XW4024-120/240-60 XW4548-120/240-60 XW6048-120/240-60 Installation Guide XW Power System XW Power Distribution Panel XW System Control Panel XW Solar Charge Controller XW Automatic Generator Start
XW Power System Installation Guide
About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 2.5 MW utility-scale systems for wind, solar, batteries, fuel cells, micro turbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the XW Power System. Scope The Guide provides safety guidelines, detailed planning and procedures for installing the XW Inverter/Charger and related system components (the “XW Power System”). It does not provide details about configuration, operation, maintenance or troubleshooting. See the Operation Guide or Owner’s Manual of each device for this information.
About This Guide Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions or practices that could result in personal injury or loss of life. CAUTION Cautions identify conditions or practices that could result in damage to the XW Power System components or other equipment. Related Information Additional information about operating the XW Inverter/Charger, see the XW Inverter/Charger Operation Guide (975-0240-01-01).
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. Use of accessories not recommended or sold by Xantrex Technology Inc.
Important Safety Instructions Limitations on Use WARNING: Limitations on Use The XW Power System is not intended for use in connection with life support systems or other medical equipment or devices. Explosive Gas Precautions 1. Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing or using your inverter/charger. 2.
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v Limitations on Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi Explosive Gas Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi FCC Information to the User - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Accessing the AC Terminal Block and AC Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17 Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18 AC Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19 AC Wiring to the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19 Wiring the XW Inverter/Charger to a XW
Contents 4 XW Solar Charge Controller Installation Installing the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Array Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Array Voltage - - - - - - - - - - - - - - - - -
Contents Appendix A Specifications Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - XW Series Overload Capability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Output Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - XW Series Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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 2-30 Figure 2-31 Figure 2-32 XW Power System Installation Diagram Example - - - - - - - - - - - - - - - - - - - - -
Figures Figure 2-33 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 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 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 B-1 Figure B-2 Figure B-3 Figure B-4 Figure B-5 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure C-5 Figure C-6 Figure C-7 xii
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 3-2 Table 3-3 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-2 975-0239-01-01 Mounting Plate Fastener Recommendations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Recommended Battery Cable Size Versus Length- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Ba
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1 Introduction Chapter 1, “Introduction” lists and describes the components and basic features of the XW Power System. For this Topic See....
Introduction System Overview The XW Power System consists of several devices, components, and optional accessories that, when installed together, create a renewable energy power system that can be customized to suit nearly any application—off grid, grid tied, or backup. Up to three inverters can be installed in parallel to create larger 120/240 V 3-wire, single-phase systems allowing for increased capacity.
System Components and Accessories System Components and Accessories XW Inverter/Charger The XW Inverter/Charger is a modular “building block” sine-wave inverter/charger that can be used for both residential and commercial stand-alone, grid-backup, and grid-tie applications with battery energy storage. The XW Series is a self-contained DC to AC inverter, battery charger, and AC transfer switch.
Introduction The XW Conduit Box comes in two pieces and mounts directly to the bottom of the inverter/charger with keyhole slots and screws. It is secured to the inverter by two #10-32 screws and is secured to the wall by two screws (not provided). Internal wire barriers (or raceways) are included to keep communications wires separate from AC and DC power wires. The XW Conduit Box also includes multiple cable strap points.
System Components and Accessories 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.
Introduction XW Solar Charge Controller The XW Solar Charge Controller (FGA # 865-1030) is a 60 amp charge controller with integrated PVGFP and separate Battery Temperature Sensor. The XW Solar Charge Controller can be used with 12-, 24-, 36-, 48-, and 60-volt DC battery systems. However, the XW Inverter/Charger can only work at 24 or 48 volts depending on the model. When the XW Solar Charge Controller is used with the XW Inverter/Charger, it is limited to 24or 48-volt battery banks.
System Components and Accessories XW Automatic Generator Start The XW Automatic Generator Start can automatically activate a generator to provide an XW Series Inverter/Charger with power to recharge depleted batteries or assist with heavy loads. The XW Automatic Generator Start adds intelligence to power management and eliminates time spent monitoring batteries and inverter loads.
