Inverter/Charger, read all instructions and cautionary markings located in this manual. Important: Be sure to obtain the appropriate permits, if necessary, prior to starting this installation. Installations must meet all local codes and standards. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System installers.

  • Page 27: Removing Internal Faceplates In The Power Distribution Panel

    Pre-Installation Removing Internal Faceplates in the Power Distribution Panel To remove the upper faceplate, remove the 4 screws holding the plate in place. To remove the lower faceplate, remove the 4 screws holding the plate in place. Figure 2-2 Removing the Internal Faceplates on the Power Distribution Panel Clearance Requirements 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 the inverter for ventilation.

  • Page 28: Mounting

    500 pounds (227 kg). To facilitate installation, a wall mounting plate (Xantrex p/n 210-0462-01-01) is provided for each XW Inverter/Charger and XW Power Distribution Panel. The mounting plate and hardware on the XW Inverter/Charger and XW Power Distribution Panel are designed to meet standards for structural and seismic stability.

  • Page 29: Figure 2-5 Mounting The Bracket For The Xw Inverter/Charger Or Distribution Panel

    Step 1: Installing the Mounting Plate Wall studs 16" on center behind wallboard Side View 2 × 4 wall stud Wallboard Plywood (optional) mounting plate Multiple mounting plates should fit together as shown. 60" (152.4 cm) from floor Add ¾" plywood if additional puts the inverter display support is needed.

  • Page 30: Step 2: Mounting The Inverter

    Inverter/Charger Installation Step 2: Mounting the Inverter Align the flange on the back of the XW Inverter/Charger with the bottom edge of the mounting plate. Lower the flange on the inverter onto the mounting plate. CAUTION: Before releasing the full weight of the unit, ensure the inverter is seated properly on the mounting plate.

  • Page 31: Step 3: Mounting The Xw Power Distribution Panel And Xw Conduit Box

    Attach the back panel of the XW Conduit Box to the bottom of the inverter with two screws through the keyhole slots under xantrex the back panel top and the xantrex NEUTRALS ? GND?

  • Page 32: Step 4: Wiring The Inverter

    Inverter/Charger Installation Step 4: Wiring the Inverter This section provides procedures for making AC and DC connections between the XW Inverter/Charger and the power distribution panel using the cables that are pre-installed in the distribution panel. This section also assumes that the XW Conduit Box was installed in the previous section.

  • Page 33: Batteries

    Step 4: Wiring the Inverter Batteries See the FAQs section of the Xantrex Web site for information on determining battery bank requirements. Consider the following recommendations for battery use. • Use only the deep discharge types for inverter applications. •...

  • Page 34: Torque Values For The Xw Series Inverter/Charger

    Inverter/Charger Installation Terminal covers Color-coded snap-on DC terminal covers are provided to prevent accidental contact with the terminals. Terminal covers are required for all installations, even if a XW Conduit Box is used. It is also recommended that the shank of the ring terminals (cable lugs) be covered with heat shrink or some other form of insulation.

  • Page 35: Torque Values For The Xw Power Distribution Panel

    Step 4: Wiring the Inverter Torque Values for the XW Power Distribution Panel Table 2-7 Torque Values for AC Disconnects and AC Breakers Wire Size Torque Value In-lb 16–10 6–4 Table 2-8 Torque Values for the Ground Bus, AC Neutral Bus, DC Negative Bus, and DC Positive Bus in the XW Power Distribution Panel Wire Size Torque Value...

  • Page 36: Wiring The Inverter To The Xw Power Distribution Panel

    Inverter/Charger Installation Wiring the Inverter to the XW Power Distribution Panel Important: If a XW Conduit Box is installed, communication and Battery Temperature Sensor cables must run through the raceway at the rear of the XW Conduit Box. Before making AC and DC connections, route all communication and Battery Temperature Sensor cables through the raceways.

  • Page 37: Installing The Battery Temperature Sensor

    Step 4: Wiring the Inverter Installing the Battery Temperature Sensor The Battery Temperature Sensor (BTS) port is for connecting to the Battery Temperature Sensor, which regulates battery charging based on battery temperature. Installing a sensor extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures.

  • Page 38: Making Dc Connections

    Inverter/Charger Installation Making DC Connections This section describes how to make DC connections between the inverter/charger and the power distribution panel (using the pre-installed DC cables in the distribution panel), between the distribution panel to the batteries (using battery cables provided by the installer—see Table 2-2 on page 2–10).

  • Page 39: Figure 2-13 Dc Connections To A Single Inverter Using A Xw Power Distribution Panel

    Step 4: Wiring the Inverter CAUTION: Damage to Equipment Do not put anything between the battery cable lug and the terminal surface. Overheating of the terminal may occur. Do not apply any type of antioxidant paste until after the battery cable wiring is tightened.

