Xantrex XW-MPPT60-150 Owner's Guide

XW Series Solar Charge Controller

XW-MPPT60-150

Owner’s Manual

XW Series Solar Charge Controller

Owner’s Guide

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products inclu de inverters, batt ery 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

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.

HE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK; AND

TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED

ANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT www.xantrex.com.

Date and Revision

April 2007 Revision A

Part Number

975-0283-01-01

Product Number

865-1030

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct) Email: customerservice@xantrex.com Web: www.xantrex.com

About This Guide

Purpose

The purpose of this Guide is to provide explanations and procedures for installing, configuring, operating, and troubleshooting the XW Series 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 two appendices. Chapter 1 describes features and functions of the Solar Charge Controller. Chapter 2 contains information and procedures to install the Solar Charge

Controller. 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. Appendix B is a guide to the Charge Controller monitoring and configuration

menus on the XW System Control Panel. The System Control Panel may be installed if the Charge Controller is part of a power management system that includes an inverter/charger.

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About This Guide

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:

attention to.

These notes describe an important action item or an item that you must pay

Abbreviations and Acronyms

AGM Absorbed Glass Mat AWG American Wire Gauge BTS Battery Temperature Sensor EMC Electro-Magnetic Compatibility

Related Information

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

iv 975-0283-01-01

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, and save these

safety instructions.

General Safety Instructions

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

• Before installing or using this device, read all instructions 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.

• To reduce the chance of short-circuits, use insulated 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.

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 around batteries.

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Safety

• Always wear eye protection, such as safety glasses, 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 installed in a well-vented area to prevent the possible buildup of explosive gasses. If the batteries are installed inside an enclosure, vent its highest point to the outdoors.

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

• 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 when 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.

vi 975-0283-01-01

Important Safety Instructions 1

Introduction

Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Maximum Power Point Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Charge Controlling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Three-Stage Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Bulk Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 Absorption Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Float Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

Two-Stage Battery Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

No Float Stage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Battery Temperature Compensation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 Equalization Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7

Auxiliary Output Functions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8

Load Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Vent Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8

Automatic PV Array Night Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

Installation

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

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

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3

Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Removing the Wiring Terminals Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Mounting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

DC Terminal Connector Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 Wire Size and Over-current Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Minimum Wire Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

975-0283-01-01 vii

Contents

Long-distance wire runs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10 Maximum One-way Distance and Wire Size - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–11

Connecting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–12 Connecting Multiple Units- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–14 Aux Output Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Disconnecting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–16 Network Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17

Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17

Ordering Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–19

Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–20

Multi-Drop Backbone Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–20

Daisy Chain Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–21 Guidelines for Routing the Network Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22 Connecting Network Cable Between Multiple Units - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22

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

Daisy Chain Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–23

Installing the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–24 Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–26

Configuration Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–26 Commissioning a Single Unit Without a System Control Panel - - - - - - - - - - - - - - - - - - - -2–27 Commissioning Multiple Units Without a System Control Panel - - - - - - - - - - - - - - - - - - -2–28 Commissioning Units Using a System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - -2–30

Configuration

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

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

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

Setting a Custom Battery Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Battery Temperature Compensation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10

Configuring Charge Controller Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11 Configuring the Auxiliary Output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Trigger Source Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14 Trigger Source Configurable Ranges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15

Configuring the LCD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–16 Device Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–18 Resetting to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20

Operation

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

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

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Charge Stages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5 Dynamic Text - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Monitoring Charge Controller Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Viewing Active Faults and Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–8 Viewing Logged System Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–11

Daily Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12 Monthly Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–12

Battery Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–13

Troubleshooting

PV Charge Control Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Replacing the Ground Fault Protection Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3

Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Default Battery Charging Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3 Output Power Versus Ambient Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3 Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4 Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4

Contents

XW System Control Panel Menus

Using the XW System Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -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–5 The Charge Controller Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6 Configuration Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7 Monitoring the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–10

Charge Controller Home Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–10 Meters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–11

Warranty and Return Information Index

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

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

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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 1–4 “Auxiliary Output Functions” page 1–8 “Automatic PV Array Night Disconnect” page 1–8

Introduction

Features

The Xantrex Solar Charge Controller is a phot ovoltaic (PV) char ge control ler that tracks the maximum power point of a PV array to deliver 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 regulate PV input, but will also work with other DC sources. The DC source must meet the specifications listed on page A–2.

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 battery life.

• True dynamic 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.

• Integrated PV Ground Fault Protection (PVGFP)

• Convection cooled (no internal or external fan) using aluminum die-cast chassis and heat sink

• 60 amp capacity

• 150 volt open circut input voltage

• Configurable auxiliary output. See “Auxiliary Output Functions” on page 1–8.

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

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

Charge Controller

1–2 975-0283-01-01

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

• Battery Temperature Sensor (BTS) to provide automatically temperaturecompensated battery charging. If the BTS is lost or damaged, a replacement can be ordered from Xantrex (part number 808-0232-02).

