Xantrex XW-MPPT-60-150 User Guide

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Smart choice for power

Solar Charge
Controller

XW-MPPT-60-150

Owner’s Manual

T

F

A

DR

www.xantrex.com

Manual Type

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Solar Charge Controller

Owner’s Guide

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About Xantrex

Xantrex T e chnology Inc. is a world-leadin g su pplier of advanced p ower electronics
and controls with pr oducts f rom 50 wa tt mobil e units to 1 MW ut ility-s cale syste ms
for wind, solar, batteries, fuel cells, microturbines, and backup power applications
in both grid-connected and stand-alone systems. Xantrex products include
inverters, battery chargers, programmable power supplies, and variable speed
drives that convert, supply, control, clean, and distribute electrical power.

Trademarks

Xantrex is a registered trademark of Xantrex International.
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

Solar Charge Controller Owner’s Manual © December 2006 Xantrex
International. All rights reserved.

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

X

ANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION

WHICH IS POSTED AT www.xantrex.com.

Date and Revision

December 2006 Revision A

Part Number

975-0283-01-01 Rev A5 DRAFT

Product Number

865-1030

Contact Informatio n

Telephone: [phone] (toll free North America)

Fax: [phone] (direct)
Email: [e-mail]
Web: www.xantrex.com

1 360 925 5097 (direct)

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About This Guide

Purpose

The purpose of this Guide is to provide explanations and
procedures for installing, configuring, operating,
maintaining, and troubleshooting the Solar Charge
Controller.

Scope

This Guide provides safety guidelines, detailed planning and
setup information, procedures for installing the unit, as well
as information about operating and troubleshooting the unit.
It does not provide details about particular brands of
photovoltaic (PV) panels. You need to consult individual PV
manufacturers for this information.

Audience

This Guide does not provide sufficient information for
anyone but a qualified installer to install this product.
Installers should be electricians or technicians fully educated
on the hazards of installing electrical equipment. The
monitoring and operation information in this manual is
intended for anyone who needs to operate the Solar Charge
Controller.

Organization

This Guide is organized into five chapters and three
appendices.

Chapter 1 describes features and functions of the Solar
Charge Controller.

Chapter 2 contains information and procedures to install the
Solar Charge Controller.

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About This Guide

Chapter 3 contains information and procedures to configure
the Solar Charge Controller.

Chapter 4 contains information about the operation of the
Solar Charge Controller.

Chapter 5 contains information about identifying and
resolving possible problems with systems using a Solar
Charge Controller.

Appendix A provides the specifications for the Solar Charge
Controller.

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings identify conditions that could result in personal injury or
loss of life.

CAUTION

Cautions identify conditions or practices that could result in
damage to the unit or to other equipment.

Important:

an item that you must pay attention to.

iv 975-0283-01-01 Rev A5 DRAFT

These notes describe an important action item or

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Abbreviations and Acronyms

AGM Absorbed Glass Mat
AWG American Wire Gauge
EMC Electro-Magnetic Compatibility
FCC Federal Communications Commission

Related Information

You can find more information about Xantrex Technology
Inc. as well as its products and services at
www.xantrex.com.

About This Guide

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Important Safety Instructions

WARNING

This manual contains important safety instructions that should be
followed during the installation and maintenance of this product. Be

sure to read, understand, an d save these safety instructions.

General Safety Instructions

• All electrical work must be done in accordance with
local, national, and/or international electrical codes.

• Before installin g or using this device , read all instruc tions
and cautionary markings located in (or on) this guide, the
unit, the batteries, PV array, and any other equipment
used.

• This product is designed for indoor mounting only. Do
not expose this unit to rain, snow or liquids of any type.

• T o reduce the chan ce of short -circuits , use insu lated tools
when installing or working with the unit or any DC
source (such as PV, hydro, wind, or batteries).

• Remove all jewelry when installing or working with the
unit or any DC source. This will greatly reduce the
chance of accidental exposure to live circuits.

• The unit contains more than one live circuit (batteries and
PV array). Power may be present at more than one
source.

• This product contains no user-serviceable parts.

