Xantrex™ XW MPPT 80 600 Solar Charge Controller Installation Guide Xan trex XW MPPT 80 600 www.schneider-electric.
Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide www.schneider-electric.
Trademarks Schneider Electric, the Schneider Electric logo, Fast Sweep, Xanbus, and Xantrex 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 they are used herein for identification purposes only. Notice of Copyright Copyright © 2012, 2010 Schneider Electric SA.
About This Guide Purpose This Guide provides explanations and procedures for installing and troubleshooting the Schneider Electric Xantrex XW MPPT 80 600 Solar Charge Controller. Scope This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the charge controller, and information about troubleshooting. It does not provide details about particular brands of photovoltaic (PV) panels or batteries.
About This Guide Conventions Used This Guide uses the term charge controller to refer to the Xantrex XW MPPT 80 600 Solar Charge Controller. This Guide uses the following conventions for conveying important safety related information: DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
About This Guide Abbreviations and Acronyms BTS CB CEC CSA DC FCC GFP IMP Battery Temperature Sensor Xantrex XW Conduit Box Canadian Electrical Code Canadian Standards Association Direct Current Federal Communications Commission Ground Fault Protection Current at maximum power per STC ISC Short circuit current rating of an PV panel under STC LCD LED MPP MPPT MSDS NEC NFPA PDP PV SCP STC UL VAC VDC VMP Liquid Crystal Display Light Emitting Diode Maximum Power Point Maximum Power Point Tracking Materia
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Important Safety Instructions This Guide contains important safety instructions that must be followed during the installation and maintenance of the charge controller. Make sure you read, understand, and save these safety instructions. DANGER HAZARD OF SHOCK, BURN, FIRE, AND EXPLOSION • The charge controller must be installed and serviced only by qualified personnel equipped with appropriate personal protective equipment and following safe electrical work practices.
Safety Personal Protection Follow these instructions to help protect yourself while working with the charge controller. DANGER HAZARD OF ELECTRIC SHOCK AND BURN Thoroughly inspect the charge controller prior to energizing. Verify that no tools or materials have been inadvertently left behind. Failure to follow these instructions will result in death or serious injury.
Safety FCC Information to the User This charge controller has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules and Industry Canada ICES-003. These limits are designed to provide reasonable protection against harmful interference when the charge controller is operated in a residential environment.
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Contents Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii 1 Introduction Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Charge Controlling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Typical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents 3 Troubleshooting Charge Controller Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Replacing the Ground Fault Protection Fuse- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Ground Faults in a Normally Ungrounded Array - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 A Specifications Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1 Introduction Chapter 1 describes features and functions of the charge controller. For information on: See: “Features” page 1–2 “Charge Controlling” page 1–3 “Typical Installation” page 1–3 975-0540-01-01 Revision B 1–1 This guide is for use by qualified personnel only.
Introduction Features This photovoltaic charge controller tracks the maximum power point of a PV array to deliver the maximum available current for optimum charging of batteries. The charge controller can be used with 24 and 48 VDC battery systems only. Key product features include a 600 VDC maximum input voltage, a Fast Sweep™ MPPT tracking algorithm, and built-in ground fault protection.
Charge Controlling Charge Controlling The charge controller can regulate PV array current at an appropriate level for 24 or 48 V batteries. It produces up to 80 amps of charging current for both battery voltages up to 2560 watts (24 V) or 4800 watts (48 V). The charge controller controls how the batteries are charged by the PV array. It can be configured to use a two-stage (no float) or three-stage charging process to maintain battery voltage at bulk, absorption, or float levels.
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2 Installation Chapter 2 provides installation instructions for the charge controller. Before installing the charge controller, read this entire chapter.
Installation DANGER HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION Installation of this equipment should only be planned and performed by qualified personnel in accordance with all applicable installation codes. See “Audience” on page iii for the definition of qualified personnel. Failure to follow these instructions will result in death or serious injury.
