Xantrex™ XW Power System Xantrex XW4024 120/240 60 Xantrex XW4548 120/240 60 Xantrex XW6048 120/240 60 Installation Guide www.schneider-electric.
Xantrex XW Power System Installation Guide www.schneider-electric.
Copyright and Contact Trademarks Schneider Electric, the Schneider Electric logo, Xantrex and Xanbus are trademarks or registered trademarks of the Schneider Electric group of companies. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only. Notice of Copyright Copyright © 2007, 2008, 2010 Xantrex Technology Inc. All rights reserved.
About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the Schneider Electric Xantrex XW Power System. Scope The Guide provides safety guidelines, detailed planning and procedures for installing the Xantrex XW Inverter/Charger and related system components (the “Xantrex XW Power System”). It does not provide details about configuration, operation, maintenance or troubleshooting.
About This Guide 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. Appendix C, “Alternate System Configurations” provides wiring diagrams for inverter/charger installations that do not require use of the power distribution panel and the Xantrex XW Conduit Box.
Important Safety Instructions WARNING This chapter contains important safety and operating instructions as required by UL and CSA standards for inverters used in residential applications. Read and keep this Installation Guide for future reference. 1. Before using the inverter, read all instructions and cautionary markings on the unit, the batteries, and all appropriate sections of this manual. 2.
Safety Limitations on Use WARNING: Limitations on Use The Xantrex XW Power System is not intended for use in connection with life support systems or other medical equipment or devices. Single-phase Operation Only CAUTION The Xantrex XW4024 120/240 600, Xantrex XW4548 120/240 60 and Xantrex XW6048 120/240 60 series of Inverter/Chargers are designed and tested for operation with single phase, three wire (120V/240V) AC sources and should not be connected to a three phase AC source.
Safety FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
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Contents Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v Limitations on Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi Single-phase Operation Only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi F
Contents Making AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AC Connections and Communication Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Accessing the AC Terminal Block and AC Ground Bar - - - - - - - - - - - - - - - - - - - - - - Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AC Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - -
Contents Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Guidelines for Routing the Xantrex Xanbus Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 Installing Xantrex Xanbus-Enabled Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 4 Xantrex XW Solar Charge Controller Installation Installing the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Connecting the Thermostats (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connecting an External Shutdown (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connecting an External Manual ON/OFF Switch (Optional) - - - - - - - - - - - - - - - - - - - - - - Connecting an External ON/OFF LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connecting the Wiring Harness to the Xantrex XW Automatic Generator Start - - - - - - Connectin
Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 Figure 2-22 Figure 2-23 Figure 2-24 Figure 2-25 Figure 2-26 Figure 2-27 Figure 2-28 Figure 2-29 Figure 2-30 Xantrex XW Power System Installation Diagram Example - - - - - -
Figures Figure 2-31 Figure 2-32 Figure 2-33 Figure 2-34 Figure 2-35 Figure 2-36 Figure 2-37 Figure 3-1 Figure 3-2 Figure 3-3 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure A-1 Figure A-2 Figure A-3 Figure A-4 Figure A-5 Figure A-6 Figure A-7 Figure A-8 Figure B-1 Figure B-2 DC Connections for a Triple-In
Figures Figure B-3 Figure B-4 Figure B-5 Figure B-6 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure C-5 Figure C-6 Single-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5 Single-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - B–6 Dual-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–7 Dual-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - -
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Tables Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 2-6 Table 2-7 Table 2-8 Table 2-9 Table 2-10 Table 2-11 Table 3-1 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 5-1 Table 5-2 Table 5-3 Table 5-4 Table 5-5 Table 5-6 Table A-1 Table A-2 Table A-3 Mounting Plate Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Recommended Battery Cable Size Versus Length - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12 Battery Cable (in Conduit) to Maxi
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1 Introduction Chapter 1, “Introduction” lists and describes the components and basic features of the Xantrex XW Power System. For this Topic See....
Introduction System Overview The Xantrex 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-volt, 3-wire, single-phase systems allowing for increased capacity.
System Components and Accessories System Components and Accessories Xantrex XW Inverter/Charger The Xantrex 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 Xantrex XW Series is a self-contained DC to AC inverter, battery charger, and AC transfer switch.
Introduction Xantrex XW Conduit Box A Xantrex XW Conduit Box (FGA # 865-1025) is available to enclose the bottom of the Xantrex XW Inverter/Charger and protect the cabling. Use of the Xantrex XW Conduit Box may be required depending on the local electrical code. Be sure to consult with the local electrical authority to ensure the installation is code-compliant.
System Components and Accessories Xantrex XW Power Distribution Panel Xantrex XW Power Distribution Panel includes: • Power Distribution Panel enclosure with a field-reversible panel door • Mounting Plate • Xantrex XW Conduit Box Mounting Plate Xantrex XW Conduit Box Xantrex XW PDP Dimensions: 30" (761mm) H x 16" (406mm) W x 8 ¼" (210mm) D Depth from the wall = 8 ¾" (223 mm) The enclosure comes pre-wired with: • 3x 60A, 120/240 Vac, 2-pole, Square-D, Type QOU, DIN-rail mounted AC breakers (pre-wire
Introduction Xantrex XW Connection Kit for INV2 The Xantrex XW Connection Kit for Inv2 (FGA # 865-1020) is the extension kit required for connecting a second or third Xantrex XW Inverter/Charger in the same system.
System Components and Accessories Xantrex XW Solar Charge Controller The Xantrex XW Solar Charge Controller (FGA # 865-1030) is a 60 amp charge controller with integrated Xantrex PV GFP and separate Battery Temperature Sensor. The Xantrex XW Solar Charge Controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems. However, the Xantrex XW Inverter/Charger can only work at 24 or 48 volts depending on the model.
Introduction Xantrex XW System Control Panel The Xantrex XW System Control Panel features a graphical, backlit liquid crystal display that displays system configuration and diagnostic information for all devices connected to the network. When installed as a Xantrex XW Power System accessory, the Xantrex XW System Control Panel eliminates the need for separate control panels for each device and gives a single point of control to set up and monitor an entire Xantrex XW Power System.