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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....
Inverter/Charger Installation Pre-Installation Before installing the 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 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 2-1 Clearance Requirements Mounting The XW Power System is designed to be mounted on a vertical surface.
Inverter/Charger Installation Step 1: Installing the Mounting Plate Each XW Inverter/Charger and XW Power Distribution Panel requires a separate mounting plate. This bracket is first attached to the wall, then the inverter/charger or distribution panel is attached to the wall bracket. The wall bracket is attached to the wall with lag bolts or other fasteners, provided by the installer. A minimum of four ¼-inch diameter fasteners are required. The fasteners must be sufficiently strong to support 500 pounds.
Step 1: Installing the Mounting Plate Wall studs 16" on center behind wallboard Side View 2 × 4 wall stud Wallboard Plywood (optional) mounting plate Multiple mounting plates should fit together as shown. Add ¾" plywood if additional support is needed. 60" (152.4 cm) from floor puts the inverter display panel at approx. 65" high. 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.
Inverter/Charger Installation Step 2: Mounting the Inverter 3 2 1 1 Align the flange on the back of the 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).
Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box 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 Figure 2-5, it is not necessary to attach the front panel until all wiring is complete.
Inverter/Charger Installation Step 4: Wiring the Inverter This section provides procedures for making AC and DC connections between the XW Inverter/Charger and the power distribution panel using the cables that are pre-installed in the distribution panel. This section also assumes that the XW Conduit Box was installed in the previous section. For diagrams and information about installing the inverter/charger without the XW Conduit Box and XW Power Distribution Panel, see Appendix C.
Step 4: Wiring the Inverter Batteries See the FAQs section of the Xantrex Web site for information on determining battery bank requirements. Consider the following recommendations for battery use. • • • Use only the deep discharge types for inverter applications. Use the same battery type for all batteries in the bank. Use only batteries from the same lot and date in your battery bank. This information is usually printed on a label located on the battery.
Inverter/Charger Installation Terminal covers Color-coded snap-on DC terminal covers are provided to prevent accidental contact with the terminals. Terminal covers are required for all installations, even if a XW Conduit Box is used. It is also recommended that the shank of the ring terminals (cable lugs) be covered with heat shrink or some other form of insulation. Table 2-2 Recommended Battery Cable Size Versus Length Inverter Model Up to 5 Feet (1.
Step 4: Wiring the Inverter Torque Values for the XW Power Distribution Panel 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 the Ground Bus, AC Neutral Bus, DC Negative Bus, and DC Positive Bus in the 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.
Inverter/Charger Installation Wiring the Inverter to the XW Power Distribution Panel Important: If a XW Conduit Box is installed, communication and Battery Temperature Sensor cables must run through the raceway at the rear of the XW Conduit Box. Before making AC and DC connections, route all communication and Battery Temperature Sensor cables through the raceways. The raceways becomes more difficult to access after all AC and DC wiring is completed.
Step 4: Wiring the Inverter 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 2-9). To install the Battery Temperature Sensor: 1.
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 2–10). This section also provides procedures for installing the battery temperature sensor.
Step 4: Wiring the Inverter CAUTION: Damage to Equipment Do not put anything between the battery cable lug and the terminal surface. Overheating of the terminal may occur. Do not apply any type of antioxidant paste until after the battery cable wiring is tightened. The same applies for all DC connections. Do not over-tighten; observe all recommended torque values.
Inverter/Charger Installation Making AC Connections This section describes how to make AC connections between the XW Inverter/Charger and the XW Power Distribution Panel (using the pre-installed AC wiring in the XW Power Distribution Panel) and between the XW Power Distribution Panel and the AC distribution panel, or sub-panel (using wiring provided by the installer). See Appendix C, “Alternate System Configurations” if the installation will not be including an XW Power Distribution Panel.
