Xantrex XW4024-120/240-60, XW4548-120/240-60,... User manual

TM
TM
XW™Power System
Installation Guide
XW4024-120/240-60
XW4548-120/240-60
XW6048-120/240-60
XW Power Distribution Panel
XW System Control Panel
XW Solar Charge Controller
XW Automatic Generator Start

®
XW Power System
Installation Guide

About Xantrex
Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in the development, manufacturing
and marketing of advanced power electronic products and systems for the renewable and mobile power markets. The company's
products convert and control raw electrical power from any central, distributed, renewable, or backup power source into high-quality
power required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver, Canada, with facilities in the
United States, Germany, Spain, and a joint venture in China.
About Schneider Electric
As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions
across multiple market segments, including leadership positions in energy and infrastructure, industrial processes, building automation,
and data centres/networks, as well as a broad presence in residential applications. Focused on making energy safe, reliable, and
efficient, the company's 120,000 employees achieved sales of more than 17.3 billion euros in 2007, through an active commitment to
help individuals and organisations "Make the most of their energy™". www.schneider-electric.com
Trademarks
Xantrex and Smart choice for power are trademarks of Schneider Electric Services International sprl, registered in the U.S. and other
countries.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for
identification purposes only.
Notice of Copyright
Copyright © 2008 Xantrex Technology Inc. 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.
161-G South Vasco Road
Livermore, California USA 94551
Xantrex Technology Inc. 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.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX®TECHNOLOGY INC. (“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER
INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER
SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH
INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK; AND
(c) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE
BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED.
APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT
WWW.XANTREX.COM.
Due to continuous quality improvement and product updates, the illustrations shown in this manual may not exactly match the unit
purchased.
Date and Revision
December 2008, Revision C
Part Number
975-0239-01-01
Product Numbers
865-1000 (XW 6048-120/240-60)
865-1005 (XW4548-120/240-60)
865-1010 (XW4024-120/240-60)
Contact Information
Telephone: [phone] (toll free in North America)
1-360-925-5097 (direct)
Fax: [phone] (toll free in North America)
1-360-925-5143 (direct)
Email: customer[email protected]
Web: www.xantrex.com

975-0239-01-01 iii
This manual for use by qualified personnel only
About This Guide
Purpose
The purpose of this Installation Guide is to provide explanations and procedures
for installing the XW Power System.
Scope
The Guide provides safety guidelines, detailed planning and procedures for
installing the XW Inverter/Charger and related system components (the “XW
Power System”). It does not provide details about configuration, operation,
maintenance or troubleshooting. See the Operation Guide or Owner’s Manual of
each device for this information. This Guide also does not provide details about
particular brands of batteries. You need to consult individual battery
manufacturers for this information.
Audience
The Guide is intended for anyone who needs to install the XW Power System.
Installers should be certified technicians or electricians.
Organization
This guide is organized into four chapters and three appendices.
Chapter 1, “Introduction” lists and describes the components and basic features of
the XW Power System.
Chapter 2, “Inverter/Charger Installation” describes how to mount and install the
XW Inverter/Charger, and the XW Power Distribution Panel and XW Conduit
Box.
Chapter 3, “Xanbus Network Installation” provides detailed information for
planning and installing the components necessary for network communication on
a Xanbus system.
Chapter 4, “XW Solar Charge ControllerInstallation” describes how to mount and
connect the XW Solar Charge Controller as part of the XW System.
Chapter 5, “XW System Accessories Installation” describes how to mount and
install the XW System Control Panel and the Automatic Generator Start.
Appendix A, “Specifications” provides the electrical and environmental
specifications for the XW Series.

About This Guide
iv 975-0239-01-01
This manual for use by qualified personnel only
Appendix B, “Wiring Diagrams” illustrate the most basic configurations and are
for reference only. Specific installations may require additional equipment to meet
national or local electric codes. Ensure all safety requirements are strictly
followed.
Appendix C, “Alternate System Configurations” provides wiring diagrams for
inverter/charger installations that do not require use of the power distribution
panel and the XW Conduit Box.
Conventions Used
The following conventions are used in this guide.
Related Information
Additional information about operating the XW Inverter/Charger, see the XW
Inverter/Charger Operation Guide (975-0240-01-01).
For more information about related components, refer to:
• XW Power System Intallation Overview (975-0238-01-01)
• XW System Control Panel Owner’s Guide (975-0298-01-01)
• XW Solar Charge Controller Owner’s Guide (975-0283-01-01)
• XW Automatic Generator Start Owner’s Guide (975-0307-01-01)
These guides are available at www.xantrex.com. Printed copies should be
included with the components.
For more information about Xantrex Technology, Inc. as well as its products and
services visit www.xantrex.com.
WARNING
Warnings identify conditions or practices that could result in personal
injury or loss of life.
CAUTION
Cautions identify conditions or practices that could result in damage to
the XW Power System components or other equipment.

