Previous Page. Next Page. 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 Inc. Page 5: About This Guide Consult individual battery manufacturers for this information. Installers must be certified technicians or electricians. Organization This guide is organized into two chapters and one appendix.
For this Topic See.. Page System Overview Introduction 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. System Diagram Page 13 Consult your local certified installer or local electrical authority to ensure compliance. Up to four inverters can be installed in parallel to create larger volt, single-phase systems, allowing for increased capacity.
It is secured to the inverter by two screws on the bottom of the inverter, and it is secured to the wall by two screws not provided.
Page 18 1— For this Topic See Page Pre-Installation Remove your choice of knockouts from the chassis to facilitate conduit installation for wire runs. Make sure no debris from this procedure remains inside the inverter enclosure. Use only the knockouts provided for conduit entry. The wall bracket is attached to the wall with lag bolts or other fasteners, provided by the installer.
Page 24 Mount 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. Lower the flange on the inverter onto the mounting plate. For maximum performance of your network, follow these guidelines when routing the communications cables.
Mount the devices according to the installation instructions for each device. Use an appropriate length of Xantrex Xanbus cable to connect each device. Insert a terminator into the open network port of the Xantrex Xanbus-enabled device at each end of the network. Page Step 4: Wiring The Inverter Also, do not allow the battery bank to become completely discharged.
If the voltage of the battery bank falls below 10 volts, the Xantrex XW Power System will not operate. Battery cables must be provided by the installer see Table on page 2— This section also provides procedures for installing the battery temperature sensor. Page Connecting The Batteries 2. They must be installed in the positive side of the DC circuit, as close as possible to the battery. A spark is normal when this connection is made.
Use a wrench to tighten the bolt to the required torque. Installing a sensor extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures.
The replacement part number is Residual Current Detection 2— The neutrals are connected to each other, requiring only one neutral connection when the installation uses a Xantrex XW Power Distribution Panel.
Figure AC Equipment Grounding 2—21 This manual for use by qualified personnel only Locate any electronic equipment susceptible to radio frequency and electromagnetic interference as far away from the inverter as possible. Fire safety Do not locate the inverter near readily flammable materials such as cloth, paper, straw, or plastic sheeting. Knockout Preparation Remove your choice of knockouts from the chassis to facilitate conduit installation for wire runs. Ensure no debris from this procedure remains inside the inverter enclosure.
Important: Do not drill, cut, or punch holes into the XW power distribution Panel. Use only the knockouts provided for conduit entry. There must be at least three feet of clearance in front of the inverter. Ensure that the vents are not obstructed with foreign objects and that the minimum clearances are met. The supporting surface must be strong enough to support a minimum of pounds kg. The wall bracket is attached to the wall with lag bolts or other fasteners, provided by the installer.
The fasteners must be sufficiently strong to support pounds. The wall bracket has mounting holes spaced 16 inches 40 cm apart and is designed to span two wall studs spaced 16 inches on-center. Additional mounting holes are also provided for flexibility in mounting options.
If the wall does not have inch on-center studs, the installer will need to provide adequate supports for the brackets. For example, a sheet of plywood can be attached to the wall, and the wall brackets can then be attached to plywood. The brackets are designed to interlock as shown in Figure , so that additional mounting plates are easily installed without additional measuring or levelling.
The type of fastener required to secure the mounting plate varies according to the vertical surface and wall structure of your installation location. Plywood should span at least three wall studs. Use recommended anchoring hardware to secure the plate see Table The brackets are designed to interlock, so additional mounting brackets are easily installed without additional measuring or levelling. When mounting the XW Conduit Box as shown in Figure , it is not necessary to attach the front panel until all wiring is complete.
Secure the bottom edge of the back panel to the wall using two screws B. Align the two holes in the front panel with the two holes in the back panel.
Use the two screws provided to secure the front panel to the back panel. AC GND? This section also assumes that the XW Conduit Box was installed in the previous section. Therefore, a small raceway has been included in the design of both the XW Power Distribution Panel and the XW Conduit Box to separate the communications cables from the power cables.
This is a small raceway run built into the bottom of both the XW Power Distribution Panel and the XW Conduit Box and is held in place by a single screw at the top of the raceway. Installation Tip Before making the AC or DC cable connections, route the communications cables through the raceway, but do not connect them to their components until after all the inverter connections are made. Once the AC and DC connections are made the run becomes difficult to access. Use different colors for the communications cables or cable tags to help make them easier to identify.
Raceway exits the panel through the back. See Figure on page 2—16 for an illustration showing the Communications Ports and where the accessories connect. Consider the following recommendations for battery use.
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. If DC power sources are connected directly to the inverter, the DC rating of the inverter can be exceeded and the inverter can be damaged.
