XW Solar Charge Controller | Xantrex Technology XW4548-120/240-60

4	XW Solar Charge Controller
	Installation

Chapter 4, “XW Solar Charge Controller Installation” describes how to mount and connect the XW Charge Controller as part of the XW System.

For this Topic

“PV Array Requirements”

“Mounting”

“Grounding”

“Wiring”

“Commissioning”

See....

page 4–2

page 4–3

page 4–8

page 4–9

page 4–14

Image 77

Xantrex Technology XW4548-120/240-60, XW6048-120/240-60, XW4024-120/240-60 manual XW Solar Charge Controller

Contents

XW Power System Page XW Power System Date and Revision Organization PurposeScope Audience Related Information Conventions Used Important Safety Instructions FCC Information to the User Explosive Gas PrecautionsLimitations on Use Contents Xanbus Network Installation XW System Accessories Installation XW Solar Charge Controller Installation Appendix C Alternate System Configurations Appendix a SpecificationsAppendix B Wiring Diagrams Figures Figures Tables Xiv For this Topic See Introduction System Overview System Diagram XW Conduit Box System Components and AccessoriesXW Inverter/Charger 4Power Distribution Panel and XW Conduit Box XW Power Distribution Panel Panel and XW Conduit Box 5XW Connection Kit for INV2 XW Connection Kit for INV2 XW System Control Panel XW Solar Charge Controller Automatic Generator Start XW Automatic Generator StartPage Inverter/ChargerInstallation Knockout Preparation Pre-InstallationLocation Mounting Clearance Requirements Structure Required Fastener Per Bracket Installing the Mounting Plate1Mounting Plate Fastener Recommendations Installing the Mounting Plate 4Mounting the XW Inverter/Charger Mounting the Inverter 5Installing the XW Conduit Box Mounting the XW Power Distribution Panel and XW Conduit Box 6Routing Communications Cables Wiring the Inverter Batteries Battery Bank RequirementsBattery Cable Requirements Torque Values for the XW Series Inverter/Charger 2Recommended Battery Cable Size Versus Length3Battery Cable in conduit to Maximum Breaker/Fuse Size Inverter Grounding Torque Values for the XW Power Distribution PanelBackfeed Protection Requirements In-lbs Grounding the DC System Wiring the Inverter to the XW Power Distribution Panel To install the Battery Temperature Sensor Installing the Battery Temperature Sensor Making DC Connections To connect the XW Power Distribution Panel to the inverter Wiring the Inverter AC Connections and Communication Ports Making AC Connections 13AC Terminal Block Accessing the AC Terminal Block and AC Ground Bar Grounding the AC System 14Grounding the AC System using the Distribution Panel AC Wiring to the XW Power Distribution Panel AC Wiring to the Inverter AC Distribution Panel Inverter/Charger Installation 16Wiring the Inverter to the XW Power Distribution Panel 17Generator Wiring Using a XW Power Distribution Panel AUX+12V Voltage Supply AUX Port User Line Wiring AUX-RPO User Remote Power Off RPO11User Connector Terminals and Functions AUX Port Terminal Assignments To apply DC power to the inverter Applying DC Power to the InverterBasic Functional Test Single Inverter Confirm All Connections To disable the inverter Enable the InverterTo enable the inverter To confirm battery charger operation Confirming Battery Charger OperationAC Voltage Check To perform an AC voltage check 23Functional Test for Single Inverter Systems To install multiple inverters Installing Additional InvertersInstallation Steps DC Wiring for a Dual-Inverter System Parts List for Dual-Inverter Configurations 24DC Connections to Dual Inverters From Main AC Distribution Panel From Generator Disconnect AC Wiring for a Dual-Inverter System 26AC Wiring for Dual-Inverter Systems DC Wiring for a Triple-Inverter System Parts List for a Triple-Inverter Configuration 27DC Connections for a Triple-Inverter System From Generator Disconnect AC Wiring for a Triple-Inverter System To Inverter AC Distribution Panel or Transfer Switch Xanbus and AC Sync Cable To install the AC Sync and Xanbus cables between inverters To perform a functional test on multiple inverters Basic Functional Test Multiple Inverters Inverter/Charger Installation 32Functional Test for Multiple Inverters Page 1 33Functional Test for Multiple Inverters Page 2 For this Topic Installation Xanbus System Xanbus-enabled Devices Conductor Name 1T568A Standard WiringNetwork Components 