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Xantrex XW Hybrid

Inverter/Charger
Xa n tre x XW4 0 2 4 2 3 0 5 0
Xa n tre x XW4 5 4 8 2 3 0 5 0
Xa n tre x XW6 0 4 8 2 3 0 5 0

I n sta lla tio n G u id e
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Xantrex XW Hybrid
Inverter/Charger
I n sta lla tio n G u id e
www.schneider-electric.com
C opyri ght and C ontact
Tra d e m a rk s
Schneider Electric, the Schneider Electric logo, Xantrex, and Xanbus are trademarks or registered trademarks
of the Schneider Electric group of companies. O ther trademarks, registered trademarks, and product names are
the property of their respective owners and are used herein for identification purposes only.
N o tic e o f C o p y rig h t
Copyright 2008, 2010 Xantrex Technology I nc. All rights reserved. No part of this document may be reproduced
in any form or disclosed to third parties without the express written consent of:
Xantrex Technology I nc.
161-G South Vasco Road
Livermore, California USA 94551
Xantrex Technology I nc. reserves the right to revise this document and to periodically make changes to the
content hereof without obligation or organization of such revisions or changes unless required to do so by prior
arrangement.
E x c lu sio n fo r D o c u m e n ta tio n
UNLESS SPECI FI CALLY AG REED TO I N WRI TI NG , XANTREX TECHNO LO G Y I NC. ( XANTREX)
( A) M AK ES NO WARRANTY AS TO THE ACCURAC Y, SUFFI CI ENCY O R SUI TABI LI TY O F ANY TECHNI CAL O R O THER I NFO RM ATI O N
PRO VI DED I N I TS M ANUALS O R O THER DO CUM ENTATI O N;
( B) ASSUM ES NO RESPO NSI BI LI TY O R LI ABI LI TY FO R LO SSES, DAM AG ES, CO STS O R EXPENSES, WHETHER SPECI AL, DI RECT,
I NDI RECT, CO NSEQ UENTI AL O R I NCI DENTAL, WHI CH M I G HT ARI SE O UT O F THE USE O F SUCH I NFO RM ATI O N. THE USE O F ANY
SUCH I NFO RM ATI O N WI LL BE ENTI RELY AT THE USERS RI SK ; AND
( C) REM I NDS YO U THAT I F THI S M ANUAL I S I N ANY LANG UAG E O THER THAN ENG LI SH, ALTHO UG H STEPS HAVE BEEN TAK EN TO
M AI NTAI N THE ACC URACY O F THE TRANSLATI O N, THE AC CURACY CANNO T BE G UARANTEED. APPRO VED XANTREX CO NTENT I S
CO NTAI NED WI TH THE ENG LI SH LANG UAG E VERSI O N WHI CH I S PO STED AT WWW.SCHNEI DER-ELEC TRI C.CO M .
D a te a n d R e v isio n
December 2010 Revision C
P a rt N u m b e r
975-0384-01-02
P ro d u c t N u m b e r
865-1035-61 ( Xantrex XW6048 230 50) , 865-1040-61 ( Xantrex XW4548 230 50) , and 865-1045-61
( Xantrex XW4024 230 50)
C o n ta c t I n fo rm a tio n
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For other country details please contact your local Schneider Electric Sales Representative or visit our website at:
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iii
This manual for use by qualified personnel only
About This Guide
P u rp o se
The purpose of this I nstallation G uide is to provide explanations and procedures
for installing the Schneider Electric Xantrex XW Power System.
S c o p e
This G uide provides safety guidelines, detailed planning, and procedures for
installing the Xantrex XW I nverter/C harger and related system components ( the
Xantrex XW Power 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. Consult individual battery
manufacturers for this information.
A u d ie n c e
This G uide is intended for anyone installing the Xantrex XW Power System.
I nstallers must be certified technicians or electricians.
O rg a n iza tio n
This guide is organized into two chapters and one appendix.
Chapter 1, I ntroduction lists and describes the components and basic features
of the Xantrex XW Power System.
Chapter 2, I nverter/Charger I nstallation describes how to mount and install the
Xantrex XW I nverter/Charger.
Appendix A, Specifications provides the electrical and mechanical
specifications for the Xantrex XW Power System.
C o n ve n tio n s U se d
The following conventions are used in this guide.
WA R N I N G
Warnings identify conditions or practices that could result in personal
injury or loss of life.
C A U T I O N
Cautions identify conditions or practices that could result in damage to
the Xantrex XW Power System components or other equipment.
About This Guide
iv 975-0384-01-02
This manual for use by qualified personnel only
Related Information
For additional information about operating the Xantrex XW Inverter/Charger, see
the Xantrex XW Inverter/Charger Operation Guide (975-0385-01-02).
For more information about related components, refer to:
Xantrex XW Power System Installation Overview (975-0238-01-01)
Xantrex XW System Control Panel Owners Guide (975-0298-01-01)
Xantrex XW Solar Charge Controller Owners Guide (975-0283-01-01)
Xantrex XW Automatic Generator Start Owners Guide (975-0307-01-01)
These guides are available at www.schneider-electric.com. Printed copies are
included with the components.
For more information about Schneider Electric as well as its products and
services, visit www.schneider-electric.com.
v
This manual for use by qualified personnel only
Important Safety Instructions
SAVE THESE I NSTRUCTI O NS
1. Before using the Xantrex XW Series I nverter/Charger, read all instructions
and cautionary markings on the Xantrex XW Series I nverter/Charger and the
batteries, as well as all appropriate sections of this guide.
2. M ake sure that the Xantrex XW Series I nverter/Charger is installed according
to the guidelines and procedures in this I nstallation G uide.
3. Do not expose the Xantrex XW Series I nverter/Charger to rain, snow, or
spray. To reduce risk of fire, do not cover or obstruct the ventilation openings.
4. Use only attachments recommended or sold by Schneider Electric. Doing
otherwise may result in a risk of fire, electric shock, or injury to persons.
5. To avoid a risk of fire and electric shock, make sure that existing wiring is in
good condition and that the wire is not undersized. Do not operate the
Xantrex XW Series I nverter/Charger with damaged or substandard wiring.
6. Do not operate the Xantrex XW Series I nverter/C harger if it has received a
sharp blow, been dropped, or been otherwise damaged in any way. I f the
Xantrex XW Series I nverter/Charger is damaged, see the Warranty section.
7. Do not disassemble the Xantrex XW Series I nverter/C harger. I t contains no
user-serviceable parts. See the Warranty for instructions on obtaining
service. Attempting to service the Xantrex XW Series I nverter/Charger
yourself may result in a risk of electrical shock or fire and will void your
warranty. I nternal capacitors remain charged after all power is disconnected.
8. To reduce the risk of electrical shock, authorized service personnel must
disconnect both AC and DC power from the Xantrex XW Series I nverter/
Charger before attempting any maintenance or cleaning or working on any
circuits connected to the Xantrex XW Series I nverter/Charger. Putting the unit
in Standby mode will not reduce this risk.
9. To reduce the chance of short-circuits, authorized service personnel must
use insulated tools when installing or working with this equipment.
WA R N I N G
This chapter contains important safety and operating instructions. Read and
keep this I nstallation G uide for future reference.
WA R N I N G : L im ita tio n s o n u s e
The Xantrex XW Power System is not intended for use in connection with life
support systems or other medical equipment or devices.
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This manual for use by qualified personnel only
I m p o rta n t S a fe ty I n stru c tio n s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1 I n tro d u c tio n
System O verview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
System Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
System Components and Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
Xantrex XW I nverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
Xantrex XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
Xantrex XW Solar Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
Xantrex XW System C ontrol Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16
Xantrex XW Automatic G enerator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16
2 I n ve rte r/C h a rg e r I n sta lla tio n
Pre-I nstallation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22
Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22
K nockout Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22
Clearance Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
M ounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
Step 1: I nstalling the M ounting Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24
Step 2: M ounting the I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
Step 3: I nstalling Communications Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
G uidelines for Routing the Communications Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
Xantrex Xanbus Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -210
Connecting Xantrex Xanbus-Enabled Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -211
Connecting AC Sync Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -211
Step 4: Wiring the I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -212
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -212
Battery Bank Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -212
Battery C able Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -212
Torque Values for the Xantrex XW Series I nverter/C harger - - - - - - - - - - - - - - - - - - - - -213
I nverter G rounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -214
Feed-in Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -214
M aking DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -215
G rounding the DC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -215
Connecting the Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -216
I nstalling the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -218
M aking AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -219
Accessing the AC Terminal Block and AC G round Bar - - - - - - - - - - - - - - - - - - - - - - - -220
AC Equipment G rounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -221
AC Wiring to the I nverter Load Sub-Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -222
AC System Bonding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -223
AC Wiring to the Xantrex XW I nverter/C harger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -223
Contents
C ontents
viii 975-0384-01-02
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Auxiliary ( AUX) Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226
AUX+ 12V Voltage Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226
AUX-RPO : User Remote Power O ff ( RPO ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227
User Line Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227
AUX Port Terminal Assignments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227
Basic Functional Test - Single I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
C onfirm All Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
Applying DC Power to the I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
Enable the I nverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229
AC Voltage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230
C onfirming Battery Charger O peration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231
Step 5: I nstalling Additional I nverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 233
I nstallation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 233
Basic Functional Test M ultiple I nverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 234
A S p e c ific a tio n s
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A2
Xantrex XW Series I nverter/Charger O verload Capability - - - - - - - - - - - - - - - - - - - - - - - - - -A3
O utput Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A4
Xantrex XW Series I nverter/Charger Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A4
I nverting Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A4
Charging Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A5
Charging Efficiency ( Power Factor Corrected) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A5
G rid-Tie Sell M ode Efficiency ( Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A6
M echanical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A8
Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A8
This manual for use by qualified personnel only
1 Introduction
Chapter 1, I ntroduction lists and
describes the components and basic
features of the Xantrex XW Power System.
