Conext XW Installation Guide

7/28/2019 Conext XW Installation Guide

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Xantrex XW Power SystemXantrex XW4024 120/240 60

Xantrex XW4548 120/240 60Xantrex XW6048 120/240 60

InstallationGuide

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Xantrex XW Power System

InstallationGuide



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Copyrighta nd Contact

Trademarks

Schneider Electric, the Schneider Electric logo, Xantrex and Xanbus are trademarks or registered trademarksof the Schneider Electric group of companies. O ther trademarks, registered trademarks, and product names arethe property of their respective owners and are used herein for identification purposes only.

Notice of Copyright

C opyright 2007, 2008, 2010 Xantrex Technology Inc. A ll rights reserved. No part of this document may bereproduced in any form or disclosed to third parties without the express written consent of:Xantrex Technology Inc.161-G South Vasco RoadLivermore, C alifornia U SA 94551Xantrex Technology Inc. reserves the right to revise this document and to periodically make changes to thecontent hereof without obligation or organization of such revisions or changes unless required to do so by priorarrangement.

Exclusion for Documentation

U NLESSSPECIFICALLYAGREED TO IN WRITING , XANTREX TE C H N OL OG Y INC . ( XANTREX )

(A ) M A K E SNO WARRANTY ASTO TH EA C C U R A C Y, SUFFICIENCYO R SUITABILITY O FANY TECHN ICALO R OTHER INFORMAT ION PROVIDED IN IT SM A N U A L SO R OTHER D OC U M E N T A T I ON;

(B) ASSUMESNO RESPON SIBILITYO R LIABILITY FO R LO SSES, D A M A G E S, C OS T SO R EXPENSES, WHETHER SPECIAL, DIRECT ,INDIRECT, CONSEQUENT IALO R INCIDENTAL, WHICH M I G H TARISEO UT O FTHEUSEO FSUCH INFORMAT ION . THEUSEO FANY SUCHINFORMAT ION WILLBE ENTIRELY AT THEUSER SRISK ; AND

(C ) REM INDSYO U THATIFTHISM A N U A LIS IN A NY L A N G U A G EOTHER THAN ENGLISH , A L T H OU G H STEPSHAVEBEEN TAKENTO MA INTA INTHEA C C U R A C Y O FTHETRANSLATION , TH EA C C U R A C Y C A N N O TBE GUARANTEED . A PPROVED XANTREXCONTENT IS CONTA INED WITH THE ENGLISH L A N G U A G EVERSIONWHICH IS POSTED AT WWW.SCHNEIDER-ELECTRIC .C O M .

Date and Revision

M arch 2010 R evision D

Part Number

975-0239-01-01

Product Number

865-1000 (Xantrex XW6048 120/240 60);865-1005 (Xantrex XW4548 120/240 60);

865-1010 (Xantrex X W4024 120/240 60)

Contact Information


North America 1 650 351 82371 866 519 1470

1 925 245 1022 re.techsupport@ schneider-electric.com

La France + 0825012999 fr-re-techsupport@ fr.schneider-electric.com

D eutschland + 49 (0) 180 575 6575 + 49 (0) 2102 404 7101 solarservice@ de.schneider-electric.com

Espaa + 34 93 498 7466 + 34 93 305 5026 re.techsupport@ es.schneider-electric.com

L 'I talia + 39 035 4151111 + 39 035415 3200 I T-pronto-contatto@ it.schneider-electric.com

For other country detai ls please contact your local Schneider Electric Sales Representative or visit our website at:http://www.schneider-electric.com/sites/corporate/en/support/operations/local-operations/local-operations.page


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975-0239-01-01 iii

This manual for use by qualified personnel only

About This Guide

Purpose

The purpose of this Installation G uide is to provide explanations and procedures

for installing the Schneider Electric Xantrex XW Power System.

Scope

The G uide provides safety guidelines, detailed planning and procedures for

installing the Xantrex X W Inverter/Charger and related system components

(the X antrex XW P ower System) . I t does not provide details about configuration,

operation, maintenance or troubleshooting. See the O peration G uide or O wners

M anual of each device for this information. This G uide also does not provide

details about particular brands of batteries. You need to consult individual

battery manufacturers for this information.

Audience

The G uide is intended for anyone who needs to install the Xantrex XW Power

System. Installers should be certified technicians or electricians.

Organization

This guide is organized into four chapters and three appendices.

C hapter 1, Introduction lists and describes the components and basic features

of the Xantrex X W P ower System.

C hapter 2, Inverter/Charger Installation describes how to mount and install theXantrex XW Inverter/C harger, and the Xantrex X W P ower D istribution Panel and

Xantrex XW C onduit Box.

C hapter 3, X antrex X anbus Network Installation provides detailed information

for planning and installing the components necessary for network

communication on a Xantrex Xanbus system.

C hapter 4, X antrex X W Solar C harge C ontroller Installation describes how to

mount and connect the Xantrex XW Solar C harge C ontroller as part of the Xantrex

XW System.

C hapter 5, X antrex XW System A ccessories Installation describes how to

mount and install the Xantrex XW System C ontrol Panel and the Xantrex XW

A utomatic G enerator Start.

A ppendix A , Specifications provides the electrical and environmental

specifications for the Xantrex XW Series.


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A bout This G uide

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A ppendix B, Wiring D iagrams 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.

A ppendix C , A lternate System C onfigurations provides wiring diagrams for

inverter/charger installations that do not require use of the power distribution

panel and the Xantrex XW C onduit Box.

Conventions Used

The following conventions are used in this guide.

Related Information

A dditional information about operating the X antrex X W Inverter/C harger, see the

Xantrex XW Inverter/C harger O peration G uide (975-0240-01-01) .

For more information about related components, refer to:

Xantrex XW Pow er System Intallation O verview(975-0238-01-01)

Xantrex XW System C ontrol Panel O w ners G uide (975-0298-01-01)

Xantrex XW Solar C harge C ontroller O w ners G uide (975-0283-01-01)

Xantrex XW Autom atic G enerator Start O w ners G uide (975-0307-01-01)

These guides are available at www.schneider-electric.com. Printed copiesshould be included with the components.

For more information about Schneider Electric as well as its products and

services visit www.schneider-electric.com.

WARNING

Warnings identify conditions or practices that could result in personal

injury or loss of life.

CAUTION

C autions identify conditions or practices that could result in damage to

the Xantrex XW Power System components or other equipment.
http://www.schneider-electric.com/http://www.schneider-electric.com/


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Important Safety Instructions

1. Before using the inverter, read all instructions and cautionary markings on

the unit, the batteries, and all appropriate sections of this manual.

2. U se of accessories not recommended or sold by Schneider Electric may

result in a risk of fire, electric shock, or injury to persons.