System Components and Accessories FGA Number: 865-1060 Figure 1-8 Xantrex XW Automatic Generator Start Generator The generator should be a 120/240V, 2-wire or 3-wire generator with Auto Start capability. Important: Do not use a 120-volt only generator. The inverter will not accept power from a generator of this kind. The generator should also supply a Generator Run signal. This signal is used by the Xantrex XW Automatic Generator Start to detect whether the generator is running.
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2 Inverter/Charger Installation Chapter 2, “Inverter/Charger Installation” describes how to mount and install the Xantrex XW Inverter/Charger, and the Xantrex XW Power Distribution Panel and Xantrex XW Conduit Box. For this Topic See....
Inverter/Charger Installation Pre-Installation Before installing the Xantrex XW Inverter/Charger, read all instructions and cautionary markings located in this manual. Important: Be sure to obtain the appropriate permits, if necessary, prior to starting this installation. Installations must meet all local codes and standards. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System installers.
Pre-Installation Knockout Preparation and Air Filter Installation Remove your choice of knockouts from the chassis to facilitate conduit installation for wire runs. Ensure no debris from this procedure remains inside the inverter enclosure. Important: Do not drill, cut, or punch holes into the Xantrex XW Power Distribution Panel. Use only the knockouts provided for conduit entry. AUX Connector Tuck the air filter into the grooves in the sides of the air vent cover.
Inverter/Charger Installation 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. Figure 2-3 Clearance Requirements Mounting The Xantrex XW Power System is designed to be mounted on a vertical surface.
Step 1: Installing the Mounting Plate Step 1: Installing the Mounting Plate Each Xantrex XW Inverter/Charger and Xantrex 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. A minimum of four ¼-inch diameter fasteners are required.
Inverter/Charger Installation Side View 2 × 4 wall stud Wall studs 16" on center behind wallboard Wallboard Plywood (optional) mounting plate Multiple mounting plates should fit together as shown. 60" (152.4 cm) from floor puts the inverter display panel at approx. 65" high. Add ¾" plywood if additional support is needed. 1 Locate the wall studs. 2 If necessary, enhance the support surface with a ¾" plywood panel secured to the wall studs. Plywood should span at least three wall studs.
Step 2: Mounting the Inverter Step 2: Mounting the Inverter 3 2 1 1 Align the flange on the back of the Xantrex XW Inverter/Charger with the bottom edge of the mounting plate. 2 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. 3 Secure the top of inverter with two #10 self-tapping screws (supplied).
Inverter/Charger Installation Step 3: Mounting the Xantrex XW Power Distribution Panel and Xantrex XW Conduit Box Mount the Xantrex XW Power Distribution Panel on the mounting bracket following the same procedure in Step 2. When mounting the Xantrex XW Conduit Box as shown in Figure 2-7, it is not necessary to attach the front panel until all wiring is complete.
Step 4: Wiring the Inverter Step 4: Wiring the Inverter This section provides procedures for making AC and DC connections between the Xantrex 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 Xantrex XW Conduit Box was installed in the previous section.
Inverter/Charger Installation Route the communications cables for any accessories being installed BEFORE making AC or DC Connections. IMPORTANT: When routing communications cables through the Xantrex XW Power Distribution Panel, the raceway conduit must be used to keep the communications cables separate from the power cables. Xantrex XW System Control Panel Xantrex XW Automatic Generator Start Raceway for Shunt Sense cable*. Raceway exits the panel through the back.
Step 4: Wiring the Inverter CAUTION: Damage to Equipment The Xantrex XW Inverter/Charger is intended to operate with batteries as its source of DC power. Do not connect DC power sources, such as PV arrays, wind turbines, or micro-hydro turbines, directly to the Xantrex XW Inverter/Charger without a battery. Connect DC power sources to a charge controller such as the Xantrex XW Solar Charge Controller instead.
Inverter/Charger Installation Battery cable length Runs should be kept as short as practical. Length should not exceed 10 feet (3 m). For best performance, the positive and negative cables should run alongside each other. Avoid cable loops. Battery cable lugs Battery cables must have crimped copper compression lugs or crimped and soldered copper compression lugs. Soldered connections alone are not acceptable. Lugs must be rated for use with fine-stranded cable.
Step 4: Wiring the Inverter Torque Values for the Xantrex XW Series Inverter/Charger Table 2-4 Torque Values for AC Wiring (AC Terminals and Ground Bar) Wire Size Torque Value AWG In-lb N-m 14–10 35 4.0 8 40 4.5 6–4 45 5.1 Table 2-5 Torque Values for the Chassis Ground Lug Wire Size Torque Value AWG In-lbs N-m 6-4 45 5.1 3-2 50 5.6 Table 2-6 Torque Values for the Inverter Battery Terminals Torque Value Ft-lbs N-m 15 20.
Inverter/Charger Installation Table 2-9 Torque Values for the Power Distribution Bars in the Xantrex XW Power Distribution Panel Wire Size Torque Value AWG In-lbs N-m 14 - 10 35 4.0 8 40 4.5 6-4 45 5.1 3 - 2/0 50 5.6 Table 2-10 Torque Values for the Battery Cables to the DC Negative Bus, and DC Positive Bus in the Xantrex XW Power Distribution Panel Torque Value Ft-lbs N-m 15 20.4 Inverter Grounding Important: The grounding requirements vary by country and by application.
Step 4: Wiring the Inverter Grounding the DC System The inverter’s chassis ground bar (see Figure 2-9) is used to connect the chassis of the inverter to the DC grounding system. The terminal accepts wires from #14 AWG to #2 AWG. Actual grounding requirements may vary. B B See Table 2-6 on page 2–13 for torque values for the Ground bars in the Xantrex XW Power Distribution Panel. A B A See Table 2-5 on page 2–13 for torque values for the AC Chassis Ground.
Inverter/Charger Installation 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. This port is also considered part of the DC interface (see Figure 2-11). To install the Battery Temperature Sensor: 1.
Step 4: Wiring the Inverter Battery Temperature Sensor Port (RJ11) 1 RJ11 jack 2 Battery Temperature Sensor Note: If other Xantrex Xanbus connected components supply a BTS or are BTS enabled, it is not necessary to install all of them at once. Only one BTS needs to be installed. If using the adhesive backing, install the Battery Temperature Sensor on the side of the battery below the electrolyte level.