F o r th is To p ic S e e . . . .
System O verview page 12
System Components and Accessories page 14
I ntroduction
12 975-0384-01-02
This manual for use by qualified personnel only
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-tie, or backup.
S yste m D ia g ra m
F ig u re 1 -1 Xantrex XW Power System I nstallation with Backup O nly Example
Hybrid Inverter / Charger
Gri d( AC1)
Gen ( AC2)
Fault/ Warning
Equali ze Battery
Charging
Inverting Fl ashi ng =sel l
System Con trol Pan el I I
Enter Exi t
Faul t/Warni n g Syst emSt at us
Bat tery 48. 2 A - 60. 5V
Bat Lev E- - F
Load 7262W
AC1 0 W 161V
Menu
Stan d b y
Power
Generat or On
Net work
Faul t
Aut omat i c Generat or Start
Single-I nverter System ( Backup O nly)
AC G enerator
M ain Utility Panel
Utility
G rid
AC Sources ( if available)
Accessories
Xantrex XW
System Control
Panel
Xantrex XW
Automatic
G enerator Start
C
o
m
m
u
n
i
c
a
t
i
o
n
AC Loads
I nverter Load Sub-Panel
AC I n
AC O ut
DC Charging and DC O ut
I M PO RTANT: All configurations must
comply with local and national electrical
code jurisdiction. Consult your local certified
installer or local electrical authority to ensure
compliance.
System O verview
975-0384-01-02 13
This manual for use by qualified personnel only
F ig u re 1 -2 Xantrex XW Power System I nstallation with Renewable Energy Example
BA
T+
PV
+
BAT

PV

XW Sol ar Charge Control l er


Hybrid Inverter / Charger
Gri d( AC1)
Gen( AC2)
Fault/ Warning
Equali ze Battery
Charging
Inverting Fl ashi ng =sel l
System Con trol Pan el I I
Enter Exi t
Faul t/Warni n g Syst emSt at us
Bat tery 48. 2 A - 60. 5V
Bat Lev E- - F
Load 7262W
AC1 0 W 161V
Menu
Stan d b y
Power
Generator On
Net work
Faul t
Aut omat i c Generat or Start
Single-I nverter System with Renewable Energy ( Solar)
AC G enerator
M ain Utility Panel
Utility
G rid
AC Sources ( if available)
Accessories
Xantrex XW
System Control
Panel
Xantrex XW
Automatic
G enerator Start
C
o
m
m
u
n
i
c
a
t
i
o
n
Renewable Energy
PV Array
AC Loads
I nverter Load Sub-Panel
AC I n
AC O ut
DC Charging and DC O ut
DC I n
I M PO RTANT: All configurations must
comply with local and national electrical
code jurisdiction. Consult your local certified
installer or local electrical authority to ensure
compliance.
I ntroduction
14 975-0384-01-02
This manual for use by qualified personnel only
System Components and Accessories
Xa n tre x XW I n ve rte r/C h a rg e r
The Xantrex XW I nverter/Charger is a modular building block sine-wave
inverter/charger that can be used for both residential and commercial
stand-alone, grid-backup, and grid-tie applications with battery energy storage.
The Xantrex XW Series I nverter/Charger is a self-contained DC to AC inverter,
battery charger, and AC transfer switch.
Up to four inverters can be installed in parallel to create larger 230-volt,
single-phase systems, allowing for increased capacity. M ultiple Xantrex XW
I nverter/C hargers can also be connected to create a three-phase system. O ne
inverter per phase is required, and up to two inverters can be connected in
parallel on each phase.
A Battery Temperature Sensor ( Part Number 808-0232-02) is included with the
Xantrex XW I nverter/Charger. The Battery Temperature Sensor monitors the
temperature of the battery bank and adjusts the charging accordingly. For
installation instructions, see page 218.
F ig u re 1 -3 Xantrex XW I nverter/Charger
System Components and Accessories
975-0384-01-02 15
This manual for use by qualified personnel only
Xa n tre x XW C o n d u it B o x
The Xantrex XW Conduit Box ( Part Number 865-1025) is available to enclose the
bottom of the Xantrex XW I nverter/Charger and protect the cabling. Use of the
conduit box may be required depending on the local electrical code. Consult the
local electrical authority to make sure the installation is code-compliant.
The Xantrex XW Conduit Box comes in two pieces and mounts directly to the
bottom of the inverter/charger with keyhole slots and screws. I t is secured to the
inverter by two #10-32 screws on the bottom of the inverter, and it is secured to
the wall by two screws ( not provided) .
I nternal wire barriers ( or raceways) are included to keep communications wires
separate from AC and DC power wires. The Xantrex XW Conduit Box also
includes multiple cable strap points.
Xa n tre x XW S o la r C h a rg e C o n tro lle r
The Xantrex XW Solar Charge Controller ( Part Number 865-1030-1) is a 60 amp
charge controller with integrated Photovoltaic G round Fault Protection ( PVG FP)
and separate Battery Temperature Sensor. The Xantrex XW Solar Charge
Controller can be used with 12-, 24-, 36-, 48-, and 60-volt battery systems. When
the Xantrex XW Solar Charge Controller is used with the Xantrex XW
I nverter/Charger, it is limited to 24- or 48-volt battery banks. The Xantrex XW
Solar Charge Controller automatically detects the 24- or 48-volt settings.
F ig u re 1 -4 Xantrex XW Conduit Box
F ig u re 1 -5 Xantrex XW Solar Charge Controller
I ntroduction
16 975-0384-01-02
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Xa n tre x XW S yste m C o n tro l P a n e l
The Xantrex XW System Control Panel ( Part Number 865-1050) features a
graphical, backlit liquid crystal display that shows system configuration and
diagnostic information for all devices connected to the network. When installed
as a Xantrex XW Power System accessory, the Xantrex XW System Control Panel
eliminates the need for separate control panels for each device and gives a
single point of control to set up and monitor an entire Xantrex XW Power System.
Xa n tre x XW A u to m a tic G e n e ra to r S ta rt
The Xantrex XW Automatic G enerator Start ( Part Number 865-1060) can
automatically activate a generator to provide a Xantrex XW Series
I nverter/C harger with power to recharge depleted batteries or assist with heavy
loads.
The Xantrex XW Automatic G enerator Start is compatible with popular
generators, and it 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. LEDs
display the status of the Xantrex XW Automatic G enerator Start, while all settings
are programmed through the Xantrex XW System Control Panel.
F ig u re 1 -6 Xantrex XW System C ontrol Panel
F ig u re 1 -7 Xantrex XW Automatic G enerator Start
System Components and Accessories
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G e n e ra to r The generator should be a 230V, single-phase generator with automatic starting
capabilities.
G e n e ra to r
C o m p a tib ility
The Xantrex XW Automatic G enerator Start supports most two- and three-wire
generator starters. Some manufacturers include, but are not limited to, O nan
( Q uiet Diesel, gasoline, and LP) , Power Tech, G enerac, Northern Lights, Fisher
Panda, Westerbeke, K ohler, Honda, and Yamaha. Check with the generator
manufacturer to make sure your generator has automatic starting capabilities
and is compatible with the Xantrex XW Automatic G enerator Start. For more
information, see the Xantrex XW Automatic G enerator Start O wners G uide.
Xa n tre x XW
S y s te m C o n tro l
P a n e l
A Xantrex XW System Control Panel is required to configure the Xantrex XW
Automatic G enerator Start and monitor generator starting and stopping activity.
18
This manual for use by qualified personnel only
2 Inverter/Charger
Installation
Chapter 2, I nverter/Charger I nstallation
describes how to mount and install the
Xantrex XW I nverter/Charger.
F o r th is To p ic S e e . . .
Pre-I nstallation page 22
Step 1: I nstalling the M ounting Plate page 24
Step 2: M ounting the I nverter page 27
Step 3: I nstalling Communications Cables page 28
Step 4: Wiring the I nverter page 212
Step 5: I nstalling Additional I nverters page 233
I nverter/C harger I nstallation
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Pre-Installation
Before installing the Xantrex XW I nverter/Charger, read all instructions and
cautionary markings located in this manual.
L o c a tio n
The Xantrex XW I nverter/Charger is certified for indoor ( heated or unheated)
installations only.
C lo se to b a tte ry
b a n k
Locate the inverter as close as possible to the batteries to keep the battery cable
length short. The maximum recommended battery cable length is 3 meters.
Locate any electronic equipment susceptible to radio frequency and
electromagnetic interference as far away from the inverter as possible.
F ire sa fe ty Do 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 600 mm from the top surface and 300 mm from either side surface
and the front of the Xantrex XW I nverter/Charger.
K n o c k o u t P re p a ra tio n
Remove your choice of knockouts from the chassis to facilitate conduit
installation for wire runs. M ake sure no debris from this procedure remains inside
the inverter enclosure.
I m p o rta n t: O btain the appropriate permits, if necessary, prior to starting this
installation. I n sta lla tio n s m u st m e e t a ll lo c a l c o d e s a n d sta n d a rd s . I nstallations
of this equipment must only be performed by skilled personnel such as qualified
electricians and certified renewable energy system installers.
WA R N I N G : P e rso n a l I n ju ry
The Xantrex XW I nverter/Charger weighs approximately 54 kg. To prevent
personal injury, always use proper lifting techniques and have someone available
to assist with lifting during installation.
