Xantrex XW4024-120/240-60, XW4548-120/240-60, XW6048-120/240-60 Installation Manual
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Xantrex XW4024-120/240-60, XW4548-120/240-60, XW6048-120/240-60 Installation Manual

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Download this manual See also: Operating Manual, Installation Manual
XW4024-120/240-60
XW4548-120/240-60
XW6048-120/240-60
Installation Guide
XW Power System
XW Power Distribution Panel
XW System Control Panel
XW Solar Charge Controller
XW Automatic Generator Start

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Summary of Contents for Xantrex XW4024-120/240-60, XW4548-120/240-60, XW6048-120/240-60

  • Page 1 XW4024-120/240-60 XW4548-120/240-60 XW6048-120/240-60 Installation Guide XW 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 About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 2.5 MW utility-scale systems for wind, solar, batteries, fuel cells, micro turbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.

  • 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”). It does not provide details about configuration, operation, maintenance or troubleshooting.
  • Page 6 XW Solar Charge Controller Owner’s Guide (975-0283-01-01) • 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...

  • 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: Limitations On Use

    Important Safety Instructions Limitations on Use WARNING: Limitations on Use The XW Power System is not intended for use in connection with life support systems or other medical equipment or devices. Explosive Gas Precautions 1. Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during normal operation.

  • Page 9: Table Of Contents

    Contents Important Safety Instructions Limitations on Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi 1 Introduction...
  • Page 10 Contents Accessing the AC Terminal Block and AC Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17 Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18 AC Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19 AC Wiring to the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19 Wiring the XW Inverter/Charger to a XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - 2–21...
  • Page 11 4 XW Solar Charge Controller Installation Installing the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Array Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Array Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2...
  • Page 12 Contents Appendix A Specifications Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2 XW Series Overload Capability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Output Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4 XW Series Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4...
  • 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 XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3...
  • Page 14 Figures 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...
  • 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 “System Overview” “System Components and Accessories” See... page 1–2 page 1–3...

  • Page 18: System Overview

    System Overview The XW Power System consists of several devices, components, and optional accessories that, when installed together, create a renewable energy power system that can be customized to suit nearly any application—off grid, grid tied, or backup. Up to three inverters can be installed in parallel to create larger 120/240 V 3-wire, single-phase systems allowing for increased capacity.

  • Page 19: 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

    The XW Conduit Box comes in two pieces and mounts directly to the bottom of the inverter/charger with keyhole slots and 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 included to keep communications wires separate from AC and DC power wires.

  • Page 21: Xw Connection Kit For Inv2

    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 Conduit Box Power Distribution Bars #6 AWG AC Wiring #4/0 AWG battery cables Figure 1-5 XW Connection Kit for INV2 975-0239-01-01...

  • Page 22: Xw Solar Charge Controller

    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

    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 “Pre-Installation” “Step 1: Installing the Mounting Plate” “Step 2: Mounting the Inverter” “Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box”...

  • Page 26: Pre-Installation

    Pre-Installation Before installing the XW Inverter/Charger, read all instructions and cautionary markings located in this manual. Important: 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: Clearance Requirements

    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. There must be at least three feet of clearance in front of the inverter. Ensure that the vents are not obstructed with foreign objects and that the minimum clearances are met.

  • Page 28: Step 1: Installing The Mounting Plate

    Step 1: Installing the Mounting Plate Each XW Inverter/Charger and XW Power Distribution Panel requires a separate mounting plate. This bracket is first attached to the wall, then the inverter/charger or distribution panel is attached to the wall bracket. The wall bracket is attached to the wall with lag bolts or other fasteners, provided by the installer.

  • Page 29: Figure 2-3 Mounting The Bracket For The Xw Inverter/Charger Or Distribution Panel

    Side View 2 × 4 wall stud Wallboard Plywood (optional) mounting plate 60" (152.4 cm) from floor puts the inverter display panel at approx. 65" high. Locate the wall studs. If necessary, enhance the support surface with a ¾" plywood panel secured to the wall studs.

