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XW6048-120/240-6
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Xantrex XW6048-120/240-6 manual available for free PDF download: Installation Manual
Xantrex XW6048-120/240-6 Installation Manual (146 pages)
XW Power System
Brand:
Xantrex
| Category:
Inverter
| Size: 4.01 MB
Table of Contents
Installation Guide
1
About this Guide
5
Conventions Used
6
Important Safety Instructions
7
Explosive Gas Precautions
8
Table of Contents
9
Introduction
17
System Overview
18
System Diagram
18
Figure 1-1 XW Power System Installation Diagram Example
18
System Components and Accessories
19
XW Inverter/Charger
19
XW Conduit Box
19
Figure 1-2 XW Inverter/Charger
19
Figure 1-3 XW Conduit Box
19
XW Power Distribution Panel Panel and XW Conduit Box
20
Figure 1-4 Power Distribution Panel and XW Conduit Box
20
XW Connection Kit for INV2
21
Figure 1-5 XW Connection Kit for INV2
21
XW Solar Charge Controller
22
XW System Control Panel
22
Figure 1-6 XW Solar Charge Controller
22
Figure 1-7 XW System Control Panel
22
XW Automatic Generator Start
23
Figure 1-8 Automatic Generator Start
23
Inverter/Charger Installation
25
Pre-Installation
26
Location
26
Knockout Preparation and Air Filter Installation
26
Figure 2-1 Air Filter and AUX Connector Installation
26
Removing Internal Faceplates in the Power Distribution Panel
27
Clearance Requirements
27
Figure 2-2 Removing the Internal Faceplates on the Power Distribution Panel
27
Figure 2-3 Clearance Requirements
27
Mounting
28
Step 1: Installing the Mounting Plate
28
Figure 2-4 Mounting Plate Dimensions
28
Table 2-1 Mounting Plate Fastener Recommendations
28
Figure 2-5 Mounting the Bracket for the XW Inverter/Charger or Distribution Panel
29
Step 2: Mounting the Inverter
30
Figure 2-6 Mounting the XW Inverter/Charger
30
Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box
31
Figure 2-7 Installing the XW Conduit Box
31
Step 3: Mounting the XW Power Distribution Panel
31
Step 4: Wiring the Inverter
32
Figure 2-8 Routing Communications Cables
32
Batteries
33
Battery Bank Requirements
33
Battery Cable Requirements
33
Torque Values for the XW Series Inverter/Charger
34
Table 2-2 Recommended Battery Cable Size Versus Length
34
Table 2-3 Battery Cable (in Conduit) to Maximum Breaker/Fuse Size
34
Table 2-4 Torque Values for AC Wiring (AC Terminals and Ground Bar)
34
Table 2-5 Torque Values for the Chassis Ground Lug
34
Table 2-6 Torque Values for the Inverter Battery Terminals
34
Torque Values for the XW Power Distribution Panel
35
Backfeed Protection Requirements
35
Inverter Grounding
35
Table 2-10 Torque Values for the Battery Cables to the DC Negative Bus, and DC Positive Bus in the XW Power Distribution Panel
35
Table 2-7 Torque Values for AC Disconnects and AC Breakers
35
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
35
Table 2-9 Torque Values for the Power Distribution Bars in the XW Power Distribution Panel
35
Wiring the Inverter to the XW Power Distribution Panel
36
Grounding the DC System
36
Figure 2-9 DC Grounding Using a Power Distribution Panel
36
Installing the Battery Temperature Sensor
37
Figure 2-10 Battery Temperature Sensor (RJ11) Port Location and Installation
37
Figure 2-11 XW Inverter/Charger DC Connections
38
Figure 2-12 Battery Cable Connection
38
Making DC Connections
38
Figure 2-13 DC Connections to a Single Inverter Using a XW Power Distribution Panel
39
Making AC Connections
40
AC Connections and Communication Ports
40
Figure 2-14 XW Inverter/Charger AC Connections and Communications Ports
40
Accessing the AC Terminal Block and AC Ground Bar
41
Figure 2-15 AC Terminal Block
41
Grounding the AC System
42
Figure 2-16 Grounding the AC System Using the Distribution Panel
42
AC Wiring to the Inverter AC Distribution Panel
43
AC Wiring to the XW Power Distribution Panel
43
Figure 2-17 Wiring the XW Power Distribution Panel to the Sub-Panel or Utility Grid
44
Wiring the XW Inverter/Charger to a XW Power Distribution Panel
45
Figure 2-18 Wiring the Inverter to the XW Power Distribution Panel
45
Generator Wiring to the XW Inverter/Charger Using a XW Power Distribution Panel
46