975-0239-01-01 v
This manual for use by qualified personnel only
Important Safety Instructions
1. Before using the inverter, read all instructions and cautionary markings
on the unit, the batteries, and all appropriate sections of this manual.
2. Use of accessories not recommended or sold by Xantrex Technology Inc. may
result in a risk of fire, electric shock, or injury to persons.
3. The inverter is designed to be permanently connected to your AC and DC
electrical systems. Xantrex recommends that all wiring be done by a certified
technician or electrician to ensure adherence to the local and national
electrical codes applicable in your jurisdiction.
4. To avoid a risk of fire and electric shock, make sure that existing wiring is in
good condition and that wire is not undersized. Do not operate the inverter
with damaged or substandard wiring.
5. Do not operate the inverter if it has been damaged in any way. If the unit is
damaged, see the Warranty and Product Information section at the end of this
manual.
6. This unit does not have any user-serviceable parts. Do not disassemble the
inverter except where noted for connecting wiring and cabling. See the
Warranty Section in the XW Inverter/Charger Operation Guide and other
component manuals for instructions on obtaining service. Attempting to
service the unit yourself may result in a risk of electrical shock or fire. Internal
capacitors remain charged after all power is disconnected.
7. To reduce the risk of electrical shock, disconnect both AC and DC power
from the inverter before attempting any maintenance or cleaning or working
on any components connected to the inverter. Turning off controls will not
reduce this risk.
8. The inverter must be provided with an equipment-grounding conductor
connected to the AC input ground.
9. Do not expose this unit to rain, snow, or liquids of any type. This product is
designed for indoor use only. Damp environments will significantly shorten
the life of this product and corrosion caused by dampness will not be covered
by the product warranty.
10. To reduce the chance of short-circuits, always use insulated tools when
installing or working with this equipment.
11. Remove personal metal items such as rings, bracelets, necklaces, and watches
when working with batteries.
WARNING
This chapter contains important safety and operating instructions as required by
UL and CSA standards for inverters used in residential applications. Read and
keep this Installation Guide for future reference.

Important Safety Instructions
vi 975-0239-01-01
Limitations on Use
Single-phase Operation Only
Explosive Gas Precautions
1. Working in the vicinity of lead acid batteries is dangerous. Batteries generate
explosive gases during normal operation. Therefore, you must read this guide and
follow the instructions exactly before installing or using your inverter/charger.
2. To reduce the risk of battery explosion, follow these instructions and those published
by the battery manufacturer and the manufacturer of the equipment in which the
battery is installed.
FCC Information to the User
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the following
measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment to a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
WARNING: Limitations on Use
The XW Power System is not intended for use in connection with life support
systems or other medical equipment or devices.
CAUTION
The XW4024-120/240-60, XW4548-120/240-60 and XW6048-120/240-60 series of
Inverter/Chargers are designed and tested for operation with single phase, three wire
(120V/240V) AC sources and should not be connected to a three phase AC source.
Connecting the device to a three phase source may result in damage to the unit and any
loads connected to the Inverter/Charger.

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Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v
1 Introduction
System Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
System Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
System Components and Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
XW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
XW Power Distribution Panel Panel and XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
XW Connection Kit for INV2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
XW Solar Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
XW Automatic Generator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
2 Inverter/Charger Installation
Pre-Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Knockout Preparation and Air Filter Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Removing Internal Faceplates in the Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Clearance Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Step 1: Installing the Mounting Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Step 2: Mounting the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Step 3: Mounting the XW Power Distribution Panel and XW Conduit Box- - - - - - - - - - - - - - - - - - - - - 2–7
Step 4: Wiring the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Battery Bank Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Battery Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Torque Values for the XW Series Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Torque Values for the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Inverter Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Backfeed Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Wiring the Inverter to the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Grounding the DC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Installing the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Making DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Making AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
AC Connections and Communication Ports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
Accessing the AC Terminal Block and AC Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17
Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18
AC Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19
AC Wiring to the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19
Wiring the XW Inverter/Charger to a XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - 2–21
Generator Wiring to the XW Inverter/Charger using a XW Power Distribution Panel - - - - - - - 2–22
Contents