  • Page 30: Step 2: Mounting The Inverter

    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

    Step 3: Mounting the XW Power Distribution Panel and XW Conduit Mount the XW Distribution Panel on the mounting bracket following 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 front panel until all wiring is complete.

  • Page 32: Step 4: Wiring The Inverter

    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

    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. • Use the same battery type for all batteries in the bank. •...

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

    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

    Torque Values for the XW Power Distribution Panel Table 2-7 Torque Values for AC Disconnects and AC Breakers Wire Size 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 14 - 10 6 - 4...

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

    Wiring the Inverter to the XW Power Distribution Panel Important: 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

    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

    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 2-11 Dc Connections To A Single Inverter Using A Xw Power Distribution Panel

    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. The same applies for all DC connections. Do not over-tighten; observe all recommended torque values.

  • Page 40: Making Ac Connections

    Making AC Connections This section describes how to make AC connections between the XW Inverter/Charger and the XW Power Distribution Panel (using the pre-installed AC wiring in the XW Power Distribution Panel) and between the XW Power Distribution Panel and the AC distribution panel, or sub-panel (using wiring provided by the installer).

  • 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. Recessed edge Remove the two screws on the AC access cover and slide it to the left of the inverter to remove it.

  • Page 42: Grounding The Ac System

    Grounding the AC System Important: 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

    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 2-15 Wiring The Xw Power Distribution Panel To The Sub-Panel Or Utility Grid

    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

    Wiring the XW Inverter/Charger to a XW Power Distribution Panel Actual wiring requirements may vary. Figure 2-16 Wiring the Inverter to the XW Power Distribution Panel 975-0239-01-01 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.

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

    Generator Wiring to the XW Inverter/Charger using a XW Power Distribution Panel CAUTION: Generators must be hard-wired to the XW Power Distribution Panel. In an off-grid installation (i.e., where no utility grid is available), the generator can be connected to the breakers provided in the XW Power Distribution Panel.

  • Page 47: Aux Port

    AUX Port The XW Series has a 12 Vdc auxiliary output that can be configured to trigger in response to one of the following battery conditions: • low battery voltage • high battery voltage • low battery temperature • high battery temperature •...

  • Page 48: Aux-Rpo: User Remote Power Off (Rpo)

    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. If the external switch is cleared (not pressed), the system can be enabled back from the front panel.

  • Page 49: Basic Functional Test - Single Inverter

    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 50: Enable The 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. If Invert Mode is disabled, the display will show (---) once out of Standby Mode.

  • Page 51: Ac Voltage Check

    AC Voltage Check Important: 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. Verify that neutral is bonded to ground in the system by measuring the hot and neutral voltages relative to ground.

  • Page 52: Figure 2-23 Functional Test For Single Inverter Systems

    Inverter/Charger Installation Figure 2-23 Functional Test for Single Inverter Systems 2–28 975-0239-01-01...

  • Page 53: Step 5: Installing Additional Inverters

    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 54: Parts List For Dual-Inverter Configurations

    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 55: 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. Figure 2-24 DC Connections to Dual Inverters 975-0239-01-01 AC Breakers shown in this illustration represent the breaker arrangement for a single AC source. Torque connections to the battery terminals according to the battery manufacturer’s recommendations.

  • Page 56: Ac Wiring For A Dual-Inverter System

    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. Remove bypass interlock bracket. 3.

  • Page 57: Figure 2-26 Ac Wiring For Dual-Inverter Systems

    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 2-26 AC Wiring for Dual-Inverter Systems 975-0239-01-01 2–33...

  • Page 58: Parts List For A Triple-Inverter Configuration

    Parts List for a Triple-Inverter Configuration ❐ 1 x XW Power Distribution Panel (PDP) and Accessory kit (mounts to first unit). ❐ 1 x 865-1020 PDP extension kit for second unit. The following items are required for the third inverter (furthest from PDP) and should be sourced and prepared prior to the installation.

  • Page 59: Figure 2-27 Dc Connections For A Triple-Inverter System

    6. Connect positive battery cable for first inverter (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 cable for third inverter (custom, see material list) to top terminal on third DC disconnect/breaker.

