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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
www.schneider-electric.com
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
iv 975-0239-01-01
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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.
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This manual for use by qualified personnel only
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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C ontents
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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 -2 Xantrex XW Series A C O verload C apab ili ty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 4
Figure A -3 Xantrex XW Series A C O verload C apab ili ty- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 5
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 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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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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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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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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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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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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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
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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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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
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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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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
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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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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
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Step 4: Wiring the Inverter
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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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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Step 4: Wiring the Inverter
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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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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)
Xantrex XW4548 #2/0 AWG (70 mm2) #4/0 AWG (120 mm2)
Xantrex XW6048 #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
Wire Size Torque Value
AWG In-lbs N-m
6-4 45 5.1
3-2 50 5.6
Table 2-6 Torque Values for the Inverter Battery Terminals
Torque Value
Ft-lbs N-m
15 20.4
Table 2-7 Torque Values for A C D isconnects and A C Breakers
Wire Size Torque Value
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
Wire Size Torque Value
AWG In-lbs N-m
14 - 10 35 4.0
8 40 4.5
6 - 4 45 5.1
3 - 2/0 50 5.6
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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
Wire Size Torque Value
AWG In-lbs N-m
14 - 10 35 4.0
8 40 4.5
6 - 4 45 5.1
3 - 2/0 50 5.6
Table 2-10 Torque Values for the Battery 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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Step 4: Wiring the Inverter
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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.
See Table 2-6 on page 213
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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Step 4: Wiring the Inverter
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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
See Table 2-6 on page 213
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.