  • Page 40: Making Ac Connections

    The auxiliary output can be configured (using a XW System Control Panel) to trigger in response to low- or high-battery voltage or high- or low-battery temperature. The auxiliary output can also be triggered manually using a XW System Control Panel. xantrex Communications Ports Dual-knockouts (¾"–1")

  • Page 41: Accessing The Ac Terminal Block And Ac Ground Bar

    Accessing the AC Terminal Block and AC Ground Bar All AC wiring connects to the AC terminal block located on the left-hand side of the inverter beneath the AC access cover. xantrex Grid (AC1 ) I n verti n g...

  • Page 42: Grounding The Ac System

    Inverter/Charger Installation Grounding the AC System Important: Place the neutral-to-ground bond in a permanently installed AC distribution panel that is part of the system. This may be a main panel or a sub-panel. See Table 2-4 on page 10 for torque values for the AC terminal and AC Ground bar. See Figure 2-8 on page 2–11 for torque requirements for the ground bar in the XW Power Distribution Panel.

  • Page 43: Ac Wiring To The Inverter Ac Distribution Panel

    Step 4: Wiring the Inverter AC Wiring to the Inverter AC Distribution Panel An inverter AC distribution panel (also known as a sub-panel or inverter load panel) and AC conduit must be installed before AC wiring is connected to the inverter. Install the inverter AC distribution panel and conduit as follows: 1.

  • Page 44: Figure 2-17 Wiring The Xw Power Distribution Panel To The Sub-Panel Or Utility Grid

    Inverter/Charger Installation 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 off-grid and the only AC source will be a generator, these wires can be connected to the GEN (AC2) terminals (L1-GEN, L2-GEN).

  • Page 45: Wiring The Xw Inverter/Charger To A Xw Power Distribution Panel

    Step 4: Wiring the Inverter Wiring the XW Inverter/Charger to a XW Power Distribution Panel 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. Actual wiring requirements may vary.

  • Page 46: Generator Wiring To The Xw Inverter/Charger Using A Xw Power Distribution Panel

    Inverter/Charger Installation Generator Wiring to the XW Inverter/Charger using a XW Power Distribution Panel In an On-grid installation, the generator will require an additional AC breaker be installed in the Power Distribution Panel. CAUTION: Generators must be hard-wired to the XW Power Distribution Panel. Actual wiring requirements may vary.

  • Page 47: Figure 2-20 Generator Wiring Using A Xw Power Distribution Panel (Off Grid)

    Step 4: Wiring the Inverter In an off-grid installation, the generator can be connected to the breakers provided in the XW Power Distribution Panel. No additional breaker is required. CAUTION: Generators must be hard-wired to the XW Power Distribution Panel. Actual wiring requirements may vary.

  • Page 48: Aux Port

    AUX+12 V and AUX-COM terminals can be used: to power a relay (3 watts maximum). Additional fuses are not required by Xantrex, but may be necessary for some installations. AUX +12 V voltage supply can be programmed for different tasks ON and OFF using the XW System Control Panel.

  • Page 49: Aux-Rpo: User Remote Power Off (Rpo)

    Step 4: Wiring the Inverter AUX-RPO: User Remote Power Off (RPO) Connecting JU-2 (AUX-RPO) and JU-3 (AUX-COM) terminals together through an external switch (normal open contact) will provide the system shut off function if the switch is closed. The external switch if pressed overrides the control provided from the front panel. To enable the AUX port remote power off function, the RPO setting must be enabled from the System Control Panel.

  • Page 50: Basic Functional Test - Single Inverter

    Inverter/Charger Installation Basic Functional Test - Single Inverter The following steps will complete a basic functional test of the XW Inverter/Charger. If any test fails, please refer to the Troubleshooting section in the XW Inverter/Charger Operation Guide for assistance. Confirm All Connections Once the AC and DC wiring have been installed and connected, take a moment to go back over all connections and make sure they are secure and have been installed correctly.

  • Page 51: Enable The Inverter

    Basic Functional Test - Single Inverter Enable the Inverter CAUTION: Equipment Damage Prior to activating the inverter, ensure that all AC loads are disconnected from the output of the inverter. By default, Invert Mode is enabled and the unit should start inverting upon transitioning from Standby Mode.

  • Page 52: Ac Voltage Check

    Inverter/Charger Installation AC Voltage Check Important: This test requires the use of a voltmeter. To perform an AC voltage check: 1. With the inverter on (INVERT [green, kW] LED on solid), verify the AC voltage at AC Loads block terminal L1-Load to N-Load. 2.