Battery Bank Requirements The DC voltage of the inverter must match the nominal voltage of the system and all battery-connected devices. If the inverter is a volt inverter, then the battery bank and all battery-connected devices in the system need to be configured for 24 volts.
Important: The minimum recommended battery bank is 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. If the voltage of the battery bank falls below 10 volts, the XW Power System will not operate. Always use a cable of proper size and length, rated for the amperage of the inverter and batteries.
Important: Use only fine-stranded copper cables for battery and inverter DC connections. Do not use coarse-stranded wire, as the lack of flexibility may damage battery and inverter terminals. Battery cable length Runs should be kept as short as practical. Length should not exceed 10 feet 3 m. For best performance, the positive and negative cables should run alongside each other.
Avoid cable loops. Battery cable lugs Battery cables must have crimped copper compression lugs or crimped and soldered copper compression lugs. Soldered connections alone are not acceptable. Lugs must be rated for use with fine-stranded cable. Overcurrent protection For safety and compliance with regulations, battery overcurrent protection is required. Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability.
Terminal covers are required for all installations, even if a XW Conduit Box is used. It is also recommended that the shank of the ring terminals cable lugs be covered with heat shrink or some other form of insulation. These items are not supplied as part of the inverter, but are included in the XW Power Distribution Panel. All installations must comply with national and local codes.
Consult local and national codes for specific grounding and bonding requirements for the desired installation. Backfeed Protection Requirements Important: Installers 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 NEC article The raceways becomes more difficult to access after all AC and DC wiring is completed.
A Actual ground requirements may vary. Installing a sensor extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures. This port is also considered part of the DC interface see Figure To install the Battery Temperature Sensor: 1.
Route the cable to the battery enclosure and connect the ring terminal on the Battery Temperature Sensor directly to a battery terminal recommended , or use the adhesive backing on the sensor back to attach the sensor to any side of the battery to be monitored. If using the adhesive backing, install the Battery Temperature Sensor on the side of the battery below the electrolyte level.
It is best to place the sensor between batteries and place the batteries in an insulated box to reduce the influence of the ambient temperature outside the battery enclosure.
Only one BTS needs to be installed. However, if multiple battery-banks are being used, multiple sensors can be installed. This section also provides procedures for installing the battery temperature sensor. Figure shows the proper stacking order of hardware. Be careful to observe proper polarity. Attach the DC terminal covers. Route the DC cables from the battery—with the cables not connected to the battery— and connect them to the XW Power Distribution Panel: negative to negative bus, positive to the input end of the DC breaker.
To properly attach and torque the positive cable to the DC breaker, you may need to temporarily remove the breaker from the rail. Overheating 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. Negative — must be connected to negative —.
Reverse polarity damage is not covered by warranty. Actual cable requirements may vary. XW Power Distribution Panel shown with door and front panel removed. A C A See Table on page 2—10 for torque values for the inverter battery connections. This will cause severe damage to the inverter which is not covered under warranty.
The AC input filters on the XW may cause nuisance tripping of ground fault protected outputs. The neutrals are connected to each other, requiring only one neutral connection when installed with an XW Power Distribution Panel. Without the XW Power Distribution Panel, additional neutral connections may be required at the input sources.
Communication Ports Four communications ports and one AUX Port are located on the bottom of the inverter and support the following features.
The two Xanbus ports are used for network connections between inverters, charge controllers, and accessories. The auxiliary output can be configured using a XW System Control Panel to trigger in response to low- or high-battery voltage or high- or low-battery temperature.
When replacing the AC access cover, ensure its recessed edge slips inside the edge of the front panel. This may be a main panel or a sub-panel. Actual ground requirements may vary. In an off-grid installation i. No additional breaker is required. Install the inverter AC distribution panel and conduit as follows: 1.
Determine which circuits the inverter will power and install the appropriate circuit breakers into the inverter panel. For On-Grid systems: a Disconnect all power to the main utility panel.
Remove unused breakers from utility panel. It is now safe to re-energize the main utility panel. Install a amp maximum disconnect main circuit breaker in the inverter panel. 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. These limits are fixed when the unit is exporting power to the grid. The unit shall not be aggregated such that it can export more than 30 kW on a single point of common connection.
See Figure on page 2—11 for torque requirements. Actual wiring requirements may vary. The power available at these terminals is 12 Vdc and maximum current is 0. Additional fuses are not required, but may be required for some installations. The external switch if pressed overrides the control provided from the front panel. If 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 local system designer or qualified technician for specific installation instructions. Carefully route the wires away from high power load cables to minimize noise effects on signal integrity.