Inverter/Charger Installation Making DC Connections This section describes how to make DC connections between the inverter/ charger and the power distribution panel (using the pre-installed DC cables in the distribution panel), between the distribution panel to the batteries (using battery cables provided by the installer—see Table 2-2 on page 2–12). This section also provides procedures for installing the battery temperature sensor.
Step 4: Wiring the Inverter Ensure nothing is between the terminal surface and the battery cable lug Terminal surface Shrink-wrap to color-code the cable Battery cable lug Flat washer Copper compression lug Split-ring washer 3/8-15 x 5/8” bolt (supplied) Figure 2-12 Battery Cable Connection CAUTION: Damage to Equipment Do not put anything between the battery cable lug and the terminal surface. Overheating of the terminal may occur.
Inverter/Charger Installation Actual cable requirements may vary. Xantrex XW Power Distribution Panel (shown with door and front panel removed.) B See Table 2-8 on page 2–13 for torque values for the Positive and Negative Bus in the Xantrex XW Power Distribution Panel. B C See Table 2-10 on page 2–14 for torque values for the Battery Connections to the Positive and Negative Bus in the Xantrex XW Power Distribution Panel.
Step 4: Wiring the Inverter CAUTION: Damage to the Inverter The inverter’s AC output must never be wired to the utility or generator output. This will cause severe damage to the inverter which is not covered under warranty. Do not use a GFCI equipped AC source to power either the grid or generator inputs. The AC input filters on the Xantrex XW may cause nuisance tripping of ground fault protected outputs.
Inverter/Charger Installation 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. When replacing the AC access cover, ensure its recessed edge slips inside the edge of the front panel.
Step 4: Wiring the Inverter Grounding the AC System Important: Place the neutral-to-ground bond in a permanently installed AC distribution panel that is part of the system. This may be a main panel or a sub-panel. See Table 2-4 on page 13 for torque values for the AC terminal and AC Ground bar. See Figure 2-8 on page 2–13 for torque requirements for the ground bar in the Xantrex XW Power Distribution Panel. *This Grounding Conductor may not be required if the DC ground is used instead.
Inverter/Charger Installation 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. Determine the location for the inverter AC distribution panel and install it according to the manufacturer’s directions. 2.
Step 4: Wiring the Inverter AC Wiring to the Xantrex XW Power Distribution Panel To connect the Xantrex XW Power Distribution Panel to the inverter: Important: The Xantrex XW Inverter/Charger is provided with fixed disconnect limits for voltage and frequency. These limits are fixed when the unit is exporting power to the grid. The unit shall not be aggregated such that it can export more than 30 kW on a single point of common connection.
Inverter/Charger Installation Power Distribution bars in the Xantrex XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–14 for torque requirements. Actual wiring requirements may vary.
Step 4: Wiring the Inverter Wiring the Xantrex XW Inverter/Charger to a Xantrex XW Power Distribution Panel Power Distribution bars in the Xantrex XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–14 for torque requirements. Actual wiring requirements may vary.
Inverter/Charger Installation Generator Wiring to the Xantrex XW Inverter/Charger using a Xantrex XW Power Distribution Panel In an On-grid installation, the generator will require an additional AC breaker be installed in the Power Distribution Panel. CAUTION: Generators must be hard-wired to the Xantrex XW Power Distribution Panel. Actual wiring requirements may vary.
Step 4: Wiring the Inverter In an off-grid installation, the generator can be connected to the breakers provided in the Xantrex XW Power Distribution Panel. No additional breaker is required. CAUTION: Generators must be hard-wired to the Xantrex XW Power Distribution Panel. Actual wiring requirements may vary.
Inverter/Charger Installation AUX Port The Xantrex 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 fault The auxiliary output can also be triggered manually.
Step 4: Wiring the Inverter AUX-RPO: User Remote Power OFF (RPO) Connecting JU-2 (AUX-RPO) and JU-3 (AUX-COM) terminals together through an external switch (normal open contact) will provide the system shut off function if the switch is closed. The external switch if pressed overrides the control provided from the front panel. To enable the AUX port remote power off function, the RPO setting must be enabled from the Xantrex XW System Control Panel.
Inverter/Charger Installation Basic Functional Test - Single Inverter The following steps will complete a basic functional test of the Xantrex XW Inverter/Charger. If any test fails, please refer to the Troubleshooting section in the Xantrex 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.
Basic Functional Test - Single Inverter Enable the Inverter CAUTION: Equipment Damage Prior to activating the inverter, ensure that all AC loads are disconnected from the output of the inverter. By default, Invert Mode is enabled and the unit should start inverting upon transitioning from Standby Mode. If Invert Mode is disabled, the display will show (---) once out of Standby Mode. If the unit powers up in Standby Mode, press the ON/OFF button momentarily to change the mode from Standby to Operating.
Inverter/Charger Installation 3. Monitor the INVERT (Green kW) LED to confirm which mode the inverter is in: • LED Off – Invert Mode is disabled. The inverter/Charger is not powering the AC loads. However, if good AC is present, it is passed through to the loads. • One blink/sec – The inverter/charger is in the Search Mode and is looking for an AC load greater than the Search Watts setting (default = 25 watts). The Display shows Sch (Search) when this mode has been enabled.
Basic Functional Test - Single Inverter Confirming Battery Charger Operation To confirm battery charger operation: 1. Apply AC from grid or generator, confirm voltage. 2. Check LEDs (AC1 or AC2) on the front panel. One of them must be illuminated for the unit to charge. Check the “A” LED. If the “A” LED is illuminated, the unit is charging and the battery current is displayed on the information panel.
Inverter/Charger Installation Figure 2-26 Functional Test for Single Inverter Systems 2–36 975-0239-01-01 This manual for use by qualified personnel only
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 2–5 and “Step 2: Mounting the Inverter” on page 2–7. 3. Install the Xantrex XW Conduit Box. See “Step 3: Mounting the Xantrex XW Power Distribution Panel and Xantrex XW Conduit Box” on page 2–8. 4. Install AC sync cable(s) as required.