WA R N I N G : E x p lo sio n a n d C o rro sio n H a za rd
Do not locate the inverter directly above the batteries or in the same
compartment as vented batteries.
I m p o rta n t: Do not drill, cut, or punch holes into the Xantrex XW I nverter/Charger.
Use only the knockouts provided for conduit entry.
Pre-I nstallation
975-0384-01-02 23
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C le a ra n c e R e q u ire m e n ts
Provide a minimum clearance of 150 mm ( 300 mm is preferred) around the top
and 150 mm at the bottom of the inverter for ventilation. The front of the inverter
must have at least one meter of clearance. M ake sure that the vents are not
obstructed with foreign objects and that the minimum clearances are met.
M o u n tin g
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 60 kg
for a single inverter/charger. To facilitate installation, a wall mounting plate ( Part
Number 210-0462-01-01) is provided for each Xantrex XW I nverter/C harger. The
mounting plate and hardware on the Xantrex XW I nverter/Charger are designed
to meet standards for structural and seismic stability.
F ig u re 2 -1 Clearance Requirements
150 mm minimum
clearance
150 mm minimum
clearance
I nverter/C harger I nstallation
24 975-0384-01-02
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Step 1: Installing the Mounting Plate
Each Xantrex XW I nverter/Charger requires a separate mounting plate. This
bracket is first attached to the wall, and then the inverter/charger 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 6 mm diameter fasteners are required. The
fasteners must be sufficiently strong to support the weight of the inverter/charger.
The type of fastener required to secure the mounting plate varies according to
the vertical surface and wall structure of the installation location.
The wall bracket has mounting holes spaced 400 mm apart and is designed to
span two wall studs spaced 400 mm on-center. Additional mounting holes are
also provided for flexibility in mounting options. I f the wall does not have 400-mm
on-center studs, the installer must 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.
The brackets are designed to interlock ( as shown in Figure 2-3) , so that
additional mounting plates are easily installed without additional measuring or
levelling.
Ta b le 2 -1 M ounting Plate Fastener Recommendations
S tru c tu re R e q u ire d F a ste n e r
N u m b e r o f
S c re w s P e r
B ra c k e t
Wood studs at 400 mm ( on center -
O .C.)
6 mm 89 mm
long lag screw
Four
Wood studs not at 400 mm O .C.
( 20 mm minimum plywood panel
required)
6 mm 25mm long
wood screw
Six
Steel studs at 400 mm O .C.
( minimum 18 gauge)
6 mm self-drilling
screw
Four
Step 1: I nstalling the M ounting Plate
975-0384-01-02 25
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F ig u re 2 -2 M ounting Plate Dimensions
432
233 175
45
153
57
406
All measurements in mm
19
49
115
I nverter/C harger I nstallation
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F ig u re 2 -3 M ounting the Bracket for the Xantrex XW I nverter/C harger or Distribution Panel
Wall studs 400 mm on center
behind wallboard
Add 20 mm plywood if
additional support is
needed.
Side View
Wall stud
Wallboard
Plywood
( optional)
M ounting
plate
152 cm from floor puts
the inverter information
panel at approx. 165 cm
high.
M ultiple mounting plates should fit together as
shown.
1 Locate the wall studs.
I f necessary, enhance the support surface with a 20 mm plywood panel secured to
the wall studs. The plywood should span at least three wall studs.
Use hardware ( not provided) sized to support the weight of the equipment to
secure the plywood to the wall.
Using a level, secure the first mounting bracket 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 are designed to
interlock, so additional mounting brackets are easily installed without additional
measuring or levelling.
2
3
4
5
Step 2: M ounting the I nverter
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Step 2: Mounting the Inverter
F ig u re 2 -4 M ounting the Xantrex XW I nverter/Charger
2
Align the flange on the back of the Xantrex XW I nverter/Charger with the
bottom edge of the mounting plate.
Lower the flange on the inverter onto the mounting plate.
CAUTI O N: Before releasing the full weight of the inverter, make sure it is
seated properly on the mounting plate.
Secure the top of inverter with two #10 self-tapping screws ( provided) .
1
3
1
2
3
I nverter/C harger I nstallation
28 975-0384-01-02
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Step 3: Installing Communications Cables
Two types of communication cables must be installed, depending on your
installation requirements:
1. Xantrex Xanbus network cables to connect the Xantrex XW I nverter/
Charger to other Xantrex Xanbus-enabled devices. Connecting Xantrex XW
I nverter/C hargers and other network components with Xantrex Xanbus
network cables simplifies and automates configuration, control, and
monitoring of the Xantrex XW Power System.
2. AC Sync cables to connect the Xantrex XW I nverter/Charger to other
Xantrex XW I nverter/Chargers in multiple-unit installations. The AC Sync
cables provide communication and AC control between multiple Xantrex XW
I nverter/C hargers.
G u id e lin e s fo r R o u tin g th e C o m m u n ic a tio n s C a b le s
For maximum performance of your network, follow these guidelines when routing
the communications cables.
Route the cables away from sharp edges that might damage the insulation.
Avoid sharp bends in the cable no less than a 100 mm radius.
Allow for some slack in the cable tension.
K eep the alignment of wire pairs inside the sheath as straight as possible.
Allow separation between communications and power cables
( communications cables should only cross a power cable at right angles) .
Do not staple the cable with metal cable staples. Use appropriate hardware
fasteners to avoid damage to the cable.
Support horizontal cables using J hooks or cable trays.
The total length of the network, including all connected Xantrex Xanbus-enabled
devices and the Xantrex XW I nverter/C harger, cannot exceed 40 m.
F ig u re 2 -5 Xantrex XW I nverter/Charger Communications Ports
:
WA R N I N G : S h o c k h a za rd
Do not route the Xantrex Xanbus or AC Sync cables in the same conduit or panel
as the AC and DC power cabling.
AC sync ports
( RJ45) ( 2)
Bottom View
Xantrex Xanbus ports
( RJ45) ( 2)
Communications Ports
Step 3: I nstalling Communications Cables
975-0384-01-02 29
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Xa n tre x Xa n b u s N e two rk C o m p o n e n ts
A Xantrex Xanbus network consists of the following components:
Xantrex Xanbus-enabled devices these include the Xantrex XW System
Control Panel, the Xantrex XW I nverter/C harger, Xantrex XW Automatic
G enerator Start, and Xantrex XW Charge Controller. The maximum number of
Xantrex Xanbus-enabled devices in a Xantrex XW Power System is eight.
Xantrex Xanbus power supply the network must have at least one device
with a power supply to run the network. The total network current supplied by
all the power-sourcing devices must be greater than or equal to the total
current drawn by the power consuming devices. The power supply must be
capable of providing 15 VDC/200 mA to each device. The Xantrex XW
I nverter/Charger can provide sufficient network power.
For example, in a system with an inverter/charger, a Xantrex XW System
Control Panel, and a Xantrex XW Automatic G enerator Start, the inverter/
charger is a power-sourcing device capable of providing 800 mA at 15 VDC
while the two other devices each consume a maximum of 200 mA for a total
maximum consumption of 400 mA. I n this example, the network is properly
configured from a power perspective because the power source is capable
of providing more current than is needed: 800 mA 400 mA.
Xantrex Xanbus cables each Xantrex Xanbus-enabled device is connected
by a Category 5 ( CAT 5 or CAT 5e) cable, a standard cable available from
Schneider Electric or any computer supply store. The cable consists of eight
conductors in four twisted pairs with an RJ45 modular connector wired to the
T568A standard.
Network terminators the Xantrex Xanbus network must be properly
terminated at each end to ensure the communication signal quality on the
network. I f the network is not properly terminated, signal quality is degraded
and performance on the network is reduced. Permanent configuration
without terminators is not supported by Schneider Electric. The Xantrex XW
Series I nverter/Charger and other Xantrex Xanbus-enabled devices ship with
one terminator. Depending on your network layout, this terminator may need
to be inserted into another device elsewhere in the network.
C A U T I O N : E q u ip m e n t D a m a g e
Do not use crossover cable.
F ig u re 2 -6 Xantrex Xanbus Cable and Network Terminators
Network terminator
Xantrex Xanbus cable
I nverter/C harger I nstallation
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N e two rk L a yo u t
Each device on the network is linked with separate lengths of Xantrex Xanbus
cable, as shown in Figure 2-7.
Two terminators are required to ensure the communication signal quality on the
network. The Xantrex Xanbus-enabled devices at each end of the chain must
have a terminator inserted into their open network ports.
C A U T I O N : U n p re d ic ta b le d e v ic e b e h a v io r
Do not connect one end of the network to the other to make a ring.
F ig u re 2 -7 Xantrex Xanbus Network Layout
Syst em Cont rol Panel II
Solar Charge Cont roller
Enter Exit
Syst em Cont rol Panel
Charge
Cont roller
Aut omat ic Generat or St art
Hybrid Inverter/Charger
Gri d(AC1)
Gen (AC2)
Faul t /
Warni ng
Equal i ze Battery
Chargi ng
Inverti ng Fl ashi ng =sell
Invert er/Charger
Terminate the network at each end.
Step 3: I nstalling Communications Cables
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C o n n e c tin g Xa n tre x Xa n b u s-E n a b le d D e vic e s
To c o n n e c t th e X a n tre x X a n b u s -e n a b le d d e v ic e s :
1. Determine and prepare the location for each device. Refer to the installation
instructions for each device.
2. Determine and measure the required cable length, taking into consideration
the network layout, the routing, and strain relief requirements. Do not exceed
the total recommended cable length of 40 m.