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Safety

WARNING: Limitations on use

The Solar Charge Controller is not intended for use in connection
with life support systems or other medical equipment or devices..

Battery Safety Information

WARNING

A battery can produce the following hazards to personal safety:

• electrical shock

• burn from high-short-circuit current

• fire or explosion from vented gasses.

Observe proper precautions when working with or arou nd batteries.

• Always wear eye prot ection, s uch as saf ety glas ses, when
working with batteries .

• Remove all jewelry before working with batteries.

• Never work alone. Have someone assist you with the
installation or be close enough to come to your aid when
working with batteries .

• Always use proper lifting techniques when handling
batteries.

• Always use identical types of batteries.

• Never install old or untested batteries. Check each
battery’s date code or label to ensure age and type.

• Batteries should be in stalled in a well-vented area to
prevent the possible buildup of explosive gasses. If the
batteries are i nstalle d inside an enclosure , vent i ts highes t
point to the outdoors.

• When installing batteries, allow at least 1 inch of air
space between batteries to promote cooling and
ventilation.

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• NEVER smoke in the vicinity of a battery or generator.

• Always connect the batteries first, then connect the
cables to the inverter or controller. This will greatly
reduce the chance of spark in the vicinity of the batteries.

• Use insulated tools whe n working with batteries.

• When connecting batteries, always verify proper voltage
and polarity.

• Do not short-circuit battery cables. Fire or explosion can
occur.

• In the event of exposure to battery electrolyte, wash the
area with soap and water. If acid enters the eyes , flood
them with running cold water for at least 15 minutes and
get immediate medical attention.

• Always recycle old batteries. Contact your local
recycling center for proper disposal information.

Safety

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Contents

Important Safety Instructions
1

Introduction

Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Maximum Power Point Tracking - - - - - - - - - - - - - - - - - - - - 1–3
Charge Controlling- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

Three-Stage Battery Charging- - - - - - - - - - - - - - - - - - - - 1–6

Bulk Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Absorption Stage - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Float Stage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7

Two-Stage Battery Charging - - - - - - - - - - - - - - - - - - - - 1–8

No Float Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Battery Temperature Compensation- - - - - - - - - - - - - - - - 1–8
Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - 1–9

Auxiliary Output Functions - - - - - - - - - - - - - - - - - - - - - - - -1–10

Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–10
Vent Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–12
Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–12

Automatic PV Array Night Disconnect - - - - - - - - - - - - - - - -1–12

- - - - - - - - - - - - - - - - - - - vii

2

Installation

PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Array Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Array Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Array Current- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
MPPT Voltage Range - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Choosing a L ocation - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Removing the Wiring Terminals Cover - - - - - - - - - - - - - 2–6
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

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Contents

Mounting the Charge Controller - - - - - - - - - - - - - - - - - - 2–8

Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10

DC Terminal Connector Locations - - - - - - - - - - - - - - - -2–10
Wire Size and Over-current Protection Requirements- - - -2–10

Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - -2–11

Minimum Wire Gauge- - - - - - - - - - - - - - - - - - - - - -2–11

Over-current Protection - - - - - - - - - - - - - - - - - - - - -2–11

Long-distance wire runs- - - - - - - - - - - - - - - - - - - - -2–12

Maximum One-way Distance and Wire Size - - - - - - -2–12
Connecting the Charge Controller - - - - - - - - - - - - - - - - -2–14

Connecting Multiple Units- - - - - - - - - - - - - - - - - - - - - - - - -2–16
Aux Output Connections - - - - - - - - - - - - - - - - - - - - - - - - - -2–17
Network Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17

Network Com ponents - - - - - - - - - - - - - - - - - - - - - - - - -2–18

Ordering Network Components- - - - - - - - - - - - - - - - 2–21
Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–21

Multi-Drop Backbone Layout - - - - - - - - - - - - - - - - -2–22

Daisy Chain Layout- - - - - - - - - - - - - - - - - - - - - - - -2–23
Guidelines for Routing the Network Cables - - - - - - - - - -2–25
Connecting Network Cab le Between Multiple Units- - - - -2–25