  • Page 53: Figure 2-26 Functional Test For Single Inverter Systems

    Basic Functional Test - Single Inverter Figure 2-26 Functional Test for Single Inverter Systems 975-0239-01-01 2–29 This manual for use by qualified personnel only...

  • Page 54: Step 5: Installing Additional Inverters

    Inverter/Charger Installation Step 5: Installing Additional Inverters Installation Steps To install multiple inverters: 1. Disconnect all power from the system. 2. Mount additional inverter(s). See “Step 1: Installing the Mounting Plate” on page 2–4 and “Step 2: Mounting the Inverter” on page 2–6. 3.

  • Page 55: Parts List For Dual-Inverter Configurations

    Step 5: Installing Additional Inverters Parts List for Dual-Inverter Configurations Installing an additional inverter using the power distribution panel requires an XW Connection Kit (part number 856-1020), which contains the following components: • XW Conduit Box • Three 60 amp, 120/240 VAC, 2-pole, Square-D Type QOU, DIN-rail mount, AC breakers for Inverter Input, Output, and Bypass •...

  • Page 56: Figure 2-27 Dc Connections To Dual Inverters

    Inverter/Charger Installation AC Breakers shown in this illustration represent the breaker arrangement for a single AC source. Torque connections to the inverter DC terminals to 10-15 ft/lbs. Actual cable requirements may vary. Torque connections to the battery terminals according to the battery manufacturer’s recommendations.

  • Page 57: Ac Wiring For A Dual-Inverter System

    Step 5: Installing Additional Inverters AC 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 bars connected to top and bottom terminals on the AC breakers. 2.

  • Page 58: Figure 2-29 Ac Wiring For Dual-Inverter Systems

    Inverter/Charger Installation 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 2–11 for torque requirements. Figure 2-29 AC Wiring for Dual-Inverter Systems 2–34 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 59: Figure 2-30 Installing The Front Internal Panels And The Ac Bypass Plate

    Step 5: Installing Additional Inverters Replace the Internal Front Panels using the hardware removed prior to wiring. Place the AC Bypass plate over the Bypass breakers as shown and secure with the hardware provided. Replace the Internal Front Panels using the hardware removed prior to wiring.

  • Page 60: Parts List For A Triple-Inverter Configuration

    For a Single AC Source Installations: ❐ 1 x 865-1024 Conduit Box for inverter ❐ 1x 250 A DC breaker (Master packs available from Xantrex P/N: 865-1065) ❐ 1.0 m (39") x CAT5 network cable for inverter AC Sync ❐ 1.0 m (39") x CAT5 network cable for Xanbus communication ❐...

  • Page 61: Dc Wiring For A Triple-Inverter System

    Step 5: Installing Additional Inverters DC Wiring for a Triple-Inverter System 1. Install the two DC disconnect/breakers (two supplied in 865-1020). 2. Install larger, three-position positive distribution plate (supplied in 865-1020) if not already done. 3. Connect negative battery cable for third inverter (supplied in 865-1020) to DC negative distribution plate.

  • Page 62: Ac Wiring For A Triple-Inverter System

    Inverter/Charger Installation AC Wiring for a Triple-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 4 distribution bars should be prepared for a single AC source and 6 distribution bars for a dual AC source.

  • Page 63: Figure 2-32 Triple-Inverter Ac Breaker Arrangement And Wiring Enlargement With Dual Ac Input Sources

    Step 5: Installing Additional Inverters 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. Figure 2-32 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement with Dual AC Input Sources Power Distribution bars in the XW Power Distribution Panel accept up to a #2/0 AWG cable...

  • Page 64: Figure 2-34 Wiring An External Bypass Switch For A Triple-Inverter Configuration

    Inverter/Charger Installation Actual wiring requirements may vary. Figure 2-34 Wiring an External Bypass Switch for a Triple-Inverter Configuration 2–40 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 65: Xanbus And Ac Sync Cable

    Step 5: Installing Additional Inverters Xanbus and AC Sync Cable A Xanbus and AC sync cable is required for multi-unit installation. The AC sync cable connects each inverter, and provides the necessary communication and control between multiple units. Install these cables, routing it through the XW Conduit Box raceway, prior to making the AC and DC wiring connections.