3. M ount the devices according to the installation instructions for each device.
4. Use an appropriate length of Xantrex Xanbus cable to connect each device.
5. I nsert a terminator into the open network port of the Xantrex Xanbus-enabled
device at each end of the network. See Figure 2-7.
C o n n e c tin g A C S yn c C a b le s
Connect AC Sync cables in the same daisy-chain layout as Xantrex Xanbus
network cables ( see Figure 2-7) . Network terminators are not required for AC
Sync connections.
To in s ta ll th e A C S y n c c a b le s :
1. I nsert the cable into one of the two AC Sync ports in inverter #1.
2. I n a two-inverter system, connect the AC Sync cable between inverter #1 and
inverter #2.
I n a three-inverter system, connect an AC Sync cable between inverter #1
and inverter #2, and then connect another AC Sync cable between the
second AC Sync port in inverter #2 and an AC Sync port in inverter #3.
I m p o rta n t: I nstalling and replacing Xantrex Xanbus-enabled devices in an
existing system must be performed with the Xantrex XW Power System in
Standby mode. For more information about Standby mode, see the Xantrex XW
System C ontrol Panel O wners G uide.
C A U T I O N : E q u ip m e n t D a m a g e
Connect only to other Xantrex Xanbus compatible devices.
Although the cabling and connectors used in this network system are the same
as Ethernet connectors, this network is not an Ethernet system. Equipment
damage may result from attempting to connect Xantrex Xanbus to different
systems.
I nverter/C harger I nstallation
212 975-0384-01-02
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Step 4: Wiring the Inverter
This section provides procedures for making AC and DC connections between
the Xantrex XW I nverter/Charger, the batteries, and the inverter load sub-panel.
B a tte rie s
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:
Use only deep discharge types for inverter applications.
Use the same battery type for all batteries in the bank.
Use only batteries from the same lot and date in your battery bank. This
information is usually printed on a label located on the battery.
B a tte ry B a n k R e q u ire m e n ts
The DC voltage of the inverter must match the nominal voltage of the system and
all battery-connected devices. I f the inverter is a 24-volt inverter, then the battery
bank and all battery-connected devices in the system must be configured for
24 volts.
B a tte ry C a b le R e q u ire m e n ts
C A U T I O N : D a m a g e to E q u ip m e n t
The Xantrex XW I nverter/Charger is intended to operate with batteries as its
source of DC power. Do not connect DC power sources, such as PV arrays, wind
turbines, or micro-hydro turbines, directly to the Xantrex XW I nverter/Charger
without a battery. Connect DC power sources to a charge controller such as the
Xantrex XW Solar Charge Controller instead. I f DC power sources are connected
directly to the inverter, the DC rating of the inverter can be exceeded and the
inverter can be damaged.
I m p o rta n t: The minimum recommended battery bank is 100 Ah. The inverter is
designed to operate with batteries and should not be operated without them.
Also, do not allow the battery bank to become completely discharged. I f the
voltage of the battery bank falls below 10 volts, the Xantrex XW Power System
will not operate.
WA R N I N G : F ire H a za rd
Undersized cables can overheat and melt, creating a fire hazard when subjected
to heavy ( peak) loads. Always use cable of proper size and length, rated for the
amperage of the inverter and batteries.
Step 4: Wiring the I nverter
975-0384-01-02 213
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B a tte ry c a b le
le n g th
Runs should be kept as short as practical. Length should not exceed 3 m. For
best performance, the positive and negative cables should run alongside each
other. Avoid cable loops.
B a tte ry c a b le lu g s 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.
O v e rc u rre n t
p ro te c tio n
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.
Te rm in a l c o ve rs Color-coded, snap-on DC terminal covers are provided to prevent accidental
contact with the terminals. Terminal covers are required for all installations. 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.
To rq u e Va lu e s fo r th e Xa n tre x XW S e rie s I n ve rte r/C h a rg e r
I m p o rta n t: Use only fine-stranded copper cables for battery and inverter DC
connections. Do not use coarse-stranded wire. The lack of flexibility could
damage battery and inverter terminals.
Ta b le 2 -2 Recommended Battery Cable Size Versus Length
I n v e rte r M o d e l U p to 1 . 5 m 9 0 C w ire ) U p to 3 m 9 0 C wire )
Xantrex XW4024 230 50 120 mm
2
( #4/0 AWG ) 120 mm
2
( #4/0 AWG )
Xantrex XW4548 230 50 70 mm
2
( #2/0 AWG ) 120 mm
2
( #4/0 AWG )
Xantrex XW6048 230 50 120 mm
2
( #4/0 AWG ) 120 mm
2
( #4/0 AWG )
I m p o rta n t: Your local electrical code may require both overcurrent protection
and a disconnect switch for residential and commercial electrical systems. These
items are not supplied with the inverter.
Ta b le 2 -3 Battery Cable ( in conduit) to M aximum Breaker/Fuse Size
C a b le S ize R e q u ire d
M a x im u m B re a k e r/F u s e
S ize
70 mm
2
( #2/0 AWG ) 175 amps
120 mm
2
( #4/0 AWG ) 250 amps
Ta b le 2 -4 Torque Values for AC Wiring ( AC Terminals and G round Bar)
Wire S ize To rq u e Va lu e
AWG m m
2
I n -lb N -m
1410 2.56 35 4
8 10 40 4.5
64 1625 45 5.1
I nverter/C harger I nstallation
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I n ve rte r G ro u n d in g
The Xantrex XW I nverter/Charger and Xantrex XW Solar Charge Controller are
provided with ground terminals that must be reliably connected to ground
( protective earth) by appropriately sized equipment grounding conductors.
System grounding for the AC and DC systems must be done according to code.
Refer to the grounding information in this manual and all applicable installation
codes.
F e e d -in P ro te c tio n R e q u ire m e n ts
Ta b le 2 -5 Torque Values for the Chassis G round Lug
Wire S ize To rq u e Va lu e
AWG m m
2
I n -lb N -m
64 1625 45 5.1
32 2535 50 5.6
Ta b le 2 -6 Torque Values for the I nverter Battery Terminals
To rq u e Va lu e
F t-lb s N -m
15 20.4
I m p o rta n t: The grounding requirements vary by country and by application. All
installations must comply with national and local codes. Consult local and
national codes for specific grounding and bonding requirements for the desired
installation.
I m p o rta n t: I nstallers must make allowance for the amount of power that can be
fed into a distribution panel and the means and location for feed-in, in
accordance with local electrical code.
Step 4: Wiring the I nverter
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M a k in g D C C o n n e c tio n s
This section describes how to make DC connections between the inverter/
charger and the batteries. Battery cables must be provided by the installer
( see Table 2-2 on page 213) . This section also provides procedures for
installing the battery temperature sensor.
G ro u n d in g th e D C S yste m
The inverters chassis ground lug is located along the rear edge of the unit
( see Figure 2-8) and is used to connect the chassis of the inverter to the DC
grounding system. The terminal accepts wires from #14 AWG to #2 AWG
( 2.5 mm
2
to 35 mm
2
) .
System grounding for the DC system, which typically involves bonding
( connecting) the battery negative circuit to ground, is dependent on the system
configuration. I n some cases, the battery negative will be bonded to ground in
another device such as a charge controller. I f a grounded DC system is desired
or required by code, make sure that the system bonding is done in one location
only and that all conductors and connections comply with applicable codes.
F ig u re 2 -8 DC G rounding Using a DC Disconnect
Hybri d Inverter /Charger
ON
OFF
L N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC OUT AC IN AC IN
L N L N
Actual grounding requirements may
Negative/
G round Bus
Battery Bank
Chassis ground lug
DC
Primary System
G round
I nverter/C harger I nstallation
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C o n n e c tin g th e B a tte rie s
To c o n n e c t D C c a b le s to th e X a n tre x X W I n ve rte r/C h a rg e r:
1. Route the DC cables from the battery bank to the inverter/charger.
2. I nstall a DC fuse and disconnect switch or a DC circuit breaker between the
inverter/charger and the battery. They must be installed in the positive side of
the DC circuit, as close as possible to the battery. See Figure 2-9, Xantrex
XW I nverter/Charger DC Connections on page 216.
This protects your battery and wiring in case of accidental shorting. Before
proceeding, make sure the DC disconnect switch is open or that the DC
circuit breaker is turned off.
3. C onnect one connector on the PO SI TI VE ( + ) cable to the PO SI TI VE DC
terminal on the inverter/charger. Be careful to observe proper polarity. Figure
2-10 shows the proper stacking order of hardware. Use a wrench to tighten
the bolt to the required torque.
4. C onnect the other connector to the PO SI TI VE ( + ) terminal on the fuse or
breaker. O bserve polarity carefully while completing the installation.
Follow the fuseholder or breaker manufacturers torque recommendation.
5. Connect the NEG ATI VE ( ) battery cable to the NEG ATI VE ( ) DC terminal on
the inverter/charger. Be careful to observe proper polarity. Figure 2-10 shows
the proper stacking order of hardware. Use a wrench to tighten the bolt to the
required torque.
6. Before proceeding, check that the cable polarity is correct: PO SI TI VE ( + ) on
the inverter/charger is connected to the PO SI TI VE ( + ) on the battery and the
NEG ATI VE ( ) cable is connected to the NEG ATI VE ( ) terminal on the
inverter/charger.
WARNING: Shock Hazard
M ake sure that all AC and DC breakers are switched off before connecting or
disconnecting the battery cables, and make sure that all sources of power ( both
AC and DC) are disconnected from the inverter.