Multi-Drop Backbone Layout - - - - - - - - - - - - - - - - -2–25

Daisy Chain Layout- - - - - - - - - - - - - - - - - - - - - - - -2–26

Installing the Battery Temperature Sensor - - - - - - - - - - - - - -2–27
Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29

Configuration Screens - - - - - - - - - - - - - - - - - - - - - - - - -2–29
Commissioning a Singl e Unit - - - - - - - - - - - - - - - - - - - -2–30
Commissioning Multiple Units - - - - - - - - - - - - - - - - - - -2–32

3

Configuration

Configuring the Charge Controller - - - - - - - - - - - - - - - - - - - 3–2
Configuration Menus - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Basic and Advanced Menus - - - - - - - - - - - - - - - - - - - - - 3–5

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Configuring Battery Characteristics and Battery Charging - - - 3–5

Setting a Custom Battery Type - - - - - - - - - - - - - - - - - - - 3–9
Battery Temperature Compensation- - - - - - - - - - - - - - - -3–11

Configuring Charge Controller Input- - - - - - - - - - - - - - - - - -3–12
Configuring the Auxiliary Output - - - - - - - - - - - - - - - - - - - -3–14

Trigger Source Descriptions - - - - - - - - - - - - - - - - - - - - -3–18
Trigger Source Configurable Ranges - - - - - - - - - - - - - - - 3–20

Configuring the LCD - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21
Device Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23
Resetting to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - -3–25

4

Operation

Viewing Operating Status - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

LCD Screens and What They Mean- - - - - - - - - - - - - - - - 4–2
Normal Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3

Charging S tates- - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Dynamic Te xt- - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Monitoring Charge Controller Operation - - - - - - - - - - - - - - - 4–9

Viewing Active Faults an d Warnings - - - - - - - - - - - - - - -4–10
Viewing Lo gged System Data- - - - - - - - - - - - - - - - - - - -4–15

Daily Logs- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–16

Monthly Log s- - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17

Contents

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Contents

Battery Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4–17

5

Troubleshooting

PV Charge Control Troubleshooting - - - - - - - - - - - - - - - - - - 5–1

A

Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Derating Cu rve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - A–3
Optional Ac cessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

B

System Control Panel Menus

Using the System Control Panel II - - - - - - - - - - - - - - - - - - - B–2

System Control Panel Menu Map - - - - - - - - - - - - - - - - - B–3
Changing Settings Using the System Control Panel - - - - - B–5

Viewing the Select Device Menu- - - - - - - - - - - - - - - B–5

Viewing the Charge Controller Setup Menu - - - - - - - B–6

The Charge Controller Setup Menu- - - - - - - - - - - - - - - - - - - B–6
Configure Me nu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–8
Monitoring the Charge Controller - - - - - - - - - - - - - - - - - - - B–11

Charge Controller Home Screen - - - - - - - - - - - - - - - - - B–11
Meters Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–12

Index
Warranty and Product Information

xiv 975-0283-01-01 Rev A5 DRAFT

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

- - - - - - - - - - - WA–1

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1

Introduction

Chapter 1 describes features and functions of the Solar

Charge Controller.

For information on: See:

“Features” page 1–2
“Maximum Power Point Tracking” page 1–3
“Charge Controlling” page 1–5
“Auxiliary Output Functions” page 1–10
“Automatic PV Array Night Disconnect” page 1–12

1–1

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Features

The Xantrex Solar Charge Controller is a photovoltaic (PV)

charge controller that tracks the electrical maximum power

point of a PV array to de li ver the maximum available current

for charging batteries. The Charge Controller can be used

with 12-, 24-, 36-, 48-, and 60-volt DC battery systems.

The Solar Charge Controller is designed to reg ula te PV input

only. It is not designed to work with wind or hydro

generators.

The Charge Controller can be installed (in single or multi-

unit configurations) with a Xantrex XW Series Inverter

Charger or in a stand-alone installation.

Figure 1-1

Standard features of the Solar Charge Controller include:

• Two- or three-stage charging process, with manual
equalization to maximize system performance and
maintain expected batt ery life.

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Charge Controller

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• Maximum Power Point Tracking (MPPT) to deliver the
maximum available power from a PV array to a bank of
batteries. See “Maximum Power Point Tracking” on
page 1–3.