Step 4: Wiring the Inverter 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. xantrex Grid (AC1) I nverti ng Flashing Gen (AC2) Faul t / Warning Equalize = sell Charging Battery Recessed edge Hybrid Inverter /Charger Remove the two screws on the AC access cover and slide it to the left of the inverter to remove it.
Inverter/Charger Installation 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 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. Actual ground requirements may vary. In an off-grid installation (i.e.
Step 4: Wiring the Inverter 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.
Inverter/Charger Installation 2. Connect the wires labelled “INV1 L1-GRID” and “INV1 L2-GRID” to the inverter. If the AC source will be the utility grid, connect to the GRID (AC1) terminals (L1-GRID, L2-GRID). If the system will be off-grid and the only AC source will be a generator, these wires can be connected to the GEN (AC2) terminals (L1-GEN, L2-GEN). No additional neutral connection is needed when using the XW Power Distribution Panel.
Step 4: Wiring the Inverter Wiring the XW Inverter/Charger to a XW Power Distribution Panel 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. Actual wiring requirements may vary.
Inverter/Charger Installation Generator Wiring to the XW Inverter/Charger using a XW Power Distribution Panel CAUTION: Generators must be hard-wired to the XW Power Distribution Panel. In an off-grid installation (i.e., where no utility grid is available), the generator can be connected to the breakers provided in the XW Power Distribution Panel. No additional breaker is required. Actual wiring requirements may vary.
Step 4: Wiring the Inverter 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 fault The auxiliary output can also be triggered manually. The 12 Vdc output can be used to trigger a relay to disconnect batteries from the inverter/ charger when battery voltage or temperature are out of the ideal range.
Inverter/Charger Installation AUX-RPO: User Remote Power Off (RPO) Connecting JU-2 (AUX-RPO) and JU-3 (AUX-COM) terminals together through an external switch (normal open contact) will provide the system shut off function if the switch is closed. The external switch if pressed overrides the control provided from the front panel. If the external switch is cleared (not pressed), the system can be enabled back from the front panel.
Basic Functional Test - Single Inverter Basic Functional Test - Single Inverter The following steps will complete a basic functional test of the XW Inverter/Charger. If any test fails, please refer to the Troubleshooting section in the XW Inverter/Charger Operation Guide for assistance. Confirm All Connections Once the AC and DC wiring have been installed and connected, take a moment to go back over all connections and make sure they are secure and have been installed correctly.
Inverter/Charger Installation 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, prese the ON/OFF button momentarily to change the mode from Standby to Operating.
Basic Functional Test - Single Inverter AC Voltage Check Important: This test requires the use of a voltmeter. To perform an AC voltage check: 1. With the inverter on (INVERT [green, kW] LED on solid), verify the AC voltage at AC Loads block terminal L1-Load to N-Load. 2. Verify that neutral is bonded to ground in the system by measuring the hot and neutral voltages relative to ground. Neutral-to-ground should equal zero (0) volts. 3.
Inverter/Charger Installation Figure 2-23 Functional Test for Single Inverter Systems 2–28 975-0239-01-01
Step 5: Installing Additional Inverters Step 5: Installing Additional Inverters Installation Steps To install multiple inverters: 1. Disconnect all power from the system. 2. Mount additional inverter(s). See “Step 1: Installing the Mounting Plate” on page 2–4 and “Step 2: Mounting the Inverter” on page 2–6. 3. Install the XW Conduit Box. See “Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box” on page 2–7. 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 an XW Connection Kit (part number 856-1020), which contains the following components: • • • • • • • • • XW Conduit Box Three 60 amp, 120/240 VAC, 2-pole, Square-D Type QOU, DIN-rail mount, AC breakers for Inverter Input, Output, and Bypass Four Power Distribution bars Custom Bypass Interlock #6 AWG AC wiring to connect the inverter to AC breakers GJ250A, 1
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 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.