F ig u re 2 -9 Xantrex XW I nverter/Charger DC Connections
Bottom View
Negative ( , black)
DC terminal
Positive ( + , red)
DC terminal
Chassis
G round Lug
BTS Port
Step 4: Wiring the I nverter
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7. Connect the other end of the cable to the NEG ATI VE ( ) terminal on the
battery.
8. Use a wrench to tighten the bolt to the required torque.
9. Attach the DC terminal covers.
I m p o rta n t: The next step is the last cable connection. A spark is normal when
this connection is made.
F ig u re 2 -1 0 Battery Cable Connection
C A U T I O N : D a m a g e to E q u ip m e n t
Do not put anything between the battery cable lug and the terminal surface.
O verheating of the terminal may occur. Do not apply any type of antioxidant
paste until after the battery cable wiring is tightened. The same applies for all DC
connections. Do not over-tighten; observe all recommended torque values.
C A U T I O N : R e ve rse P o la rity D a m a g e
Before making the final DC connection or closing the DC breaker or disconnect,
check cable polarity at both the battery and the inverter/charger. Positive ( + )
must be connected to positive ( + ) . Negative ( ) must be connected to
negative ( ) .
Reverse polarity damage is not covered by warranty.
Terminal surface
Copper compression lug
M ake sure 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 lock washer
I nverter/C harger I nstallation
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I n sta llin g th e B a tte ry Te m p e ra tu re S e n so r
The Battery Temperature Sensor ( BTS) regulates battery charging based on
battery temperature. I nstalling a sensor extends battery life by preventing
overcharging in warm temperatures and undercharging in cold temperatures.
The BTS is supplied with the Xantrex XW I nverter/Charger. The replacement part
number is 808-0232-02.
F ig u re 2 -1 1 DC Connections to a Single I nverter
Hybri d Inverter /Charger
_BatteryConnections -EU.vsd/SI noBOS/April 10, 2008
2007 XantrexTechnologyInc .
(+) ()
FUS E
CLAS S
T
300
AMP
FUS E
CLAS S
T
300
AMP
ON
OFF
(+)
()
(+)
()
L N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC OUT AC IN AC IN
L N L N
Actual cable and grounding
requirements may vary.
See Table 2-6 on page 214
for torque values for the
inverter battery
connections.
Battery
Negative (
Positive ( + )
G round
Battery
Fuse
Block
( optional)
Circuit
Breaker/DC
Disconnect
DC
Disconnect
Negative/
G round Bus
BTS Cable
Battery
System
Bonding Wire
( if required)
Battery
Torque connections to the battery terminals according
to the battery manufacturers recommendations.
Step 4: Wiring the I nverter
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To in s ta ll th e B a tte ry Te m p e ra tu re S e n s o r:
1. I nsert the Battery Temperature Sensor plug into the BTS port. See Figure 2-9
and Figure 2-11.
2. Route the cable to the battery enclosure and connect the ring terminal on the
BTS directly to a battery terminal ( recommended) , or use the adhesive
backing on the sensor back to attach the sensor to any side of the battery to
be monitored.
I f using the adhesive backing, install the BTS on the side of the battery below
the electrolyte level. I t is best to place the sensor between batteries and
place the batteries in an insulated box to reduce the influence of the ambient
temperature outside the battery enclosure.
M a k in g A C C o n n e c tio n s
This section describes how to make AC connections between the Xantrex XW
I nverter/Charger, the main utility panel, and the inverter load sub-panel. All wiring
must be provided by the installer.
Do not use an RCD
1
-equipped AC source to power the Xantrex XW I nverter/
Charger grid or generator inputs. The AC input filters on the Xantrex XW I nverter/
Charger may cause nuisance tripping of ground fault-protected outputs.
Not e: I f other Xantrex Xanbus-connected components supply a BTS or are
BTS-enabled, it is not necessary to install all of them at once. O nly one BTS
needs to be installed.
However, if multiple battery banks are being used, multiple sensors can be
installed. I n this case, the system uses the highest temperature from all the
input as its operational parameter.
C A U T I O N : D a m a g e to th e I n ve rte r
The inverters AC output must never be wired to the utility or generator output.
This will cause severe damage to the inverter which is not covered under the
warranty.
1.Residual C urrent Detection
I nverter/C harger I nstallation
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A c c e ssin g th e A C Te rm in a l B lo c k a n d A C G ro u n d B a r
The AC terminal block includes two terminals each ( L and Neutral) for AC G rid
input, AC G enerator input, and AC Load connections. The neutrals are
connected to each other, requiring only one neutral connection when the
installation uses a Xantrex XW Power Distribution Panel. Without the Xantrex XW
Power Distribution Panel, additional neutral connections may be required at the
input sources.
The AC terminal block is located on the left side of the inverter beneath the AC
access cover. See Figure 2-12.
F ig u re 2 -1 2 AC Terminal Block and G round Bar
Hybrid Inverter /Charger
Gri d(AC1)
Gen (AC2)
Faul t / Warni ng
Equal i ze Battery
Chargi ng
Inverti ng Flashing = sell
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC
OUT
AC IN AC IN
L N L N L N
When replacing the AC
access cover, make sure its
recessed edge slips inside
the edge of the front panel.
Recessed
edge
Remove the two screws on
the AC access cover and
slide it to the left of the
inverter to remove it.
AC Terminals
AC G round Bar
Step 4: Wiring the I nverter
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A C E q u ip m e n t G ro u n d in g
See Table 2-4 on page 213 for torque values for the AC terminal and AC G round
bar.
F ig u re 2 -1 3 AC Equipment G rounding
Hybri d Inverter /Charger
_Grounding.vsd/AC Grounding/April 10, 2008
2006 XantrexTechnologyInc .
G N
L
LIVE OUT
N
G
LIVE IN
L N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC OUT AC IN AC IN
L N L N
M ain Utility Panel
( 230 V)
AC
G enerator
G enerator Disconnect
230 V
Primary System
G round
I nverter Load
Sub-Panel ( 230 V)
Actual grounding requirements may
I nverter/C harger I nstallation
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A C Wirin g to th e I n ve rte r L o a d S u b -P a n e l
An inverter load sub-panel ( also known as an inverter AC distribution panel) and
AC conduit must be installed before AC wiring is connected to the inverter.
To in sta ll th e in ve rte r lo a d su b -p a n e l a n d c o n d u it:
1. Determine the location for the inverter load sub-panel, and install it
according to the manufacturers directions.
2. I nstall an AC conduit between the Xantrex XW I nverter/C harger and the
inverter load sub-panel.
3. Determine which circuits the inverter will power, and install the appropriate
circuit breakers into the inverter panel.
4. For on-grid systems:
a) Disconnect all power to the main utility panel.
b) Determine which circuits will be supplied by the inverter( s) and remove
their wires from the main panel.
c) Reroute these wires to the new inverter load sub-panel.
5. Remove unused breakers from utility panel.
6. I nstall a 60-amp maximum ( disconnect) main circuit breaker in the inverter
panel. Later, this will be wired to the inverters output.
WA R N I N G : S h o c k H a za rd
Before making any electrical connections, make sure all AC and DC disconnect
devices are in the O PEN ( disconnect) position.
C A U T I O N : D a m a g e to th e I n v e rte r
The inverters AC output must never be wired to the utility or generator output.
This will cause severe damage to the inverter which is not covered under
warranty.
Step 4: Wiring the I nverter
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A C S yste m B o n d in g
S y s te m B o n d in g Refers to connection ( bonding) of one of the current-carrying
conductors of an electrical system to ground. This creates a grounded
conductor" or "neutral" that is at ground potential, but is separate from the
equipment ground conductor. System bonding must be done in one place only to
avoid ground loops, and it must be done differently in on-grid and off-grid
systems.
S y s te m B o n d in g
fo r O n -g rid
S y s te m s
The Xantrex XW I nverter/Charger does not connect the neutral to ground. The AC
input neutral is already bonded to ground by the incoming utility grid system. The
installer must not connect the neutral to ground in any additional location.
The Xantrex XW I nverter/C harger does not switch or disconnect the AC neutral in
any mode of operation, so even in invert ( back-up) mode, the inverter load
sub-panel neutral is bonded to ground by the utility grid system. I t must not be
grounded again in the inverter load sub-panel.
S y s te m B o n d in g
fo r O ff-g rid
S y s te m s
I n a system without a generator, or with a generator that does not provide a
grounded neutral, the connection from neutral to ground must be made by
the installer in the inverter load sub-panel.
I n a system with a generator that provides a grounded neutral, no additional
connection from neutral to ground is needed. The installer must not connect
neutral to ground in the inverter load sub-panel.
A C Wirin g to th e Xa n tre x XW I n ve rte r/C h a rg e r
M ake sure the AC system, including the Xantrex XW I nverter/Charger and
generator, is correctly grounded according to local electrical codes. See AC
Equipment G rounding on page 221.
To c o n n e c t th e in ve rte r to th e in ve rte r lo a d s u b -p a n e l:
1. See Figure 2-14. Connect the neutral wire from the inverter panel neutral bus
to the N-LO AD terminal on the inverter.
2. Connect the L ( LI VE) wire from the input terminal on the inverter panel to the
AC Load ( L-LO AD) terminal on the inverter.
WA R N I N G : F ire a n d S h o c k H a za rd a n d R isk o f
E q u ip m e n t D a m a g e
Verify that only one neutral-to-ground bond exists in the system. Having more
than one neutral-to-ground bond in a system violates local electrical codes, may
create a shock or fire hazard, and may cause some sensitive equipment to
malfunction.
WA R N I N G : S h o c k H a za rd
Before making any electrical connections, make sure all AC and DC disconnect
devices are in the O PEN ( disconnect) position.