3. The inverter is designed to be permanently connected to your A C and D C

electrical systems. Schneider Electric recommends that all wiring be done by

a certified technician or electrician to ensure adherence to the local and

national electrical codes applicable in your jurisdiction.

4. To avoid a risk of fire and electric shock, make sure that existing wiring is in

good condition and that wire is not undersized. D o not operate the inverter

with damaged or substandard wiring.

5. D o not operate the inverter if it has been damaged in any way. I f the unit is

damaged, see the Warranty and Product Information section at the end of

this manual.

6. This unit does not have any user-serviceable parts. D o not disassemble the

inverter except where noted for connecting wiring and cabling. See the

Warranty Section in the Xantrex XW Inverter/C harger O peration G uide andother component manuals for instructions on obtaining service. A ttempting to

service the unit yourself may result in a risk of electrical shock or fire. Internal

capacitors remain charged after all power is disconnected.

7. To reduce the risk of electrical shock, disconnect both AC and D C power

from the inverter before attempting any maintenance or cleaning or working

on any components connected to the inverter. Turning off controls will not

reduce this risk.

8. The inverter must be provided with an equipment-grounding conductor

connected to the AC input ground.

9. D o not expose this unit to rain, snow, or liquids of any type. T his product is

designed for indoor use only. D amp envi ronments will significantly shorten

the life of this product and corrosion caused by dampness will not becovered by the product warranty.

10. To reduce the chance of short-circuits, always use insulated tools when

installing or working with this equipment.

11. R emove personal metal items such as rings, bracelets, necklaces, and

watches when working with batteries.

WARNING

This chapter contains important safety and operating instructions as required by

U L and C SA standards for inverters used in residential applications. Read and

keep this Installation Guide for future reference.


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Safety

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Limitations on Use

Single-phase Operation Only

Explosive Gas Precautions

1. Working in the vicinity of lead acid batteries is dangerous. B atteries 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. To reduce the risk of battery explosion, follow these instructions and those

published by the battery manufacturer and the manufacturer of the

equipment in which the battery is installed.

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.

CAUTION

The Xantrex X W4024 120/240 600, X antrex X W4548 120/240 60 and Xantrex

XW6048 120/240 60 series of Inverter/C hargers are designed and tested for

operation with single phase, three wire (120V/240V) A C sources and should notbe connected to a three phase AC source. C onnecting the device to a three

phase source may result in damage to the unit and any loads connected to the

Inverter/C harger.


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Safety

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FCC Information to the User

This equipment has been tested and found to comply with the limits for a C lass B

digi tal device, pursuant to part 15 of the FC C R ules. These limits are designed to

provide reasonable protection against harmful interference in a residentialinstallation. 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. However, there is no

guarantee that interference will not occur in a particular installation. I f this

equipment does cause harmful interference to radio or television reception,

which can be determined by turning the equipment off and on, the user is

encouraged to try to correct the interference by one or more of the following

measures:

R eorient or relocate the receiving antenna.

Increase the separation between the equipment and the receiver.

C onnect the equipment to a circuit different from that to which the receiver is

connected.

C onsult the dealer or an experienced radio/TV technician for help.


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Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vLimitations on U se - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi

Single-phase O peration O nly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi

Explosive G as Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vi

FC C Information to the U ser - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii

1 Introduction

System O verview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

System D iagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

System C omponents and A ccessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

Xantrex XW Inverter/C harger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

Xantrex XW C onduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14Xantrex XW P ower D istribution Panel Panel and X antrex X W C ondui t Box - - - - - - - - - - - - - - 14

Xantrex XW C onnection K it for INV2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Xantrex XW Solar C harge C ontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Xantrex XW A utomatic G enerator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

2 Inverter/Charger Installation

Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

K nockout P reparation and A ir Filter Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

Removing Internal Faceplates on the Power D istribution Panel - - - - - - - - - - - - - - - - - - - - - - 23C learance R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

M ounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

Step 1: Installing the M ounting P late- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Step 2: M ounting the I nverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

Step 3: M ounting the Xantrex XW P ower D istribution Panel and Xantrex XW C onduit Box - - - - - - 28

Step 4: Wiring the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210

Battery Bank R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 211

Battery C able R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 211

Torque Values for the Xantrex XW Series Inverter/C harger - - - - - - - - - - - - - - - - - - - - - 213

Torque Values for the Xantrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - 213Inverter G rounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214

Back feed Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214

Wiring the Inverter to the Xantrex X W P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - 214

G rounding the D C System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 215

Installing the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 216

M aking D C C onnections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218

Contents


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M aking A C C onnections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220

A C C onnections and C ommunication Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 221

A ccessing the A C Terminal B lock and A C G round B ar - - - - - - - - - - - - - - - - - - - - - - - 222

G rounding the A C System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223

A C Wiring to the Inverter A C D istribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 224

A C Wiring to the Xantrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - 225

Wiring the Xantrex XW Inverter/Charger to

a X antrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227

G enerator Wiring to the Xantrex XW Inverter/C harger using

a X antrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228

A U X Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230

A U X+ 12V Voltage Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230

A U X-RPO : U ser Remote Power O FF ( R PO ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

U ser L ine Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

A U X Port Terminal A ssignments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

Basic Functional Test - Single I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232

C onfirm A ll C onnections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232

A pplying D C Power to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232

Enable the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 233

A C Voltage C heck - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 234

C onfirm ing Battery C harger O peration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 235

Step 5: Installing A dditional Inverters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237

Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237

Parts List for D ual-Inverter C onfigurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238

C onverting a Single-Inverter Power D istribution Panel to

a D ual-Inverter P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238

D C Wiring for a D ual-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238

A C Wiring for a D ual-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 240

Parts List for a T riple-Inverter C onfiguration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 243

C onverting a Single-Inverter Power D istribution Panel to

a T riple-Inverter Power D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 244

D C Wiring for a T riple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 244

A C Wiring for a Triple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 245

Xantrex Xanbus and A C Sync C able - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 249

Basic Functional Test - M ultiple I nverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 250

3 Xantrex Xanbus Network Installation

Xantrex Xanbus-enabled D evices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

The Xantrex Xanbus System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

Network C omponents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

O rdering N etwork C omponents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Installing the N etwork - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36

Before Y ou Begin the I nstallation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36


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Installation Tools and M aterials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36

G uidelines for Routing the Xantrex X anbus C ables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

Installing Xantrex X anbus-Enabled D evices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

4 Xantrex XW Solar Charge Controller Installation

Installing the C harge C ontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

PV A rray R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

M PPT Voltage R ange - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

M ounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

C hoosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

Removing the Wiring C ompartment C over - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

Removing K nock outs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

M ounting the C ontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

G rounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

Internal G round Fault P rotection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

D isabling G round Fault Protection for N egative G rounded and U ngrounded A rrays - - - - - - 411

Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 412

DC Terminal C onnector Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 412

Wire Size and O ver-current Protection R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 412