Inverter/Charger Installation Parts List for Dual-Inverter Configurations Installing an additional inverter using the power distribution panel requires a Xantrex XW Connection Kit (manufacturer part number 856-1020), which contains the following components: • Xantrex 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 • Four Power Distribution bars • Custom Bypass Interlock • #6 AWG AC wiring to connect the inver
Step 5: Installing Additional Inverters AC Breakers shown in this illustration represent the breaker arrangement for a single AC source. Torque connections to the inverter DC terminals to 10-15 ft/lbs. Actual cable requirements may vary. Torque connections to the battery terminals according to the battery manufacturer’s recommendations.
Inverter/Charger Installation 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. Disconnect INV1 AC LOAD (INV1 L1-LOAD, INV1 L2-LOAD) wires from top terminals on right-hand side breaker. 4.
Step 5: Installing Additional Inverters Actual wiring requirements may vary. Power Distribution bars in the Xantrex XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–14 for torque requirements.
Inverter/Charger Installation 1 Replace the Internal Front Panels using the hardware removed prior to wiring. 2 Place the AC Bypass plate over the Bypass breakers as shown and secure with the hardware provided. 1 Replace the Internal Front Panels using the hardware removed prior to wiring. To put the Bypass Plate in "Normal" position, loosen the screws slightly and slide the plate to the right. Retighten the screws to secure the plate in place.
Step 5: Installing Additional Inverters Parts List for a Triple-Inverter Configuration ❐ 1 x Xantrex XW Power Distribution Panel (Xantrex XW PDP) and Accessory kit (mounts to first unit). ❐ 1 x 865-1020 Xantrex XW PDP Connection Kit for INV2. The following items are required for the third inverter (furthest from Xantrex XW PDP) and should be sourced and prepared prior to the installation. (Note that all wiring will have to be custom cut to fit the third unit.
Inverter/Charger Installation Converting a Single-Inverter Power Distribution Panel to a Triple-Inverter Power Distribution Panel ◆ Remove upper wire cover and lower wire cover on the Xantrex XW Power Distribution Panel. DC Wiring for a Triple-Inverter System 1. Install the two DC disconnect/breakers (two supplied in 865-1020). 2. Install larger, three-position positive distribution plate (supplied in 865-1020) if not already done. 3.
Step 5: Installing Additional Inverters Power Distribution bars in the Xantrex XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–14 for torque requirements. AC Breakers shown in this illustration represent the breaker arrangement for multiple AC source. Torque connections to the inverter DC terminals to 10-15 ft/lbs. Actual cable requirements may vary. Torque connections to the battery terminals according to the battery manufacturer’s recommendations.
Inverter/Charger Installation 3. Connect L1 and L2, AC wiring from each INV Grid breaker to the corresponding AC Input (AC1) terminal on each of the three inverters. 4. If the installation includes a second AC source, connect L1 and L2 AC wiring from each INV Gen breaker to the corresponding AC Input (AC2) terminal on each of the three inverters. 5.
Step 5: Installing Additional Inverters Power Distribution bars in the Xantrex XW Power Distribution Panel accept up to a #2/0 AWG cable (maximum). See Figure 2-9 on page 2–14 for torque requirements.
Inverter/Charger Installation Actual wiring requirements may vary.
Step 5: Installing Additional Inverters Xantrex Xanbus and AC Sync Cable A Xantrex 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 Xantrex XW Conduit Box raceway, prior to making the AC and DC wiring connections. See Figure 2-35.
Inverter/Charger Installation Basic Functional Test - Multiple Inverters The following steps will complete a basic functional test of multiple Xantrex XW Inverter/Chargers. If any test fails, please refer to the Troubleshooting section in the Xantrex XW Inverter/Charger Operation Guide for assistance. To perform a functional test on multiple inverters: 1. Check/verify all wiring and cable connections. 2.
Basic Functional Test - Multiple Inverters 11. Using the Xantrex XW System Control Panel, enable the System a) Go to System Settings menu b) Change System Mode to “Operating” c) Press Exit until you see the System Status screen. 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.
Inverter/Charger Installation Figure 2-36 Functional Test for Multiple Inverters - Page 1 of 2 2–52 975-0239-01-01 This manual for use by qualified personnel only
Basic Functional Test - Multiple Inverters Figure 2-37 Functional Test for Multiple Inverters - Page 2 of 2 975-0239-01-01 2–53 This manual for use by qualified personnel only
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3 Xantrex Xanbus Network Installation Chapter 3, “Xantrex Xanbus Network Installation” provides detailed information for planning and installing the components necessary for network communication on a Xantrex Xanbus system. For this Topic See....
Xantrex Xanbus Network Installation Xantrex Xanbus-enabled Devices The Xantrex Xanbus-enabled designation means that the product works on a Xantrex Xanbus network. Xantrex Xanbus-enabled products are: • Easy to use. The Xantrex Xanbus network simplifies operation and automates routine tasks. • Reliable. Software control eliminates errors due to analog signalling. • Accurate. Digital information is less susceptible to interference and line loss.
The Xantrex Xanbus System Network Components A Xantrex Xanbus network consists of the following components: • Xantrex Xanbus-enabled devices—these include the Xantrex XW System Control Panel, the Xantrex XW Inverter/Charger, Xantrex XW Automatic Generator Start, and Xantrex XW Solar Charge Controller. The maximum number of Xantrex Xanbus devices connected to a single Xantrex Xanbus network should not exceed eight devices.
Xantrex Xanbus Network Installation • Network terminators — the Xantrex Xanbus network must be properly terminated at each 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. Permanent configuration without terminators is not supported by Schneider Electric. The Xantrex XW Series and other Xantrex Xanbus-enabled devices ship with one terminator already installed.
The Xantrex Xanbus System Network Layout Each device on the network is linked with separate lengths of Xantrex Xanbus cable, as shown in Figure 3-3. This layout does not require network connectors. Two terminators are required to ensure the communication signal quality on the network. The Xantrex Xanbus-enabled devices at each end of the chain must have a male terminator inserted into their open network ports.
Xantrex Xanbus Network Installation Installing the Network Important: Installing and replacing Xantrex Xanbus-enabled devices in an existing system must be performed with the Xantrex XW Power System in Standby mode. For more information about Standby mode, see the Xantrex 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.