2Xanbus Cable and RJ45 Connector Pin Numbers Network Layouts Ordering Network ComponentsMulti-Drop Backbone Layout 2Xanbus Network Components and Part Numbers 5Multi-Drop Backbone Layout Daisy Chain Layout Before You Begin the Installation Installing the NetworkInstallation Tools and Materials Guidelines for Routing the Xanbus Cables To mount a network connector Mounting a Network Connector3Minimum and Maximum Cable Length Cable Length Minimum Maximum To install the Xanbus-enabled devices Installing Xanbus-Enabled DevicesCompleting the Multi-Drop Backbone Layout To complete the multi-drop backbone layout To complete the daisy chain layout Completing the Daisy Chain Layout XW Solar Charge Controller PV Array Requirements Installing the Charge ControllerArray Size Array Voltage Mppt Voltage Range MountingChoosing a Location 1MPPT Operational Window Location Minimum Clearance Minimum Clearance Requirements Removing Knockouts Removing the Wiring Terminals Cover Mounting the Controller 4Knockout Dimensions Xantrex Grounding XW Solar Charge Controller Safety Ground Connector Wire Size and Over-current Protection Requirements WiringDC Terminal Connector Locations PV Circuit Battery Circuit 5One-Way Wire Distance and Wire Size for a 48 Vdc System 4One-Way Wire Distance and Wire Size for a 24 Vdc System To connect the XW Solar Charge Controller 8Connecting Solar DC Sources in the Power Distribution Panel Commissioning Configuration ScreensCommissioning Units Using a XW System Control Panel To copy the XW Solar Charge Controller setup to another unit XW Solar Charge Controller Installation XWInstallationSystem Accessories 1XW System Control Panel Xanbus Port Locations XW System Control Panel Mounting the XW System Control Panel Materials and Tools Required 2Inserting the Mounting Plate 4Connecting the Network Cables 6Surface Mounting the XW System Control Panel To surface mount the XW System Control Panel Preparing an Installation Verifying the InstallationXW Automatic Generator Start Materials and Tools Required Routing the Connections Choosing a LocationDry Cool Safe 8XW Automatic Generator Start External Connections Installing the XW Automatic Generator Start Mounting the Unit Wiring to the 20-contact ConnectorTo mount the XW Automatic Generator Start 1Circuit Limitations Wire Required Wiring Size Based on Length of CableNumber Function Wire Color Ft m Over 30 ft m Connecting the Generator Connecting an External Shutdown optional Connecting the Thermostats optional4Wiring for Connecting Thermostats 5Wiring for Connecting an External Shutdown 6Wiring for Connecting an External Manual ON/OFF Switch Connecting an External Manual ON/OFF Switch optional 975-0239-01-01 Connecting an External ON/OFF LED 11XW Automatic Generator Start External Connections 12Connecting the SCP 13Verifying Power is Available Verifying Power Is Available Specifications Model XW6048-120/240-60 XW4548-120/240-60 XW4024-120/240-60 Electrical SpecificationsTable A-1XW Power System Electrical Specifications Figure A-1 XW Series AC Overload Capability 975-0239-01-01 XW Series Overload Capability Inverting Efficiency Typical Output Power Versus Ambient TemperatureXW Series Efficiency Sell Mode Efficiency Typical Mechanical SpecificationsTable A-2XW Power System Mechanical Specifications Charging Efficiency Typical Accessory Part Number Accessories For See Wiring DiagramsPage Wiring Diagrams Single-Inverter System Backup only 975-0239-01-01 Wiring DiagramSingle-Inverter System Renewable Energy Solar Single-Inverter System Renewable Energy Wind or Hydro Figure B-4Dual-Inverter System Renewable Energy Solar Dual-Inverter System Renewable Energy Solar Dual-Inverter System Renewable Energy Wind or Hydro Wiring Diagram 975-0239-01-01 Configurations Figure C-1DC Grounding for an Inverter only DC Grounding for Single-Inverter Systems Figure C-2DC Connections to a Single Inverter Battery Connections for Single Inverter Systems Figure C-3Grounding the AC System AC Grounding for Single-Inverter Systems AC Output Wiring to the Inverter AC Distribution Panel Figure C-5Generator Wiring directly to the Inverter Generator Wiring to the Inverter Figure C-6Utility Wiring to the Inverter Input Utility Wiring to the Inverter Input Wind or Hydro DC Sources Figure C-7Connecting Wind or Hydro DC Sources 975-0239-01-01 IX-1 IX-2 975-0239-01-01 Page Xantrex Technology Inc