Connecting this signal shuts down system operation. Confirm All Connections Once the AC and DC wiring have been installed and connected, take a moment to go back over all connections and make sure they are secure and have been installed correctly.
To apply DC power to the inverter: 1. Before applying DC power to the inverter, measure the voltage and polarity of the cables measure at the battery side of the disconnect or breaker. Important: Voltage should be between 40 to 60 volts for a volt system, and 20 to 30 volts for a volt system. If the DC voltage is low, the battery bank needs to be charged externally. Charge the battery bank and restart the functional test. Apply battery DC power to the inverter by closing the battery bank DC disconnect.
The inverter will power up, the display will illuminate, but the inverter will remain in the Standby Mode as shown in Figure Note: If the inverter was previously powered up then it will power-up in the last operating state Operating or standby All LEDs temporarily illuminate.
By default, Invert Mode is enabled and the unit should start inverting upon transitioning from Standby Mode. If Invert Mode is disabled, the display will show once out of Standby Mode. This display indicates the inverter is disabled.
All LEDs temporarily illuminate. Figure Enable the Inverter 3. However, if good AC is present, it is passed through to the loads. The Display shows Sch Search when this mode has been enabled. The inverter is operating and is able to provide power to the AC loads. This is the default mode on initial powerup once the unit is taken out of Standby Mode. Check the Fault LED. If the fault LED is illuminated, check for a fault code on the information panel.
Correct the reported fault if possible and clear the fault. To perform an AC voltage check: 1. Verify that neutral is bonded to ground in the system by measuring the hot and neutral voltages relative to ground. Neutral-to-ground should equal zero 0 volts. 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. Confirm that the AC load that was just applied works properly.
Apply AC from grid or generator, confirm voltage. One of them must be illuminated for the unit to charge. This completes the functional test. If all tests pass, the inverter is ready for use. Disconnect all power from the system.
Mount additional inverter s. Install the XW Conduit Box. Install AC sync cable s as required. Install a XW System Control Panel to configure programmable settings and to name specific network components e. Convert the XW Power Distribution Panel to accommodate the extra inverter by installing the additional breakers and components.
See page 2—30 for instructions on converting the XW Power Distribution Panel to a dual-inverter configuration. Attach Bypass interlock plate to distribution panel cover. Connect DC wiring. See Figure on page 2—31 for dual-inverter configurations and Figure on page 2—35 for triple-inverter configurations.
Connect AC wiring. See Figure on page 2—33 for dual-inverter configurations. Miscellaneous bushings Important: When installing more than one inverter at a location, a XW System Control Panel will be required to give each inverter as well as other Xanbus-enabled devices a unique name and to modify the factory-installed default settings to match and support the installed configuration. Replace the factory-installed DC positive bus bar with the larger positive bus bar provided in the Connect negative battery cable for second inverter supplied in to DC negative distribution plate.
Connect positive and negative battery cables to second inverter. Re-install lower wire cover. Disconnect the AC wires from the utility grid or generator and to the sub-panel and remove the factory-installed distribution bars connected to top and bottom terminals on the AC breakers.
Remove bypass interlock bracket. Add three additional dual-pole AC breakers supplied in next to the existing three dual-pole AC breakers.
Attach the four distribution bars supplied in to top and bottom of AC breakers as shown in dual-inverter system wiring diagrams. Remove the knockouts on upper wire cover for additional breakers to fit through. Re-install upper wire cover.
Install bypass interlock plate with provided screws and nylon shoulder washers supplied in The following items are required for the third inverter furthest from PDP and should be sourced and prepared prior to the installation. Note that all wiring will have to be custom cut to fit the third unit. Wiring supplied with the extension kit is intended for a second inverter in a two inverter system.
Therefore, an external Bypass Switch may be needed. See Figure on page 2—37 for an illustration of how to wire an External Bypass Switch. Install larger positive distribution plate supplied in Connect negative battery cable for first inverter supplied with PDP to DC negative distribution plate.
Connect negative battery cable for second inverter custom, see material list to DC negative distribution plate. Connect positive and negative battery cables to first inverter. Connect positive and negative battery cables to third inverter. AC Breakers shown in this illustration represent the breaker arrangement for multiple AC source. Prepare power distribution bars supplied in by cutting away one of the four tabs, only three tabs per power distribution bar are required in a three inverter system.
A total of 6 distribution bars should be prepared. The AC sync cable connects each inverter, and provides the necessary communication and control between multiple units.
See Figure To install the AC Sync and Xanbus cables between inverters: 1 Remove the two factory-installed raceways for the communication cabling by removing the screw holding each raceway in place.