  • Page 66: Basic Functional Test - Multiple Inverters

    Inverter/Charger Installation Basic Functional Test - Multiple Inverters The following steps will complete a basic functional test of multiple XW Inverter/ Chargers. If any test fails, please refer to the Troubleshooting section in the XW Inverter/ Charger Operation Guide for assistance. To perform a functional test on multiple inverters: 1.
  • Page 67 Basic Functional Test - Multiple Inverters 12. Confirm Master inverter displays “0.00” and Slave(s) displays “---” on their front panels. 13. Check for faults. If fault condition(s) exist, correct and restart Functional Test. 14. Check voltage at AC LOAD terminals of the Master Inverter. 15.
  • Page 68 Inverter/Charger Installation Figure 2-36 Functional Test for Multiple Inverters - Page 1 of 2 2–44 975-0239-01-01 This manual for use by qualified personnel only...
  • Page 69 Basic Functional Test - Multiple Inverters Figure 2-37 Functional Test for Multiple Inverters - Page 2 of 2 975-0239-01-01 2–45 This manual for use by qualified personnel only...
  • Page 70 2–46...
  • Page 71 Basic Functional Test - Multiple Inverters 975-0239-01-01 2–47 This manual for use by qualified personnel only...
  • Page 72 Inverter/Charger Installation 2–48 975-0239-01-01 This manual for use by qualified personnel only...
  • Page 73 Basic Functional Test - Multiple Inverters 975-0239-01-01 2–49 This manual for use by qualified personnel only...
  • Page 74 Inverter/Charger Installation 2–50 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 75: Xanbus Network Installation

    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. For this Topic See..“Xanbus-enabled Devices” page 3–2 “The Xanbus System” page 3–2 “Installing the Network” page 3–5 This manual for use by qualified personnel only...

  • Page 76: Xanbus-Enabled Devices

    Xanbus Network Installation 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 routine tasks. • Reliable. Software control eliminates errors due to analog signalling. •...

  • Page 77: Network Components

    Xanbus cables—each Xanbus-enabled device is connected by a Category 5 (CAT 5 or CAT 5e) cable, a standard cable available from Xantrex or any computer supply store. The cable consists of eight conductors in four twisted pairs with an RJ45 modular connector wired to the T568A standard.

  • Page 78: Ordering Network Components

    Table 3-1 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.

  • Page 79: Installing The Network

    Materials The following materials may be required to complete your installation. ❐ CAT 5 or CAT 5e cables (available from Xantrex or computer supply stores) ❐ Network connectors, if installing multi-drop backbone layout ❐ # 6 screws, 2 per each network connector installed ❐...

  • Page 80: Installing Xanbus-Enabled Devices

    Xanbus Network Installation Installing Xanbus-Enabled Devices If you are installing a Xanbus-enabled device on an existing Xanbus System, put the system in Standby mode using the System Settings menu on the XW System Control Panel. CAUTION: Equipment Damage Connect only to other Xanbus compatible devices. Although the cabling and connectors used in this network system are the same as ethernet connectors, this network is not an ethernet system.
  • Page 81 XW Solar Charge Controller Installation Chapter 4, “XW Solar Charge Controller Installation” describes how to mount and connect the XW Solar Charge Controller as part of the XW System. For this Topic See..“PV Array Requirements” page 4–2 “Mounting” page 4–3 “Grounding”...

  • Page 82: Xw Solar Charge Controller Installation

    XW Solar Charge Controller Installation Installing the Charge Controller This chapter describes installing the XW Solar Charge Controller (XW SCC) 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 Requirements Note The following information provides only general guidelines.

  • Page 83: Mounting

    The instructions in this section apply to an installation including the power distribution panel. Installation procedures will vary according to your specific application. For special applications, consult a qualified electrician or your Xantrex Certified Dealer. Important: Installations must be compliant with all local electrical codes. Installation of this equipment should only be performed by a qualified electrician or by a Certified Renewable Energy (RE) System installer.

  • Page 84: Removing The Wiring Compartment Cover

    Before mounting, you must remove the wiring compartment cover to access the mounting holes and the wiring terminals. The wiring compartment cover is secured with two Phillips #8-32 × 2 ½-inch (63.5 mm) screws on the front cover of the unit. See Figure 4-2. xantrex Remove screws to access the field-wiring terminals.

  • Page 85: Figure 4-3 Dimensions And Knockout Locations

    Mounting Keyhole slot for wall mounting Side screws for power distribution panel mounting 2 7/8" (73 mm) 11" (280 mm) Additional mounting holes ¼" (6.35 mm) 2 3/8" 2 1/16" (60 mm) (53 mm) 4 5/8" 1" 9/16" (25.4 mm) (118 mm) (14 mm) 5 ¾"...

  • Page 86: Mounting The Controller

    XW Solar Charge Controller Installation Mounting the Controller The XW SCC can be mounted to either the side or the top of the power distribution panel. The power distribution panel has keyhole slots and screw holes for side mounting, and two pairs of conduit holes for top mounting the XW SCC.