Inverter/Charger Installation Parts List for a Triple-Inverter Configuration ❐ 1 x XW Power Distribution Panel (PDP) and Accessory kit (mounts to first unit). ❐ 1 x 865-1020 PDP extension kit for second unit. The following items are required for the third inverter (furthest from PDP) and should be sourced and prepared prior to the installation. (Note that all wiring will have to be custom cut to fit the third unit.
Step 5: Installing Additional Inverters 6. Connect positive battery cable for first inverter (supplied with PDP) to top terminal on first DC disconnect/breaker. 7. Connect positive battery cable for second inverter (supplied in 865-1020) to top terminal on second DC disconnect/breaker. 8. Connect positive battery cable for third inverter (custom, see material list) to top terminal on third DC disconnect/breaker. 9. Connect positive and negative battery cables to first inverter. 10.
Inverter/Charger Installation AC Wiring for a Triple-Inverter System 1. Prepare power distribution bars (supplied in 865-1020) by cutting away one of the four tabs, only three tabs per power distribution bar are required in a three inverter system. A total of 6 distribution bars should be prepared. 2. Mount the nine breakers on the din rail and install power distribution bars as follows: a) Two distribution bars, L1 and L2 at the input (top) terminals of the INV1, INV2 and INV3 Grid breakers.
Step 5: Installing Additional Inverters FROM AC LOAD ON INV3 INV 1 OUT (AC LOADS) INV 2 OUT (AC LOADS) INV 3 OUT (AC LOADS) TO AC1 OR AC2 ON INV3 TO AC1 OR AC2 ON INV2 TO AC1 OR AC2 ON INV1 INV1 IN INV3 IN INV2 IN (GRID OR GEN) (GRID OR GEN) ( GRID OR GEN) FROM AC LOAD ON INV2 FROM AC SOURCE DISCONNECT OR TRANSFER SWITCH FROM AC LOAD ON INV1 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.
Inverter/Charger Installation Xanbus and AC Sync Cable A Xanbus and AC sync cable is required for multi-unit installation. The AC sync cable connects each inverter, and provides the necessary communication and control between multiple units. Install these cables, routing it through the XW Conduit Box raceway, prior to making the AC and DC wiring connections. See Figure 2-31.
Basic Functional Test - Multiple Inverters Basic Functional Test - Multiple Inverters The following steps will complete a basic functional test of multiple XW Inverter/ Chargers. If any test fails, please refer to the Troubleshooting section in the XW Inverter/ Charger Operation Guide for assistance. To perform a functional test on multiple inverters: 1. Check/verify all wiring and cable connections. 2.
Inverter/Charger Installation 12. Confirm Master inverter displays “0.00” and Slave(s) displays “---” on their front panels. 13. Check for faults. If fault condition(s) exist, correct and restart Functional Test. 14. Check voltage at AC LOAD terminals of the Master Inverter. 15. Switch the AC Load breakers ON. 16. Confirm operation of connected AC loads. 17. Disconnect AC LOAD breakers. 18. Using the XW System Control Panel, reduce Maximum Charge Rate.
Basic Functional Test - Multiple Inverters Figure 2-32 Functional Test for Multiple Inverters - Page 1 of 2 975-0239-01-01 2–41
Inverter/Charger Installation Figure 2-33 Functional Test for Multiple Inverters - Page 2 of 2 2–42 975-0239-01-01
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 Network Installation Xanbus-enabled Devices The Xanbus™-enabled designation means that the product works on a Xanbus network. Xanbus-enabled products are: • • • Easy to use. The Xanbus network simplifies operation and automates routine tasks. Reliable. Software control eliminates errors due to analog signalling. Accurate. Digital information is less susceptible to interference and line loss.
The Xanbus System Network Components A Xanbus network consists of the following components: • • Xanbus-enabled devices—these include the XW System Control Panel, the XW Inverter/Charger, XW Automatic Generator Start, and XW Charge Controller. The maximum number of Xanbus devices connected to a single Xanbus network should not exceed eight devices. Xanbus power supply—the network must have at least one device with a power supply to run the network.