I nverter/C harger I nstallation
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To c o n n e c t th e in v e rte r to th e m a in u tility p a n e l:
1. See Figure 2-14. Connect the neutral wire from the main utility panel to the
inverter G RI D ( AC 1) neutral terminal.
2. C onnect the AC LI VE wire from the main utility panel to the inverter G RI D
( AC1) L terminal.
To c o n n e c t th e in v e rte r to th e A C g e n e ra to r:
1. See Figure 2-15. Connect the neutral wire from the generator breaker or
disconnect to the inverter G EN ( AC2) neutral terminal.
2. Connect the AC LI VE wire from the generator breaker or disconnect to the
inverter G EN ( AC2) L terminal.
F ig u re 2 -1 4 Wiring the Xantrex XW I nverter/Charger to the I nverter Load Sub-Panel and Utility G rid
LIVE OUT
N
G
LIVE
IN
_AC Wiring (all)-EU.vsd/AC WiringtoSubPanel /April 10, 2008
2007 XantrexTechnologyInc .
G
N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC
OUT
AC IN AC IN
L N L N L N
Hybri d Inverter /Charger
L N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC OUT AC IN AC IN
L N L N
_AC Wiring-to-subpanel-EU.vsd May3, 2010
I nverter Load
Sub-Panel ( 230 V)
AC
Neutral
AC LI VE
G roun
Primary System G round
M ain Utility Panel
230 V
Torque all inverter terminal block connections
according to Table 2-4 on page 213.
Actual wiring and grounding requirements may vary.
The Neutral-to-G round bond, which
is provided in the utility grid system,
may be located upstream.
Step 4: Wiring the I nverter
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F ig u re 2 -1 5 G enerator Wiring to the I nverter
AC Wiring - Generator.vsd May 3, 2010
Hybri d Inverter /Charger
G N
L
L N
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC OUT AC IN AC IN
L N L N
Torque all inverter terminal block connections
according to Table 2-4 on page 213.
Actual wiring and grounding requirements may vary.
AC G enerator
G enerator
Disconnect
I nverter/C harger I nstallation
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A u x ilia ry A U X) P o rt
The auxiliary output is designed to provide the following functions:
Auxiliary 12 VDC power supply
Remote power off
The auxiliary port provides 12 VDC/250 mA output to control a relay, fan,
indicator light, or other device. The auxiliary output can be configured ( using a
Xantrex XW System Control Panel) to trigger in response to:
low battery voltage
high battery voltage
low battery temperature
high battery temperature
any device fault
The auxiliary output can also be triggered manually using the Xantrex XW System
Control Panel.
The 12 VDC output can trigger a relay to disconnect batteries from the inverter/
charger when battery voltage or temperature are out of the ideal range.
A U X+1 2 V Vo lta g e S u p p ly
DC voltage is available between JU-1 ( AUX + 12 V) and JU-3 ( AUX-CO M , signal
return) . The power available at these terminals is 12 VDC, and maximum current
is 250 mA ( 3 watts) .
The AUX+ 12 V and AUX-CO M terminals can be used to power a relay ( 3 watts
maximum) . Additional fuses are not required, but may be required for some
installations. The default status of AUX+ 12 V is O FF.
F ig u re 2 -1 6 AUX Port Location
AUX Port
Step 4: Wiring the I nverter
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A U X-R P O : U se r R e m o te P o we r O ff R P O )
Connecting JU-2 ( AUX-RPO ) and JU-3 ( AUX-CO M ) terminals together through
an external switch ( normal open contact) provides the system shut off function if
the switch is closed.
The external switch, if pressed, overrides the control provided from the front
panel.
I f the external switch is cleared ( not pressed) , the system can be enabled back
from the front panel.
Select an external switch with normal open contact. Consult your system
designer or qualified technician for specific installation instructions.
U se r L in e Wirin g
Use twisted pairs of #24 AWG to #12 AWG ( 0.5 mm
2
to 2.5 mm
2
) for connections.
Carefully route the wires away from high power load cables to minimize noise
effects on signal integrity.
A U X P o rt Te rm in a l A ssig n m e n ts
Ta b le 2 -7 User Connector Terminals and Functions
P in R e fe re n c e N a m e F u n c tio n
JU-1 AUX+ 12V + 12 V User
Voltage Supply
+ 12 VDC Voltage source: 250 mA
maximum
JU-2 AUX-RPO Remote Power
O ff
Remote Power O ff Logic Level:
Active Low. Activating this signal
shuts down system operation.
JU-3 AUX-CO M Common G round
Reference
Return Common G round
Reference for 12V, Remote Power
O ff signals.
JU-4 Not
O perational
Not O perational Not O perational
JU-5 Not
O perational
Not O perational Not O perational
I nverter/C harger I nstallation
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Basic Functional Test - Single Inverter
The following steps perform a basic functional test of the Xantrex XW I nverter/
C harger. I f any test fails, refer to the Troubleshooting section in the Xantrex XW
Hybrid I nverter/C harger O peration G uide for assistance.
C o n firm A ll C o n n e c tio n s
O nce the AC and DC wiring have been installed and connected, go back over all
connections and make sure they are secure and have been installed correctly.
A p p lyin g D C P o we r to th e I n ve rte r
To a p p ly D C p o w e r to th e in v e rte r:
1. Before applying DC power to the inverter, measure the voltage and polarity of
the battery cables ( measure at the battery side of the disconnect or breaker) .
2. Apply battery power to the inverter by closing the battery bank DC
disconnect.
The inverter will power up and the display will turn on, but the inverter will
remain in Standby mode ( as shown in Figure 2-17) .
C A U T I O N : R e v e rs e P o la rity D a m a g e
Before making the final DC connection or closing the DC breaker or disconnect,
check cable polarity at both the battery and the inverter/charger. Positive ( + )
must be connected to positive ( + ) . Negative ( ) must be connected to
negative ( ) .
Reverse polarity damage is not covered by warranty.
I m p o rta n t: Voltage should be between 40 to 64 volts for a 48-volt system, and
20 to 32 volts for a 24-volt system. I f the DC voltage is low, the battery bank must
be charged externally. Charge the battery bank, and then restart the functional
test.
I f the DC voltage is lower than the Low Battery Cut O ut ( LBCO ) setting ( 46 volts
for a 48-volt system and 23 volts for a 24-volt system) a DC Under Voltage Fault
( F48) will be triggered. I f the DC voltage is lower than the default LBCO voltage,
lower the LBCO setting accordingly to avoid triggering the fault.
I f the DC voltage is lower than 40 volts for a 48-volt system or 20 volts for a
24-volt system, the battery should be charged externally.
Basic Functional Test - Single I nverter
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E n a b le th e I n ve rte r
By default, I nvert mode is enabled and the unit should start inverting upon
transitioning from Standby mode. I f I nvert mode is disabled, the display will show
once out of Standby mode. I f the unit powers up in Standby mode, press
the O N/O FF button momentarily to change the mode from Standby to O perating.
To e n a b le th e in ve rte r:
Press the inverters O N/O FF button and the Equalize button at the same time.
co briefly appears on the inverter information panel to indicate that the
inverter is enabled.
To d is a b le th e in ve rte r:
Press the inverters O N/O FF button and the Equalize button at the same time.
o5 briefly appears on the inverter information panel to indicate that the
inverter is disabled.
F ig u re 2 -1 7 Power-up Display
C A U T I O N : E q u ip m e n t D a m a g e
Prior to activating the inverter, make sure that all AC loads are disconnected from
the output of the inverter.
O N/O FF Button
All LEDs temporarily turn on.
Note: I f the inverter was
previously powered up then it
will power-up in the last
operating state ( O perating or
Standby)
I nverter/C harger I nstallation
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3. M onitor the I NVERT ( G reen kW) LED to confirm which mode the inverter is in:
LED is off I nvert mode is disabled. The inverter/charger is not powering
the AC loads. However, if qualified AC is present from the utility or a
generator, it is passed through to the loads.
5co on the display The inverter/charger is in the Search mode and is
looking for an AC load greater than the Search Watts setting
( default = 25 watts) .
LED is on The inverter/charger is on. The inverter is operating and is
able to provide power to the AC loads. This is the default mode on initial
power-up once the unit is taken out of Standby mode.
I f the inverter is not operating or the I NVERT LED ( kW) does not turn on, check
all connections. Check the inverters DC voltage on the positive ( + ) and
negative ( ) terminals. Check the Fault LED. I f the Fault LED is on, check for a
fault code on the information panel. Correct the reported fault if possible and
clear the fault. I f the DC voltage is low, the battery bank needs to be charged
externally. Charge the battery bank and restart the functional test.
A C Vo lta g e C h e c k
To p e rfo rm a n A C v o lta g e c h e c k :
1. With the inverter on ( I NVERT [ green, kW] LED is on and steady) , verify the AC
voltage at the AC Loads block terminal L-Load to N-Load.
2. Verify that neutral is bonded to ground in the system by measuring the live
and neutral voltages relative to ground. Neutral-to-ground should equal zero
( 0) volts.
3. After confirming the correct AC voltage, turn on your AC output breaker and
place a load on the inverter ( plug in a light or other load to an outlet the
inverter is powering) .
4. Confirm that the AC load just applied works properly.
F ig u re 2 -1 8 Enable the I nverter
O N/O FF
Button
Briefly press the Equalize button and the O N/O FF button at the
same time to enable or disable I nvert mode.
Equalize
Button
This display indicates the
inverter is disabled.
I m p o rta n t: This test requires the use of a voltmeter.