  • Page 87: Figure 4-5 Mounting The Xw Solar Charge Controller

    Mounting ¼" 6 mm Place keyhole slot over the mounting screw. xantrex Solar Charge Controller Secure with two more screws. Figure 4-5 Mounting the XW Solar Charge Controller 975-0239-01-01 4–7 This manual for use by qualified personnel only...

  • Page 88: Grounding

    XW Solar Charge Controller Installation Grounding The XW SCC can be configured to be compatible with either negative-grounded or ungrounded PV systems. The maximum size of the ground conductor is #6 AWG (16 mm ). This wire gauge is determined by electrical code requirements regarding conduit knockout sizes, wire bending radius, and space available within the XW Series wiring compartment.

  • Page 89: Disabling Ground Fault Protection For Negative Grounded And Ungrounded Arrays

    WARNING: Fire Hazard Ensure there is no other ground connection in the DC wiring or the PV-GFP will be defeated and will not protect the array from ground fault conditions. xantrex This symbol identifies the protective conductor Solar Charge Controller (grounding) connection.

  • Page 90: Wiring

    XW Solar Charge Controller Installation Enabled Disabled Figure 4-7 PV Negative Ground Jumper Location Wiring Important: Installations must meet all local electrical codes. Installations of this equipment should only be performed by a qualified electrician or a Certified Renewable Energy (RE) System Installer.

  • Page 91: Wire Size And Over-Current Protection Requirements

    Wiring Wire Size and Over-current Protection Requirements The wiring, over-current protection devices (fuses and circuit breakers), and installation methods used must conform to all national and local electrical code requirements. Wiring must be protected from physical damage with conduit or a strain relief clamp. To preserve signal integrity on communication cables, the BTS, auxiliary output, and network cables must pass through a different conduit than the conduits used for PV and battery cables.

  • Page 92: Maximum One-Way Distance And Wire Size

    XW Solar Charge Controller Installation Table 4-3 Recommended Circuit Breakers for the XW Solar Charge Controller Xantrex Part Number Description 865-1065 Qty 6, Breaker 250A, 160 Vdc, Stud Terminal, Panel Mount, UL/CSA 865-1070 Qty 12, Breaker 80A, 125 Vdc, Panel Mount, UL/CSA...

  • Page 93: Connecting The Xw Solar Charge Controller To The Distribution Panel

    Wiring Table 4-5 One-Way Wire Distance and Wire Size for a 48 Vdc System Maximum one-way wire distance for a < 3% voltage drop assuming 60 Adc charging current For 48 Vdc systems Distance in feet (meters) Distance in feet (meters) Amps 12 AWG 10 AWG...
  • Page 94 XW Solar Charge Controller Installation 4. Connect the PV array’s positive (+) output to the PV array disconnect. 5. Route another positive (+) cable from the other end of the PV disconnect to the XW SCC terminal marked 6. Connect the negative (–) battery cable to the XW SCC terminal marked –.

  • Page 95: Figure 4-9 Connecting Solar Dc Sources In The Power Distribution Panel

    Wiring Actual wiring requirements may vary. Figure 4-9 Connecting Solar DC Sources in the Power Distribution Panel 975-0239-01-01 4–15 This manual for use by qualified personnel only...

  • Page 96: Commissioning

    XW Solar Charge Controller Installation Commissioning During commissioning, the XW Solar Charge Controller prompts the installer to enter important system information such as the nominal battery voltage, battery type, and battery bank capacity. Ensure the system information is available prior to commissioning. If a XW System Control Panel is present, the XW System Control Panel is intended to be the configuration interface, so the prompt screens are suppressed.
  • Page 97 Commissioning 4. On the MPPT Setup menu, ensure the Advanced Settings item is displayed. If Advanced Settings are not displayed (and Basic Settings appears as the last item on the menu), press the up arrow, down arrow and Exit keys together. (For more information about Advanced Settings, see Appendix B in the XW Solar Charge Controller Owner’s Guide.) 5.
  • Page 98 XW Solar Charge Controller Installation 4. Press Enter. The settings are automatically copied from the selected unit. Note The Copy From command will not give you any indication that it has completed its task. However, you can quickly check for yourself that the charger settings you have chosen have been copied properly by viewing some of the settings you originally configured.

  • Page 99: Xw System Accessories Installation

    XW System Accessories Installation Chapter 5, “XW System Accessories Installation” describes how to mount and install the XW System Control Panel and the Automatic Generator Start. For this Topic See..“The XW System Control Panel” page 5–2 “The XW Automatic Generator Start” page 5–8 This manual for use by qualified personnel only...