C urrent R ating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 413

M inimum Wire G auge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 413

O ver-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 413

Long-Distance Wire R uns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 414

M aximum O ne-way Distance and Wire Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 415

C onnecting the Xantrex XW Solar C harge C ontroller to the D istribution Panel - - - - - - - - - - 417

C ommissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 419

C onfiguration Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 419

C ommissioning Units U sing a Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - 420

5 Xantrex XW System Accessories Installation

The Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

M aterials and Tools R equired - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

C hoosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

M ounting the Xantrex X W System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

Verifying the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

The Xantrex XW A utomatic G enerator Start- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

Preparing an Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

M aterials and Tools R equired - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

C hoosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

R outing the C onnections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 510

Installing the Xantrex XW A utomatic G enerator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - 511

M ounting the U nit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 511

Wiring to the 20-contact C onnector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 512

C onnecting the G enerator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 515


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C onnecting the T hermostats (O ptional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 516

C onnecting an External Shutdown ( O ptional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 516

C onnecting an External M anual O N/O FF Switch (O ptional) - - - - - - - - - - - - - - - - - - - - - - - 517

C onnecting an External O N/O FF LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 518

C onnecting the Wiring H arness to the Xantrex XW Automatic G enerator Start - - - - - - - 519

C onnecting the Xantrex XW A utomatic G enerator Start to the Xantrex Xanbus Network 520

Verifying Power I s A vailable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 521

A Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 2

Xantrex XW Series O verload C apability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 3

O utput Power Versus A mbient T emperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 5

Xantrex XW Series Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 6

Inverting Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 6

C harging Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A6

C harging Power Factor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 7

G rid-tie Sell M ode Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 7

M echanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 8

A ccessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 9

B Wiring Diagrams

Single-Inverter System (Backup O nly) Without a Power D istribution P anel- - - - - - - - - - - - - - - - - B3

Single-Inverter System ( Backup O nly) With a Power D istribution Panel - - - - - - - - - - - - - - - - - - - B4

Single-Inverter System R enewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B 5

Single-Inverter System R enewable Energy (Wind or H ydro) - - - - - - - - - - - - - - - - - - - - - - - - - - - B6

D ual-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B7

D ual-Inverter System Renewable Energy (Wind or H ydro) - - - - - - - - - - - - - - - - - - - - - - - - - - - - B8

C Alternate System Configurations

D C G rounding for S ingle-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 2

Battery C onnections for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 3

A C G rounding for Single-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 4

A C O utput Wiring to the Inverter A C D istribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 5

G enerator Wiring to the I nverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 6

U tility Wiring to the Inverter Input- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C 7


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Figure 1-1 Xantrex X W P ower System Installation D iagram Example - - - - - - - - - - - - - - - - - - - - - - 12

Figure 1-2 Xantrex XW Inverter/C harger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

Figure 1-3 Xantrex XW C onduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

Figure 1-4 Power D istribution Panel and Xantrex XW C onduit Box - - - - - - - - - - - - - - - - - - - - - - - - 15

Figure 1-5 Xantrex XW C onnection K it for I NV2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Figure 1-6 Xantrex XW Solar C harge C ontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Figure 1-7 Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Figure 1-8 Xantrex XW A utomatic G enerator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Figure 2-1 A ir Fi lter and A U X C onnector Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

Figure 2-2 R emoving the Internal Faceplates on the Power D istribution Panel - - - - - - - - - - - - - - - 23

Figure 2-3 C learance R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

Figure 2-4 M ounting P late D imensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25Figure 2-5 M ounting the Bracket for the Xantrex XW Inverter/C harger or D istribution Panel - - - - - - 26

Figure 2-6 M ounting the Xantrex XW Inverter/C harger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

Figure 2-7 Installing the Xantrex XW C onduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

Figure 2-8 R outing C ommunications C ables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210

Figure 2-9 DC G rounding Using a Power D istribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - 215

Figure 2-10 Battery Temperature Sensor (R J11) P ort Location and Installation - - - - - - - - - - - - - - - 217

Figure 2-11 Xantrex X W Inverter/Charger D C C onnections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218

Figure 2-12 Battery C able C onnection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219

Figure 2-13 D C C onnections to a Single Inverter U sing a Xantrex XW Power D istribution Panel - - - 220

Figure 2-14 Xantrex XW Inverter/C harger A C C onnections and C ommunications Ports - - - - - - - - - 221

Figure 2-15 A C Terminal Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222Figure 2-16 G rounding the A C System using the D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - 223

Figure 2-17 Wiring the Xantrex XW P ower Distribution Panel to the Sub-panel or Utility G rid - - - - - 226

Figure 2-18 Wiring the Inverter to the Xantrex X W P ower D istribution Panel - - - - - - - - - - - - - - - - - 227

Figure 2-19 G enerator Wiring Using a Xantrex XW Power D istribution Panel (O n G rid) - - - - - - - - - 228

Figure 2-20 G enerator Wiring Using a Xantrex XW Power D istribution Panel (O ff G rid) - - - - - - - - - 229

Figure 2-21 A U X Port L ocation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230

Figure 2-22 Power-up D isplay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232

Figure 2-23 Enable the Inverter- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 233

Figure 2-24 C hecking A C Voltage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 234

Figure 2-25 C heck ing C harging O peration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 235

Figure 2-26 Functional T est for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 236Figure 2-27 D C C onnections to D ual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 239

Figure 2-28 D ual Inverter A C Breaker Arrangement and Wiring Enlargement

with M ultiple A C Input Sources- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 240

Figure 2-29 A C Wiring for D ual-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 241

Figure 2-30 Installing the Front Internal P anels and the AC Bypass Plate - - - - - - - - - - - - - - - - - - - 242

Figures


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Figure 2-31 D C C onnections for a T riple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 245

Figure 2-32 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement

with D ual A C Input Sources - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246

Figure 2-33 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement

with a Single A C Input Source - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 247

Figure 2-34 Wiring an External Bypass Switch for a Triple-Inverter Configuration - - - - - - - - - - - - - 248

Figure 2-35 Installing the A C Sync C able - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 249

Figure 2-36 Functional Test for M ultiple Inverters - Page 1 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - 252

Figure 2-37 Functional Test for M ultiple Inverters - Page 2 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - 253

Figure 3-1 Network-M anaged Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

Figure 3-2 Xantrex Xanbus C able, R J45 C onnector Pin Numbers and N etwork Terminators - - - - - 33

Figure 3-3 Network Layout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Figure 4-1 M inimum C learance R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

Figure 4-2 R emoving the Wiring C ompartment C over- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

Figure 4-3 D imensions and K nock out Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

Figure 4-4 K nockout D imensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

Figure 4-5 M ounting the Xantrex XW Solar C harge C ontroller - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

Figure 4-6 Xantrex X W Solar C harge C ontroller Safety G round C onnector - - - - - - - - - - - - - - - - - 410