Contents
viii 975-0239-01-01
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AUX Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
AUX+12V Voltage Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
AUX-RPO: User Remote Power Off (RPO) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
User Line Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
AUX Port Terminal Assignments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Basic Functional Test - Single Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Confirm All Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Applying DC Power to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Enable the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27
AC Voltage Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
Confirming Battery Charger Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
Step 5: Installing Additional Inverters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–30
Installation Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–30
Parts List for Dual-Inverter Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–31
Converting a Single-Inverter Power Distribution Panel to a Dual-Inverter Power Distribution Panel 2–31
DC Wiring for a Dual-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–31
AC Wiring for a Dual-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–33
Parts List for a Triple-Inverter Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–36
Converting a Single-Inverter Power Distribution Panel to a Triple-Inverter Power Distribution Panel 2–36
DC Wiring for a Triple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–37
AC Wiring for a Triple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–38
Xanbus and AC Sync Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–41
Basic Functional Test - Multiple Inverters- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–42
3 Xanbus Network Installation
Xanbus-enabled Devices- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
The Xanbus System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Ordering Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Installing the Network - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Before You Begin the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Guidelines for Routing the Xanbus Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Installing Xanbus-Enabled Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
4 XW Solar Charge Controller Installation
Installing the Charge Controller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
MPPT Voltage Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Removing the Wiring Compartment Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Mounting the Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Contents
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Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8
Internal Ground Fault Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8
Disabling Ground Fault Protection for Negative Grounded and Ungrounded Arrays - - - - - - - - - - - - 4–9
Wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10
DC Terminal Connector Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10
Wire Size and Over-current Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11
Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11
Minimum Wire Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11
Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11
Long-distance wire runs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11
Maximum One-way Distance and Wire Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12
Connecting the XW Solar Charge Controller to the Distribution Panel - - - - - - - - - - - - - - - - - - - - 4–13
Commissioning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–16
Configuration Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–16
Commissioning Units Using a XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–16
5 XW System Accessories Installation
The XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Materials and Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Mounting the XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3
Verifying the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7
The XW Automatic Generator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8
Preparing an Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8
Materials and Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9
Routing the Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9
Installing the XW Automatic Generator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10
Mounting the Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11
Wiring to the 20-contact Connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11
Connecting the Generator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–13
Connecting the Thermostats (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14
Connecting an External Shutdown (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14
Connecting an External Manual ON/OFF Switch (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–15
Connecting an External ON/OFF LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–16
Connecting the Wiring Harness to the XW Automatic Generator Start - - - - - - - - - - - - - - - - - 5–17
Connecting the XW Automatic Generator Start to the Xanbus Network - - - - - - - - - - - - - - - - 5–18
Verifying Power Is Available - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–19
A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
XW Series Overload Capability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Output Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
XW Series Efficiency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Inverting Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5

Contents
x975-0239-01-01
This manual for use by qualified personnel only
Charging Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
Charging Power Factor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
Grid-tie Sell Mode Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7
Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–8
B Wiring Diagrams
Single-Inverter System (Backup only) Without a Power Distribution Panel - - - - - - - - - - - - - - - - - - - -B–3
Single-Inverter System (Backup only) With a Power Distribution Panel- - - - - - - - - - - - - - - - - - - - - - -B–4
Single-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5
Single-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6
Dual-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
Dual-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8
C Alternate System Configurations
DC Grounding for Single-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Battery Connections for Single Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3
AC Grounding for Single-Inverter Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–4
AC Output Wiring to the Inverter AC Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–5
Generator Wiring to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–6
Utility Wiring to the Inverter Input- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–7