  • Page 100: The Xw System Control Panel

    XW System Accessories Installation The XW System Control Panel The XW Series Inverter/Charger can be controlled remotely by connecting a XW System Control Panel. The XW System Control Panel is optional for single inverter systems. The XW System Control Panel is required for configuring systems with multiple inverters. The XW System Control Panel allows access to programming features of the inverter and allows the system to be modified to specific installation requirements.

  • Page 101: Materials And Tools Required

    ❐ Two #8 screws (supplied) ❐ Cable clamps or hardware fasteners ❐ Xantrex network cables or equivalent (CAT 5 or CAT 5E cable with RJ45 connectors wired to T568A standard) A 7-foot cable is provided. ❐ Xantrex male network terminator (supplied).

  • Page 102: Figure 5-2 Inserting The Mounting Plate

    XW System Accessories Installation 3. Insert the mounting plate with the two tabs in a vertical position into the hole (see Figure 5-2). Tabs in vertical position Figure 5-2 Inserting the Mounting Plate 4. Secure the mounting plate by tightening the 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.

  • Page 103: Figure 5-4 Connecting The Network Cables

    The XW System Control Panel Figure 5-4 Connecting the Network Cables 6. Place the unit into the mounting plate and secure it with four #6 screws. Figure 5-5 Securing the XW System Control Panel 7. Peel off the protective plastic coating covering the screen and indicator light. To flush mount the XW System Control Panel with no mounting plate: 1.
  • Page 104 XW System Accessories Installation CAUTION: Equipment damage Connect the XW System Control Panel only to other Xanbus-enabled devices. Although the cabling and connectors used in this network system are the same as Ethernet connectors, this network is not an Ethernet system. Equipment damage may result from attempting to connect these two different systems.

  • Page 105: Verifying The Installation

    The XW System Control Panel Figure 5-6 Surface Mounting the XW System Control Panel Verifying the Installation If network power (from an inverter/charger) is present, the backlight will come on and the XW System Control Panel will show the startup screen (see the XW Inverter/Charger Operation Guide), then show the System Home screen.

  • Page 106: The Xw Automatic Generator Start

    The following tools and materials may be needed to install the XW Automatic Generator Start: ❐ Mounting template (supplied) ❐ Wiring harness (Xantrex part number 809-0917, supplied) ❐ Four #6 screws, 1¼ inch (supplied) ❐ #16 or #18 AWG wire (see “Wire Size and Length” on page 5–12) ❐...

  • Page 107: Choosing A Location

    The XW Automatic Generator Start Choosing a Location The XW Automatic Generator Start should be installed in a location that meets the following requirements: The unit is intended for use in a dry location. The XW Automatic Generator Start complies with UL458 Marine Supplement drip-test requirements, but the location should be as dry as possible.

  • Page 108: Installing The Xw Automatic Generator Start

    XW System Accessories Installation Network ports 20-contact connector Network cables to other Wiring harness (connection Xanbus-enabled devices to generator, thermostats, and external switches) Figure 5-8 XW Automatic Generator Start External Connections Installing the XW Automatic Generator Start Installation Installing the XW Automatic Generator Start involves the following steps: Overview 1.

  • Page 109: Mounting The Unit

    The XW Automatic Generator Start Mounting the Unit The XW Automatic Generator Start is to be mounted vertically on a wall with the connectors facing downwards. To mount the XW Automatic Generator Start: 1. Hold the unit flush and square against the wall, panel, or horizontal surface. •...

  • Page 110: Figure 5-9 Xw Automatic Generator Start Wiring Harness

    XW System Accessories Installation To install the XW Automatic Generator Start using the wiring harness: 1. Connect each wire on the harness to its intended wire or contact on the generator, thermostats, or external switches. 2. Plug the harness into the connector on the bottom panel of the XW Automatic Generator Start.

  • Page 111: Connecting The Generator

    The XW Automatic Generator Start Table 5-3 Contact Numbers and Functions (Continued) Wire Wiring Harness Number Function Wire Color Constant 12/24 V B+ (battery positive) for External ON/OFF/LED Indicator External ON/OFF/LED Indicator return (connected internally to Black wire number 13) Generator run signal (switched B+) sense input Violet Generator run signal (switched B+) sense return (generator battery...

  • Page 112: Connecting The Thermostats (Optional)

    XW System Accessories Installation This section describes the generator configurations and provides diagrams for connecting the wiring harness to the generator’s start wiring. Important: For an explanation of the terminology used in the following section, refer to Appendix B of the XW Automatic Generator Start Owner’s Guide. For more information about XW Automatic Generator Start internal relay activity and timing, see the Automatic Generator Start Owner’s Guide.