Basic Functional Test - Single I nverter
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C o n firm in g B a tte ry C h a rg e r O p e ra tio n
To c o n firm b a tte ry c h a rg e r o p e ra tio n :
1. Apply AC from grid or generator, and then confirm voltage.
2. Check LEDs ( AC1 or AC2) on the front panel. O ne of them must be on for the
unit to charge. Check the amp A LED. I f the A LED is on, the unit is
charging and the battery current is displayed on the information panel.
This completes the functional test. I f all tests pass, the inverter is ready for use. I f
any of the inverters internal set points need to be adjusted, consult the
configuration chapter of the operation guide.
F ig u re 2 -1 9 Checking AC Voltage
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC
OUT
AC IN AC IN
L N L N L N
F ig u re 2 -2 0 Checking Charging O peration
I m p o rta n t: Unless the inverter/charger settings have been changed, the inverter
will charge as if it has a large ( > 440 Ah) flooded battery bank ( factory default
setting) . Therefore, ALL systems may need to have the battery charging set
points configured to avoid damage to the batteries.
Amp ( A) LED
I nverter/C harger I nstallation
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F ig u re 2 -2 1 Functional Test for Single I nverter Systems
AC
LOAD
GRID
(AC1)
GEN
(AC2)
AC
OUT
AC IN AC IN
L N L N L N
Check and verify all
wiring and cable
connections
M easure DC voltage
and confirm the correct
polarity of the cable
connections
Within tolerance?
2332 V for a 24 V system
4664 V for a 48 V system
Polarity correct?
Check battery bank.
Recharge with external
charger if necessary.
Correct polarity.
Restart functional test.
No
Yes
Apply DC power
Check display for
startup self-test
I f unit powers up in 5cb,
enable operating mode
Enable inverter
Check for faults
Faults?
Yes
Correct fault
condition. Restart
functional test.
No
Check AC
voltage
Within
range?
No
Yes
Consult Troubleshooting
section of O peration G uide.
Restart functional test
Close AC
load breaker
Confirm
operation of AC
load
O pen AC
load breaker
Proceed to
Charger
Functional Test
Power-up Display
Standby Display
Fault Display
Press the O N/O FF button momentarily to
enable operating mode
Press the O N/O FF and Equalize buttons
simultaneously to enable invert mode. co is
displayed briefly.
Step 5: I nstalling Additional I nverters
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Step 5: Installing Additional Inverters
I n s ta lla tio n S te p s
To in s ta ll m u ltip le in v e rte rs :
1. Disconnect all power from the system.
2. M ount additional inverters. See Step 1: I nstalling the M ounting Plate on
page 24 and Step 2: M ounting the I nverter on page 27.
3. I nstall conduit and cable clamps for DC cables, AC wiring, and AC Sync
cables in accordance with local electrical codes.
4. I nstall Xantrex Xanbus and AC Sync cables as required. See Step 3:
I nstalling Communications Cables on page 28.
5. I nstall a Xantrex XW System Control Panel. When installing more than one
inverter at a location, a Xantrex XW System C ontrol Panel is required to give
each inverter ( and other Xantrex Xanbus-enabled devices) a unique name
and to modify the factory-installed default settings to match and support the
installation.
6. I nstall additional breakers and components in the inverter load sub-panel
and the main utility panel to accommodate the extra inverters.
7. Connect DC wiring.
8. Connect AC wiring.
I nverter/C harger I nstallation
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Basic Functional TestMultiple Inverters
The following steps perform a basic functional test of multiple Xantrex XW
I nverter/C hargers. I f any test fails, refer to the Troubleshooting section in the
Xantrex XW Hybrid I nverter/Charger O peration G uide for assistance.
To p e rfo rm a fu n c tio n a l te s t o n m u ltip le in v e rte rs :
1. Check/verify all wiring and cable connections.
2. M easure DC voltage at the DC terminals on the inverter and confirm that it is
within range and has correct polarity. The default acceptable range is 2332
VDC for 24 V systems or 4664 VDC for 48 V systems.
3. Connect DC power to the first inverter.
4. C heck the inverters display for startup self-test during which all LEDs will
flash momentarily. O nce the self-test is complete, the inverter displays 5cb.
The Fault/Warning LED may flash for a few seconds but eventually will turn
off. I f the Fault/Warning LED persists, make sure the battery temperature
sensor is connected. Also, if the inverter has been pre-configured, it may go
straight into normal operating mode.
5. Using the Xantrex XW System Control Panel, set the first ( M aster) inverters
device number.
a) G o to the inverters Advanced Settings menu by pressing the down
arrow, and then Enter from System Status screen. Next, simultaneously
press Enter + up arrow + down arrow.
b) Select the M ulti Unit Config menu.
c) C hange Dev Number from 00 to 01. The inverter will now appear as
XW6048 01 ( or XW4548 01 or XW4024 01) on the Xantrex XW System
Control Panel.
d) I f performing a test on a three-phase installation, change I nvtr M ode to
3Ph L1M aster. For more information, see Three Phase Configuration
in the Xantrex XW Hybrid I nverter/C harger O peration G uide.
e) Press Exit until the Xantrex XW System C ontrol Panel displays the System
Status screen again.
6. Connect DC power to the next inverter.
7. Check the inverter display for startup self-test during which all LEDs will flash
momentarily. O nce the self-test is complete, the inverter displays 5cb. ( I f the
inverter has been pre-configured, it may go straight into normal operating
mode or display GG warning.)
8. Using the Xantrex XW System Control Panel, set the second ( Slave) inverters
device number and inverter mode.
a) Select the new inverter XW6048 00 ( or XW4548 00 or XW4024 00) from
the Select Device menu. You can also press the down arrow from the
System Status screen until the home screen for Xantrex XW I nverter/
Charger 00 is displayed, and then press Enter.
b) G o to the inverters Advanced Settings > M ulti-Unit C onfig menu.
c) C hange Dev Number from 00 to 02 ( or the next number that has not
been used) . The inverter will now appear as XW6048 02 ( or XW4548 02
or XW4024 02) on the Xantrex XW System Control Panel.
Basic Functional Test M ultiple I nverters
975-0384-01-02 235
This manual for use by qualified personnel only
d) Change I nvtr M ode from 1Ph M aster to 1Ph Slave. I f performing a test
in a three-phase installation, change the I nvtr M ode to 3Ph L1Slave,
3Ph L2Slave, or 3Ph L3Slave depending on the line to which the unit
is connected.
e) Press Exit until the Xantrex XW System Control Panel displays the System
Status screen again.
9. Check for faults. I f fault conditions exist, correct them and then restart the
Functional Test.
10. I f a third inverter is installed, repeat steps to configure it as a Slave.
11. Using the Xantrex XW System Control Panel, enable the system.
a) G o to the System Settings menu.
b) Change System M ode to O perating.
c) Press Exit until the Xantrex XW System Control Panel displays the System
Status screen again.
12. Confirm that the M aster inverter displays 0.00 and the Slaves display
on their front panels.
13. Check for faults. I f fault conditions exist, correct and then restart the
Functional Test.
14. Check voltage at AC LO AD terminals of the M aster I nverter.
15. Switch the AC Load breakers on.
16. Confirm operation of connected AC loads.
17. Disconnect AC LO AD breakers.
18. Using the Xantrex XW System Control Panel, reduce the M aximum Charge
Rate.
a) From the System Status screen, go to the Select Device menu. Select
System Settings, and then enable Cascading ( if not enabled) . With
Cascading enabled, a change to a setting in one inverter will
automatically apply to other inverters in the system.
b) G o to Advanced Settings > Charger Settings in one of the inverters.
c) Set M ax Chg Rate to 10% .
d) Press Exit until the Xantrex XW System Control Panel displays the System
Status screen again.
19. Switch AC I nput breakers on. Note that all inverters in the system must be
connected to the same AC I nput source before they will qualify the source.
20. Confirm that inverters start charging. Note that with M ax Chg Rate set to 10%
the maximum charge rate is limited to 10 A on each inverter. Depending on
the battery banks state of charge, the output from one or more inverters may
quickly drop to zero. This is considered normal operation.
21. Check for faults. I f fault conditions exist, correct and then restart the
Functional Test.
I nverter/C harger I nstallation
236 975-0384-01-02
This manual for use by qualified personnel only
F ig u re 2 -2 2 Functional Test for M ultiple I nverters - Page 1 of 2
Check all wiring
and cable
connections
M easure DC voltage
and confirm correct
polarity of DC cables
Within tolerance?
2332 V for a 24 V system
4664 V for a 48 V system
Polarity correct?
Check battery bank.
Recharge with external
charger if necessary.
Correct polarity.
Restart functional test.
No
Yes
Apply DC power to
inverter #1
Check display on
I nv #1 for startup
self-test
Check display for
faults
Faults?
Yes
Correct fault condition.
Restart functional test.
Power-up
Fault Display
Power-up Display
Check display on
I nverter #2 for
startup self-test
Apply DC Power to
I nverter #2
Use the Xantrex XW
SCP to specify
configuration settings
1. Set up I nverter #1
as the M aster
2. G ive it a unique
device number
( e.g. 01)
1. Set up I nverter #2 as
the Slave
2. G ive it a unique
device number
( e.g. 02)
Use the Xantrex XW
SCP to specify
configuration settings
No
Basic Functional Test M ultiple I nverters
975-0384-01-02 237
This manual for use by qualified personnel only
F ig u re 2 -2 3 Functional Test for M ultiple I nverters - Page 2 of 2
From previous page...