Mounting WARNING HAZARD OF ELECTRIC SHOCK AND FIRE The PV array voltage must never exceed 600 VOC, including the local temperature correction factor required by the local electrical code. The PV array maximum circuit current must not exceed 35 A, including the multiplier required by the local electrical code. For example, the multiplier required by the NEC and the CEC is 125%, so the array STC Isc must not exceed 28 A (28 A x 125% = 35 A).
Installation To help ensure optimal and safe operation, make sure there is adequate clearance around the charge controller. See Table 2-1 and Figure 2-1. If clearances are reduced below these minimums, charging performance might be impaired. Table 2-1 Minimum clearance requirements Location Minimum Clearance Above 6 inches (150 mm). Do not mount charge controllers in a vertical and below stack.
Mounting Removing the Wiring Compartment Cover DANGER HAZARD OF ELECTRIC SHOCK AND ENERGY Before removing the wiring compartment cover, make sure all sources of electricity have been disconnected for at least two minutes. Before energizing the charge controller, make sure the wiring compartment cover has been replaced with all fasteners. Failure to follow these instructions will result in death or serious injury.
Installation Removing Knockouts Fourteen knockouts are provided for conduit or cable entry into the charge controller (see Figure 2-4 and Figure 2-5): • Three single (one on each side and one on the back) for battery wires: 1.73 in. (44.0 mm). • Two single on the back and six dual on the sides (three on each side) for PV array wires: 1.38 in. (35.0 mm). • Three dual (one on each side and one on the back) for routing BTS and network cables: 1.11 in. (28.2 mm).
Mounting 764.0 (30.0) 673.4 (26.5) Keyhole slot for wall mounting 44.0 (1.73) KNOCKOUT 35.0 (1.38)/ 28.2 (1.11) DUAL KNOCKOUT 3PL 108.4 (4.27) 219.7 (8.65) 61.9 (2.44) 28.2 (1.11)/ 22.2(0.87) DUAL KNOCKOUT 220.5 (8.68) All measurements in mm (in.) Figure 2-5 Dimensions and knockout locations Mounting the Charge Controller The charge controller must be vertically mounted to the wall using three ¼-inch × ½-inch (6.35 mm × 12.5 mm) pan head screws.
Installation ¼" (6 mm) Place keyhole slot over the mounting screw. Secure with two more screws. Figure 2-6 Mounting the charge controller PV Grounding You can configure the charge controller to be compatible with either negativegrounded, positive-grounded, or ungrounded (floating) PV systems. For information about routing the ground connection, see Figure 2-9 on page 2–13. Chassis Grounding The recommended size of the chassis ground conductor is #8 AWG (8.5 mm2)1.
Wiring DANGER HAZARD OF ELECTRIC SHOCK AND FIRE • Do not ground either PV conductor outside of the unit. • Grounded arrays: Install a fuse in the correct holder: (+) or (–). Replace the fuse with the same type and rating (Littelfuse KLKD 1 or equivalent). Fuses must be replaced by qualified service personnel only. • Ungrounded (floating) arrays: Leave both fuse holders empty. Failure to follow these instructions will result in death or serious injury.
Installation XANB US X ANB US B TS AUX COM NO NC B_ATTE R Y + NE G. GND P V . P OS . G ND PV. PVPV+ T E R MINAL T OR QU E T E R MINAL T OR QU E 25 lbf.in ( 2.8 N m) 15 lbf.in ( 1.7 N m) Figure 2-8 DC terminal connector locations A label providing details on each connector and torque requirements for each terminal is affixed to the inside of the wiring compartment cover plate.
Wiring Over-current Protection WARNING HAZARD OF ELECTRIC SHOCK, ENERGY, AND FIRE Over-current protection must be provided, external to the unit, to protect the PV and battery wiring. External disconnecting means must also be provided for the PV and battery circuits. Consult local electrical codes to establish the correct fuse or circuit breaker ratings and for required locations of protection and disconnecting means. Failure to follow these instructions can result in death or serious injury.