Xanbus Network Installation Pins: 8 7 6 5 4 3 2 1 Figure 3-2 Xanbus Cable and RJ45 Connector Pin Numbers • Network terminators (Figure 3-3)—the Xanbus network must be properly terminated at each end with male or female network terminators to ensure the communication signal quality on the network. If the network is not properly terminated, signal quality is degraded and performance on the network is reduced. Permanent configuration without terminators is not supported by Xantrex.
The Xanbus System Ordering Network Components Table 3-2 provides a partial list of network components and part numbers. Ready-made cables are available in standard lengths from 3 feet to 75 feet. For the most up-to-date list, call an authorized Xantrex dealer or visit the Outlet Store at www.xantrex.com.
Xanbus Network Installation Terminate network at each end with a female terminator. 3-way connectors Terminate network at each end with a female terminator. Figure 3-5 Multi-Drop Backbone Layout Daisy Chain Layout In a daisy chain layout, each device on the network is linked with separate lengths of Xanbus cable, as shown in Figure 3-6. This layout does not require network connectors.
Installing the Network Installing the Network Important: Do not mix the two types of network layouts. Mixed configurations are not supported by Xantrex. Important: Installing and replacing Xanbus-enabled devices in an existing system must be performed with the XW Power System in Standby mode. For more information about Standby mode, see the XW System Control Panel Owner’s Guide. Before You Begin the Installation • • Read the entire section before installing the network.
Xanbus Network Installation 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.
Installing the Network Installing Xanbus-Enabled Devices If you are installing a Xanbus-enabled device on an existing Xanbus System, put the system in Standby mode using the System Settings menu on the XW System Control Panel. CAUTION: Equipment Damage Connect only to other Xanbus compatible devices. Although the cabling and connectors used in this network system are the same as ethernet connectors, this network is not an ethernet system.
Xanbus Network Installation Completing the Daisy Chain Layout To complete the daisy chain layout: ◆ Insert a male terminator into the open network port of the Xanbus-enabled device at each end of the network. See Figure 3-9. Figure 3-9 Completing a Daisy-Chain Layout CAUTION: Unpredictable device behavior After connecting the Xanbus-enabled devices and terminating the network, do not plug terminators or other cables into any remaining open network ports on any Xanbus-enabled devices.
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....
XW Solar Charge Controller Installation Installing the Charge Controller This chapter describes installing the XW Solar Charge Controller with the XW Power System, including the power distribution panel. For stand-alone installation, see the XW Solar Charge Controller Owner’s Guide. PV Array Requirements Each Charge Controller must be connected to its own PV array. For optimum performance, each individual array must be composed of the same type of solar panel, with the same Voc and Vmp specifications.
Mounting MPPT Voltage Range The XW Solar Charge Controller maximum power point tracking algorithm maximizes the output power of PV arrays as long as the operating voltage is within the MPPT operational window. Ensure that the PV array used in the system operates within the MPPT operational window. Effects of array voltages outside of the MPPT operational window are shown in Table 4-1.
XW Solar Charge Controller Installation WARNING: Explosion/Corrosion Hazard To reduce the risk of fire or explosion, do not install the XW Solar Charge Controller in sealed compartments containing batteries or in locations that require ignition-protected equipment. To reduce the risk of corrosion from hydrogen-sulfide gas vented by batteries, do not install the XW Solar Charge Controller in sealed compartments containing batteries.
Mounting Removing the Wiring Terminals Cover Before mounting, you must remove the wiring terminals cover to access the mounting holes and the wiring terminals. The wiring terminals cover is secured with two Phillips #8-32 × 2 ½-inch screws on the front cover of the unit. See Figure 4-2. xantrex Remove screws to access the field-wiring terminals.
XW Solar Charge Controller Installation 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.
