Xantrex XW4024-120/240-60 - Manual

Page 3 - XW Power System; Installation Guide

Page 5 - About This Guide; Purpose; installing the XW Power System.; Scope; Installers should be certified technicians or electricians.; Organization; and the XW Conduit Box.

975-0239-01-01 iii 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 comp...

Page 6 - Conventions Used; The following conventions are used in this guide.; Related Information; These guides are available at; WARNING

About This Guide iv 975-0239-01-01 Conventions Used The following conventions are used in this guide. Related Information Additional information about operating the XW Inverter/Charger, see the XW Inverter/Charger Operation Guide (975-0240-01-01). For more information about related components, refer...

Page 7 - Important Safety Instructions; unit, the batteries, and all appropriate sections of this manual.; working with this equipment.; Read and keep this

975-0239-01-01 v 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, e...

Page 8 - Limitations on Use; Reorient or relocate the receiving antenna.; WARNING: Limitations on Use

Important Safety Instructions vi 975-0239-01-01 Limitations on Use Explosive Gas Precautions 1. Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before inst...

Page 9 - Contents

975-0239-01-01 vii Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Limitations on Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - viExplosive ...

Page 10 - Xanbus Network Installation

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

Page 11 - XW Solar Charge Controller Installation

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

Page 13 - Figures

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

Page 15 - Tables

975-0239-01-01 xiii Table 2-1 Mounting Plate Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Table 2-2 Recommended Battery Cable Size Versus Length - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Table 2-3 Battery Cable (in conduit) to Maxi...

Page 17 - Introduction; For this Topic; “System Overview”

1 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

Page 18 - System Overview; System Diagram; XW Power System Installation Diagram Example

Introduction 1–2 975-0239-01-01 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 thre...

Page 19 - System Components and Accessories; XW Conduit Box

System Components and Accessories 975-0239-01-01 1–3 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 ba...

Page 20 - XW Power Distribution Panel Panel and XW Conduit Box; Power Distribution Panel and XW Conduit Box

Introduction 1–4 975-0239-01-01 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 racewa...

Page 21 - XW Connection Kit for INV2

System Components and Accessories 975-0239-01-01 1–5 XW Connection Kit for INV2 The XW Connection Kit for Inv2 (FGA # 865-1020) is the extension kit required for connecting a second or third XW Inverter/Charger in the same system. Figure 1-5 XW Connection Kit for INV2 XW Conduit Box XW Connection Ki...

Page 22 - XW Solar Charge Controller

Introduction 1–6 975-0239-01-01 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. ...

Page 23 - XW Automatic Generator Start; Generator

System Components and Accessories 975-0239-01-01 1–7 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 ad...

Page 25 - “Step 1: Installing the Mounting Plate”

2 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: ...

Page 26 - Location; Fire safety; Knockout Preparation; WARNING: Personal Injury

Inverter/Charger Installation 2–2 975-0239-01-01 Pre-Installation Before installing the XW Inverter/Charger, read all instructions and cautionary markings located in this manual. Location The XW Inverter/Charger is certified for indoor (heated or unheated) installations only. Close to battery bank L...

Page 27 - Clearance Requirements

Pre-Installation 975-0239-01-01 2–3 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 th...

Page 28 - Step 1: Installing the Mounting Plate; Mounting Plate Fastener Recommendations; Structure; Mounting Plate Dimensions

Inverter/Charger Installation 2–4 975-0239-01-01 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 brac...

Page 30 - Step 2: Mounting the Inverter; Mounting the XW Inverter/Charger

Inverter/Charger Installation 2–6 975-0239-01-01 Step 2: Mounting the Inverter Figure 2-4 Mounting the XW Inverter/Charger 2 Align the flange on the back of the XW Inverter/Charger with the bottom edge of the mounting plate. Lower the flange on the inverter onto the mounting plate. CAUTION : Before ...

Page 31 - Installing the XW Conduit Box

Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box 975-0239-01-01 2–7 Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box 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 Figur...

Page 32 - Step 4: Wiring the Inverter; Installation Tip

Inverter/Charger Installation 2–8 975-0239-01-01 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...

Page 33 - Batteries; Use only the deep discharge types for inverter applications.; Battery Bank Requirements; Battery cable length; CAUTION: Damage to Equipment; Do not

Step 4: Wiring the Inverter 975-0239-01-01 2–9 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 ...

