Xantrex Technology XW6048-120/240-60, XW4024-120/240-60 guide

Inverter/Charger Installation

Parts List for Dual-Inverter Configurations

Installing an additional inverter using the power distribution panel requires an XW

Connection Kit (part number 856-1020), which contains the following components:

•XW Conduit Box

•Three 60 amp, 120/240 VAC, 2-pole, Square-D Type QOU, DIN-rail mount, AC breakers for Inverter Input, Output, and Bypass

•Four Power Distribution bars

•Custom Bypass Interlock

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

•GJ250A, 160VDC, 3/8" Stud, DC Breaker with copper bus bar for DC positive

•one pair #4/0 battery cables to connect the inverter to DC breakers

•Xanbus and AC Sync Cable (CAT 5 cable with RJ45 connectors wired to T568A standard).

•Miscellaneous bushings

Important: When installing more than one inverter at a location, a XW System Control Panel will be required to give each inverter (as well as other Xanbus-enabled devices) a unique name and to modify the factory-installed default settings to match and support the installed configuration.

Converting a Single-Inverter Power Distribution Panel to a Dual-Inverter Power Distribution Panel

◆Remove upper wire cover and lower wire cover on the XW Power Distribution Panel.

DC Wiring for a Dual-Inverter System

1.Remove positive distribution plate attached to bottom terminal on existing DC disconnect/breaker.

2.Install second DC disconnect/breaker (supplied in 865-1020) next to existing DC disconnect/breaker.

3.Replace the factory-installed DC positive bus bar with the larger positive bus bar provided in the 865-1020. This larger DC positive bus bar supports up to three GJ250 Adc disconnect/breakers.

4.Connect positive battery cable for second inverter (supplied in 865-1020) to top terminal on second DC disconnect/breaker.

5.Connect negative battery cable for second inverter (supplied in 865-1020) to DC negative distribution plate.

6.Connect positive and negative battery cables to second inverter.

7.Remove knockout on the lower cover for additional disconnect/breaker to fit through.

8.Re-install lower wire cover.

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Xantrex Technology XW6048-120/240-60 Parts List for Dual-Inverter Configurations, DC Wiring for a Dual-Inverter System