Figure 2-19 Generator Wiring Using a XW Power Distribution Panel (on Grid)
46
Figure 2-20 Generator Wiring Using a XW Power Distribution Panel (off Grid)
47
AUX Port
48
AUX+12V Voltage Supply
48
Figure 2-21 AUX Port Location
48
AUX-RPO: User Remote Power off (RPO)
49
User Line Wiring
49
AUX Port Terminal Assignments
49
Table 2-11 User Connector Terminals and Functions
49
Basic Functional Test - Single Inverter
50
Confirm All Connections
50
Applying DC Power to the Inverter
50
Figure 2-22 Power-Up Display
50
Enable the Inverter
51
Figure 2-23 Enable the Inverter
51
AC Voltage Check
52
Confirming Battery Charger Operation
52
Figure 2-24 Checking AC Voltage
52
Figure 2-25 Checking Charging Operation
52
Figure 2-26 Functional Test for Single Inverter Systems
53
Step 5: Installing Additional Inverters
54
Installation Steps
54
Chapter 2 , “Inverter/Charger Installation” Describes How to Mount
54
Panel and XW Conduit Box
54
Parts List for Dual-Inverter Configurations
55
Converting a Single-Inverter Power Distribution Panel to a Dual-Inverter Power Distribution Panel
55
DC Wiring for a Dual-Inverter System
55
Figure 2-27 DC Connections to Dual Inverters
56
AC Wiring for a Dual-Inverter System
57
Figure 2-29 AC Wiring for Dual-Inverter Systems
58
Figure 2-30 Installing the Front Internal Panels and the AC Bypass Plate
59
Parts List for a Triple-Inverter Configuration
60
Converting a Single-Inverter Power Distribution Panel to a Triple-Inverter Power Distribution Panel
60
DC Wiring for a Triple-Inverter System
61
Figure 2-31 DC Connections for a Triple-Inverter System
61
AC Wiring for a Triple-Inverter System
62
Figure 2-32 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement with Dual AC Input Sources
63
Figure 2-34 Wiring an External Bypass Switch for a Triple-Inverter Configuration
64
Xanbus and AC Sync Cable
65
Figure 2-35 Installing the AC Sync Cable
65
Basic Functional Test - Multiple Inverters
66
For this Topic See
75
Xanbus-Enabled Devices
76
The Xanbus System
76
Figure 3-1 Network-Managed Power System
76
Figure 3-2 Xanbus Cable, RJ45 Connector Pin Numbers and Network Terminators
77
Network Components
77
Figure 3-3 Network Layout
78
Network Layout
78
Ordering Network Components
78
Table 3-1 Xanbus Network Components and Part Numbers
78
Installing the Network
79
Before You Begin the Installation
79
Installation Tools and Materials
79
Guidelines for Routing the Xanbus Cables
79
Installing Xanbus-Enabled Devices
80
Xanbus Network Installation
75
XW Solar Charge Controller Installation
82
Installing the Charge Controller
82
PV Array Requirements
82
MPPT Voltage Range
82
Table 4-1 MPPT Operational Window
82
Mounting
83
Choosing a Location
83
Table 4-2 Minimum Clearance Requirements
83
Removing the Wiring Compartment Cover
84
Removing Knockouts
84
Figure 4-1 Minimum Clearance Requirements
84
Figure 4-2 Removing the Wiring Compartment Cover
84
Figure 4-3 Dimensions and Knockout Locations
85
Figure 4-4 Knockout Dimensions
85
Mounting the Controller
86
Figure 4-5 Mounting the XW Solar Charge Controller
87
Grounding
88
Internal Ground Fault Protection
88
Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays
89
Figure 4-6 XW Solar Charge Controller Safety Ground Connector
89
Wiring
90
DC Terminal Connector Locations
90
Figure 4-7 PV Negative Ground Jumper Location
90
Figure 4-8 DC Connection Terminals
90
Wire Size and Over-Current Protection Requirements
91
Current Rating
91
Minimum Wire Gauge
91
Over-Current Protection
91
Long-Distance Wire Runs
91
Maximum One-Way Distance and Wire Size
92
Table 4-3 Recommended Circuit Breakers for the XW Solar Charge Controller
92
Table 4-4 One-Way Wire Distance and Wire Size for a 24 VDC System
92
Connecting the XW Solar Charge Controller to the Distribution Panel
93
Table 4-5 One-Way Wire Distance and Wire Size for a 48 VDC System
93
Figure 4-9 Connecting Solar DC Sources in the Power Distribution Panel
95
Commissioning
96
Configuration Screens
96
Commissioning Units Using a XW System Control Panel
96
Chapter 4 , “XW Solar Charge Controller Installation” Describes How
99
XW System
99
For this Topic See
99
The XW System Control Panel
100
Figure 5-1 XW System Control Panel Xanbus Port Locations