Figure 4-7 PV Negative G round Jumper Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 411

Figure 4-8 D C C onnection Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 412

Figure 4-9 C onnecting Solar D C Sources in the Power D istribution Panel - - - - - - - - - - - - - - - - - 418

Figure 5-1 Xantrex X W System C ontrol Panel X antrex X anbus Port Locations- - - - - - - - - - - - - - - - 52

Figure 5-2 Inserting the M ounting P late- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

Figure 5-3 Securing the M ounting P late - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

Figure 5-4 C onnecting the N etwork C ables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

Figure 5-5 Securing the Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56

Figure 5-6 Surface M ounting the Xantrex X W System C ontrol P anel - - - - - - - - - - - - - - - - - - - - - - 57

Figure 5-7 C onnecting the Xantrex XW AG S C ommunications C able to the Xantrex XW Series - - - 58

Figure 5-8 Xantrex X W A utomatic G enerator Start External C onnections - - - - - - - - - - - - - - - - - - 510

Figure 5-9 Xantrex XW A utomatic G enerator Start Wiring H arness - - - - - - - - - - - - - - - - - - - - - - 513

Figure 5-10 External O N /O FF Switch and LED Wiring D iagram - - - - - - - - - - - - - - - - - - - - - - - - - - 518

Figure 5-11 Xantrex X W A utomatic G enerator Start External C onnections - - - - - - - - - - - - - - - - - - 519

Figure 5-12 C onnecting the Xantrex XW SC P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 520

Figure 5-13 Verifying P ower is Available - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 521

Figure A -1 Xantrex XW Series A C O verload C apab ili ty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 4



Figure A -4 O utput Power Versus A mbient T emperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 5

Figure A -5 Inverting Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 6

Figure A -6 C harging Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 6

Figure A -7 C harging Power Factor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 7

Figure A-8 G rid-tie Sell M ode Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 7

Figure B-1 Single-Inverter System (Backup O nly) Without a Power D istribution Panel - - - - - - - - - - B 3

Figure B-2 Single-Inverter System (B ackup O nly) With a Power D istribution P anel - - - - - - - - - - - - B 4


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Figure B-3 Single-Inverter System R enewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - -B5

Figure B-4 Single-Inverter System R enewable Energy (Wind or H ydro) - - - - - - - - - - - - - - - - - - - - B6

Figure B-5 D ual-Inverter System R enewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - B7

Figure B-6 D ual-Inverter System R enewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - - - B8

Figure C -1 D C G rounding for an Inverter O nly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C 2

Figure C -2 D C C onnections to a Single I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C 3

Figure C -3 G rounding the A C System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C 4

Figure C-4 A C O utput Wiring to the Inverter A C D istribution Panel - - - - - - - - - - - - - - - - - - - - - - - -C 5

Figure C -5 G enerator Wiring directly to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C 6

Figure C -6 U tility Wiring to the Inverter Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C 7


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Table 2-1 M ounting P late Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

Table 2-2 R ecommended B attery Cable Size Versus Length - - - - - - - - - - - - - - - - - - - - - - - - - - 212

Table 2-3 Battery C able ( in C onduit) to M aximum Breaker/Fuse Size - - - - - - - - - - - - - - - - - - - - 212

Table 2-4 Torque Values for A C Wiring (A C Terminals and G round B ar) - - - - - - - - - - - - - - - - - - 213

Table 2-5 Torque V alues for the Chassis G round Lug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 213

Table 2-6 Torque V alues for the Inverter Battery Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - 213

Table 2-7 Torque Values for AC D isconnects and AC Breakers - - - - - - - - - - - - - - - - - - - - - - - - 213

Table 2-8 Torque Values for the G round Bus, A C N eutral Bus, D C Negative Bus,

and D C Positive Bus in the Xantrex X W P ower D istribution Panel - - - - - - - - - - - - - 213

Table 2-9 Torque Values for the Power D istribution Bars

in the Xantrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214

Table 2-10 Torque Values for the Battery C ables to the D C Negative Bus, and D C Positive Bus

in the Xantrex XW P ower D istribution P anel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214

Table 2-11 U ser C onnector Terminals and Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

Table 3-1 Xantrex X anb us Network C omponents and P art N umbers- - - - - - - - - - - - - - - - - - - - - - 34

Table 4-1 M PPT O perational Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43

Table 4-2 M inimum C learance R equirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

Table 4-3 R ecommended C ircuit Breakers for the Xantrex XW Solar C harge C ontroller - - - - - - - 414

Table 4-4 O ne-Way Wire D istance and Wire Size for a 24 Vdc System - - - - - - - - - - - - - - - - - - - 415

Table 4-5 O ne-Way Wire D istance and Wire Size for a 48 Vdc System - - - - - - - - - - - - - - - - - - - 416

Table 5-1 C ircuit Lim itations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 512

Table 5-2 R equired Wiring S ize Based on Length of Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - 513

Table 5-3 C ontact Numbers and Functions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 514

Table 5-4 Wiring for C onnecting Thermostats - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 516

Table 5-5 Wiring for C onnecting an External Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 516

Table 5-6 Wiring for C onnecting an External M anual O N/O FF Switch - - - - - - - - - - - - - - - - - - - - 517

Table A-1 Xantrex X W P ower System Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - -A 2

Table A-2 Xantrex X W P ower System M echanical Specifications - - - - - - - - - - - - - - - - - - - - - - - -A 8

Table A-3 Xantrex X W P ower System R egulatory Approvals- - - - - - - - - - - - - - - - - - - - - - - - - - - -A 9

Tables


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1Introduction

C hapter 1, Introduction lists and describes

the components and basic features of theXantrex XW P ower System.

For this Topic See....

System O verview page 12

System C omponents and A ccessories page 13


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Introduction

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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. U p to three inverters can be installed in parallel to create

larger 120/240-volt, 3-wire, single-phase systems allowing for increased

capacity.

System Diagram

CAUTION

The Xantrex XW4024 120/240 60, Xantrex X W4548 120/240 60 and Xantrex

XW6048 120/240 60 series of Inverter/C hargers are designed and tested for

operation with single phase, three wire (120V/240V) A C sources and should not

be connected to a three phase AC source. C onnecting the device to a three

phase source may result in damage to the unit and any loads connected to the

Inverter/C harger.

Figure 1-1 Xantrex XW P ower System Installation D iagram Example


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System C omponents and A ccessories

975-0239-01-01 13


System Components and Accessories

Xantrex XW Inverter/Charger

The Xantrex X W Inverter/C harger is a modular building b lock sine-waveinverter/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 D C to A C inverter, battery charger, and

A C transfer switch. U p to three inverters can be installed in parallel to create

larger 120-240-volt, 3-wire, single-phase systems allowing for increased

capacity.

A Battery Temperature Sensor (FG A # 808-0232-02) is also included with the

Xantrex XW Inverter/Charger. T he Battery Temperature Sensor monitors thetemperature of the battery bank and adjusts the charging accordingly.