Page 34 - Terminal covers; Torque Values for the XW Series Inverter/Charger; Recommended Battery Cable Size Versus Length

Inverter/Charger Installation 2–10 975-0239-01-01 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 r...

Page 35 - Torque Values for the XW Power Distribution Panel; Inverter Grounding; Torque Values for AC Disconnects and AC Breakers

Step 4: Wiring the Inverter 975-0239-01-01 2–11 Torque Values for the XW Power Distribution Panel Inverter Grounding Backfeed Protection Requirements Table 2-7 Torque Values for AC Disconnects and AC Breakers Wire Size Torque Value AWG In-lb N-m 16–10 45 5 8 45 5 6–4 45 5 Table 2-8 Torque Values for...

Page 36 - Wiring the Inverter to the XW Power Distribution Panel; Grounding the DC System; DC Grounding Using a Power Distribution Panel

Inverter/Charger Installation 2–12 975-0239-01-01 Wiring the Inverter to the XW Power Distribution Panel Grounding the DC System The inverter’s chassis ground bar (see Figure 2-7) is used to connect the chassis of the inverter to the DC grounding system. The terminal accepts wires from #14 AWG to #2...

Page 37 - Installing the Battery Temperature Sensor; To install the Battery Temperature Sensor:; Battery Temperature Sensor (RJ11) Port Location and Installation

Step 4: Wiring the Inverter 975-0239-01-01 2–13 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 preventi...

Page 38 - Making DC Connections; To connect the XW Power Distribution Panel to the inverter:; cables from the XW Power Distribution Panel to the battery.; WARNING: Shock Hazard; XW Inverter/Charger DC Connections; Battery Cable Connection

Inverter/Charger Installation 2–14 975-0239-01-01 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 (usin...

Page 40 - Making AC Connections; AC Connections and Communication Ports; AC Connections; CAUTION: Damage to the Inverter

Inverter/Charger Installation 2–16 975-0239-01-01 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 P...

Page 41 - Accessing the AC Terminal Block and AC Ground Bar; AC Terminal Block

Step 4: Wiring the Inverter 975-0239-01-01 2–17 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. Figure 2-13 AC Terminal Block xantrex Hybrid Inverter /Charger Gri d (AC1) Gen ...

Page 42 - Grounding the AC System; Grounding the AC System using the Distribution Panel

Inverter/Charger Installation 2–18 975-0239-01-01 Grounding the AC System 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. Important: Place the Neutral-to-groun...

Page 43 - AC Wiring to the Inverter AC Distribution Panel; the manufacturer’s directions.; AC Wiring to the XW Power Distribution Panel

Step 4: Wiring the Inverter 975-0239-01-01 2–19 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 pa...

Page 45 - Wiring the XW Inverter/Charger to a XW Power Distribution Panel

Step 4: Wiring the Inverter 975-0239-01-01 2–21 Wiring the XW Inverter/Charger to a XW Power Distribution Panel Figure 2-16 Wiring the Inverter to the XW Power Distribution Panel Actual wiring requirements may vary. Power Distribution bars in the XW Power Distribution Panel accept up to a #2/0 AWG c...

Page 46 - Generator Wiring Using a XW Power Distribution Panel

Inverter/Charger Installation 2–22 975-0239-01-01 Generator Wiring to the XW Inverter/Charger using a XW Power Distribution Panel Figure 2-17 Generator Wiring Using a XW Power Distribution Panel Actual wiring requirements may vary. CAUTION : Generators must be hard-wired to the XW Power Distribution...

Page 47 - AUX+12V Voltage Supply; AUX Port Location

Step 4: Wiring the Inverter 975-0239-01-01 2–23 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 • any device...

Page 48 - User Line Wiring; User Connector Terminals and Functions; Pin

Inverter/Charger Installation 2–24 975-0239-01-01 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 ove...

Page 49 - Basic Functional Test - Single Inverter; Operation Guide; Confirm All Connections; To apply DC power to the inverter:; cables (measure at the battery side of the disconnect or breaker).; CAUTION: Reverse Polarity Damage; Voltage should be between 40 to 60 volts for a 48-volt

Basic Functional Test - Single Inverter 975-0239-01-01 2–25 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 assi...