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This manual for use by qualified personnel only
Figure 1-1 XW Power System Installation Diagram Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2
Figure 1-2 XW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
Figure 1-3 XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3
Figure 1-4 Power Distribution Panel and XW Conduit Box- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4
Figure 1-5 XW Connection Kit for INV2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–5
Figure 1-6 XW Solar Charge Controller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6
Figure 1-7 XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–6
Figure 1-8 Automatic Generator Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–7
Figure 2-1 Air Filter and AUX Connector Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2
Figure 2-2 Removing the Internal Faceplates on the Power Distribution Panel - - - - - - - - - - - - - - - - - - - -2–3
Figure 2-3 Clearance Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3
Figure 2-4 Mounting Plate Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4
Figure 2-5 Mounting the Bracket for the XW Inverter/Charger or Distribution Panel- - - - - - - - - - - - - - - -2–5
Figure 2-6 Mounting the XW Inverter/Charger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6
Figure 2-7 Installing the XW Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7
Figure 2-8 Routing Communications Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–8
Figure 2-9 DC Grounding Using a Power Distribution Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Figure 2-10 Battery Temperature Sensor (RJ11) Port Location and Installation - - - - - - - - - - - - - - - - - - - 2–13
Figure 2-11 XW Inverter/Charger DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Figure 2-12 Battery Cable Connection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Figure 2-13 DC Connections to a Single Inverter Using a XW Power Distribution Panel- - - - - - - - - - - - - 2–15
Figure 2-14 XW Inverter/Charger AC Connections and Communications Ports - - - - - - - - - - - - - - - - - - - 2–16
Figure 2-15 AC Terminal Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17
Figure 2-16 Grounding the AC System using the Distribution Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18
Figure 2-17 Wiring the XW Power Distribution Panel to the Sub-panel or Utility Grid - - - - - - - - - - - - - - 2–20
Figure 2-18 Wiring the Inverter to the XW Power Distribution Panel- - - - - - - - - - - - - - - - - - - - - - - - - - 2–21
Figure 2-19 Generator Wiring Using a XW Power Distribution Panel (On Grid) - - - - - - - - - - - - - - - - - - 2–22
Figure 2-20 Generator Wiring Using a XW Power Distribution Panel (Off Grid) - - - - - - - - - - - - - - - - - - 2–23
Figure 2-21 AUX Port Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–24
Figure 2-22 Power-up Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Figure 2-23 Enable the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27
Figure 2-24 Checking AC Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
Figure 2-25 Checking Charging Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28
Figure 2-26 Functional Test for Single Inverter Systems- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–29
Figure 2-27 DC Connections to Dual Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–32
Figure 2-28 Dual Inverter AC Breaker Arrangement and Wiring Enlargement with Multiple AC Input Sources - -2–33
Figure 2-29 AC Wiring for Dual-Inverter Systems- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–34
Figure 2-30 Installing the Front Internal Panels and the AC Bypass Plate - - - - - - - - - - - - - - - - - - - - - - - 2–35
Figure 2-31 DC Connections for a Triple-Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–37
Figure 2-32 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement with Dual AC Input Sources- - - -2–39
Figure 2-33 Triple-Inverter AC Breaker Arrangement and Wiring Enlargement with a Single AC Input Source - -2–39
Figure 2-34 Wiring an External Bypass Switch for a Triple-Inverter Configuration- - - - - - - - - - - - - - - - - 2–40
Figure 2-35 Installing the AC Sync Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–41
Figure 2-36 Functional Test for Multiple Inverters - Page 1 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–44
Figure 2-37 Functional Test for Multiple Inverters - Page 2 of 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–45
Figures