Installing the Network Guidelines for Routing the Xantrex Xanbus Cables WARNING: Shock hazard : Do not route the Xantrex Xanbus cables in the same conduit or panel as the AC and DC power cabling. To ensure maximum performance of your network, follow these guidelines when routing the Xantrex Xanbus cables. • Route the cables away from sharp edges that might damage the insulation. Avoid sharp bends in the cable—no less than a 4-inch (100 mm) radius.
Xantrex Xanbus Network Installation Installing Xantrex Xanbus-Enabled Devices If you are installing a Xantrex Xanbus-enabled device on an existing Xantrex Xanbus System, put the system in Standby mode using the System Settings menu on the Xantrex XW System Control Panel. CAUTION: Equipment Damage Connect only to other Xantrex 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.
4 Xantrex XW Solar Charge Controller Installation Chapter 4, “Xantrex XW Solar Charge Controller Installation” describes how to mount and connect the Xantrex XW Solar Charge Controller as part of the Xantrex XW System. For this Topic See....
Xantrex XW Solar Charge Controller Installation Installing the Charge Controller This chapter describes installing the Xantrex XW Solar Charge Controller (Xantrex XW SCC) with the Xantrex XW Power System, including the power distribution panel. For stand-alone installation, see the Xantrex XW Solar Charge Controller Owner’s Guide. PV Array Requirements Note: The following information provides only general guidelines.
Mounting MPPT Voltage Range The Xantrex XW SCC maximum power point tracking algorithm maximizes the output energy 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. Effects of array voltages outside of the MPPT operational window are shown in Table 4-1.
Xantrex XW Solar Charge Controller Installation Choosing a Location The Xantrex XW Solar Charge Controller is designed to be mounted vertically to the side or the top of the power distribution panel. The Xantrex XW SCC must be installed indoors in a dry, protected location away from flammable materials, sources of high temperature, moisture, and vibration, and direct sunlight. The location must also be sheltered from direct sunlight, rain, snow, and wind-blown debris.
Mounting 6 inches (150 mm) on top and side(s) Figure 4-1 Minimum Clearance Requirements Removing the Wiring Compartment Cover Before mounting, you must remove the wiring compartment cover to access the mounting holes and the wiring terminals. The wiring compartment cover is secured with two Phillips #8-32 × 2 ½-inch (63.5 mm) screws on the front cover of the unit. See Figure 4-2. Remove screws to access the field-wiring terminals.
Xantrex XW Solar Charge Controller Installation Removing Knockouts Six dual and two single knockouts are provided for routing battery, PV array, BTS, and network cables into the Xantrex XW SCC. Bushings or conduits must be used to protect the wiring from damage from rough edges around the knockout holes. When removing knockouts, ensure that no metal shavings or fragments fall into the wiring compartment. Important: Do not drill, cut, or punch holes in the Xantrex XW SCC.
Mounting Single knockouts intended for BTS and network cables DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) 2 PL DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) 2 PL KNOCKOUT 27.78 (1 1/16 KNOCKOUT 27.78 (1 1/16) 31.50 (1 ¼) DUAL KNOCKOUT 34.52 (1 3/16) & 27.78 (1 1/16) 25.9 (1) 26.47 (1) 26.47 (1) 20.20 (¾) 50.00 (2) 50.80 (2) 25.0 (1) 50.80 (2) 50.
Xantrex XW Solar Charge Controller Installation To mount the Xantrex XW SCC away from the power distribution panel: 1. Remove the wiring terminals cover. 2. Mark the location of the keyhole slot on the wall. 3. Secure the top mounting screw in the location marked. Leave the screw head backed out approximately ¼ inch (6 mm). 4. Place the Xantrex XW SCC onto the screw and pull it down into the keyhole slot. 5. Insert two screws in the two mounting holes provided to secure the unit to the wall. 6.
Grounding Grounding The Xantrex XW SCC can be configured to be compatible with either negative-grounded or ungrounded PV systems. The maximum size of the ground conductor is #6 AWG (16 mm2). This wire gauge is determined by electrical code requirements regarding conduit knockout sizes, wire bending radius, and space available within the Xantrex XW Series wiring compartment. For ground conductor requirements for your specific installation, consult your local electrical code.
Xantrex XW Solar Charge Controller Installation WARNING: Fire Hazard Ensure there is no other ground connection in the DC wiring or the Xantrex PV GFP will be defeated and will not protect the array from ground fault conditions. This symbol identifies the protective conductor (grounding) connection. Chassis ground terminals.
Grounding Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays To install the Xantrex XW SCC in a system where an external negative-ground bond is required or where the PV array must not be grounded, the Xantrex XW SCC internal Xantrex PV GFP circuit and ground bond must be disabled. To disable the unit’s Xantrex PV GFP circuit and ground bond, move the jumper connector located on the circuit board within the wiring compartment. See Figure 4-7.
Xantrex XW Solar Charge Controller Installation Wiring Important: Installations must meet all local electrical codes. Installations of this equipment should only be performed by a qualified electrician or a Certified Renewable Energy (RE) System Installer. 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.
Wiring Current Rating The Xantrex XW SCC PV input is rated for 60 A maximum Isc. Since PV outputs can vary due to the array size or sunlight angle, the safe minimum wire size must be chosen for maximum array short-circuit current. Consult PV array manufacturer specifications. Minimum Wire Gauge For installations where the PV array output is the maximum allowable 60 A Isc, the minimum allowable wire gauge is #6 AWG (16 mm2) copper wire with a 90 °C (194 °F) insulation rating.
Xantrex XW Solar Charge Controller Installation Long-Distance Wire Runs If there is a significant distance between the PV array and the Xantrex XW SCC or between the Xantrex XW SCC and the battery, larger wires can be used to reduce the voltage drop and improve performance. Refer to Table 4-4 or Table 4-5. WARNING: Equipment damage Do not connect an array capable of delivering over 60 A Isc to the Xantrex XW SCC.
Wiring Maximum One-way Distance and Wire Size Refer to Table 4-4 or Table 4-5 and find the maximum current in the left column, and the one-way distance from the PV array to the Xantrex XW SCC (or the distance from the Xantrex XW SCC to the battery) on the same line, then read the wire size required at the top of the column. For equivalent metric wire sizes, consult a local electrician or certified installer.