• Configurable auxiliary output. See “Auxiliary Output
Functions” on page 1–10.

• Two-line, 16-character liquid crystal display (LCD) and
four buttons for configuration and system monitoring.

• Input over-voltage and under-voltage protection, output
over-current protection, and backfeed (reverse current)
protection. Warning and Fault messages appear on the
LCD when the unit shuts down as a protective measure.

• Over-temperature protection and power derating when
output power and ambient temperature are high.

• Battery Temperature Sensor (BTS) to provide
automatically temperature-compensated battery
charging.

• Xanbus

®

-enabled. Xanbus is a network communications
protocol developed by Xantre x. The Charge Controller is
able to communicate its settings and activity to other
Xanbus-enabled devices, such as the XW Series Inverter/
Charger, the System Control Panel II (SCP), XW
Automatic Generator Start (XW-AGS), and other
Xantrex XW-MPPT-60-150 Solar Charge Controllers.

• 5-year limited warranty.

Maximum Power Point Tracking

Maximum Power Point Tracking

Maximum Pow er Point Tracking allows the Charge
Controller to harve st th e maximum en er gy avail able from th e
PV array and deliver it to the batterie s.

The MPPT algorithm continuously adjusts the operating
points in an attempt to fi nd the maximum power point of the
array. The algorithm can then determine if it is har vesting
more or less power than the previous operating points.

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The Charge Controller applies a variable load on the array—
shown by the power curve (solid line) in Figure 1-2—until it
finds the maximum wattage (the greates t number of amps per
volt), as indicated by “MPP” in Figure 1-2. The Charge
Controlle r then holds the array at this point for as long as the
array continues to produce the required current. As panel
shading, cloud cover, and sunlight angle shift, the Charge
Controller finds the new maximum power point without
interrupting its output power flow.

20

18

16

I

sc

14

I

mp

12

10

8

6

4

Current (I) Amps / Power (P) Watts

2

0

0102030405060708090

Vol t ag e (V) Vo l t s

MPP

V

mp

V

oc

Figure 1-2

Maximum Powe r Point Curve

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Charge Controlling

The Charge Controller can regulate PV array current at 12,
24, 36, 48 or 60 volts DC for charging batteries. It produces
up to 3500 watts and 60 amps of charging current for all
battery voltages except 60 V.

Charge Controlling

Figure 1-3

PV Charge Controller

The Charge Cont ro ll er controls how the batteries ar e charged
by the DC source (the PV arr ay). It ca n be config ured to use a
two-stage (“No Float”) or three-stage charging process to
maintain battery voltage at bulk or flo at levels.

When charging, the Charge Controller regulates the battery
voltage and the output current based on the amount of DC
power available from the PV array and the state of charge of
the battery.

The Charge Controller is able to charge a lower nominal­voltage battery from a higher-nominal voltage array. For
example, the Charge Controller can charge a 12-volt battery
from a 36-volt array. This gives flexibility to installers to use
longer wiring runs without compromising efficiency on a
higher-voltage array.

The Charge Controller is not able to charge a higher-voltage
battery from a lower-voltage array.

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Three-Stage Battery Charging

The three-stage charging process results in more efficient
charging compared to on-off relay type or constant voltage
solid-state regulators. The final float stage reduces battery
gassing, minimizes electrolyte loss, and en sures complete
battery recharging. Battery voltage and current vary during
the three-stage charging process as shown in Figure 1-4 on
page 1–7.

Bulk Stage

During the bulk stage, the Charge Controller sets its voltage
limit to the bulk/absorption voltage setting. If the batteries are
discharged, the Charge Controller operates in constant
current mode, delivering its maximum current to the
batteries. When the battery voltage reaches the Float voltage
setting, the controller will transit ion to the absorption stage.

Absorption Stage

During the absorption stage, the Charge Controller continues
to deliver its maximum available current output until the
battery voltage reaches the bulk/absorption voltage setting.
The Charge Controller then operates in constant voltage
mode, holding the battery voltage at the bulk/absorption
voltage setting for a pre-set time limit (the default time limit
is four hours). During this time, current falls gradually as the
battery capacity i s reached . The Char ge Cont roller transition s
to the float s tage if any one of three criteria are met:

1. The charge current allowed by the batteries falls below
the exit current threshold, which is equal to 2% of battery
capacity (for a 500 Ah batt ery ban k, this wou ld be 10 A),
for one minute.