Mounting 5. Insert two screws in the two mounting holes provided to secure the unit to the wall. 6. Provide strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires. ¼" Place keyhole slot over the mounting screw. xantrex Solar Charge Controller Secure with two more screws.
XW Solar Charge Controller Installation Grounding The XW Solar Charge Controller is designed to work only with negative-grounded electrical systems. Grounding for both PV and battery circuits is provided inside the wiring compartment. Each ground connection can accommodate up to #6 AWG wire size. A fuse rated at 1 A, 600 V (accessible from inside the wiring compartment) grounds the negative conductor of the PV array and provides PV ground-fault protection (PV-GFP).
Wiring 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. The labels above the DC wiring terminals and inside the wiring compartment identify all the connection points.
XW Solar Charge Controller Installation Table 4-3 Recommended Circuit Breakers for the XW Solar Charge Controller Xantrex Part Number Description 865-1065 Master Pack - Qty 6, Breaker 250A, 160 Vdc, Stud Terminal, Panel Mount, UL/CSA 865-1070 Master Pack - Qty 12, Breaker 80A, 125 Vdc, Panel Mount, UL/CSA 865-1075 Master Pack - Qty 48, Breaker 60A, 160 Vdc, Panel Mount, UL/CSA Battery Circuit The DC-rated fuse or circuit breaker between the battery and the XW Solar Charge Controller must have a max
Wiring 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)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 17.6 (5.36) 28.0 (8.54) 44.4 (13.54) 70.6 (21.52) 112.2 (34.2) 141.8 (43.22) 179.2 (54.62) 225.0 (68.58) 283.4 (86.38) 12 14.6 (4.46) 23.2 (7.08) 37.0 (11.28) 58.8 (17.92) 93.4 (18.
XW Solar Charge Controller Installation Connecting the XW Solar Charge Controller to the Distribution Panel WARNING: Shock Hazard Whenever a PV array is exposed to light, a shock hazard exists at the output wires or exposed terminals. To reduce the risk of shock during installation, cover the array with an opaque (dark) material before making the connections. PV arrays generate voltage whenever light strikes the surface of the array.
Wiring Actual wiring requirements may vary.
XW Solar Charge Controller Installation Commissioning During commissioning, the XW Solar Charge Controller prompts the installer to enter important system information such as the nominal battery voltage, battery type, and battery bank capacity. Ensure the system information is available prior to commissioning. If a XW System Control Panel is present, the XW System Control Panel is intended to be the configuration interface, so the prompt screens are suppressed.
Commissioning 3. From the Select Device menu on the SCP, select a XW Solar Charge Controller (each unit should appear as “MPPT60 00” where the 60 stands for 60A, and the 00 is its device number). 4. On the MPPT Setup menu, ensure the Advanced Settings item is displayed. If Advanced Settings are not displayed (and Basic Settings appears as the last item on the menu), press the up arrow, down arrow and Exit keys together. (See “Advanced menu” on page B-7 of the XW Inverter/Charger Operation Guide.) 5.
XW Solar Charge Controller Installation 3. On the Advanced Settings menu, select Copy From, then select the XW Solar Charge Controller you want to copy from. You should select the unit with the device number that matches the first unit you configured. 4. Press Enter. The settings are automatically copied from the selected unit. Note: The Copy From command will not give you any indication that it has completed its task.
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....
XW System Accessories Installation The XW System Control Panel The XW Series Inverter/Charger can be controlled remotely by connecting a XW System Control Panel. The XW System Control Panel is optional for single inverter systems. The XW System Control Panel is required for configuring systems with multiple inverters. The XW System Control Panel allows access to programming features of the inverter and allows the system to be modified to specific installation requirements.
The XW System Control Panel Materials and Tools Required You will need these materials and tools to complete the installation: ❐ Mounting template sticker (supplied) ❐ Mounting plate (supplied) ❐ mounting plate (supplied) ❐ Four #6 screws (supplied) ❐ Two #8 screws (supplied) ❐ Cable clamps or hardware fasteners ❐ Xantrex network cables or equivalent (CAT 5 or CAT 5E cable with RJ45 connectors wired to T568A standard) A 7-foot cable is provided. ❐ Xantrex male network terminator (supplied).