See page 216 for installation instructions for this accessory.

Figure 1-2 Xantrex XW Inverter/C harger

Includes:

M ounting Panel

DC terminal C overs

Network T erminator

Battery Temperature Sensor Air Filter

M ounting H ardware

AU X Port C onnector


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Introduction

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Xantrex XW Conduit Box

A Xantrex XW C onduit Box ( FG A # 865-1025) is available to enclose the bottom

of the Xantrex XW Inverter/Charger and protect the cabling. U se of the Xantrex

XW C onduit Box may be required depending on the local electrical code.

Be sure to consult with the local electrical authority to ensure the installation iscode-compliant.

The Xantrex XW C onduit Box comes in two pieces and mounts directly to the

bottom of the inverter/charger with keyhole slots and screws. It is secured to theinverter 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 A C and D C power wires. T he Xantrex XW C onduit Box also

includes multiple cable strap points.

Xantrex XW Power Distribution Panel Panel and Xantrex XW Conduit Box

The Xantrex XW P ower D istribution Panel (FG A : 865-1015) includes a mounting

plate and Xantrex XW C onduit Box. It is factory wired and labelled with

everything to support a code-compliant single-inverter installation. It is designed

to mount on the right side of the inverter/charger, but it can also be configured to

mount on the left side. Internal wiring and breakers can be added to expand the

Xantrex X W P ower System with up to three inverters, four charge controllers, or

other equipment to support 120/240-volt, 3-wire, single-phase systems.

The Xantrex XW P ower D istribution Panel and Xantrex XW C onduit Box

interface with:

Xantrex XW4024 120/240 60, and Xantrex XW6048 120/240 60

Xantrex XW Solar C harge C ontrollers (requires customer supplied breakers

and wiring)

Xantrex C -Series Charge C ontrollers ( requires customer supplied breakers

and wiring) .

Internal wire barriers (or raceways) are included to keep communications wires

separate from A C and D C power wires.

Figure 1-3 Xantrex XW C onduit Box


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975-0239-01-01 15


Figure 1-4 Power D istribution Panel and Xantrex XW C onduit Box

Xantrex XW Power Distribution Panel includes:

Power Distribution Panel enclosure with a field-reversible panel door

M o unting P late

Xantrex XW Conduit Box

Xantrex XW P ower D istribution Panel

M ounting Plate Xantrex XW C onduit Box

The panel door can be mounted on the right or left side of the Xantrex XW

Power D istribution P anel.

AC K nockout slots = 9 (for dual 60A Square D , type Q O U breakers)*

DC K nockout slots = 8 small ( for 60A D C breakers) and 3 large(for G J breakers)

*AC Breakers cannot exceed 60A .

The enclosure comes pre-wired with:

3x 60A, 120/240 Vac, 2-pole, Square-D , Type Q O U , DI N-railmounted AC breakers (pre-wired to connect to one Xantrex XW

inverter)

1x G J250A 160 Vdc, 3/8" stud DC breaker

2x Ground terminal bus bars

1x Neutral terminal bus bar

1x Negative bus bar

1 pair #4/0 AWG Battery C ables

Xantrex XW P D P D imensions:

30" (761mm) H x 16" (406mm) W x 8 " (210mm) D

D epth from the wall = 8 " (223 mm)


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Introduction

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Xantrex XW Connection Kit for INV2

The Xantrex XW C onnection K it for Inv2 (FG A # 865-1020) is the extension ki t

required for connecting a second or third Xantrex XW Inverter/Charger in the

same system.

Figure 1-5 Xantrex XW C onnection K it for INV2

Xantrex XW C onduit BoxXantrex XW Connection Kit includes:

Xantrex XW Conduit Box with raceway barriers and cable strap

connections points,

3x 60 A, 120/240 Vac, 2-pole, Square-D, Type Q O U, Din-Rail

mountable, A C breakers (includes bypass plate)

#6 AWG AC wiring to connect the inverter to the AC breakers

( includes 4 conduit bushings)

#2 A WG g round wire

4x Power Distribution Bars (replaces factory-installed bars)

1x G J250A 160 Vdc, 3/8" stud DC breaker

1x Bus Bar for DC positive

1 pair #4/0 AWG battery cables

AC Sync and Xantrex Xanbus cables (not shown)

Power D istribution Bars

A C Bypass Plate 60A , 120/240Vac AC Breakers

15/16" bushing for AC sync and

Xantrex Xanbus knockouts (x1)

1-3/8" bushings for AC

Wiring knockouts (x3)

D C Positive Bus Bar

G J250A D C breaker

#6 AWG A C Wiring

#4/0 AWG battery cables

#2 AWG G round Wire


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975-0239-01-01 17


Xantrex XW Solar Charge Controller

The Xantrex XW Solar C harge C ontroller (FG A # 865-1030) is a 60 amp charge

controller with integrated Xantrex PV G FP and separate Battery Temperature

Sensor. T he Xantrex X W Solar C harge C ontroller can be used with 12-, 24-, 36-,

48-, and 60-volt DC battery systems. H owever, the Xantrex XW I nverter/Chargercan only work at 24 or 48 volts depending on the model. When the Xantrex XW

Solar C harge C ontroller is used with the Xantrex XW Inverter/C harger, i t is limited

to 24- or 48-volt battery banks. The Xantrex XW Solar C harge C ontroller will

automatically detect the 24- or 48-volt settings.

Figure 1-6 Xantrex X W Solar C harge C ontroller


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Introduction

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Xantrex XW System Control Panel

The Xantrex XW System C ontrol Panel features a graphical, back lit 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 X W System C ontrol Panel eliminates the need forseparate control panels for each device and gives a single point of control to set

up and monitor an entire Xantrex XW Power System.

Xantrex XW Automatic Generator Start

The Xantrex XW A utomatic G enerator Start can automatically activate a

generator to provide a Xantrex XW Series Inverter/Charger with power to

recharge depleted batteries or assist with heavy loads. The Xantrex XW

A utomatic G enerator Start adds intelligence to power management and

eliminates time spent monitoring batteries and inverter loads.

The Xantrex X W A utomatic G enerator Start is compatible with popular

generators, and can be configured to start the generator in response to low

battery voltage, thermostat operation, or load size on the inverter battery. A quiet

time setting prevents the generator from starting at inconvenient times. LED s

display the status of the Xantrex XW A utomatic G enerator Start, while all

user-defined settings are programmed through the Xantrex X W System C ontrol

Panel.

Figure 1-7 Xantrex X W System C ontrol Panel

FG A N umber:

865-1050


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975-0239-01-01 19


Generator The generator should be a 120/240V, 2-wire or 3-wire generator with A uto Start

capability.