Installation Connecting the Unit The following procedure is illustrated in Figure 2-9 on page 2–13. DANGER HAZARD OF ELECTRIC SHOCK Whenever a PV array is exposed to light, a shock hazard exists at the output wires or exposed terminals. Open the array disconnect switch before making the connections. Failure to follow these instructions will result in death or serious injury. To connect the charge controller in a negative-grounded system: 1.
Wiring For negative-grounded PV array, install fuse here. The positive or negative of the battery can be grounded independent of the array grounding. For positive-grounded PV array, install fuse here. 4800 W STC array (2 x 2400 W strings) BAT PV - PV + CHASSIS GROUND To inverter 100 ADC (typical) Disconnect (configuration will vary) 48 V battery bank Ground LEGEND Ground DC Positive DC Negative Grounding and disconnect locations will vary according to system design and local electrical codes.
Installation To connect the charge controller in a positive-grounded or floating system: ◆ Follow the same steps as above for a negative-grounded charge controller, except note the location of the PV array disconnect switch will vary as follows: • For positive-grounded systems, the PV array disconnect switch must be in the negative conductor.
Connecting Multiple Units Connecting Multiple Units In a multiple-unit installation, each charge controller must be connected to a separate PV array. See Figure 2-10. For other multiple-unit installation considerations, see “Network Installation” on page 2–17. CAUTION PV ARRAY AND CHARGE CONTROLLER DAMAGE Make sure that each charge controller is correctly connected to its own PV array(s) and that no wires are interconnected between charge controllers.
Installation Auxiliary Output Connections The auxiliary output (dry relay contacts) provides a connector which can accept wire sized from #22 to #14 AWG (0.5 to 2.5 mm2), copper solid or stranded. As shown in Figure 2-11, the auxiliary output can control 12 VDC power to a fan to vent the battery compartment. For this application, the charge controller’s auxiliary output must be configured to activate when the batteries reach a pre-set voltage level.
Network Installation Network Installation The charge controller is a Xanbus-enabled device. Xanbus is a network communications protocol. The charge controller is able to communicate its settings and status to other Xanbus-enabled devices, such as Xantrex XW Hybrid Inverter/Chargers, the SCP, the Xantrex XW Automatic Generator Start (AGS), and other charge controllers.
Installation • Network terminators (see Figure 2-12): The Xanbus network must be properly terminated at each end to help ensure communication signal quality on the network. Network terminators plug into network ports on Xanbus-enabled devices. The charge controller and other Xanbus-enabled devices ship with one terminator. Depending on your network layout, this terminator might need to be inserted into another device elsewhere in the network.
Network Installation Connecting Network Cables Between Multiple Units WARNING HAZARD OF ELECTRIC SHOCK Do not route the network cables in the same conduit or panel as the PV or battery input and output cables, and make sure the network cables are not intermingled with conductors from those systems. Failure to follow these instructions can result in death or serious injury.
Installation Installing the Battery Temperature Sensor Installing a BTS is recommended for optimum charging performance and battery life extension. If a BTS is not installed and the batteries must operate in hot or cold conditions, manually adjust the temperature settings to suit the conditions. See “Configuring Battery Characteristics and Battery Charging” in the Xantrex XW MPPT 80 600 Solar Charge Controller Operation Guide.
Installing the Battery Temperature Sensor Figure 2-14 Attaching the BTS to a battery terminal WARNING HAZARD OF ELECTRIC SHOCK The BTS cable must not pass through the same conduit used for PV wiring and battery cables. Failure to follow these instructions can result in death or serious injury. 4. Pass the other end of the BTS cable through the knockout and strain relief bushing on the charge controller, and then insert the BTS plug into the BTS RJ-11 port. See Figure 2-15. 5.