XW System Accessories Installation Tabs in vertical position Figure 5-2 Inserting the Mounting Plate 4. Secure the mounting plate by tightening the two screws to rotate the tabs to the horizontal position (see Figure 5-3) and pull the tabs tight against the inner surface of the wall. Be careful not to overtighten the screws and damage the wall. Rotate tabs to horizontal position Figure 5-3 Securing the Mounting Plate 5.
The XW System Control Panel Figure 5-4 Connecting the Network Cables 6. Place the unit into the mounting plate and secure it with four #6 screws. Figure 5-5 Securing the XW System Control Panel 7. Peel off the protective plastic coating covering the screen and indicator light. To flush mount the XW System Control Panel with no mounting plate: 1. Peel the backing from the supplied mounting template sticker and place it in your chosen installation location.
XW System Accessories Installation CAUTION: Equipment damage Connect the XW System Control Panel only to other Xanbus-enabled devices. : Although the cabling and connectors used in this network system are the same as Ethernet connectors, this network is not an Ethernet system. Equipment damage may result from attempting to connect these two different systems. 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.
The XW Automatic Generator Start Verifying the Installation If network power (from an inverter/charger) is present, the backlight will come on and the XW System Control Panel will show the startup screen (see the XW Inverter/Charger Operation Guide), then show the System Home screen. The XW Automatic Generator Start Some generators allow automatic starting.
XW System Accessories Installation ❐ #16 or #18 AWG wire (see “Wire Size and Length” on page 5–11) ❐ Xantrex network cables or equivalent (Category 5) ❐ Network terminators (if required) ❐ Phillips screwdriver ❐ Wire cutters and wire strippers Choosing a Location The XW Automatic Generator Start should be installed in a location that meets the following requirements: Dry The unit is intended for use in a dry location.
The XW Automatic Generator Start Network ports 20-contact connector Network cables to other Xanbus-enabled devices Wiring harness (connection to generator, thermostats, and external switches) Figure 5-8 XW Automatic Generator Start External Connections Installing the XW Automatic Generator Start Installation Overview Installing the XW Automatic Generator Start involves the following steps: 1. Mounting the unit. 2.
XW System Accessories Installation Mounting the Unit The XW Automatic Generator Start is to be mounted vertically on a wall with the connectors facing downwards. To mount the XW Automatic Generator Start: 1. Hold the unit flush and square against the wall, panel, or horizontal surface. • If the mounting surface requires pre-drill holes for the screws, use the supplied mounting template to mark, then drill, four holes. 2.
The XW Automatic Generator Start The wires on the wiring harness can be extended to meet installation requirements. When extending the wire harness, ensure that the extension wires are the same color as the wires on the harness. To install the XW Automatic Generator Start using the wiring harness: 1. Connect each wire on the harness to its intended wire or contact on the generator, thermostats, or external switches. 2.
XW System Accessories Installation Table 5-3 Contact Numbers and Functions (Continued) Wire Number Function Wiring Harness Wire Color 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) for External ON/OFF/LED Indicator Red 11 External ON/OFF/LED Indicator return (connected internally to wire number 13) Black 12 Generator run signal (switched B+) sense input Violet 13 Ge
The XW Automatic Generator Start Important: You can only change GenType after you have put the system or the XW Automatic Generator Start into Standby mode. See the XW Inverter/Charger Operation Guide for instructions on putting the system in Standby Mode. This section describes the generator configurations and provides diagrams for connecting the wiring harness to the generator’s start wiring.
XW System Accessories Installation 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.
The XW Automatic Generator Start 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.
XW System Accessories Installation Connecting the Wiring Harness to the XW Automatic Generator Start After all the external connections have been wired to the wiring harness, the connector on the wiring harness must be plugged into the 20-contact connector on the XW Automatic Generator Start.