Page 50 - To enable the inverter:; CAUTION: Equipment Damage; Enable the Inverter

Inverter/Charger Installation 2–26 975-0239-01-01 Enable 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. If the unit powers up in Standby Mode, ...

Page 51 - AC Voltage Check; To perform an AC voltage check:; Confirm that the AC load that was just applied works properly.; Confirming Battery Charger Operation; To confirm battery charger operation:; Checking AC Voltage

Basic Functional Test - Single Inverter 975-0239-01-01 2–27 AC Voltage Check 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 meas...

Page 52 - Functional Test for Single Inverter Systems

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

Page 53 - Step 5: Installing Additional Inverters; Installation Steps; To install multiple inverters:; and “Step 2: Mounting the Inverter” on page 2–6.

Step 5: Installing Additional Inverters 975-0239-01-01 2–29 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...

Page 54 - Parts List for Dual-Inverter Configurations; DC Wiring for a Dual-Inverter System

Inverter/Charger Installation 2–30 975-0239-01-01 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 VA...

Page 55 - DC Connections to Dual Inverters

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

Page 56 - AC Wiring for a Dual-Inverter System; breakers as shown in dual-inverter system wiring diagrams.

Inverter/Charger Installation 2–32 975-0239-01-01 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 in...

Page 57 - AC Wiring for Dual-Inverter Systems

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

Page 58 - Parts List for a Triple-Inverter Configuration; Note that all wiring will have to be custom; DC Wiring for a Triple-Inverter System; negative distribution plate.

Inverter/Charger Installation 2–34 975-0239-01-01 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 ...

Page 59 - terminal on second DC disconnect/breaker.

Step 5: Installing Additional Inverters 975-0239-01-01 2–35 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/br...

Page 60 - AC Wiring for a Triple-Inverter System; and INV3 Grid breakers.

Inverter/Charger Installation 2–36 975-0239-01-01 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 ...

Page 62 - Xanbus and AC Sync Cable; Installing the AC Sync Cable; To install the AC Sync and Xanbus cables between inverters:

Inverter/Charger Installation 2–38 975-0239-01-01 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 throug...

Page 63 - Basic Functional Test - Multiple Inverters; To perform a functional test on multiple inverters:

Basic Functional Test - Multiple Inverters 975-0239-01-01 2–39 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 G...

Page 64 - System Settings

Inverter/Charger Installation 2–40 975-0239-01-01 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. Sw...

Page 65 - Functional Test for Multiple Inverters - Page 1 of 2

Basic Functional Test - Multiple Inverters 975-0239-01-01 2–41 Figure 2-32 Functional Test for Multiple Inverters - Page 1 of 2

Page 66 - Functional Test for Multiple Inverters - Page 2 of 2

Inverter/Charger Installation 2–42 975-0239-01-01 Figure 2-33 Functional Test for Multiple Inverters - Page 2 of 2

Page 67 - “Xanbus-enabled Devices”

3 Xanbus Network Installation Chapter 3, “Xanbus Network Installation” provides detailed information for planning and installing the components necessary for network communication on a Xanbus system. For this Topic See.... “Xanbus-enabled Devices” page 3–2 “The Xanbus System” page 3–2 “Installing th...

Page 68 - Xanbus-enabled Devices; Network-Managed Power System

Xanbus Network Installation 3–2 975-0239-01-01 Xanbus-enabled Devices The Xanbus™-enabled designation means that the product works on a Xanbus network. Xanbus-enabled products are:• Easy to use. The Xanbus network simplifies operation and automates routine tasks. • Reliable. Software control elimina...

Page 69 - Network Components; T568A Standard Wiring; Pin Number

The Xanbus System 975-0239-01-01 3–3 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 conn...

Page 70 - Xanbus Cable and RJ45 Connector Pin Numbers

Xanbus Network Installation 3–4 975-0239-01-01 • 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...

Page 71 - Ordering Network Components; Multi-Drop Backbone Layout; Advantages; still keeping the network operating.; Disadvantage; The main disadvantage of this layout is the cost of the network; Network Component

The Xanbus System 975-0239-01-01 3–5 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 St...

Page 72 - Daisy Chain Layout; Advantage; network connectors are not required.; The disadvantage of the daisy chain layout is that Xanbus-enabled; Daisy Chain Network Layout

Xanbus Network Installation 3–6 975-0239-01-01 Daisy Chain Layout In a daisy chain layout, each device on the network is linked with 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 req...