Installation Commissioning Use the SCP to commission a charge controller. For information about SCP navigation and menus, see the appendix, “Xantrex XW System Control Panel Menus” in the Xantrex XW MPPT 80 600 Solar Charge Controller Operation Guide. Before you begin, make sure you have important system information such as the nominal battery voltage, battery type, and battery bank capacity available. If you are commissioning one charge controller, follow these procedures: 1.
Commissioning 6. Press Enter to select Advanced Settings. The Config menu opens. 7. Scroll to Multi Unit Config, and then press Enter. The Multi menu opens. The LEDs on the charge controller you are configuring will start to flash when you enter this menu, providing visual confirmation of the charge controller you are configuring. 8. Scroll to Dev Number, and then press Enter. Scroll again to set it to a number other than 00, and then press Enter to confirm the new device number.
Installation 5. Configure PV input (PV In) and DC output or the battery bank (DC Conn). If the system only has one battery bank, leave DC Conn at the default setting. The PV In setting allows you to differentiate which array is going to which charge controller. This setting is used for status reporting only, not for any internal controls. Setting PV In to a non-default value is optional. 6. Press Exit until the Config menu is displayed. 7. Scroll to Charger Settings, and then press Enter.
Commissioning If you are commissioning multiple charge controllers, follow these steps to copy the settings from the configured charge controller to the other charge controllers: 1. On the Select Device menu, select the next charge controller for configuration. The Setup menu opens. 2. Press Enter to select Advanced Settings. The Config menu opens. 3. Scroll to Copy from, and then press Enter to select the charge controller from which you want to copy.
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3 Troubleshooting Chapter 3 provides information about identifying and resolving problems that might arise while using the charge controller. For information on: See: “Charge Controller Troubleshooting” page 3–2 “Replacing the Ground Fault Protection Fuse” page 3–4 “Ground Faults in a Normally Ungrounded Array” page 3–5 975-0540-01-01 Revision B 3–1 This guide is for use by qualified personnel only.
Troubleshooting Charge Controller Troubleshooting DANGER HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION This chapter includes hazardous tasks that must be performed only by qualified personnel equipped with appropriate personal protective equipment and following safe electrical work practices. Review the “Important Safety Instructions” beginning on page vii before proceeding. Failure to follow these instructions will result in death or serious injury.
Charge Controller Troubleshooting Table 3-1 Charge controller problems Problem Possible Cause Solution The charge controller’s Error/ Warning (red) LED is on or flashing. An active fault, error, or warning is present on the charge controller. See “Viewing Active Faults, Errors, and Warnings” in the Xantrex XW MPPT 80 600 Solar Charge Controller Operation Guide to determine which alarm is active on the charge controller.
Troubleshooting Table 3-1 Charge controller problems Problem Possible Cause Solution All of the charge controller’s LEDs are off and the charge controller does not show up on the SCP. A. No battery connection to the charge controller. A. Change the battery disconnect from the off position to the on position. B. The charge controller is miswired. B. Check all connections and correct the wiring if voltage is not present on the charge controller’s battery terminals. C. Failed charge controller. C.
Ground Faults in a Normally Ungrounded Array 3. Remove the blown fuse and replace it with a new AC/DC midget cartridge, DC-rated 600 VDC, 1 A (Littelfuse KLKD 1 or equivalent). Be careful not to damage the fuse clips, circuit board, and surrounding components. 4. Replace the wiring compartment cover. 5. Clear the fault and reset the system by removing and then reapplying both PV and battery power.
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A Specifications Appendix A provides specifications for the charge controller. For information on: See: “Electrical Specifications” page A–2 “Default Battery Charger Settings” page A–5 “Mechanical Specifications” page A–5 “Accessories” page A–6 “Regulatory Approvals” page A–6 All specifications are subject to change without notice. 975-0540-01-01 Revision B A–1 This guide is for use by qualified personnel only.