The generator should also supply a G enerator R un signal. This signal is used by

the Xantrex XW A utomatic G enerator Start to detect whether the generator is

running. Some generator manufacturers refer to this signal as the Hour M eter

Signal or Switched B+ .

GeneratorCompatibility

The Xantrex XW A utomatic G enerator Start supports most two and three-wire

generator starters. Some manufacturers include, but are not limited to, O nan

(Q uiet D iesel, gasoline, and LP ) , Power Tech, G enerac, N orthern Lights, Fisher

Panda, Westerbeke, K ohler, H onda, and Yamaha. C heck with the generator

manufacturer to ensure the generator in question includes automatic starting

capabilities.

Xantrex XWSystem Control

Panel

A Xantrex XW System C ontrol Panel is required to configure the Xantrex XW

A utomatic G enerator Start and monitor generator starting and stopping activity.

The Xantrex XW System C ontrol Panel also provides real-time clock information

for the Xantrex XW A utomatic G enerator Start Q uiet T ime and Exercise T ime

features.

Figure 1-8 Xantrex XW A utomatic G enerator Start

FG A Number:

865-1060

Important: D o not use a 120-volt only generator. T he inverter will notaccept power from a generator of this kind.


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2Inverter/ChargerInstallation

C hapter 2, Inverter/C harger Installationdescribes how to mount and install the XantrexXW Inverter/C harger, and the Xantrex XWPower D istribution Panel and Xantrex XWC onduit Box.

For this Topic See....

Pre-Installation page 22

Step 1: Installing the M ounting P late page 25

Step 2: M ounting the Inverter page 27

S tep 3: M ounting the Xantrex XW Power D istribution Panel

and Xantrex XW C onduit Box

page 28

Step 4: Wiring the Inverter page 29

Step 5: Installing A dditional Inverters page 237


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Inverter/C harger Installation

22 975-0239-01-01


Pre-Installation

Before installing the Xantrex XW Inverter/Charger, read all instructions and

cautionary markings located in this manual.

Location

The Xantrex XW Inverter/Charger is certified for indoor (heated or unheated)

installations only.

Close to batterybank

Locate the inverter as close to the batteries as possible in order to keep the

battery cable length short. The maximum recommended battery cable length is

10 feet (3 m) .

Locate any electronic equipment susceptible to radio frequency and

electromagnetic interference as far away from the inverter as possible.

Fire safety D o not locate the inverter near readily flammable materials such as cloth, paper,straw, or plastic sheeting. Flammable materials should be kept a minimum

distance of 24 inches (60 cm) from the top surface and 12 inches (30 cm) from

either side surface and the front of the Xantrex XW Inverter/Charger.

Important: Be sure to obtain the appropriate permits, if necessary, prior tostarting 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 C ertified R enewable Energy (R E) System

installers.

WARNING: Personal Injury

The Xantrex X W Inverter/C harger weighs approximately 120 pounds (54 kg) .

To prevent personal injury, always use proper lifting techniques and have

someone assist with lifting during installation.

WARNING: Explosion and Corrosion Hazard

D o not locate the inverter directly above the batteries or in the same

compartment as vented batteries.


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Pre-Installation

975-0239-01-01 23


Knockout Preparation and Air Filter Installation

R emove 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.

Removing Internal Faceplates on the Power Distribution Panel

Important: D o not drill, cut, or punch holes into the Xantrex XW PowerD istribution P anel. U se only the knock outs provided for conduit entry.

Figure 2-1 A ir Filter and AU X C onnector Installation

Figure 2-2 R emoving the Internal Faceplates on the Power D istribution Panel

A ir Filter

Tuck the air filter

into the grooves

in the sides of the

air vent cover.

If planning on using the

Aux Port features,

insert the AU X

C onnector into the Aux

Port.

See AUX Port onpage 230 for wiring

details.

AU X C onnector

To remove the upper faceplate,

remove the 4 screws holding the

plate in place.

To remove the lower faceplate,

remove the 4 screws holding the

plate in place.


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24 975-0239-01-01


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 ob jects and that the minimumclearances are met.

Mounting

The Xantrex XW Power System is designed to be mounted on a vertical surface.

The supporting surface must be strong enough to support a minimum of

500 pounds (227 kg) . To facilitate installation, a wall mounting p late

(manufacturer part number 210-0462-01-01) is provided for each Xantrex XW

Inverter/C harger and Xantrex X W P ower D istribution Panel. The mounting plate

and hardware on the Xantrex X W Inverter/C harger and Xantrex XW Power

D istribution Panel are designed to meet standards for structural and seismic

stability. When properly installed, the system also meets Section 59 of UL 1741

for Static Loads.

Figure 2-3 C learance Requirements


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Step 1: I nstalling the M ounting P late

975-0239-01-01 25


Step 1: Installing the Mounting Plate

Each X antrex XW Inverter/C harger and Xantrex X W P ower D istribution 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 -inch diameter fasteners are required.

The fasteners must be sufficiently strong to support 500 pounds.

The wall bracket has mounting holes spaced 16 inches (40 cm) apart and is

designed to span two wall studs spaced 16 inches on-center. A dditional

mounting holes are also provided for flexibility in mounting options. If the wall

does not have 16-inch on-center studs, the installer will need to provide

adequate supports for the brackets. For example, a sheet of plywood can be

attached to the wall, and the wall brackets can then be attached to plywood.

Both the Xantrex XW Inverter/C harger and Xantrex XW P ower D istribution Panel

use the same wall bracket. The brackets are designed to interlock (as shown in

Figure 2-5), so that additional mounting plates are easily installed without

additional measuring or levelling.

The type of fastener required to secure the mounting plate varies according to

the vertical surface and wall structure of your installation location.

Table 2-1 M ounting Plate Fastener R ecommendations

Structure Required Fastener

Number of Screws Per

Bracket

Wood studs at 16" (on center - O .C. ) 1/4" 3 1/2" long lag screw Four

Wood studs not at 16" O .C .

(3/4" minimum plywood panel required)

1/4" 1" long wood screw Six

Steel studs at 16" O .C. (minimum 18 gauge) 1/4" self-dri lling screw Four

Figure 2-4 M ounting P late D imensions

17 (432)

9 3/16

(233)6 7/8

(175)1 3/4 (45)

6 (153)

2 1/4

(57)

4 1/2 (115)

16 (406)

all measurements in inches

(millimeters)3/4 (19)

2 (49)


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26 975-0239-01-01


Figure 2-5 M ounting the Bracket for the Xantrex X W Inverter/C harger or Distribution P anel

Wall studs 16" on center behind wallboard

Add " plywood if additional

support is needed.

Side View2 4 wall stud

Wallboard

Plywood

(optional)

mounting

plate

60" (152.4 cm) from floor

puts the inverter display

panel at approx. 65" high.

M ultiple mounting plates should fit

together as shown.