Route any additional communication cables through the raceways. Replace the wiring raceways, ensuring not to pinch the cables. Secure the raceways to the XW Conduit Box with the screw that was removed earlier. To perform a functional test on multiple inverters: 1.
Measure DC voltage at the DC terminals on the inverter and confirm its within range and has correct polarity. Check inverter display for startup self-test during which all LED's will flash momentarily. Once self-test is complete, inverter will display "Stb".
Also, if the inverter has been pre-configured, it may go straight into normal operating mode. The inverter will now appear as XW in the device list.
If the inverter has been pre-configured, it may go straight into normal operating mode or display F66 warning. Check for faults. If fault condition s exist, correct and restart Functional Test. If a third inverter is installed, repeat steps to configure it as a Slave. Confirm operation of connected AC loads. With Cascading enabled, a change to a setting in one inverter will automatically ripple through to the other inverter s in the system. Note - all inverters in the system must be connected to the same AC Input source before they will qualify the source.
Confirm both inverters start charging. This is considered normal operation. The Xanbus network simplifies operation and automates routine tasks. Software control eliminates errors due to analog signalling. Digital information is less susceptible to interference and line loss. The Xanbus System What is a network? A network is a collection of devices that perform individual functions, but also communicate and interact with the other devices.
The network capability of the XW Power System provides a robust, integrated product solution that simplifies and automates the installation, configuration, control, monitoring, and integration of devices that deliver and distribute AC or DC power.
Network components Each device is integrated into the network using cables, network connectors, and terminators. An example of a network-managed power system is shown in Figure Figure Network-Managed Power System Network configurations 3—2 The network can be installed in one of two configurations: as a multi-drop backbone see Figure or as a daisy chain see Figure The maximum number of Xanbus devices connected to a single Xanbus network should not exceed eight devices.
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. Important: See the specifications for each Xanbus device to determine how much power each device consumes or supplies.
The cable consists of eight conductors in four twisted pairs with an RJ45 modular connector wired to the TA standard. Table contains the arrangements of wire colors to pin numbers for the TA standard. If 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 Xantrex. The XW Series and other Xanbus-enabled devices ship with one male terminator already installed.
Depending on your network layout, this terminator may need to be removed and inserted into another device elsewhere in the network. All three inputs are wired identically and can accept either Xanbus cables or terminators. One input is available for connecting to a Xanbus-enabled device.
The remaining inputs are reserved for connection to other network connectors, a Xanbus cable terminated with a female terminator, or a male terminator. The network connector is mounted to a bulkhead or a wall, as shown in Figure To network connector or teminator To network connector To device Figure 3-Way Network Connector sample configuration 3—4 The Xanbus System Ordering Network Components Table provides a partial list of network components and part numbers.
Ready-made cables are available in standard lengths from 3 feet to 75 feet. For the most up-to-date list, call an authorized Xantrex dealer or visit the Outlet Store at www. It is up to the installer or system designer to decide which layout is best for the installation. Important: Do not mix the two types of network layouts. Mixed configurations are not supported by Xantrex. Multi-Drop Backbone Layout In a multi-drop backbone layout, each Xanbus-enabled device on the network is connected by a drop cable to the network bus or backbone with a network connector, as shown in Figure Terminators are required at both ends of the multi-drop backbone cable, as shown in Figure Therefore, the Xanbus-enabled devices do not require their own termination.
With only one terminator, the signal quality is degraded and performance on the network is reduced. Permanent configuration with only one terminator is not supported by Xantrex. If cables are placed at the end of the network, female terminators are required. Otherwise, male terminators can be inserted directly into the open jack of each network connector at the end of the network.
Advantages In this layout, Xanbus-enabled devices can be removed or replaced while still keeping the network operating. Disadvantage The main disadvantage of this layout is the cost of the network connectors a daisy chain layout uses no network connectors.
Each device in this layout requires its own network connector. This layout does not require network connectors. As in the multi-drop backbone layout, two terminators are required to ensure the communication signal quality on the network. The Xanbus-enabled devices at each end of the chain must have a male terminator inserted into their open network ports. Advantage The advantage of this layout is that it is less expensive to install because network connectors are not required.
Disadvantage The disadvantage of the daisy chain layout is that Xanbus-enabled devices cannot be removed from the network without interrupting the network. To make the network function after removing a device, you must connect the Xanbus-enabled devices on either side of the missing device to each other or replace the device. Male Terminator Terminate the network at each end. Important: Installing and replacing Xanbus-enabled devices in an existing system must be performed with the XW Power System in Standby mode.
Assemble all the tools and materials required for the installation. Installation Tools and Materials Tools The following tools may be required to install the Xanbus cables.
Avoid sharp bends in the cable—no less than a 4-inch mm radius. Allow for some slack in the cable tension.
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