  • Page 60: Ac Wiring For A Triple-Inverter System

    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 6 distribution bars should be prepared. 2.

  • Page 61: Figure 2-29 Triple-Inverter Ac Breaker Arrangement And Wiring Enlargement With A

    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 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement with a Single AC Input Source Figure 2-30 Wiring an External Bypass Switch for a Triple-Inverter Configuration 975-0239-01-01 FROM AC SOURCE DISCONNECT...

  • Page 62: Xanbus And Ac Sync Cable

    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 63: Basic Functional Test - Multiple Inverters

    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 64 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. Switch the AC Load breakers ON. 16.
  • Page 65 Basic Functional Test - Multiple Inverters Figure 2-32 Functional Test for Multiple Inverters - Page 1 of 2 975-0239-01-01 2–41...
  • Page 66 Inverter/Charger Installation Figure 2-33 Functional Test for Multiple Inverters - Page 2 of 2 2–42 975-0239-01-01...

  • Page 67: 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 “Xanbus-enabled Devices” “The Xanbus System” “Installing the Network” See... page 3–2 page 3–2 page 3–7...

  • Page 68: Xanbus-Enabled Devices

    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 69: Network Components

    Network Components A Xanbus network consists of the following components: • Xanbus-enabled devices—these include the XW System Control Panel, the XW Inverter/Charger, XW Automatic Generator Start, and XW Charge Controller. The maximum number of Xanbus devices connected to a single Xanbus network should not exceed eight devices.

  • Page 70: Figure 3-2 Xanbus Cable And Rj45 Connector Pin Numbers

    Figure 3-2 Xanbus Cable and RJ45 Connector Pin Numbers • Network terminators (Figure 3-3)—the Xanbus network must be properly terminated at each end with male or female network terminators to ensure the communication signal quality on the network. If the network is not properly terminated, signal quality is degraded and performance on the network is reduced.

  • Page 71: Ordering Network Components

    Ordering Network Components Table 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.

  • Page 72: Daisy Chain Layout

    Terminate network at each end with a female terminator. Figure 3-5 Multi-Drop Backbone Layout Daisy Chain Layout In a daisy chain layout, each device on the network is linked with separate lengths of Xanbus cable, as shown in Figure 3-6. This layout does not require network connectors. As in the multi-drop backbone layout, two terminators are required to ensure the communication signal quality on the network.

  • Page 73: Installing The Network

    Installing the Network Important: supported by Xantrex. Important: performed with the XW Power System in Standby mode. For more information about Standby mode, see the XW System Control Panel Owner’s Guide. Before You Begin the Installation • Read the entire section before installing the network. It’s important to plan the installation from beginning to end.

  • Page 74: Mounting A Network Connector

    The total length of the network, including all connected Xanbus-enabled devices and the XW Series, cannot exceed 130 feet (40 m). See Table 3-3. Table 3-3 Minimum and Maximum Cable Length Cable Length Backbone or daisy chain Total backbone length or daisy chain 4 inches (10 cm) Drop cable on backbone Mounting a Network Connector To mount a network connector:...

  • Page 75: Installing Xanbus-Enabled Devices

    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 76: Completing The Daisy Chain Layout

    Completing the Daisy Chain Layout To complete the daisy chain layout: ◆ Insert a male terminator into the open network port of the Xanbus-enabled device at each end of the network. See Figure 3-9. Figure 3-9 Completing a Daisy-Chain Layout CAUTION: Unpredictable device behavior After connecting the Xanbus-enabled devices and terminating the network, do not plug terminators or other cables into any remaining open network ports on any Xanbus-enabled devices.

  • Page 77: Figure 1-6 Xw Solar Charge Controller

    XW Solar Charge Controller Installation Chapter 4, “XW Solar Charge Controller Installation” describes how to mount and connect the XW Charge Controller as part of the XW System. For this Topic “PV Array Requirements” “Mounting” “Grounding” “Wiring” “Commissioning” See... page 4–2 page 4–3 page 4–8 page 4–9...