  • Page 113: Connecting An External Manual On/Off Switch (Optional)

    The XW Automatic Generator Start Connecting an External Manual ON/OFF Switch (optional) The external manual ON/OFF inputs (wires 7 and 8 on the wiring harness) are intended for wiring to one or more remote ON/OFF switches for starting and stopping the generator manually.

  • Page 114: Connecting An External On/Off Led

    XW System Accessories Installation Connecting an External ON/OFF LED Wires 9 (White/Blue) and 11 (Black) on the wiring harness can be connected to an LED or other light to accompany a remote external ON/OFF switch. This light turns on when the generator run signal is active to visually indicate that the generator is running.

  • Page 115: Connecting The Wiring Harness To The Xw Automatic Generator Start

    The XW Automatic Generator Start Connecting the Wiring Harness to the XW Automatic Generator Start After all the external connections have been wired to the wiring harness, the connector on the wiring harness must be plugged into the 20-contact connector on the XW Automatic Generator Start.

  • Page 116: Connecting The Xw Automatic Generator Start To The Xanbus Network

    XW System Accessories Installation Connecting the XW Automatic Generator Start to the Xanbus Network CAUTION: Equipment Damage Connect only to other Xanbus-enabled devices. Although the cabling and connectors used in this network system are the same as Ethernet connectors, this network is not an Ethernet system. Equipment damage may result from attempting to connect a Xanbus-enabled device to an Ethernet system.

  • Page 117: Verifying Power Is Available

    The XW Automatic Generator Start Verifying Power Is Available When the XW Automatic Generator Start has been installed properly, the Power and Network indicator lights illuminate. If one or both lights are out, check the network connections and ensure the network power supply is on.
  • Page 118 5–20...

  • Page 119: Specifications

    Specifications Appendix A, “Specifications” provides the electrical and environmental specifications for the XW Series. This manual for use by qualified personnel only...

  • Page 120: Electrical Specifications

    Specifications Electrical Specifications Table A-1 XW Power System Electrical Specifications Model XW6048-120/240-60 XW4548-120/240-60 XW4024-120/240-60 Continuous Output Power 6,000 W 4,500 W 4,000 W Surge Rating (10 seconds) 12,000 W (15 s) 9,000 W (20 s) 8,000 W (20 s) (stand-alone invert mode)

  • Page 121: Xw Series Overload Capability

    Loads presented to the inverter are seldom constant. Typically, large loads are operated for only short periods of time. In order to provide the maximum utility, Xantrex inverters are allowed to operate at power levels that exceed their continuous power ratings. This graph shows how loads that are larger than the inverter can sustain continuously can be operated for useful periods of time.

  • Page 122: Figure A-2 Xw Series Ac Overload Capability

    Specifications Figure A-2 XW Series AC Overload Capability Figure A-3 XW Series AC Overload Capability A–4 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 123: Output Power Versus Ambient Temperature

    Electrical Specifications Output Power Versus Ambient Temperature When the internal temperature of the XW Series exceeds its rated range, the unit reduces it energy output to ensure maximum component ratings are not exceeded. XW Series Power Derating 7000 6000 5000 Output 4000 XW6048-Pwr_der...

  • Page 124: Charging Efficiency (Typical

    Specifications Charging Efficiency (Typical) 100% Efficiency XW6048 XW4024 XW4548 Charge Current (Amps) Figure A-6 Charging Efficiency (Typical) Charging Power Factor 100% XW4548 XW4024 XW6048 Power Factor Charge Current (Amps) Figure A-7 Charging Power Factor A–6 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 125: Grid-Tie Sell Mode Efficiency (Typical

    Output Power (Watts) Figure A-8 Grid-tie Sell Mode Efficiency (Typical) Mechanical Specifications Table A-2 XW Power System Mechanical Specifications Model XW6048-120/240-60 XW4548-120/240-60 XW4024-120/240-60 Supported Battery Types Flooded (default), Gel, AGM, Custom Battery bank size 100–2000 Ah Non Volatile Memory Display Panel Status LEDs indicate AC In status, faults/warnings, equalize mode, battery level.

  • Page 126: Accessories

    Table A-2 XW Power System Mechanical Specifications Model XW6048-120/240-60 XW4548-120/240-60 XW4024-120/240-60 Inverter Dimensions (H × W × D) 23 × 16 × 9" (580 × 410 × 230 mm) Shipping Dimensions 28 x 22.5 x 15.5" (711 x 572 x 394 mm) XW Power Distribution Panel 30 ×...

  • Page 127: B Wiring Diagrams

    Wiring Diagrams Appendix B, “Wiring Diagrams” illustrate the most basic configurations and are for reference only. Specific installations may require additional equipment to meet national or local electric codes. Ensure all safety requirements are strictly followed. For..See..“Single-Inverter System (Backup only) Without a Power page B–3 Distribution Panel”...
  • Page 128 B–2...