Xantrex XW Solar Charge Controller Installation Table 4-5 One-Way Wire Distance and Wire Size for a 48 Vdc System Maximum one-way wire distance for a < 3% voltage drop assuming 60 Adc charging current For 48 Vdc systems Distance in feet (meters)a Distance in feet (meters) Amps 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 3 AWG 2 AWG 1 AWG 1/0 AWG 10 70.4 (21.44) 112.0 (34.16) 177.6 (54.16) 282.4 448.8 (86.80) (136.8) 567.2 (172.88) 716.8 (218.48) 900.0 (274.32) 1133.6 (345.52) 12 58.4 (17.84) 92.
Wiring Connecting the Xantrex 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. WARNING: Shock Hazard Do not connect the battery negative to ground. Bonding the battery negative to ground disables PV ground-fault protection.
Xantrex XW Solar Charge Controller Installation 8. Connect a second positive (+) cable to the other side of the battery disconnect and connect to the positive (+) battery terminal. 9. Torque the Xantrex XW SCC terminals according to the following table: Wire Size Torque Value AWG mm2 in-lb Nm 14–10 2.5–6 15 1.7 8 10 18 2.0 6 16 20 2.25 Be careful not to overtighten. Allow some slack on the cables within the controller and secure the wiring with strain reliefs or cable clamps.
Commissioning Commissioning During commissioning, the Xantrex 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 Xantrex XW System Control Panel is present, the Xantrex XW System Control Panel is intended to be the configuration interface, so the prompt screens are suppressed.
Xantrex XW Solar Charge Controller Installation Commissioning Units Using a Xantrex XW System Control Panel In systems where a Xantrex XW System Control Panel (Xantrex XW SCP) is present, the Xantrex XW SCP is intended to be the configuration interface. For information about Xantrex XW SCP navigation and menus, see Appendix B, “Xantrex XW System Control Panel Menus” in the Xantrex XW Solar Charge Controller Owner’s Guide. Commissioning units using a Xantrex XW SCP involves three separate procedures: 1.
Commissioning To configure Connections and Charger Settings for the first Xantrex XW Solar Charge Controller: 1. On the Select Device Menu, select “MPPT60 01.” 2. Navigate to the Multi Unit Config menu and select Connections. On the Connections menu, you can configure PV In (PV input) and DC Conn (DC output, or the battery bank). If the system has only one battery bank, leave DC Conn at the default setting.
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5 Xantrex XW System Accessories Installation Chapter 5, “Xantrex XW System Accessories Installation” describes how to mount and install the Xantrex XW System Control Panel and the Xantrex XW Automatic Generator Start. For this Topic See....
Xantrex XW System Accessories Installation The Xantrex XW System Control Panel The Xantrex XW Series Inverter/Charger can be controlled remotely by connecting a Xantrex XW System Control Panel. The Xantrex XW System Control Panel is optional for single inverter systems. The Xantrex XW System Control Panel is required for configuring systems with multiple inverters.
The Xantrex XW System Control Panel The Xantrex XW System Control Panel is designed to be wall mounted (see “Mounting the Xantrex XW System Control Panel” on page 5–4), and requires no connections other than the network cables or terminators that plug into the back of the unit. Because you cannot access the Xantrex XW System Control Panel network inputs after the unit is mounted, the network cables need to be routed through the wall and connected before securing the Xantrex XW System Control Panel.
Xantrex XW System Accessories Installation Mounting the Xantrex XW System Control Panel The Xantrex XW System Control Panel can be mounted three ways: • Flush mounted through an opening in a wall using the mounting plate • Surface mounted using the mounting plate • Flush mounted through an opening in a wall and secured with four #6 screws. WARNING: Shock hazard Before making an opening in a wall or panel, ensure there is no wiring or other obstruction within the wall.
The Xantrex XW System Control Panel 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 5. Connect the network cable(s) (and terminator if necessary) to either input on the back of the Xantrex XW System Control Panel. See Figure 5-4.
Xantrex XW System Accessories Installation 6. Place the unit into the mounting plate and secure it with four #6 screws. Figure 5-5 Securing the Xantrex XW System Control Panel 7. Peel off the protective plastic coating covering the screen and indicator light. To flush mount the Xantrex XW System Control Panel with no mounting plate: 1. Peel the backing from the supplied mounting template sticker and place it in your chosen installation location.
The Xantrex XW System Control Panel To surface mount the Xantrex XW System Control Panel: CAUTION: Equipment damage : Provide adequate space within the wall for the Xantrex Xanbus cables to bend. Do not bend the cable to one side after it leaves the Xantrex Xanbus port. The mounting bracket itself does not provide enough space for the cables to bend.
Xantrex XW System Accessories Installation Verifying the Installation If network power (from an inverter/charger) is present, the backlight will come on and the Xantrex XW System Control Panel will show the startup screen (see the Xantrex XW Inverter/Charger Operation Guide), then show the System Home screen. The Xantrex XW Automatic Generator Start Some generators allow automatic starting.
The Xantrex XW Automatic Generator Start Preparing an Installation Before installing the Xantrex XW Automatic Generator Start Module, consider how and where the unit will be mounted. Pre-plan the connection routes between the Xantrex XW Automatic Generator Start, the generator, thermostats, and the Xantrex XW Automatic Generator Start. Refer to the Xantrex XW AGS Owner’s Guide for additional information.
Xantrex XW System Accessories Installation Routing the Connections WARNING: Explosion Hazard This equipment is not ignition protected. To prevent fire or explosion, do not install the Xantrex XW Automatic Generator Start in locations that require ignition-protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other connections between components of a fuel system.
The Xantrex XW Automatic Generator Start Installing the Xantrex XW Automatic Generator Start Installation Overview Installing the Xantrex XW Automatic Generator Start involves the following steps: 1. Mounting the unit. 2. Connecting the wiring harness to: • the generator (page 5–15) • thermostats (optional) (page 5–16) • external shutdown switch (optional) (page 5–16) • external ON/OFF switch and LED (optional) (page 5–17) 3.