Page 73 - Installing the Network; Before You Begin the Installation; WARNING: Shock hazard

Installing the Network 975-0239-01-01 3–7 Installing the Network Before You Begin the Installation • Read the entire section before installing the network. It’s important to plan the installation from beginning to end. • Assemble all the tools and materials required for the installation. Installatio...

Page 74 - Mounting a Network Connector; To mount a network connector:; Minimum and Maximum Cable Length; Cable Length; Recommended Mounting Orientation for Network Connector

Xanbus Network Installation 3–8 975-0239-01-01 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. Mounting a Network Connector To mount a network connector: 1. Select an appropriate location with the connec...

Page 75 - Installing Xanbus-Enabled Devices; for each device elsewhere in this manual.; Completing the Multi-Drop Backbone Layout; To complete the multi-drop backbone layout:; this network is not an ethernet system; Options for Completing a Multi-Drop Backbone Layout

Installing the Network 975-0239-01-01 3–9 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. To install the Xanbus-enabled devices: 1. Determine an...

Page 76 - Completing the Daisy Chain Layout; To complete the daisy chain layout:; Completing a Daisy-Chain Layout; CAUTION: Unpredictable device behavior

Xanbus Network Installation 3–10 975-0239-01-01 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: Unp...

Page 77 - “PV Array Requirements”

4 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 See.... “PV Array Requirements” page 4–2 “Mounting” page 4–3 “Grounding” page 4–8 “Wiring” page 4–9 “Com...

Page 78 - Installing the Charge Controller; Array Size

XW Solar Charge Controller Installation 4–2 975-0239-01-01 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 Guid...

Page 79 - MPPT Voltage Range; Mounting; Choosing a Location; MPPT Operational Window; Voltage

Mounting 975-0239-01-01 4–3 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 op...

Page 80 - Minimum Clearance Requirements

XW Solar Charge Controller Installation 4–4 975-0239-01-01 If using “sealed” batteries, the controller can be mounted in the same enclosure as long as it is adequately ventilated.For optimal and safe operation, ensure there is adequate clearance around the XW Solar Charge Controller. See Table 4-2. ...

Page 81 - Removing the Wiring Terminals Cover; Dimensions and Knockout Locations

Mounting 975-0239-01-01 4–5 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 Figur...

Page 82 - Mounting the Controller; Back out the top side screw on the XW Solar Charge Controller by

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

Page 83 - terminal block from pulling on the wires.

Mounting 975-0239-01-01 4–7 5. Insert two screws in the two mounting holes provided to secure the unit to the wall.6. Provide strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires. Figure 4-5 Mounting the XW Solar Charge Controller xantre...

Page 84 - Grounding; XW Solar Charge Controller Safety Ground Connector

XW Solar Charge Controller Installation 4–8 975-0239-01-01 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 #...

Page 85 - Wiring; DC Terminal Connector Locations; Current rating; . Since PV outputs can; minimum allowable wire gauge is; DC Connection Terminals; CONNECTIONS DIAGRAM

Wiring 975-0239-01-01 4–9 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. See Figure 4-7. Wire Size and Over-current Prot...

Page 86 - Battery Circuit; of the array but will not exceed the 60 A rating.; Description; WARNING: Equipment damage

XW Solar Charge Controller Installation 4–10 975-0239-01-01 Battery Circuit The DC-rated fuse or circuit breaker between the battery and the XW Solar Charge Controller must have a maximum size of 1.25 × 60 A (the maximum current rating of the XW Solar Charge Controller). That is, the fuse or circuit...

Page 87 - One-Way Wire Distance and Wire Size for a 24 Vdc System; For 24 Vdc systems; One-Way Wire Distance and Wire Size for a 48 Vdc System; For 48 Vdc systems

Wiring 975-0239-01-01 4–11 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 For 24 Vdc systems Distance in feet (meters) Distance in feet (meters) a a.These wire sizes are not approved by UL to...

Page 88 - To connect the XW Solar Charge Controller:

XW Solar Charge Controller Installation 4–12 975-0239-01-01 Connecting the XW Solar Charge Controller to the Distribution Panel To connect the XW Solar Charge Controller: 1. Connect the PV array’s positive (+) output to the PV array disconnect.2. Route another (+) cable from the other end of the PV ...