• Xanbus

-enabled. Xanbus is a network communications protocol developed by Xantrex. The Charge Controller is able to communicate its settings and activity to other Xanbus-enabled devices, such as the XW Series Inverter/ Charger, the XW System Control Panel (SCP), XW Automatic Generator Start (XW-AGS), and other XW-MPPT60-150 Solar Charge Controllers.

• Five-year limited warranty .

Maximum Power Point Tracking

Maximum Power Point Tracking allows the Charge Controller to harvest the maximum energy available from the PV array and deliver it to the batteries.

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

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 point at which both operating voltage and current can be maximized at the same time), as indicated by “MPP” in Figure 1-2. The Charge Controller then holds the array at this point for as long as the array continues to produce the maximum power possible. As panel shading, cloud cover, and sunlight angle shift, the Charge Controller finds the new maximum power point without interrupting its output power flow.

Maximum Power Po int Tracking

Current (I) Amps

0102030405060708090

Figure 1-2

Maximum Power Point Curve

Voltag e (V) Volts

MPP

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Introduction

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.

Figure 1-3

The Charge Controller controls how the batteries are charged by the DC source (the PV array). It can be configured to use a two-stage (“No Float”) or three-stage charging process to maintain battery voltage at bulk or float levels.

When charging, the Char ge 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 nominal-voltage 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-volt age battery from a lo wervoltage array.

PV Charge Controller

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 ensures complete battery recharging. Battery voltage and current vary during the three-stage charging process as shown in Figure 1-4 on page 1–5.

Bulk Stage

During the bulk stage, the Charge Controller sets its voltage limit to the bulk 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 transition to the absorption stage.

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Absorption Stage

Float Stage

Charge Controlling

During the absorption stage, the Charge Controller continues to deliver its maximum available current output until the battery voltage reaches the absorption voltage setting. The Charge Controller then operates in constant voltage mode, holding the battery voltage at the absorption voltage setting for a pre-set time limit (the default time limit is three hours). During this time, current falls gradually as the battery capacity is reached. The Charge Controller transitions to the float stage 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 battery bank, this would be 10 A), for one minute.

2. The battery voltage has been at or above the float voltage (which it reached during the bulk stage) for eight hours.

3. The battery voltage has been at the bulk/absorption voltage setting for a preset time limit (the Max Absorb Time).

During the float stage, the voltage of the battery is held at the float voltage setting. Full current can be provided to the loads connected to the battery during the float stage from the PV array. When battery voltage drops below the ReCharge Volts setting for 1 minute, a new bulk cycle will be triggered.

Figure 1-4

Bulk Stage

Bulk Stage Absorption Stage

Current

Max Current Limit

Voltage

Float voltage

Absorption— constant current

Absorption Stage

Absorption— constant voltage

Exit Current Threshold

Bulk/Absorption Voltage

Max Absorb Time—3 hours (adjustable 2–6 hours)

Maximum 8 hours (fixed)

Three-stage Battery Charging Cycle

Float Stage

Float Voltage Threshold

ReCharge Voltage Threshold

Time

a.An actual charging cycle for a PV-based system that is in use while it is being charged will likely differ from the cycle represented in Figure 1-4. This is because a PV system’s output is limited by the amount of solar energy available, and also because DC loads will affect the charge current and the measured battery voltage.

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Introduction

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 offgrid 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. The relationship between charging current and battery voltage during the two-stage charging process is shown in Figure 1-5.

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 ReCharge Volts setting for one minute.

Note: For more information about battery charging settings, see Table 3-2, “Battery

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

Figure 1-5

Bulk Stage

Bulk Stage Absorption Stage

Current

Max Current Limit

Voltage

Float Voltage

Absorption— constant current

Absorption Stage

Absorption— constant voltage

Exit Current Threshold

Bulk/Absorption Voltage

Max Absorb Time—3 hours (adjustable 2–6 hours)

Maximum 8 hours (fixed)

Two-Stage Battery Charging Cycle

No Float Stage

Float Stage

ReCharge Voltage Threshold

Return to Bulk Stage

Time

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Battery Temperature Compensation

The Battery T emperature Se nsor (BTS) automatically adjusts the charging process of the Charge Controller. With the BTS installed, the Charge Controller increases or decreases the battery charging voltage 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.

Charge Controlling

Figure 1-6

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.

Only one BTS is required if multiple Charge Controllers or a complete XW Power System with XW Inverter/Chargers are networked together using Xanbus. All networked XW Series devices share battery temperature information, and the BTS can be connected to a Charge Controller or an XW Inverter/Charger.

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 the battery. The equalization charge is generally performed only on flooded, vented (non-sealed or “wet”) lead-acid batteries, as recommended by the battery manufacturer.

To avoid damaging your batteries, be sure to read all cautions and warnings concerning equalization charging. For more information, see “Battery Equalization” on page 4–17.

Battery Temperature Sensor

Important:

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.