Xantrex XW System Accessories Installation Wiring to the 20-contact Connector WARNING: Fire, Shock, and Energy Hazards The 20-contact connector is intended for connection to Class 2 ELV (Extra Low Voltage) circuits only. Do not exceed the circuit limitations specified in the following section. CAUTION: Shock Hazard All installation wiring should be performed by a qualified installer or electrician. ELV Circuits ELV (Extra-Low Voltage) circuits have an open-circuit voltage of not more than 30 Vrms or 42.
The Xantrex XW Automatic Generator Start To install the Xantrex XW Automatic Generator Start using the wiring harness: 1. Connect each wire on the harness to its intended wire or contact on the generator, thermostats, or external switches. 2. Plug the harness into the connector on the bottom panel of the Xantrex XW Automatic Generator Start. Wire Identification Each wire on the harness is identified by a number and a color.
Xantrex XW System Accessories Installation Table 5-3 Contact Numbers and Functions Wire Number Function Wiring Harness Wire Color 1 Thermostat 1 input Yellow 2 Thermostat 1 return Gray 3 Thermostat 2 input Orange 4 Thermostat 2 return Gray 5 External shutdown input White/Black 6 External shutdown return Gray 7 External manual on input White/Green 8 External manual off input White/Red 9 External ON/OFF LED Indicator output White/Blue 10 Constant 12/24 V B+ (battery positive) fo
The Xantrex XW Automatic Generator Start Connecting the Generator To connect the Xantrex 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.
Xantrex XW System Accessories Installation Connecting the Thermostats (Optional) Wires 1, 2, 3, and 4 on the wiring harness can be connected to two thermostats. Wires 1 (yellow) and 2 (gray) are intended for thermostat 1 and wires 3 (orange) and 4 (gray) are intended for thermostat 2.
The Xantrex XW Automatic Generator Start Connecting an External Manual ON/OFF Switch (Optional) The external manual ON/OFF inputs (wires 7 and 8 on the wiring harness) are intended for wiring to one or more remote ON/OFF switches for starting and stopping the generator manually. The other contact of the switch should be connected to ground.
Xantrex XW System Accessories Installation Connecting an External ON/OFF LED Wires 9 (White/Blue) and 11 (Black) on the wiring harness can be connected to an LED or other light to accompany a remote external ON/OFF switch. This light turns on when the generator run signal is active to visually indicate that the generator is running. Important: With some generators, the generator run signal becomes active during the preheat stage, before the generator is actually running.
The Xantrex XW Automatic Generator Start Connecting the Wiring Harness to the Xantrex 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 Xantrex XW Automatic Generator Start.
Xantrex XW System Accessories Installation Connecting the Xantrex XW Automatic Generator Start to the Xantrex Xanbus Network CAUTION: Equipment Damage Connect only to other Xantrex 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 Xantrex Xanbus-enabled device to an Ethernet system.
The Xantrex XW Automatic Generator Start Verifying Power Is Available When the Xantrex 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. Verify Power and Network indicator lights are illuminated.
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A Specifications Appendix A, “Specifications” provides the electrical and environmental specifications for the Xantrex XW Series.
Specifications Electrical Specifications Table A-1 Xantrex XW Power System Electrical Specifications Model Xantrex XW6048 120/240 60 Xantrex XW4548 120/240 60 Xantrex XW4024 120/240 60 Continuous Output Power 6,000 W 4,500 W 4,000 W Surge Rating (10 seconds) (stand-alone invert mode) 12,000 W (15 s) 9,000 W (20 s) 8,000 W (20 s) Surge Current L-n: 105 Arms (15 s) L-n: 75 Arms (20 s) L-n: 70 Arms (20 s) (stand-alone invert mode) L-L: 52.
Electrical Specifications Table A-1 Xantrex XW Power System Electrical Specifications Xantrex XW6048 120/240 60 Xantrex XW4548 120/240 60 Xantrex XW4024 120/240 60 Maximum Output Fault Current and Duration - Grid-Interactive Mode 425 A peak 425 A peak 80 A peak ~0.4 ms ~0.4 ms ~25 ms AC Output Breaker 60 A double-pole AC Output Frequency 60.0 ±0.
Specifications Figure A-1 Xantrex XW Series AC Overload Capability Figure A-2 Xantrex XW Series AC Overload Capability A–4 975-0239-01-01 This manual for use by qualified personnel only
Electrical Specifications Figure A-3 Xantrex XW Series AC Overload Capability Output Power Versus Ambient Temperature When the internal temperature of the Xantrex XW Series exceeds its rated range, the unit reduces its energy output to ensure maximum component ratings are not exceeded.
Specifications Xantrex XW Series Efficiency Inverting Efficiency (Typical) 100% Xantrex XW4024 95% Xantrex XW6048 90% Efficiency (%) Xantrex XW4548 85% 80% 75% 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Output Power (Watts) Figure A-5 Inverting Efficiency (Typical) Charging Efficiency (Typical) 100% 95% Xantrex XW6048 Efficiency (%) Xantrex XW4024 90% Xantrex XW4548 85% 80% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Charge Current (A
Electrical Specifications Charging Power Factor 100% Xantrex XW4024 Xantrex XW6048 Xantrex XW4548 95% 90% Power Factor (%) 85% 80% 75% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Charge Current (Amps) Figure A-7 Charging Power Factor Grid-tie Sell Mode Efficiency (Typical) 100% Xantrex XW4024 95% Xantrex XW6048 90% Efficiency (%) Xantrex XW4548 85% 80% 75% 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Output Power (Watts) Figure A-8 Gr
Specifications Mechanical Specifications Table A-2 Xantrex XW Power System Mechanical Specifications Model Xantrex XW6048 120/240 60 Xantrex XW4548 120/240 60 Xantrex XW4024 120/240 60 Supported Battery Types Flooded (default), Gel, AGM, Custom Battery bank size 100–2000 Ah Non Volatile Memory Yes Display Panel Status LEDs indicate AC In status, faults/warnings, equalize mode, battery level. Three-character display indicates output power or charge current, fault/warning codes.
Accessories Table A-3 Xantrex XW Power System Regulatory Approvals Model Xantrex XW6048 120/240 60 Xantrex XW4548 120/240 60 Xantrex XW4024 120/240 60 Emissions FCC Class B Regulatory approvals UL 1741 1st Edition: 2005 Version, CSA 107.1-01 Surge Rating IEEE 62.41.