Page 89 - Connecting Solar DC Sources in the Power Distribution Panel

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

Page 90 - Commissioning; Configuration Screens; To set the Device Numbers for all

XW Solar Charge Controller Installation 4–14 975-0239-01-01 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 av...

Page 91 - To configure Connections and Charger Settings for the first

Commissioning 975-0239-01-01 4–15 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 Advanc...

Page 92 - The settings are automatically copied from the selected unit.

XW Solar Charge Controller Installation 4–16 975-0239-01-01 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...

Page 93 - “The XW System Control Panel”

5 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 5–7

Page 94 - The XW System Control Panel; XW System Control Panel Xanbus Port Locations

XW System Accessories Installation 5–2 975-0239-01-01 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 config...

Page 95 - Materials and Tools Required; Cable clamps or hardware fasteners; Surface mounted using the mounting plate; To flush mount the XW System Control Panel with mounting plate:; WARNING: Explosion hazard

The XW System Control Panel 975-0239-01-01 5–3 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) ❐ Ca...

Page 96 - Inserting the Mounting Plate; Securing the Mounting Plate; must

XW System Accessories Installation 5–4 975-0239-01-01 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. ...

Page 97 - To flush mount the XW System Control Panel with no mounting plate:; Connecting the Network Cables

The XW System Control Panel 975-0239-01-01 5–5 6. Place the unit into the mounting plate and secure it with four #6 screws. 7. Peel off the protective plastic coating covering the screen and indicator light. To flush mount the XW System Control Panel with no mounting plate: 1. Peel the backing from ...

Page 98 - To surface mount the XW System Control Panel:; screws and the access hole for the network cables.; CAUTION: Equipment damage; this network is not an Ethernet system; Surface Mounting the XW System Control Panel

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

Page 99 - Verifying the Installation; The XW Automatic Generator Start; Preparing an Installation; Connecting the AGS Communications Cable to the XW Series

The XW Automatic Generator Start 975-0239-01-01 5–7 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 scre...

Page 100 - Xantrex network cables or equivalent (Category 5); Connection Types; Dry; WARNING: Explosion Hazard

XW System Accessories Installation 5–8 975-0239-01-01 ❐ #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 ...

Page 101 - Installing the XW Automatic Generator Start; XW Automatic Generator Start External Connections

The XW Automatic Generator Start 975-0239-01-01 5–9 Installing the XW Automatic Generator Start Installation Overview Installing the XW Automatic Generator Start involves the following steps:1. Mounting the unit.2. Connecting the wiring harness to: • the generator (page 5–12) • thermostats (optional...

Page 102 - Mounting the Unit; To mount the XW Automatic Generator Start:; Wiring to the 20-contact Connector; CAUTION: Shock Hazard; Circuit Limitations; Circuit Parameter

XW System Accessories Installation 5–10 975-0239-01-01 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 su...

Page 103 - Plug the harness into the connector on the bottom panel of the XW; Function

The XW Automatic Generator Start 975-0239-01-01 5–11 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 t...

Page 104 - Connecting the Generator; Ground

XW System Accessories Installation 5–12 975-0239-01-01 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 op...

Page 105 - Connecting an External Shutdown (optional); Wiring for Connecting Thermostats; Wire Number; Wiring for Connecting an External Shutdown; Wire number Function

The XW Automatic Generator Start 975-0239-01-01 5–13 This section describes the generator configurations and provides diagrams for connecting the wiring harness to the generator’s start wiring. Connecting the Thermostats (optional) Wires 1, 2, 3, and 4 on the wiring harness can be connected to two t...

Page 106 - Wiring for Connecting an External Manual ON/OFF Switch; Wire Number Function

XW System Accessories Installation 5–14 975-0239-01-01 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 ot...

Page 107 - Connecting an External ON/OFF LED; External On/Off Switch and LED Wiring Diagram; START PUSH BUTTON

The XW Automatic Generator Start 975-0239-01-01 5–15 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 visu...

Page 108 - To connect the wiring harness to the XW Automatic Generator Start:

XW System Accessories Installation 5–16 975-0239-01-01 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 Gen...