1 Locate the wall studs.

If necessary, enhance the support surface with a " plywood panel

secured to the wall studs. Plywood should span at least three wall

studs.

U se hardware sized to support a minimum of 500 lbs (not provided)

to secure the plywood to the wall.

U sing a level, secure the first mounting brack et to the wall. Use

recommended anchoring hardware to secure the plate (see

Table 2-1) .

M ount the next bracket adjacent to the first one. The brackets aredesigned to interlock, so additional mounting brackets are easily

installed without addi tional measuring or levelling.

2

3

4

5


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Step 2: M ounting the Inverter

975-0239-01-01 27


Step 2: Mounting the Inverter

Figure 2-6 M ounting the Xantrex XW Inverter/C harger

2

A lign the flange on the back of the Xantrex XW Inverter/C harger with the bottom edge

of the mounting plate.

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.

Secure the top of inverter with two #10 self-tapping screws (supplied) .

1

3

1

2

3


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28 975-0239-01-01


Step 3: Mounting the Xantrex XW Power Distribution Panel

and Xantrex XW Conduit Box

M ount the Xantrex X W P ower D istribution Panel on the mounting bracket

following the same procedure in Step 2.

When mounting the Xantrex XW C onduit Box as shown in Figure 2-7, it is not

necessary to attach the front panel until all wiring is complete.

Figure 2-7 Installing the Xantrex XW C onduit Box

Attach the back panel of the

Xantrex XW C onduit Box to the

bottom of the inverter with two

screws through the keyhole

slots under the back panel top

and the corresponding holes in

the bottom of the inverter (A ) .

Secure the bottom edge of the

back panel to the wall usingtwo screws (B).

A ttach the front panel of the

Xantrex XW C onduit Box by

sliding the bottom lip of the

front panel over the lower edge

of the back panel. A lign the two

holes in the front panel with the

two holes in the back panel.

U se the two #10-32 screws

provided to secure the front

panel to the back panel.

2

1

A

B


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Step 4: Wiring the Inverter

975-0239-01-01 29



This section provides procedures for mak ing A C and D C 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 C onduit Box was installed in the previous section.

For diagrams and information about installing the inverter/charger without the

Xantrex X W C onduit Box and X antrex XW Power D istribution Panel,

see A ppendix C.

Installation Tip Before mak ing the AC or DC cable connections, route the communicationscables through the raceway, but do not connect them to their components until

after all the inverter connections are made. O nce the A C and D C connections are

made the run becomes difficult to access. U se different colors for the

communications cables (or cable tags) to help make them easier to identify.

Important: C ommunication and signal cables must be segregated from all DC

and A C wiring. T herefore, a small raceway has been included in the design of

both the Xantrex XW P ower D istribution Panel and the Xantrex XW C onduit Box to

separate the communications cables from the power cables. This is a small

raceway run built into the bottom of both the Xantrex XW P ower Distribution P anel

and the Xantrex XW C onduit Box and is held in place by a single screw at the top

of the raceway.


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210 975-0239-01-01


Batteries

See the FAQ s section of the Schneider Electric Web site for information on

determining battery bank requirements.

C onsider the following recommendations for battery use.

U se only the deep discharge types for inverter applications.

U se the same battery type for all batteries in the bank.

U se only batteries from the same lot and date in your battery bank.

This information is usually printed on a label located on the battery.

Figure 2-8 R outing C ommunications Cables

Route the communications cables for any

accessories being installed BEFO RE

making AC or D C C onnections.

IMPORTANT: When routing communications cables through

the Xantrex XW Power D istribution Panel, the raceway conduit

must be used to keep the communications cables separate

from the power cab les.

Raceway for

C ommunications

C ables*

Raceway for

C ommunications

C ables*

Do not connect to

the BT S to the

batteries until the

battery bank has

been prepared

and is ready to

connect to the

inverter.

Xantrex XW

Automatic

G enerator Start

Xantrex XW System

C ontrol Panel

BTS

See Figure 2-14 on

page 221 for an

illustration showing

the C ommunications

Ports and where the

accessories connect.

Raceway for Shunt

Sense cable*.

Raceway exits the

panel through the

back.

*To remove, remove the screws at

the top ( O r side) of the raceway.


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975-0239-01-01 211


Battery Bank Requirements

The D C voltage of the inverter must match the nominal voltage of the system and

all battery-connected devices. If the inverter is a 24-volt inverter, then the battery

bank and all battery-connected devices in the system need to be configured for

24 volts.

Battery Cable Requirements

CAUTION: Damage to Equipment

The Xantrex XW Inverter/C harger is intended to operate with batteries as its

source of DC power. D o not connect D C power sources, such as PV arrays, wind

turbines, or micro-hydro turbines, directly to the Xantrex XW Inverter/C hargerwithout a b attery. C onnect DC power sources to a charge controller such as the

Xantrex X W Solar C harge C ontroller instead. I f D C power sources are connected

directly to the inverter, the DC rating of the inverter can be exceeded and the

inverter can be damaged.

Important: The minimum recommended battery bank is 100 A h. The inverter isdesigned to operate with batteries and should not be operated without them.

A lso, do not allow the battery bank to become completely discharged. I f the

voltage of the battery bank falls below 10 volts, the Xantrex X W P ower System

will not operate.

WARNING: Fire Hazard

U ndersized cables can overheat and melt, creating a fire hazard when subjectedto heavy (peak) loads. A lways use a cable of proper size and length, rated for the

amperage of the inverter and batteries.

Important: U se only fine-stranded copper cables for battery and inverter DC

connections. D o not use coarse-stranded wire, as the lack of flexibi lity may

damage battery and inverter terminals.


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212 975-0239-01-01


Battery cablelength

R uns should be k ept 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. A void 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.

Overcurrentprotection

For safety and compliance with regulations, battery overcurrent protection is

required. Fuses and disconnects must be sized to protect the wiring in the

system and are required to open before the wire reaches its maximum current

carrying capability.

Terminal covers C olor-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 Xantrex XW C onduit Box is used. I t 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 R ecommended B attery C able Size Versus Length

Inverter Model Up to 5 Feet (1.5 m) (90C wire)Up to 10 Feet (3 m)(90C wire)

Xantrex XW4024 #4/0 AWG (120 mm2) #4/0 AWG (120 mm2)



Important: The NEC /CEC requires both overcurrent protection and a disconnectswitch for residential and commercial electrical systems. These items are not

supplied as part of the inverter, but are included in the Xantrex XW Power

D istribution P anel.