  • Page 78: Xw Solar Charge Controller Installation

    Installing the Charge Controller This chapter describes installing the XW Solar 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 Requirements Each Charge Controller must be connected to its own PV array. For optimum performance, each individual array must be composed of the same type of solar panel, with the same V Important:...

  • Page 79: Mppt Voltage Range

    MPPT Voltage Range The XW Solar Charge Controller maximum power point tracking algorithm maximizes the output power of PV arrays as long as the operating voltage is within the MPPT operational window. Ensure that the PV array used in the system operates within the MPPT operational window.

  • Page 80: Figure 4-1 Minimum Clearance Requirements

    WARNING: Explosion/Corrosion Hazard To reduce the risk of fire or explosion, do not install the XW Solar Charge Controller in sealed compartments containing batteries or in locations that require ignition-protected equipment. To reduce the risk of corrosion from hydrogen-sulfide gas vented by batteries, do not install the XW Solar Charge Controller in sealed compartments containing batteries.

  • Page 81: Removing The Wiring Terminals Cover

    Removing the Wiring Terminals Cover Before mounting, you must remove the wiring terminals cover to access the mounting holes and the wiring 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. Figure 4-2 Removing the Wiring Terminals Cover Removing Knockouts Six dual and two single knockouts are provided for routing battery, PV array, BTS, and...

  • Page 82: Mounting The Controller

    26.47 DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) Figure 4-4 Knockout Dimensions 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 distribution panel has keyhole slots and screw holes for side mounting, and two pairs of conduit holes for top mounting the XW Solar Charge Controller.

  • Page 83: Figure 4-5 Mounting The Xw Solar Charge Controller

    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. ¼" Place keyhole slot over the mounting screw.

  • Page 84: Grounding

    Grounding The XW Solar Charge Controller is designed to work only with negative-grounded electrical systems. Grounding for both PV and battery circuits is provided inside the wiring compartment. Each ground connection can accommodate up to #6 AWG wire size. A fuse rated at 1 A, 600 V (accessible from inside the wiring compartment) grounds the negative conductor of the PV array and provides PV ground-fault protection (PV-GFP).

  • Page 85: Wiring

    Wiring Important: should only be performed by a qualified electrician or a Certified Renewable Energy (RE) System Installer. WARNING: Shock Hazard Disconnect battery and PV sources before wiring. DC Terminal Connector Locations Terminal connectors for DC wiring are located inside the wiring compartment. The labels above the DC wiring terminals and inside the wiring compartment identify all the connection points.

  • Page 86: Table 4-3 Recommended Circuit Breakers For The Xw Solar Charge Controller

    Table 4-3 Recommended Circuit Breakers for the XW Solar Charge Controller Xantrex Part Number 865-1065 865-1070 865-1075 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 Charge Controller).

  • Page 87: Table 4-4 One-Way Wire Distance And Wire Size For A 24 Vdc System

    Table 4-4 One-Way Wire Distance and Wire Size for a 24 Vdc System Maximum one-way wire distance for a < 3% voltage drop assuming 60 Adc charging current Distance in feet (meters) Amps 12 AWG 10 AWG 17.6 (5.36) 28.0 (8.54) 14.6 (4.46) 23.2 (7.08) 12.6 (3.84)

  • Page 88: Connecting The Xw Solar Charge Controller To The Distribution Panel

    Connecting the XW Solar Charge Controller to the Distribution Panel WARNING: Shock Hazard Whenever a PV array is exposed to light, a shock hazard exists at the output wires or exposed terminals. To reduce the risk of shock during installation, cover the array with an opaque (dark) material before making the connections.

  • Page 89: Figure 4-8 Connecting Solar Dc Sources In The Power Distribution Panel

    Wiring Actual wiring requirements may vary. Figure 4-8 Connecting Solar DC Sources in the Power Distribution Panel 975-0239-01-01 4–13...

  • Page 90: Commissioning

    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 91 3. From the Select Device menu on the SCP, select a XW Solar Charge Controller (each unit should appear as “MPPT60 00” where the 60 stands for 60A, and the 00 is its device number). 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.
  • Page 92 3. On the Advanced Settings menu, select Copy From, then select the XW Solar Charge Controller you want to copy from. You should select the unit with the device number that matches the first unit you configured. 4. Press Enter. The settings are automatically copied from the selected unit.