Page 109 - Connecting the SCP

The XW Automatic Generator Start 975-0239-01-01 5–17 Connecting the XW Automatic Generator Start to the Xanbus Network To connect the XW Automatic Generator Start to the Xanbus network, plug a Category 5 network cable into one of the network ports on the bottom panel of the XW Automatic Generator St...

Page 110 - Verifying Power Is Available; Verifying Power is Available

XW System Accessories Installation 5–18 975-0239-01-01 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...

Page 111 - Specifications

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

Page 112 - Electrical Specifications; XW Power System Electrical Specifications; Model

Specifications A–2 975-0239-01-01 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 9,000 W 8,000 W Surge Current L-n: 105 A rms ...

Page 113 - XW Series Overload Capability; XW Series AC Overload Capability

Electrical Specifications 975-0239-01-01 A–3 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 e...

Page 114 - Output Power Versus Ambient Temperature

Specifications A–4 975-0239-01-01 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 Efficiency Inverting Efficiency (Typical) Figure A-2 Out...

Page 115 - Mechanical Specifications; XW Power System Mechanical Specifications

Mechanical Specifications 975-0239-01-01 A–5 Charging Efficiency (Typical) 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, Cus...

Page 116 - Accessories; Accessory

Specifications A–6 975-0239-01-01 Accessories System Network Xanbus (publish-subscribe network, no need for hubs or special cards) Emissions FCC Class B Regulatory approvals UL 1741 1st Edition: 2005 Version, CSA 107.1-01 Enclosure Type NEMA Type 1 - Indoor (sensitive electronic components sealed in...

Page 117 - Wiring Diagrams

B 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-Inver...

Page 126 - DC Grounding for Single-Inverter Systems; DC Grounding for an Inverter only

Alternate System Configurations C–2 975-0239-01-01 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 Batt...

Page 127 - Battery Connections for Single Inverter Systems; DC Connections to a Single Inverter

Battery Connections for Single Inverter Systems 975-0239-01-01 C–3 Battery Connections for Single Inverter Systems Figure C-2 DC Connections to a Single Inverter Torque connections to the inverter DC terminals to 10-15 ft./lbs. Torque connections to the battery terminals per battery manufacturer’s r...

Page 128 - AC Grounding for Single-Inverter Systems

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

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 975-0239-01-01 C–5 AC Output Wiring to the Inverter AC Distribution Panel Figure C-4 AC Output Wiring to the Inverter AC Distribution Panel Actual wiring requirements may vary.

Page 130 - Generator Wiring to the Inverter; Generator Wiring directly to the Inverter

Alternate System Configurations C–6 975-0239-01-01 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 b...

Page 131 - Utility Wiring to the Inverter Input; Utility Wiring to the Inverter Input

Utility Wiring to the Inverter Input 975-0239-01-01 C–7 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 cove...

Page 132 - Wind or Hydro DC Sources; Connecting Wind or Hydro DC Sources

Alternate System Configurations C–8 975-0239-01-01 Wind or Hydro DC Sources Figure C-7 Connecting Wind or Hydro DC Sources Actual wiring requirements may vary.

Page 133 - ii–vi

Index 975-0239-01-01 IX–1 A AC Connections 2–16 AC sync cable 2–38 AC Terminal Block 2–17 Additional Inverters 2–29 Automatic Generator Start 1–7, 5–7 AUX Port 2–23 AUX Port Terminal Assignments 2–24 AUX+12V Voltage Supply 2–23 AUX-RPO User Remote Power Off 2–24 B B+ wires 5–12 battery bank requirem...

Page 134 - i–iv

Index IX–2 975-0239-01-01 T thermostat connecting 5–13 inputs and returns 5–11, 5–13 U User Line Wiring 2–24 V verifying network power 5–7, 5–18 W web site i–iv Wind C–8 Wire Size and Over-current Protection Requirements 4–9 Wiring 4–9 Wiring the Inverter 2–8 X Xantrex web site iv, i–iv XW Inverter/...

Page 136 - Xantrex Technology Inc.

Xantrex Technology Inc. 800 670 0707 Tel Toll Free in North America360 925 5097 Tel direct800 994 7828 Fax Toll Free in North America360 925 5143 Fax [email protected] 975-0239-01-01 Printed in China

Xantrex XW4024-120/240-60 - Manual

Table of Contents:

Summary

Other Xantrex Models