Table 2-3 Battery C able (in C onduit) to M aximum Breaker/Fuse Size

Cable Size Required Maximum Breaker/Fuse Size

#2/0 (00) AWG 175 amps

#4/0 ( 0000) A WG 250 amps


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Torque Values for the Xantrex XW Series Inverter/Charger

Torque Values for the Xantrex XW Power Distribution Panel

Table 2-4 Torque Values for AC Wiring ( A C Terminals and G round B ar)

Wire Size Torque Value

AWG In-lb N-m

1410 35 4.0

8 40 4.5

64 45 5.1

Table 2-5 Torque Values for the C hassis G round Lug


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 20.4

Table 2-7 Torque Values for A C D isconnects and A C Breakers


AWG In-lb N-m

1610 45 5.18 45 5.1

64 45 5.1

Table 2-8 Torque Values for the G round Bus, AC Neutral Bus, D C Negative Bus,and D C Positive Bus in the Xantrex XW P ower D istribution Panel


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


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Inverter Grounding

Backfeed Protection Requirements

Wiring the Inverter to the Xantrex XW Power Distribution Panel

Table 2-9 Torque Values for the Power Distribution Bars in the Xantrex XW P owerD istribution Panel


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 C ables to the D C Negative Bus, and D C

Positive Bus in the Xantrex XW Power D istribution Panel

Torque Value

Ft-lbs N-m

15 20.4

Important: The grounding requirements vary by country and by application.

A ll installations must comply with national and local codes. C onsult local and

national codes for specific grounding and bonding requirements for the desired

installation.

Important: Installers must mak e allowance for the amount of power that can befed into a distribution panel and the means and location for feed-in, in

accordance with NEC 2005 article 690.64 or similar requirements of the local

electrical code.

Important: If a Xantrex XW C onduit Box is installed, communication and BatteryTemperature Sensor cables must run through the raceway at the rear of the

Xantrex XW C onduit Box. B efore mak ing A C and D C connections, route all

communication and B attery Temperature Sensor cables through the raceways.

The raceways becomes more difficult to access after all A C and D C wiring is

completed.


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Grounding the DC System

The inverters chassis ground bar (see Figure 2-9) is used to connect the chassis

of the inverter to the D C grounding system. The terminal accepts wires from

#14 AWG to #2 AWG .

Figure 2-9 D C G rounding U sing a P ower Distribution Panel

Actual grounding requirements may vary.

See Table 2-5 on page 213

for torque values for the AC

C hassis G round.


for torque values for the

G round bars in the Xantrex

XW Power D istribution

Panel.

B

BB

A

A


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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 alsoconsidered part of the D C interface (see Figure 2-11) .

To install t he Battery Temperature Sensor:

1. Pass the end of the Battery Temperature Sensor cable through a conduit hole

and insert the Battery Temperature Sensor plug into the Battery Temperature

Sensor port.

2. R oute the cable to the battery enclosure and connect the ring terminal on the

Battery Temperature Sensor directly to a battery terminal ( recommended) ,

or use the adhesive back ing on the sensor back to attach the sensor to any

side of the battery to be monitored.

If using the adhesive backing, install the Battery Temperature Sensor on the

side of the battery below the electrolyte level. It is best to place the sensorbetween batteries and place the batteries in an insulated box to reduce the

influence of the ambient temperature outside the battery enclosure.


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Figure 2-10 Battery Temperature Sensor (R J11) Port Location and Installation

Battery Temperature Sensor

Battery Temperature

Sensor Port (RJ11)

1

RJ11 jack

If using the adhesive backing,

install the Battery Temperature

Sensor on the side of the battery

below the electrolyte level.

Note: If other Xantrex Xanbus connected components supply a BTS

or are BTS enab led, it is not necessary to install all of them at once.

O nly one BT S needs to be installed.

However, i f multiple battery-strings are being used to form a battery

bank , multiple sensors can be installed. I n this case, the system will

use the highest temperature from all the inputs as its operational

parameter.

2


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Making DC Connections

This section describes how to make D C connections between the inverter/

charger and the power distribution panel (using the pre-installed D C 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 212) .This section also provides procedures for installing the battery temperature

sensor. See A ppendix C , A lternate System C onfigurations if the installation will

not be including a Xantrex X W P ower D istribution Panel.

To connect the Xantrex XW Power Distribution Panel to the inverter:

1. C onnect the pre-installed D C cables from the Xantrex XW Power D istribution

Panel to the inverter DC terminals. Figure 2-12 shows the proper stacking

order of hardware. Be careful to observe proper polarity.

2. A ttach the D C terminal covers.

3. R oute the DC cables from the battery with the cables not connected to the

battery and connect them to the Xantrex X W P ower D istribution Panel:

negative to negative bus, positive to the input end of the DC breaker.

To properly attach and torque the positive cable to the DC breaker, you may

need to temporarily remove the breaker from the rail.

4. Perform the procedures in M aking AC C onnections before connecting the

D C cables from the Xantrex XW P ower D istribution Panel to the battery.

WARNING: Shock Hazard

Ensure that all A C and D C breakers are switched O FF before connecting or

disconnecting the battery cables and that all sources of power (both A C and D C )

are disconnected from the inverter.

Figure 2-11 Xantrex XW Inverter/C harger D C C onnections

Bottom View

Negative (, black)

battery terminal

Positive (+ , red)

battery terminal

BT S port (R J11)

C hassis G round

Lug

Battery Temperature

Sensor (included)

(FG A #808-0232-02)


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975-0239-01-01 219


Figure 2-12 Battery C able C onnection

CAUTION: Damage to Equipment

D o not put anything between the battery cable lug and the terminal surface.

O verheating of the terminal may occur. D o not apply any type of antioxidant

paste until after the battery cable wiring is tightened. The same applies for all

D C connections. Do not over-tighten; observe all recommended torque values.

CAUTION: Reverse Polarity Damage

Before mak ing the final DC connection or closing the D C breaker or disconnect,

check cable polarity at both the battery and the inverter/charger. P ositive (+ )

must be connected to positive ( + ) . N egative () must be connected to

negative ().

R everse polarity damage is not covered by warranty.

Terminal surface

C opper compression lug

Ensure nothing is between the terminal

surface and the battery cable lug

Battery cable lug

Flat washer

3/8-15 x 5/8 bolt (supplied)

Shrink-wrap to color-code

the cable

Split-ring washer


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Making AC Connections

This section describes how to make AC connections between the Xantrex XW

Inverter/C harger and the Xantrex X W P ower Distribution Panel (using the

pre-installed A C wiring in the Xantrex XW P ower D istribution Panel) and between

the Xantrex XW Power D istribution Panel and the A C distribution panel, or

sub-panel (using wiring provided by the installer). See A ppendix C , A lternate

System C onfigurations if the installation will not be including a Xantrex XW

Power Distribution Panel.

Figure 2-13 D C C onnections to a Single Inverter Using a X antrex XW Power D istribution Panel

Actual cable requirements may vary.

Torque connections to the battery terminals according

to the battery manufacturers recommendations.

A


for torque values for the

inverter battery

connections.

See Table 2-8 on page 213 for

torque values for the Positive

and N egative Bus in the Xantrex

XW Power D istribution Panel.

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