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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....
B–2
Single-Inverter System (Backup Only) Without a Power Distribution Panel Single-Inverter System (Backup Only) Without a Power Distribution Panel Xantrex XW Inverter/Charger Xantrex XW Inverter/Charger Communication Ports (on Bottom of Inverter) Xantrex XW System Control Panel (optional) Xantrex Xanbus Network Terminator Xantrex XW Automatic Generator Start (optional) Xantrex Xanbus Network Terminator Figure B-1 Single-Inverter System (Backup Only) Without a Power Distribution Panel 975-0239-01-01 B–
Wiring Diagrams Single-Inverter System (Backup Only) With a Power Distribution Panel Xantrex XW Inverter/Charger Xantrex XW Power Distribution Panel Note: If no Grid is available, the generator can be connected to the AC breakers in the Xantrex XW Power Distribution Panel, instead of to a separate AC breaker.
Single-Inverter System Renewable Energy (Solar) Single-Inverter System Renewable Energy (Solar) Xantrex XW Inverter/Charger Xantrex XW Power Distribution Panel Xantrex XW Solar Charge Controller Xantrex Xanbus Network Terminator Xantrex XW System Control Panel (optional) Xantrex XW Automatic Generator Start (optional) Xantrex Xanbus Network Terminator Xantrex XW Inverter/Charger Communication Ports (on Bottom of Inverter) Note: If no Grid is available, the generator can be connected to the AC brea
Wiring Diagrams Single-Inverter System Renewable Energy (Wind or Hydro) Xantrex XW Inverter/Charger Communication Ports (on Bottom of Inverter) Xantrex XW Inverter/Charger Xantrex XW System Control Panel (optional) Xantrex XW Automatic Generator Start (optional) Xantrex Xanbus Network Terminator Xantrex Xanbus Network Terminator Note: If no Grid is available, the generator can be connected to the AC breakers in the Xantrex XW Power Distribution Panel, instead of to a separate AC breaker.
Dual-Inverter System Renewable Energy (Solar) Dual-Inverter System Renewable Energy (Solar) Xantrex XW Power Distribution Panel Xantrex XW Solar Charge Controller Xantrex Xanbus Network Terminator Xantrex XW System Control Panel Xantrex Xanbus Network Terminator Xantrex XW Automatic Generator Start (optional) Xantrex XW Solar Charge Controller Xantrex XW Inverter/Charger Communication Ports (on Bottom of Inverter) Note: If no Grid is available, the generator can be connected to the AC breakers in t
Wiring Diagrams Dual-Inverter System Renewable Energy (Wind or Hydro) Xantrex XW System Control Panel Xantrex Xanbus Network Terminator Xantrex Xanbus Network Terminator Xantrex XW Automatic Generator Start (optional) Xantrex XW Inverter/Charger Communication Ports (on Bottom of Inverter) Note: If no Grid is available, the generator can be connected to the AC breakers in the Xantrex XW Power Distribution Panel, instead of to a separate AC breaker.
C 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 Xantrex XW Conduit Box.
Alternate System Configurations DC Grounding for Single-Inverter Systems See Table 2-4, “Torque Values for AC Wiring (AC Terminals and Ground Bar),” on page 13. See Table 2-5, “Torque Values for the Chassis Ground Lug,” on page 13. See Table 2-6, “Torque Values for the Inverter Battery Terminals,” on page 13. This illustrates an example only. Actual ground requirements may vary.
Battery Connections for Single Inverter Systems Battery Connections for Single Inverter Systems Torque connections to the inverter DC terminals to 1015 ft./lbs. Torque connections to the battery terminals per battery manufacturer’s recommendations.
Alternate System Configurations AC Grounding for Single-Inverter Systems This illustrates an example only. Actual ground requirements may vary.
AC Output Wiring to the Inverter AC Distribution Panel AC Output Wiring to the Inverter AC Distribution Panel Actual wiring requirements may vary.
Alternate System Configurations Generator Wiring to the Inverter WARNING: Shock Hazard Before making any electrical connections, ensure both the AC and DC disconnect devices are in the OPEN (disconnect) position. Important: If the load is too big for the inverter to operate from battery power, do not install the load in the inverter powered electrical panel. This illustrates an example only. Actual wiring requirements may vary. Torque all inverter terminal block connections to 25 inch-pounds.
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. Actual wiring requirements may vary.
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Index A F AC Connections 2–20 AC sync cable 2–49 AC Terminal Block 2–22 Additional Inverters 2–37 Automatic Generator Start 1–8, 5–8 AUX Port 2–30 AUX Port Terminal Assignments 2–31 AUX+12V Voltage Supply 2–30 AUX-RPO User Remote Power Off 2–31 FCC information to the user ii–vii Fire safety 2–2 functional test 2–32, 2–50 generator run signal 5–14 Generator Wiring 2–28 Ground Bar 2–22 Grounding 2–14, 2–15, 4–9 Grounding the DC System 2–15 B I B+ wires 5–14 battery bank requirements 2–10 battery cable
Index S safety instructions ii–v Schneider Electric web site iv, i–iv Single-Inverter System B–3, B–4 Single-Inverter System Renewable Energy (Solar) B–5 Single-Inverter System Renewable Energy (Wind or Hydro) B–6 switched B+ wires 5–14 T thermostat connecting 5–16 inputs and returns 5–14, 5–16 U User Line Wiring 2–31 V verifying network power 5–8, 5–21 W web site i–iv wire size 4–12 Wire Size and Over-current Protection Requirements 4–12 Wiring 4–12 Wiring the Inverter 2–9 X XW Inverter/Charger 1–3 X
Schneider Electric www.schneider-electric.com ☎ North America 1 650 351 8237 1 866 519 1470 ✉ 1 925 245 1022 re.techsupport@schneider-electric.com La France +0825012999 fr-re-techsupport@fr.schneider-electric.com Deutschland +49 (0) 180 575 6575 +49 (0) 2102 404 7101 solarservice@de.schneider-electric.com España +34 93 498 7466 +34 93 305 5026 re.techsupport@es.schneider-electric.com L'Italia +39 035 4151111 +39 035415 3200 IT-pronto-contatto@it.schneider-electric.