  • Page 129: Single-Inverter System (Backup Only) Without A Power Distribution Panel

    Wiring Diagrams Single-Inverter System (Backup only) Without a Power Distribution Panel Figure B-1 Single-Inverter System (Backup only) Without a Power Distribution Panel 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 130: Single-Inverter System (Backup Only) With A Power Distribution Panel

    Wiring Diagram Single-Inverter System (Backup only) With a Power Distribution Panel Figure B-2 Single-Inverter System (Backup only) With a Power Distribution Panel This manual for use by qualified personnel only 975-0239-01-01...

  • Page 131: Single-Inverter System Renewable Energy (Solar

    Wiring Diagrams Single-Inverter System Renewable Energy (Solar) Figure B-3 Single-Inverter System Renewable Energy (Solar) 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 132: Single-Inverter System Renewable Energy (Wind Or Hydro

    Wiring Diagram Single-Inverter System Renewable Energy (Wind or Hydro) Figure B-4 Single-Inverter System Renewable Energy (Wind or Hydro) This manual for use by qualified personnel only 975-0239-01-01...

  • Page 133: Dual-Inverter System Renewable Energy (Solar

    Wiring Diagrams Dual-Inverter System Renewable Energy (Solar) Figure B-5 Dual-Inverter System Renewable Energy (Solar) 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 134: Dual-Inverter System Renewable Energy (Wind Or Hydro

    Wiring Diagram Dual-Inverter System Renewable Energy (Wind or Hydro) Figure B-6 Dual-Inverter System Renewable Energy (Wind or Hydro) This manual for use by qualified personnel only 975-0239-01-01...

  • Page 135: C Alternate System Configurations

    Alternate System Configurations Appendix C, “Alternate System Configurations” provides wiring diagrams for inverter/charger installations that do not require use of the power distribution panel and the XW Conduit Box. This manual for use by qualified personnel only...

  • Page 136: Dc Grounding For Single-Inverter Systems

    Alternate System Configurations DC Grounding for Single-Inverter Systems See Table 2-4, “Torque Values for AC Wiring (AC Terminals and Ground Bar),” on page 10. See Table 2-5, “Torque Values for the Chassis Ground Lug,” on page 10. See Table 2-6, “Torque Values for the Inverter Battery Terminals,” on page 10. This illustrates an example only.

  • Page 137: Battery Connections For Single Inverter Systems

    Battery Connections for Single Inverter Systems Battery Connections for Single Inverter Systems 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 only. Actual cable requirements may vary. Figure C-2 DC Connections to a Single Inverter 975-0239-01-01 C–3...

  • Page 138: Ac Grounding For Single-Inverter Systems

    Alternate System Configurations AC Grounding for Single-Inverter Systems This illustrates an example only. Actual ground requirements may vary. Figure C-3 Grounding the AC System C–4 975-0239-01-01 This manual for use by qualified personnel only...

  • Page 139: Ac Output Wiring To The Inverter Ac Distribution Panel

    AC Output Wiring to the Inverter AC Distribution Panel AC Output Wiring to the Inverter AC Distribution Panel Actual wiring requirements may vary. Figure C-4 AC Output Wiring to the Inverter AC Distribution Panel 975-0239-01-01 C–5 This manual for use by qualified personnel only...

  • Page 140: Generator Wiring To The Inverter

    Alternate System Configurations Generator Wiring to the Inverter WARNING: Shock Hazard Before making any electrical connections, 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 the inverter powered electrical panel.

  • Page 141: Utility Wiring To The Inverter Input

    Utility Wiring to the Inverter Input Utility Wiring to the Inverter Input CAUTION: Damage to Equipment The inverter’s AC LOAD terminals must never be wired to any AC source such as a generator output or utility panel. This will cause severe damage to the inverter which is not covered under warranty.
  • Page 142 C–8...
  • Page 143 Index 2–16 5–13 AC Connections generator run signal 2–41 2–22 AC sync cable Generator Wiring 2–17 2–17 AC Terminal Block Ground Bar 2–30 2–11, 2–12, 4–8 Additional Inverters Grounding 1–7, 5–8 2–12 Automatic Generator Start Grounding the DC System 2–24 AUX Port 2–25 AUX Port Terminal Assignments...
  • Page 144 5–7, 5–19 verifying network power i–iv web site 4–11 wire size 4–11 Wire Size and Over-current Protection Requirements 4–10 Wiring 2–8 Wiring the Inverter Xantrex iv, i–iv web site 1–3 XW Inverter/Charger 1–6, 5–2 XW System Control Panel IX–2 975-0239-01-01...
  • Page 146 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...

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