Specifications Electrical Specifications Maximum PV Array Open Circuit Voltage 600 VDC PV Array Voltage Operating Range 195 to 550 VDC a PV Array Voltage Full Power Range 230 to 550 VDC Maximum Power Point Tracking Range 195 to 510 VDC PV Input Start Voltage 230 VDC Maximum Operating Current 23 A Maximum Array Short Circuit Current at STC 28 A Absolute Maximum Array Short Circuit Current Under Any Conditions 35 A (See the Notice on the next page for more information) Nominal Battery Voltage
Electrical Specifications NOTICE • PV array voltages often exceed STC voltage specifications, especially when the array is cold. A voltage temperature correction factor based on the local code (i.e., NEC 690 or CEC Section 50), ambient temperature conditions, and module manufacturer specifications must be applied to the array STC VOC to keep array voltage within specifications listed above.
Specifications 90 80 70 60 Output 50 Current (Amps) 40 Battery Voltage = 54V Battery Voltage = 58V Battery Voltage 64V Battery Voltage = 64V 30 20 10 0 195 200 205 210 215 220 225 230 235 240 Input Voltage (Volts) Figure A-2 Maximum expected output current versus input voltage 5000 4500 4000 3500 3000 Output O Power 2500 (Watts) Battery Voltage = 54V Battery Voltage = 58V 2000 Battery Voltage = 64V 1500 1000 500 0 195 200 205 210 215 220 225 230 235 240 Input Voltage (Volts)
Default Battery Charger Settings Default Battery Charger Settings All settings in the following table are based on a 48 V nominal battery bank. For a 24 V nominal battery bank, divide the voltage values in this table by two. Battery Type Floodeda Setting Gel AGM Equalize Voltage 64.0 V n/a n/a ReCharge Voltage 50.0 V 50.0 V 50.0 V Bulk Voltage 57.6 V 56.8 V 57.2 V Absorption Voltage 57.6 V 56.8 V 57.2 V Float Voltage 54.0 V 55.2 V 53.
Specifications Accessories The SCP (865-1050) is required for installation of the charge controller, and it is strongly recommended for continued operation of the charge controller. It is the primary interface to the charge controller. It must be used for setup and configuration, and it is recommended to be used for monitoring and fault reporting once installation is complete. Only one SCP is required to monitor multiple charge controllers. NOTICE You must use an SCP with firmware version 1.05.
Index A abbreviations v accessories A–6 acronyms v auxiliary output connections 2–16 vent fan application 2–16 B batteries charging current 1–3 default charger settings A–5 over-current protection 2–11 requirements 1–2 safety information viii sealed 2–3 battery temperature sensor attaching to battery terminal 2–21 installation diagram 2–21 installing 2–20 overview 2–20 using multiple 2–20 configuring charger settings 2–23 connections 2–23 connecting multiple PV array strings 2–14 multiple units 2–15 netwo
Index K O knockouts dimensions 2–7 locations 2–7 overview 2–6 removing 2–6 ordering network components 2–18 over-current protection battery circuit 2–11 PV 2–11 requirements 2–11 L P Lexan barrier 2–5 limitations on use vii location choosing 2–3 minimum clearance requirements 2–4 personal protection viii positive-grounded PV system 2–8 power supply, Xantrex Xanbus 2–17 protection, personal viii PV array requirements 2–2 PV disconnect switch 2–11 PV grounding floating 2–8 negative 2–8 overview 2–8 po
Index T television reception interference ix terminators, network 2–18 three-stage charge controlling 1–3 troubleshooting 3–2 two-stage charge controlling 1–3 U ungrounded PV system 2–8 W WARNING, definition iv wire gauge, minimum 2–10 wiring DC terminal connector locations 2–9 diagram 2–13 wiring compartment Lexan barrier 2–5 removing cover 2–5 X Xantrex Gateway 1–2 Xantrex Xanbus overview 2–17 power supply 2–17 Xantrex XW System Control Panel 1–2 975-0540-01-01 Revision B IX–3 This guide is for use
Index IX–4 975-0540-01-01 Revision B This guide is for use by qualified personnel only.
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