Figures
xii 975-0239-01-01
This manual for use by qualified personnel only
Figure 3-1 Network-Managed Power System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Figure 3-2 Xanbus Cable, RJ45 Connector Pin Numbers and Network Terminators - - - - - - - - - - - - - - - - 3–3
Figure 3-3 Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Figure 4-1 Minimum Clearance Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Figure 4-2 Removing the Wiring Compartment Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Figure 4-3 Dimensions and Knockout Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5
Figure 4-4 Knockout Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–5
Figure 4-5 Mounting the XW Solar Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
Figure 4-6 XW Solar Charge Controller Safety Ground Connector- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–9
Figure 4-7 PV Negative Ground Jumper Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10
Figure 4-8 DC Connection Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–10
Figure 4-9 Connecting Solar DC Sources in the Power Distribution Panel- - - - - - - - - - - - - - - - - - - - - - 4–15
Figure 5-1 XW System Control Panel Xanbus Port Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2
Figure 5-2 Inserting the Mounting Plate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–4
Figure 5-3 Securing the Mounting Plate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–4
Figure 5-4 Connecting the Network Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Figure 5-5 Securing the XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5
Figure 5-6 Surface Mounting the XW System Control Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7
Figure 5-7 Connecting the AGS Communications Cable to the XW Series - - - - - - - - - - - - - - - - - - - - - - 5–8
Figure 5-8 XW Automatic Generator Start External Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10
Figure 5-9 XW Automatic Generator Start Wiring Harness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–12
Figure 5-10 External On/Off Switch and LED Wiring Diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–16
Figure 5-11 XW Automatic Generator Start External Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–17
Figure 5-12 Connecting the SCP- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–18
Figure 5-13 Verifying Power is Available - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–19
Figure A-1 XW Series AC Overload Capability- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Figure A-2 XW Series AC Overload Capability- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Figure A-3 XW Series AC Overload Capability- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Figure A-4 Output Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Figure A-5 Inverting Efficiency (Typical)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Figure A-6 Charging Efficiency (Typical)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
Figure A-7 Charging Power Factor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–6
Figure A-8 Grid-tie Sell Mode Efficiency (Typical) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7
Figure B-1 Single-Inverter System (Backup only) Without a Power Distribution Panel - - - - - - - - - - - - - -B–3
Figure B-2 Single-Inverter System (Backup only) With a Power Distribution Panel - - - - - - - - - - - - - - - -B–4
Figure B-3 Single-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5
Figure B-4 Single-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - - - - -B–6
Figure B-5 Dual-Inverter System Renewable Energy (Solar) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7
Figure B-6 Dual-Inverter System Renewable Energy (Wind or Hydro) - - - - - - - - - - - - - - - - - - - - - - - - -B–8
Figure C-1 DC Grounding for an Inverter only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2
Figure C-2 DC Connections to a Single Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–3
Figure C-3 Grounding the AC System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–4
Figure C-4 AC Output Wiring to the Inverter AC Distribution Panel- - - - - - - - - - - - - - - - - - - - - - - - - - -C–5
Figure C-5 Generator Wiring directly to the Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–6
Figure C-6 Utility Wiring to the Inverter Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–7

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Table 2-1 Mounting Plate Fastener Recommendations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Table 2-2 Recommended Battery Cable Size Versus Length- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-3 Battery Cable (in conduit) to Maximum Breaker/Fuse Size - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-4 Torque Values for AC Wiring (AC Terminals and Ground Bar) - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-5 Torque Values for the Chassis Ground Lug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-6 Torque Values for the Inverter Battery Terminals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Table 2-7 Torque Values for AC Disconnects and AC Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Table 2-8 Torque Values for the Ground Bus, AC Neutral Bus, DC Negative Bus, and
DC Positive Bus in the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Table 2-9 Torque Values for the Power Distribution Bars in the XW Power Distribution Panel - - - - - - - 2–11
Table 2-10 Torque Values for the Battery Cables to the DC Negative Bus, and DC Positive Bus
in the XW Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Table 2-11 User Connector Terminals and Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Table 3-1 Xanbus Network Components and Part Numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Table 4-1 MPPT Operational Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Table 4-2 Minimum Clearance Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Table 4-3 Recommended Circuit Breakers for the XW Solar Charge Controller - - - - - - - - - - - - - - - - - 4–12
Table 4-4 One-Way Wire Distance and Wire Size for a 24 Vdc System - - - - - - - - - - - - - - - - - - - - - - - 4–12
Table 4-5 One-Way Wire Distance and Wire Size for a 48 Vdc System - - - - - - - - - - - - - - - - - - - - - - - 4–13
Table 5-1 Circuit Limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11
Table 5-2 Required Wiring Size Based on Length of Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–12
Table 5-3 Contact Numbers and Functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–12
Table 5-4 Wiring for Connecting Thermostats - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14
Table 5-5 Wiring for Connecting an External Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14
Table 5-6 Wiring for Connecting an External Manual ON/OFF Switch - - - - - - - - - - - - - - - - - - - - - - - 5–15
Table A-1 XW Power System Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Table A-2 XW Power System Mechanical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–7
Table A-3 XW Power System Regulatory Approvals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–8
Tables

xvi

This manual for use by qualified personnel only
1Introduction
Chapter 1, “Introduction” lists and describes the components and
basic features of the XW Power System.
For this Topic See....
“System Overview” page 1–2
“System Components and Accessories” page 1–3