100
Choosing a Location
101
Materials and Tools Required
101
Mounting the XW System Control Panel
101
Figure 5-2 Inserting the Mounting Plate
102
Figure 5-3 Securing the Mounting Plate
102
Figure 5-4 Connecting the Network Cables
103
Figure 5-5 Securing the XW System Control Panel
103
Figure 5-6 Surface Mounting the XW System Control Panel
105
Verifying the Installation
105
The XW Automatic Generator Start
106
Preparing an Installation
106
Materials and Tools Required
106
Figure 5-7 Connecting the AGS Communications Cable to the XW Series
106
Choosing a Location
107
Routing the Connections
107
Installing the XW Automatic Generator Start
108
Figure 5-8 XW Automatic Generator Start External Connections
108
Mounting the Unit
109
Table 5-1 Circuit Limitations
109
Wiring to the 20-Contact Connector
109
Figure 5-9 XW Automatic Generator Start Wiring Harness
110
Table 5-2 Required Wiring Size Based on Length of Cable
110
Table 5-3 Contact Numbers and Functions
110
Connecting the Generator
111
Connecting an External Shutdown (Optional)
112
Connecting the Thermostats (Optional)
112
Table 5-4 Wiring for Connecting Thermostats
112
Table 5-5 Wiring for Connecting an External Shutdown
112
Connecting an External Manual ON/OFF Switch (Optional)
113
Table 5-6 Wiring for Connecting an External Manual ON/OFF Switch
113
Connecting an External ON/OFF LED
114
Figure 5-10 External On/Off Switch and LED Wiring Diagram
114
Connecting the Wiring Harness to the XW Automatic Generator Start
115
Figure 5-11 XW Automatic Generator Start External Connections
115
Connecting the XW Automatic Generator Start to the Xanbus Network
116
Figure 5-12 Connecting the SCP
116
Verifying Power Is Available
117
Figure 5-13 Verifying Power Is Available
117
Specifications
119
Electrical Specifications
120
Table A-1 XW Power System Electrical Specifications
120
XW Series Overload Capability
121
Figure A-1 XW Series AC Overload Capability
121
Figure A-2 XW Series AC Overload Capability
122
Figure A-3 XW Series AC Overload Capability
122
Output Power Versus Ambient Temperature
123
XW Series Efficiency
123
Inverting Efficiency (Typical
123
Figure A-4 Output Power Versus Ambient Temperature
123
Figure A-5 Inverting Efficiency (Typical
123
Charging Efficiency (Typical
124
Charging Power Factor
124
Figure A-6 Charging Efficiency (Typical
124
Figure A-7 Charging Power Factor
124
Grid-Tie Sell Mode Efficiency (Typical
125
Mechanical Specifications
125
Figure A-8 Grid-Tie Sell Mode Efficiency (Typical
125
Table A-2 XW Power System Mechanical Specifications
125
Accessories
126
Table A-3 XW Power System Regulatory Approvals
126
XW System Accessories Installation
99
B Wiring Diagrams
127
Single-Inverter System (Backup Only) Without a Power Distribution Panel
129
Figure B-1 Single-Inverter System (Backup Only) Without a Power Distribution Panel
129
Single-Inverter System (Backup Only) with a Power Distribution Panel
130
Figure B-2 Single-Inverter System (Backup Only) with a Power Distribution Panel
130
Single-Inverter System Renewable Energy (Solar
131
Figure B-3 Single-Inverter System Renewable Energy (Solar
131
Single-Inverter System Renewable Energy (Wind or Hydro
132
Figure B-4 Single-Inverter System Renewable Energy (Wind or Hydro
132
Dual-Inverter System Renewable Energy (Solar
133
Figure B-5 Dual-Inverter System Renewable Energy (Solar
133
Dual-Inverter System Renewable Energy (Wind or Hydro
134
Figure B-6 Dual-Inverter System Renewable Energy (Wind or Hydro
134
C Alternate System Configurations
135
DC Grounding for Single-Inverter Systems
136
Figure C-1 DC Grounding for an Inverter Only
136
Battery Connections for Single Inverter Systems
137
Figure C-2 DC Connections to a Single Inverter
137
AC Grounding for Single-Inverter Systems
138
Figure C-3 Grounding the AC System
138
AC Output Wiring to the Inverter AC Distribution Panel
139
Figure C-4 AC Output Wiring to the Inverter AC Distribution Panel
139
Generator Wiring to the Inverter
140
Figure C-5 Generator Wiring Directly to the Inverter
140
Utility Wiring to the Inverter Input
141
Figure C-6 Utility Wiring to the Inverter Input
141
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