Contents

XW Power System Page XW Power System Date and Revision Purpose Scope AudienceOrganization Conventions Used Related Information Important Safety Instructions Explosive Gas Precautions Limitations on UseFCC Information to the User Contents Xanbus Network Installation XW Solar Charge Controller Installation XW System Accessories Installation Appendix a Specifications Appendix B Wiring DiagramsAppendix C Alternate System Configurations Figures Figures Tables Xiv Introduction For this Topic See System Diagram System Overview System Components and Accessories XW Inverter/ChargerXW Conduit Box XW Power Distribution Panel Panel and XW Conduit Box 4Power Distribution Panel and XW Conduit Box XW Connection Kit for INV2 5XW Connection Kit for INV2 XW Solar Charge Controller XW System Control Panel XW Automatic Generator Start Automatic Generator StartPage Inverter/ChargerInstallation Pre-Installation LocationKnockout Preparation Clearance Requirements Mounting Installing the Mounting Plate 1Mounting Plate Fastener RecommendationsStructure Required Fastener Per Bracket Installing the Mounting Plate Mounting the Inverter 4Mounting the XW Inverter/Charger Mounting the XW Power Distribution Panel and XW Conduit Box 5Installing the XW Conduit Box Wiring the Inverter 6Routing Communications Cables Battery Bank Requirements Battery Cable RequirementsBatteries 2Recommended Battery Cable Size Versus Length 3Battery Cable in conduit to Maximum Breaker/Fuse SizeTorque Values for the XW Series Inverter/Charger Backfeed Protection Requirements Torque Values for the XW Power Distribution PanelInverter Grounding In-lbs Wiring the Inverter to the XW Power Distribution Panel Grounding the DC System Installing the Battery Temperature Sensor To install the Battery Temperature Sensor To connect the XW Power Distribution Panel to the inverter Making DC Connections Wiring the Inverter Making AC Connections AC Connections and Communication Ports Accessing the AC Terminal Block and AC Ground Bar 13AC Terminal Block 14Grounding the AC System using the Distribution Panel Grounding the AC System AC Wiring to the Inverter AC Distribution Panel AC Wiring to the XW Power Distribution Panel Inverter/Charger Installation 16Wiring the Inverter to the XW Power Distribution Panel 17Generator Wiring Using a XW Power Distribution Panel AUX Port AUX+12V Voltage Supply 11User Connector Terminals and Functions AUX-RPO User Remote Power Off RPOUser Line Wiring AUX Port Terminal Assignments Basic Functional Test Single Inverter Applying DC Power to the InverterTo apply DC power to the inverter Confirm All Connections Enable the Inverter To enable the inverterTo disable the inverter AC Voltage Check Confirming Battery Charger OperationTo confirm battery charger operation To perform an AC voltage check 23Functional Test for Single Inverter Systems Installing Additional Inverters Installation StepsTo install multiple inverters Parts List for Dual-Inverter Configurations DC Wiring for a Dual-Inverter System 24DC Connections to Dual Inverters AC Wiring for a Dual-Inverter System From Main AC Distribution Panel From Generator Disconnect 26AC Wiring for Dual-Inverter Systems Parts List for a Triple-Inverter Configuration DC Wiring for a Triple-Inverter System 27DC Connections for a Triple-Inverter System AC Wiring for a Triple-Inverter System From Generator Disconnect To Inverter AC Distribution Panel or Transfer Switch To install the AC Sync and Xanbus cables between inverters Xanbus and AC Sync Cable Basic Functional Test Multiple Inverters To perform a functional test on multiple inverters Inverter/Charger Installation 32Functional Test for Multiple Inverters Page 1 33Functional Test for Multiple Inverters Page 2 Installation For this Topic Xanbus-enabled Devices Xanbus System 1T568A Standard Wiring Network ComponentsConductor Name 2Xanbus Cable and RJ45 Connector Pin Numbers Multi-Drop Backbone Layout Ordering Network ComponentsNetwork Layouts 2Xanbus Network Components and Part Numbers Daisy Chain Layout 5Multi-Drop Backbone Layout Installation Tools and Materials Installing the NetworkBefore You Begin the Installation Guidelines for Routing the Xanbus Cables 3Minimum and Maximum Cable Length Mounting a Network ConnectorTo mount a network connector Cable Length Minimum Maximum Completing the Multi-Drop Backbone Layout Installing Xanbus-Enabled DevicesTo install the Xanbus-enabled devices To complete the multi-drop backbone layout Completing the Daisy Chain Layout To complete the daisy chain layout XW Solar Charge Controller Array Size Installing the Charge ControllerPV Array Requirements Array Voltage Choosing a Location MountingMppt Voltage Range 1MPPT Operational Window Minimum Clearance Requirements Location Minimum Clearance Removing the Wiring Terminals Cover Removing Knockouts 4Knockout Dimensions Mounting the Controller Xantrex XW Solar Charge Controller Safety Ground Connector Grounding Wiring DC Terminal Connector LocationsWire Size and Over-current Protection Requirements Battery Circuit PV Circuit 4One-Way Wire Distance and Wire Size for a 24 Vdc System 5One-Way Wire Distance and Wire Size for a 48 Vdc System To connect the XW Solar Charge Controller 8Connecting Solar DC Sources in the Power Distribution Panel Configuration Screens Commissioning Units Using a XW System Control PanelCommissioning To copy the XW Solar Charge Controller setup to another unit XW Solar Charge Controller Installation XWInstallationSystem Accessories XW System Control Panel 1XW System Control Panel Xanbus Port Locations Materials and Tools Required Mounting the XW System Control Panel 2Inserting the Mounting Plate 4Connecting the Network Cables To surface mount the XW System Control Panel 6Surface Mounting the XW System Control Panel XW Automatic Generator Start Verifying the InstallationPreparing an Installation Materials and Tools Required Dry Choosing a LocationRouting the Connections Cool Safe Installing the XW Automatic Generator Start 8XW Automatic Generator Start External Connections To mount the XW Automatic Generator Start Wiring to the 20-contact ConnectorMounting the Unit 1Circuit Limitations Number Function Wire Color Required Wiring Size Based on Length of CableWire Ft m Over 30 ft m Connecting the Generator 4Wiring for Connecting Thermostats Connecting the Thermostats optionalConnecting an External Shutdown optional 5Wiring for Connecting an External Shutdown Connecting an External Manual ON/OFF Switch optional 6Wiring for Connecting an External Manual ON/OFF Switch Connecting an External ON/OFF LED 975-0239-01-01 11XW Automatic Generator Start External Connections 12Connecting the SCP Verifying Power Is Available 13Verifying Power is Available Specifications Electrical Specifications Table A-1XW Power System Electrical SpecificationsModel XW6048-120/240-60 XW4548-120/240-60 XW4024-120/240-60 XW Series Overload Capability Figure A-1 XW Series AC Overload Capability 975-0239-01-01 Output Power Versus Ambient Temperature XW Series EfficiencyInverting Efficiency Typical Table A-2XW Power System Mechanical Specifications Mechanical SpecificationsSell Mode Efficiency Typical Charging Efficiency Typical Accessories Accessory Part Number Wiring Diagrams For SeePage Single-Inverter System Backup only Wiring Diagrams Wiring Diagram Single-Inverter System Renewable Energy Solar975-0239-01-01 Single-Inverter System Renewable Energy Wind or Hydro Dual-Inverter System Renewable Energy Solar Figure B-4Dual-Inverter System Renewable Energy Solar Dual-Inverter System Renewable Energy Wind or Hydro Wiring Diagram 975-0239-01-01 Configurations DC Grounding for Single-Inverter Systems Figure C-1DC Grounding for an Inverter only Battery Connections for Single Inverter Systems Figure C-2DC Connections to a Single Inverter AC Grounding for Single-Inverter Systems Figure C-3Grounding the AC System AC Output Wiring to the Inverter AC Distribution Panel Generator Wiring to the Inverter Figure C-5Generator Wiring directly to the Inverter Utility Wiring to the Inverter Input Figure C-6Utility Wiring to the Inverter Input Figure C-7Connecting Wind or Hydro DC Sources Wind or Hydro DC Sources 975-0239-01-01 IX-1 IX-2 975-0239-01-01 Page Xantrex Technology Inc