Use Xantrex
XW SCP to
enable system
Set System
M ode to
O perating
Use Xantrex XW
SCP to enable
both inverters
Use System Settings
to enable invert mode
on both inverters
Confirm invert
mode has
been enabled
Check
display for
Faults
Faults?
Yes
Correct fault
condition. Restart
functional test.
No
Check AC voltage at
terminals of M aster
Close both AC
load breakers
Confirm
operation of
AC load
Disconnect
AC load
breakers
Proceed to
Charger
Functional Test
M aster
M aster
Slave
Slave
Confirm that M aster
shows output but Slave
is not inverting
Check for faults on both
information panels and
Xantrex XW SCP
238
This manual for use by qualified personnel only
A Specifications
Appendix A, Specifications provides the
electrical and mechanical specifications
for the Xantrex XW Power System.
Specifications
A2 975-0384-01-02
This manual for use by qualified personnel only
Electrical Specifications
Ta b le A -1 Xantrex XW Power System Electrical Specifications
Xa n tre x
X W6 0 4 8 2 3 0 5 0
Xa n tre x
X W4 5 4 8 2 3 0 5 0
Xa n tre x
X W4 0 2 4 2 3 0 5 0
Continuous O utput Power 6, 000 W 4, 500 W 4, 000 W
Surge Rating 12, 000 W ( 15 s) 9, 000 W ( 20 s) 8, 000 W ( 20 s)
Surge Current 53 A
rms
( 15 s) 40 A
rms
( 20 s) 35 A
rms
( 20 s)
Peak Efficiency 95.4% 95.6 % 94.0%
Full Load Efficiency 92% 93.0 % 89%
Waveform True Sine Wave
I dle Consumption invert mode, no load 28 W 26 W 24 W
I dle Consumption search mode < 7 W
AC O utput Voltage 230 Vac 3%
AC I nput Voltage Range ( Bypass/Charge M ode) 156280 Vac
AC I nput Breaker 60 A
AC I nput Frequency Range ( Bypass/Charge
M ode)
4555 Hz ( default)
4068 Hz ( allowable)
AC O utput Continuous Current 26.1 A 19.6 A 17.4 A
AC O utput Frequency 50.0 0.1 Hz
Total Harmonic Distortion < 5% at rated power
Automatic Transfer Relay 56 A
Auxiliary Relay O utput 012 Vdc, maximum 250 mA DC
DC I nput Voltage ( Nominal) 50.4 Vdc 50.4 Vdc 25.2 Vdc
DC I nput Voltage Range 4064 Vdc 4064 Vdc 2032 Vdc
DC Current at Nominal Power 131 A 96 A 178 A
Continuous Charge Rate at Nominal Voltage 100 A 85 A 150 A
Power Factor Corrected Charging PF ( 0.98)
Electrical Specifications
975-0384-01-02 A3
This manual for use by qualified personnel only
Xa n tre x XW S e rie s I n ve rte r/C h a rg e r O ve rlo a d C a p a b ility
Loads connected to the inverter are seldom constant, and large loads are often
operated for short periods. To accommodate larger loads, the Xantrex XW
I nverter/Charger can temporarily exceed its continuous output power rating. The
graphs below illustrate approximate operation time versus load.
I nverter operation time during overload is limited by both inverter internal
temperature protection and by the product of AC output current and
elapsed time.
F ig u re A -1 Xantrex XW Series I nverter/Charger AC O verload Capability
Xantrex XW4548 AC Overload Capability
Xantrex XW4024 AC Overload Capability
Xantrex XW6048 AC Overload Capability
Specifications
A4 975-0384-01-02
This manual for use by qualified personnel only
O u tp u t P o we r Ve rsu s A m b ie n t Te m p e ra tu re
When the internal temperature of the Xantrex XW Series I nverter/Charger
exceeds a preset limit, it begins to limit output power automatically so that
maximum internal temperatures are not exceeded.
X a n tre x X W S e rie s I n v e rte r/C h a rg e r E ffic ie n c y
I n ve rtin g E ffic ie n c y Typ ic a l
F ig u re A -2 O utput Power Versus Ambient Temperature
O
u
t
p
u
t

P
o
w
e
r

(
W
a
t
t
s
)
Ambient Temperature ( C )
0
1000
2000
3000
4000
5000
6000
7000
-25 -15 -5 5 15 25 35 45 55 65 75
Xantrex XW Seri es Power Derati ng
Xantrex XW6048-Pwr_der
Xantrex XW4548-Pwr_der
Xantrex XW4024-Pwr_der
E
f
f
i
c
i
e
n
c
y

(
%
)
O utput Power ( Watts)
75%
80%
85%
90%
95%
100%
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
XW4024
XW4548
XW6048
Xantrex
XW6048
Xantrex
XW4548
Xantrex
XW4024
Electrical Specifications
975-0384-01-02 A5
This manual for use by qualified personnel only
C h a rg in g E ffic ie n c y Typ ic a l
C h a rg in g E ffic ie n c y P o we r F a c to r C o rre c te d )
E
f
f
i
c
i
e
n
c
y

(
%
)
Charge Current ( Amps)
80%
85%
90%
95%
100%
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
XW4024
XW4548
XW6048
Xantrex
XW6048
Xantrex
XW4548
Xantrex
XW4024
P
o
w
e
r

F
a
c
t
o
r

(
%
)
Charge Current ( Amps)
75%
80%
85%
90%
95%
100%
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
XW4548 XW4024
XW6048 Xantrex
XW6048
Xantrex
XW4548
Xantrex
XW4024
Specifications
A6 975-0384-01-02
This manual for use by qualified personnel only
G rid -T ie S e ll M o d e E ffic ie n c y Typ ic a l
O utput Power ( Watts)
E
f
f
i
c
i
e
n
c
y

(
%
)
75%
80%
85%
90%
95%
100%
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
XW4548
XW4024
XW6048
Xantrex
XW6048
Xantrex
XW4548
Xantrex
XW4024
M echanical Specifications
975-0384-01-02 A7
This manual for use by qualified personnel only
Mechanical Specifications
Ta b le A -2 Xantrex XW Power System M echanical Specifications
M o d e l
X a n tre x
X W6 0 4 8 2 3 0 5 0
X a n tre x
XW4 5 4 8 2 3 0 5 0
Xa n tre x
XW4 0 2 4 2 3 0 5 0
Supported Battery Types Flooded ( default) , G el, AG M , C ustom
Battery bank size 10010000 Ah
Non Volatile M emory Yes
Display Panel Status LEDs indicate AC I n status, faults/warnings, equalize mode,
and battery level.
Three-character display indicates output power or charge current,
and fault/warning codes.
O N/O FF and equalize button.
System Network Xantrex Xanbus ( publish-subscribe network, no need for hubs or
special cards)
Enclosure Type I P 20, indoor, unheated
Rated Temperature Range
( meets all specifications)
040 C
O perational Temperature
Range
-2570 C
Storage Temperature Range -4085 C
I nverter Dimensions
( H W D)
580 410 230 mm
Shipping Dimensions
( H W D)
711 572 394 mm
I nverter Weight 57 kg 52 kg 52 kg
Shipping Weight 60 kg 55 kg 55 kg
Specifications
A8 975-0384-01-02
This manual for use by qualified personnel only
Accessories
Regulatory Approvals
CE marked and complies with the following:
Low Voltage Directive 2006/95/EC, per:
EN50178 Electronic Equipment for Use in Power I nstallations.
EM C Directive 2004/108/EC, per:
EN61000-6-3 Emission Standard for Residential, Commercial, and
Light-I ndustrial Environments
EN61000-6-1 I mmunity for Residential, Commercial, and Light-I ndustrial
Environments
RCM marked and complies with the following:
AS 4777.2 I nverter requirements
AS 4777.3 G rid protection requirements
AS/NZS 3100 G eneral requirements for electrical equipment
A c c e ss o ry P a rt N u m b e r
Power Distribution Panel 865-1015
Xantrex XW C onduit Box 865-1025
I nverter #2 Connection K it 865-1020
Xantrex XW M PPT60 150 Solar Charge
Controller
865-1030-1
Xantrex XW System Control Panel 865-1050
Xantrex XW Automatic G enerator Start 865-1060
Network cables 3 ft ( 0.9 m) : 809-0935
25 ft ( 7.6 m) : 809-0940
75 ft ( 22.9 m) : 809-0942
Network terminators 100-0224-01-01
Index
975-0384-01-02 I X1

A
AC Connections 219
accessories A8
Additional I nverters 233
Automatic G enerator Start 16
AUX Port 226
AUX Port Terminal Assignments 227
AUX+ 12V Voltage Supply 226
AUX-RPO
User Remote Power O ff 227
B
battery bank requirements 212
battery cable lugs 213
Battery Cable Requirements 212
Battery Cable Size 213
Battery Temperature Sensor 218
Breaker/Fuse Size 213
C
charge controller 15
Clearance 23
D
DC Connections
Connecting Batteries 216
E
electrical specifications A2
F
Fire safety 22
functional test 228, 234
G
G rounding 214, 215
G rounding the DC System 215
I
I nverter Panel M ounting 222
K
K nockout 22
L
LED Status I ndicators
I nverting 230
Location 22
lugs, battery cable 213
M
mechanical specifications A7
M ounting 23
M ounting Bracket 24
M ounting the I nverter 27
O
overcurrent protection, requirements 213
S
specifications
electrical A2
mechanical A7
U
User Line Wiring 227
W
Website
Schneider Electric iv
Wiring the I nverter 212
X
XW I nverter/Charger 14
XW System Control Panel 16
I X-2
975-0384-01-02
Schneider Electric
www.schneider-electric.com

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1 866 519 1470
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