2. The battery voltage has been a t or a bove th e floa t volt ag e
(which it reached during the bulk stage) for eight hours.

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3. The battery voltage has been at the bulk/absorption
voltage setting for a pre-set time limit (the Absorb CV
Time).

Float Stage

During the float stage , the volta ge of the bat tery is held at the
float voltage setti ng. Full curr ent can be provi ded to the loa ds
connected to the battery during the float stage from the PV
array. When battery voltage drops below the Exit to Bulk
Voltage threshold for 1 minute, a new bulk cycle will be
triggered.

Charge Controlling

Current

Volt age

Figure 1-4

Bulk St age

Max Current Limit

Float voltage

Absorption—
constant current

Absorption Stage

Absorption—
constant voltage

Ex i t Cu r r en t T h r e s h o l d

Bulk/Absor ption Voltage

Absorb CV Time—4 hours
(adjustable 2–6 hours)

Maximum 8 hours (f ix ed)

Three-stage Battery Charging Process

Float Stage

Float Voltage Thres hold

Exit to Bulk Vo ltage Thre shold

a

a.An actual char ging cycle f or a PV-based system that is in use while it is being charged wil l
likely differ from the cycle represented in Figure 1-4. This is because a PV system’s output
is limited by th e amount of solar energy availab le, an d also because DC loads will af fect th e
charge current and the measured battery voltage.

Time

Time

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Two-Stage Battery Charging

The two-stage charging process includes the bulk and
absorption stages, but uses a “No Float” stage instead of
“Float.” Two-stage charging is recommended for off-grid
applications, where batteries are used more frequently and
maintaining them at the float voltage is both less important
and less practical. Two-stage charging can extend the life of
most batteries.

No Float Stage

During the No Float stage the Charge Controller does not
produce any charge current. Instead the Charge Controller
monitors the battery voltage and transitions back to the bulk
stage once the voltage drops below the Exit To Bulk Voltage
setting for 1 minute.

Note: For more information about battery charg ing settings, see

Table 3-2, “Battery Menu Values” on page 3–7 and Table 3-3,
“Custom Battery Menu Values” on page 3–10.

Battery Temperature Compensation

The Battery T emperature Sensor (BTS) automatically adjusts
the charging process of the Charge Controller. With the BTS
installed, the Charge Controller will increase or decrease the
battery char gi ng v olt age depending on the temperature of the
battery to optimize the charge to the battery and to protect it
from over-charge or damage. Using the BTS can extend
battery life and improve overall charging.

The BTS plugs into the BTS jack located inside the wiring
compartment of the Charge Controller. The BTS can be
installed on the negative battery post or on the side of the
battery.

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Charge Controlling

Figure 1-5

Battery Tem perature Sensor

If the BTS is not installed, the voltage settings for charging
are based on one of three temperature settings (Cold, Warm,
or Hot) available on the Charge Controller configuration
menu. See “Configuring Battery Characteristics and Battery
Charging” on page 3–5.

Equalization Charging

The Charge Controller can be used to provide the battery
bank with an equalize charge.

Equalization is a deliberate overcharge designed to return
each battery cell to optimum condition by reducing sulfation
and stratification in th e battery. The equalization charge is
generally performed only on flooded, vented (non-sealed or
“wet”) lead-acid batteries, as recommended by the battery
manufacturer.

T o avoid damagi ng your batte ries, be sur e to read all cau tions
and warnings concerning equalization charging. For more
information, see “Battery Equalization” on page 4–17.

Important:

limited to 72 V for a 60 V battery system, which is the bulk
voltage setting for 60 V batteries. Because of this output limit, the
Charge Controller does not equalize 60 V batteries.

The Charge Controller maximum ou tput volta ge is

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Auxiliary Output Functions

The Charge Controller has a configurable auxiliary output
(producing 5 to 13 volts at 200 mA) to drive a relay for load
control or to turn on devices such as vent fans or indicator
alarms. The auxiliary output can be configured to perform
only one function at a time.