Introduction
1–2 975-0239-01-01
This manual for use by qualified personnel only
System Overview
The XW Power System consists of several devices, components, and optional accessories
that, when installed together, create a renewable energy power system that can be
customized to suit nearly any application—off grid, grid tied, or backup. Up to three
inverters can be installed in parallel to create larger 120/240-volt, 3-wire, single-phase
systems allowing for increased capacity.
System Diagram
CAUTION
The XW4024-120/240-60, XW4548-120/240-60 and XW6048-120/240-60 series of
Inverter/Chargers are designed and tested for operation with single phase, three wire
(120V/240V) AC sources and should not be connected to a three phase AC source.
Connecting the device to a three phase source may result in damage to the unit and any
loads connected to the Inverter/Charger.
Figure 1-1 XW Power System Installation Diagram Example

System Components and Accessories
975-0239-01-01 1–3
This manual for use by qualified personnel only
System Components and Accessories
XW Inverter/Charger
The XW Inverter/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 XW Series is a self-contained DC to AC
inverter, battery charger, and AC transfer switch. Up to three inverters can be installed in
parallel to create larger 120-240-volt, 3-wire, single-phase systems allowing for increased
capacity.
A Battery Temperature Sensor (FGA # 808-0232-02) is also included with the XW
Inverter/Charger. The Battery Temperature Sensor monitors the temperature of the battery
bank and adjusts the charging accordingly. See page 2–13 for installation instructions for
this accessory.
XW Conduit Box
A conduit box (FGA # 865-1025) is available to enclose the bottom of the XW
Inverter/Charger and protect the cabling. Use of the conduit box may be required
depending on the local electrical code. Be sure to consult with the local electrical
authority to ensure the installation is code-compliant.
The XW Conduit Box comes in two pieces and mounts directly to the bottom of the
inverter/charger with keyhole slots and screws. It is secured to the inverter by two
#10-32 screws and is secured to the wall by two screws (not provided).
Figure 1-2 XW Inverter/Charger
Includes:
• Mounting Panel
• DC terminal Covers
• Network Terminator
• Battery Temperature Sensor
•AirFilter
• Mounting Hardware
• AUX Port Connector
Figure 1-3 XW Conduit Box

Introduction
1–4 975-0239-01-01
This manual for use by qualified personnel only
Internal wire barriers (or raceways) are included to keep communications wires separate
from AC and DC power wires. The XW Conduit Box also includes multiple cable strap
points.
XW Power Distribution Panel Panel and XW Conduit Box
The XW Power Distribution Panel (FGA: 865-1015) includes a mounting plate and XW
Conduit Box. It is factory wired and labelled with everything to support a code-compliant
single-inverter installation. It is designed to mount on the right side of the
inverter/charger, but it can also be configured to mount on the left side. Internal wiring
and breakers can be added to expand the XW Power System with up to three inverters,
four charge controllers, or other equipment to support 120/240-volt, 3-wire, single-phase
systems.
The XW Power Distribution Panel and XW Conduit Box interface with:
• XW4024, XW4548, and XW6048 inverter/chargers
• XW Solar Charge Controllers (requires customer supplied breakers and wiring)
• C-Series Charge Controllers (requires customer supplied breakers and wiring).
Internal wire barriers (or raceways) are included to keep communications wires separate
from AC and DC power wires.
Figure 1-4 Power Distribution Panel and XW Conduit Box
XW Power Distribution Panel
Mounting Plate XW Conduit Box
XW Power Distribution Panel includes:
• Power Distribution Panel enclosure with a field-reversible panel door
• Mounting Plate
• XW Conduit Box
The panel door can be mounted on the right or left side of the XW Power
Distribution Panel.
AC Knockout slots = 9 (for dual 60A Square D, type QOU breakers)*
DC Knockout slots = 8 small (for 60A DC breakers) and 3 large (for GJ breakers)
*AC Breakers cannot exceed 60A.
The enclosure comes pre-wired with:
• 3x 60A, 120/240 Vac, 2-pole, Square-D, Type QOU, DIN-rail
mounted AC breakers (pre-wired to connect to one XW inverter)
• 1x GJ250A 160 Vdc, 3/8" stud DC breaker
• 2x Ground terminal bus bars
• 1x Neutral terminal bus bar
• 1x Negative bus bar
• 1 pair #4/0 AWG Battery Cables
XW PDP Dimensions:
30" (761mm) H x 16" (406mm) W x 8 ¼" (210mm) D
Depth from the wall = 8 ¾" (223 mm)