The XW Automatic Generator Start Connecting the XW Automatic Generator Start to the Xanbus Network CAUTION: Equipment Damage Connect only to other Xanbus-enabled devices. Although the cabling and connectors used in this network system are the same as Ethernet connectors, this network is not an Ethernet system. Equipment damage may result from attempting to connect a Xanbus-enabled device to an Ethernet system.
XW System Accessories Installation Verifying Power Is Available When the XW Automatic Generator Start has been installed properly, the Power and Network indicator lights illuminate. If one or both lights are out, check the network connections and ensure the network power supply is on. Verify Power and Network indicator lights are illuminated.
A Specifications Appendix A, “Specifications” provides the electrical and environmental specifications for the XW Series.
Specifications 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 Arms (7 sec) L-L: 52.
Electrical Specifications XW Series Overload Capability Loads presented to the inverter are seldom constant. Typically, large loads are operated for only short periods of time. In order to provide the maximum utility, Xantrex inverters are allowed to operate at power levels that exceed their continuous power ratings. This graph shows how loads that are larger than the inverter can sustain continuously can be operated for useful periods of time.
Specifications 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.
Mechanical Specifications Charging Efficiency (Typical) 100 Efficiency (%) 95 Power Factor 90 Efficiency 85 80 7 15 25 35 45 55 65 75 89 100 Battery Current (Amps) Sell Mode Efficiency (Typical) 100 Efficiency (%) 97 94 91 88 85 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.
Specifications Table A-2 XW Power System Mechanical Specifications Model XW6048-120/240-60 System Network XW4548-120/240-60 Xanbus (publish-subscribe network, no need for hubs or special cards) Emissions FCC Class B Regulatory approvals Enclosure Type XW4024-120/240-60 UL 1741 1st Edition: 2005 Version, CSA 107.
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
Wiring Diagrams Single-Inverter System (Backup only) Figure B-1 Single-Inverter System (Backup only) 975-0239-01-01 B-3
Wiring Diagram Single-Inverter System Renewable Energy (Solar) Figure B-2 Single-Inverter System Renewable Energy (Solar) B-4 975-0239-01-01
Wiring Diagrams Single-Inverter System Renewable Energy (Wind or Hydro) Figure B-3 Single-Inverter System Renewable Energy (Wind or Hydro) 975-0239-01-01 B-5
Wiring Diagram Dual-Inverter System Renewable Energy (Solar) Figure B-4 Dual-Inverter System Renewable Energy (Solar) B-6 975-0239-01-01
Wiring Diagrams Dual-Inverter System Renewable Energy (Wind or Hydro) Figure B-5 Dual-Inverter System Renewable Energy (Wind or Hydro) 975-0239-01-01 B-7
Wiring Diagram B-8 975-0239-01-01
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 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 10. See Table 2-5, “Torque Values for the Chassis Ground Lug,” on page 10. See Table 2-6, “Torque Values for the Inverter Battery Terminals,” on page 10. 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. This illustrates an example only. Actual cable requirements may vary.
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. Torque all inverter terminal block connections to 25 inch-pounds. This illustrates an example only. Actual wiring requirements may vary.
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.
Alternate System Configurations Wind or Hydro DC Sources Actual wiring requirements may vary.
Index A G 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 generator run signal 5–12 Generator Wiring 2–22 Ground Bar 2–17 Grounding 2–11, 2–12, 4–8 Grounding the DC System 2–12 B installation mounting 5–3, 5–5 planning 5–3 Inverter Panel Mounting 2–19 B+ wires 5–12 battery bank requirements 2–9 battery cable lugs 2–9
Index 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/Charger 1–3 XW System Control Panel 1–6, 5–2 IX–2 975-0239-01-01
Xantrex Technology Inc. 800 670 0707 Tel Toll Free in North America 360 925 5097 Tel direct 800 994 7828 Fax Toll Free in North America 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.