  • Page 93: 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 “The XW System Control Panel” “The XW Automatic Generator Start” See... page 5–2 page 5–7...

  • Page 94: The Xw System Control Panel

    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 95: Materials And Tools Required

    Materials and Tools Required You will need these materials and tools to complete the installation: ❐ Mounting template sticker (supplied) ❐ Mounting plate (supplied) ❐ mounting plate (supplied) ❐ Four #6 screws (supplied) ❐ Two #8 screws (supplied) ❐ Cable clamps or hardware fasteners ❐...

  • Page 96: Figure 5-2 Inserting The Mounting Plate

    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. Be careful not to overtighten the screws and damage the wall. Rotate tabs to horizontal position Figure 5-3 Securing the Mounting Plate...

  • Page 97: Figure 5-4 Connecting The Network Cables

    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 98: Figure 5-6 Surface Mounting The Xw System Control Panel

    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 99: Verifying The Installation

    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. The XW Automatic Generator Start Some generators allow automatic starting.

  • Page 100: Choosing A Location

    ❐ #16 or #18 AWG wire (see “Wire Size and Length” on page 5–11) ❐ Xantrex network cables or equivalent (Category 5) ❐ Network terminators (if required) ❐ Phillips screwdriver ❐ Wire cutters and wire strippers Choosing a Location The XW Automatic Generator Start should be installed in a location that meets the following requirements: Cool Safe...

  • Page 101: Installing The Xw Automatic Generator Start

    Network ports Network cables to other Xanbus-enabled devices 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. Mounting the unit. 2. Connecting the wiring harness to: •...

  • Page 102: Mounting The Unit

    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 103: Figure 5-9 Xw Automatic Generator Start Wiring Harness

    The wires on the wiring harness can be extended to meet installation requirements. When extending the wire harness, ensure that the extension wires are the same color as the wires on the harness. To install the XW Automatic Generator Start using the wiring harness: 1.

  • Page 104: Connecting The Generator

    Table 5-3 Contact Numbers and Functions (Continued) Wire Number Function Connecting the Generator To connect the XW Automatic Generator Start to a generator, you must identify the start wiring configuration of the generator you want to use. Generators must be auto-start capable, and generators equipped with remote operation connections are ideal.

  • Page 105: Connecting The Thermostats (Optional)

    Important: Generator Start into Standby mode. See the XW Inverter/Charger Operation Guide for instructions on putting the system in Standby Mode. This section describes the generator configurations and provides diagrams for connecting the wiring harness to the generator’s start wiring. Important: Appendix B of the XW Automatic Generator Start Owner’s Guide.

  • Page 106: Connecting An External Manual On/Off Switch (Optional)

    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. The other contact of the switch should be connected to ground. In order for the XW Automatic Generator Start to be able to detect these switches, wire the positive of the generator battery to the constant 12-volt/24-volt generator battery positive (wire 10 on the XW Automatic Generator Start wiring harness).

  • Page 107: Connecting An External On/Off Led

    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. Important: during the preheat stage, before the generator is actually running.

  • Page 108: Connecting The Wiring Harness To 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. To connect the wiring harness to the XW Automatic Generator Start: ◆...

  • Page 109: Connecting The Xw Automatic Generator Start To The Xanbus Network

    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 110: Verifying Power Is Available

    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. Figure 5-13 Verifying Power is Available 5–18 Verify Power and Network indicator...

  • Page 111: Appendix A Specifications

    Specifications Appendix A, “Specifications” provides the electrical and environmental specifications for the XW Series.

  • Page 112: Electrical Specifications

    Electrical Specifications Table A-1 XW Power System Electrical Specifications Model Continuous Output Power Surge Rating (10 seconds) Surge Current Waveform Idle Consumption—invert mode, no load Idle Consumption—search mode AC Output Voltage AC Input voltage range (Bypass/Charge Mode) AC Input Current (maximum 75% imbalance between L1-n, L2-n) AC Input Breaker AC Input Frequency Range (Bypass/...