See “Configuring the Auxiliary Output” on page 3–14 for
information about auxili ary output trigge r sources and how to
enable and configure the auxiliary output for your
application.

CAUTION

The auxiliary output is intended only to energize a low-current
circuit such as a relay coil. Connection to a high-amperage device
will open the fuse in the common line and possibly damage the unit.

Load Control

The Charge Controller auxiliary output can be configured to
drive a relay to disconnect or reconnect loads depending on
battery voltage. This load control function enables the Charge
Controller to help preve nt damage to the battery from over­discharge during periods of poor charging (due to ambient
temperature, for example) or excessive loads.

To use the Charge Controller to control loads and protect
your batteries, you must connect the Charge Controller
auxiliary output to a relay that controls a battery disconnect
to disconnect the load from the batteries. The Charge
Controller auxiliary output must be configured to activate
when the batteries reach a pre-set voltage level.

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Auxiliary Output Functions

xantrex

BAT

BAT

PV+PV

+

–

–



-

+

+

-

Relay (200 mA)

LEGE N D

Ground

-

+

-

+

DC Positive
DC Negative

Figure 1-6

Load Control Wiring

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Vent Fan

The Charge Controller auxiliary output can be configured to
power a small DC fan to clear a battery compartment of
harmful gases. The Charge Controller auxiliary output must
be configured to activate when the batteries reach their
gassing voltage.

The auxiliary output can also power a small DC fan to cool
the Charge Controller heat sink when the heat sink
temperature rises above a pre-set temperature.

Alarms

The auxiliary output can be configured to trigger an alarm or
indicator light when a pre-set condition occurs, such as low
or high battery voltage, high PV array voltage, or a Charge
Controller fault.

Automatic PV Array Night Disconnect

At night, or when the PV array volta ge is les s than the bat tery
voltage, the Charge Contro ller opens an internal rel ay to
prevent battery current from flowing back to the PV array. In
this mode of operation the Charge Controller draws minimal
power from the battery.

This automatic night-time disconnect eliminates the need for
a blocking diode between the battery and the PV array. If the
PV array consists of thin-film or amorphous solar modules,
diodes may still be required to prevent damage during times
of partial shading of the array. Check the documentation
provided with the PV modules.

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2

Installation

Chapter 2 contains information and procedures to install
the Solar Charge Controller.

For information on: See:

“PV Array Requirements” page 2–2
“Mounting” page 2–4
“Grounding” page 2–9
“Wiring” page 2–10
“Installing the Battery Temperature Sensor” page 2–27
“Commissioning” page 2–29

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PV Array Requirements

Note: The following information provides only general

guidelines. The installation and rated performance of your PV
array is subject to inspection and approval by the authority having
jurisdiction.

Array Size

For PV array sizing guidelines, use the XW Solar Charge
Controller PV array sizing tool accessible from
www.xantrex.com/support.

Although the Solar Charge Controller can harvest a
maximum of 3500 W, the PV array size can be as high as
6720 W (based on 48 A × 140 Vdc = 6720 W).

Array Voltage

CAUTION: Eq uipment damage

The PV array voltage must never exceed 150 Voc (open circuit
voltage) un der any conditions.

The maximum V
MPPT operation) is 140 Vdc. The difference between V
and V

When calculating PV array size for the Solar Charge
Controller you should consider the expected V
under all possible conditions. Panel voltage increases with
decreasing temperature. The array needs to be sized so that
the 150 Vdc does not occ ur , even at the lowest expect ed panel
temperature during open circuit. The panel manufacturer
provides a V
(77

°F). Ensure that the V

temperature does not exceed 150 Vdc. A factor of 1.25 is
applied to the rated V

-21 °C.

(PV array voltage for Charge Controller

mpp

is shown in Figure 1-2 on page 1–4.

oc

rating per pa nel, b ut it is us ually rat ed at 25°C

oc

rating at the coldest ambient

oc

at 25 °C when the panel is colder than

oc

of the array

oc

mpp

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