  • Page 113: Xw Series Overload Capability

    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 114: Output Power Versus Ambient Temperature

    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. Figure A-2 Output Power Versus Ambient Temperature XW Series Efficiency Inverting Efficiency (Typical) A–4 XW Series Power Derating...

  • Page 115: Charging Efficiency (Typical

    Charging Efficiency (Typical) Sell Mode Efficiency (Typical) Mechanical Specifications Table A-2 XW Power System Mechanical Specifications Model Supported Battery Types Battery bank size Non Volatile Memory Display Panel Multiple Unit Configurations 975-0239-01-01 Battery Current (Amps) 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 Export Pow er (kW) XW6048-120/240-60 XW4548-120/240-60...

  • Page 116: Accessories

    Table A-2 XW Power System Mechanical Specifications Model System Network Emissions Regulatory approvals Enclosure Type Rated Temperature Range (meets all specifications) Operational Temperature Range Storage Temperature Range Inverter Dimensions (H × W × D) Shipping Dimensions XW Power Distribution Panel Dimensions (H ×...

  • Page 117: Appendix 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... “Single-Inverter System (Backup only)” “Single-Inverter System Renewable Energy (Solar)”...
  • Page 118 B–2...

  • Page 119: Figure B-1 Single-Inverter System (Backup Only

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

  • Page 120: Single-Inverter System Renewable Energy (Solar

    Wiring Diagram Single-Inverter System Renewable Energy (Solar) Figure B-2 Single-Inverter System Renewable Energy (Solar) 975-0239-01-01...

  • Page 121: Single-Inverter System Renewable Energy (Wind Or Hydro

    Wiring Diagrams Single-Inverter System Renewable Energy (Wind or Hydro) Figure B-3 Single-Inverter System Renewable Energy (Wind or Hydro) 975-0239-01-01...

  • Page 122: Dual-Inverter System Renewable Energy (Solar

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

  • Page 123: Dual-Inverter System Renewable Energy (Wind Or Hydro

    Wiring Diagrams Dual-Inverter System Renewable Energy (Wind or Hydro) Figure B-5 Dual-Inverter System Renewable Energy (Wind or Hydro) 975-0239-01-01...
  • Page 124 Wiring Diagram 975-0239-01-01...

  • Page 125: Appendix 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.

  • Page 126: Dc Grounding For Single-Inverter Systems

    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. Figure C-1 DC Grounding for an Inverter only C–2 This illustrates an example only.

  • Page 127: Battery Connections For Single Inverter Systems

    Battery Connections for Single Inverter Systems This illustrates an example only. Actual cable requirements may vary. Figure C-2 DC Connections to a Single Inverter 975-0239-01-01 Torque connections to the inverter DC terminals to 10- 15 ft./lbs. Torque connections to the battery terminals per battery manufacturer’s recommendations.

  • Page 128: 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...

  • Page 129: 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...

  • Page 130: Generator Wiring To The Inverter

    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 131: 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 132: Wind Or Hydro Dc Sources

    Alternate System Configurations Wind or Hydro DC Sources Actual wiring requirements may vary. Figure C-7 Connecting Wind or Hydro DC Sources C–8 975-0239-01-01...
  • Page 133 2–16 AC Connections 2–38 AC sync cable 2–17 AC Terminal Block 2–29 Additional Inverters 1–7, 5–7 Automatic Generator Start 2–23 AUX Port 2–24 AUX Port Terminal Assignments 2–23 AUX+12V Voltage Supply AUX-RPO 2–24 User Remote Power Off 5–12 B+ wires 2–9 battery bank requirements 2–9...
  • Page 134 Index thermostat 5–13 connecting 5–11, 5–13 inputs and returns 2–24 User Line Wiring 5–7, 5–18 verifying network power i–iv web site C–8 Wind Wire Size and Over-current Protection Requirements 4–9 Wiring 2–8 Wiring the Inverter Xantrex iv, i–iv web site 1–3 XW Inverter/Charger 1–6, 5–2...
  • Page 136 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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