975-0283-01-01 1–7

The Charge Controller maximum output voltage is limited to 72 V for a

Introduction

Auxiliary Output Functions

The Charge Controller has a configurable auxiliary output (producing 5 to 13 volts and up to 200 milliamps) 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 auxiliary output trigger 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 prevent damage to the battery from over-discharge during periods of poor charging (due to ambient temperature, for example) or excessive loads.

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.

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 voltage is less than the battery voltage, the Charge Controller opens an internal relay 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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Installation

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

For information on: See:

“PV Array Requirements” page 2–2 “Mounting” page 2–3 “Grounding” page 2–8 “Wiring” page 2–9 “Installing the Battery Temperature Sensor” page 2–24 “Commissioning” page 2–26

Installation

PV Array Requirements

Each Charge Controller must be connected to its own PV array. For optimum performance, each individual array must be composed of the same type of solar panel, with the same V

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

and V

specifications.

mpp

Array Current

CAUTION: Equipment damage

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

The maximum V 140 Vdc. The difference between V

When calculating PV array size for the Solar Charge Controller you should consider the expected V increases with decreasing temperature. The array needs to be sized so that 150 Vdc does not occur, even at the lowest expected panel temperature during open circuit. The panel manufacturer provides a V usually rated at 25

Important:

input current rating of the Charge Controller at any time.

Panels rated up to 48 A at 25 °C (77 °F) are recommended to allow for increases

at low panel temperatures and at solar noon. Ensure that the Isc rating under

in I

all conditions does not exceed 60 A. A factor of 1.25 is applied to the rated I 25 °C when the panel is colder than -21 °C.

(PV array voltage for Charge Controller MPPT operation) is

mpp

and Voc is shown in Figure 1-2 on page 1–3.

mpp

of the array under all possible conditions. Panel voltage

rating per panel, but it is

°C (77 °F).

The Isc (short circuit current) rating of the array must not exceed the 60 A

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MPPT Voltage Range

The Charge Controller maximum power point tracking algorithm maximizes the output energy of PV arrays as long as the operating voltage is within the MPPT operational window. Ensure that the PV array used in the system operates within the MPPT operational window.

Effects of array voltages outside of the MPPT operational window are shown in Table 2-1.

Mounting

Table 2-1

Voltage Effect of Array Voltage Charge Controller Mode

< V

(system battery voltage) V

MPP

120 Vdc < V

MPP

(or V

MPPT Operational Window

batt

< V

batt

= V

to 120 Vdc Maximum harvest of solar

batt

< 140 Vdc Charge Controller reduces the

MPP

> 140 Vdc

> 140 Vdc)

Charge Controller not operating.

Harvest of solar energy less than optimal.

energy.

output current limit to protect the unit from voltage spikes.

Charge Controller shuts down. Unit may be damaged if V

150 V.

Low Light

Charging

Charging (MPPT window)

Input voltage derating

Over-voltage fault

The instructions in this chapter are applicable to the typical stand-alone installation. Installation procedures will vary according to your specific application. For special applications, consult a qualified electrician or your Xantrex Certified Dealer.

If installing the Charge Controller as part of an XW System, see the XW Power System Installation Guide for additional information.

Important:

of this equipment should only be performed by a qualified electrician or by a Certified Renewable Energy (RE) System installer.

Installations must be compliant with all local electrical codes. Installation

Choosing a Location

The Charge Controller must be mounted vertically and installed indoors in a dry, protected location away from flammable materials, sources of high temperature, moisture, and vibration. The location must also be sheltered from direct sunlight, rain, snow, and wind-blown debris.

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Installation

CAUTION: Equipment damage

Never install the Charge Controller where it is exposed to salt water spray. Exposure to salt water will void the warranty and may cause a shock hazard.

WARNING: Explosion/corrosion hazard

To reduce the risk of fire or explosion, do not install the Charge Controller in sealed compartments containing batteries or in locations that require ignition-protected equipment. To reduce the risk of corrosion from hydrogen-sulfide gas vented by batteries, do not install the Charge Controller in sealed compartments containing batteries.

If using “sealed” batteries, the Charge Controller can be mounted in the same enclosure as long as it is adequately ventilated.

For optimal and safe operation, ensure there is adequate clearance around the Charge Controller. See Table 2-2 and Figure 2-1. If clearances are reduced below these minimums, rated performance may not be achieved.

Table 2-2

Location Minimum Clearance

Above 150 mm (6 inches). When units are mounted in a vertical stack, the topmost

In front Sufficient room to allow for easy access to read the display, to prevent

On sides 150 mm (6 inches) on at least one side of the overall assembly. A maximum

Minimum Clearance Requirements

unit must maintain the minimum clearance to the nearest surface. Note: Minimum clearances can be ignored when mounting two units on the side of the XW Power Distribution Panel information, XW Hybrid Inverter/Charger. Other installations must follow the guidelines in this Owner’s Guide.

accidental contact with the heat sink, and to perform maintenance.

of two u Power Distribution Panel. In both configurations, the minimum clearance around the outermost unit must be maintained.

see the XW Power System Installation Guide, available with the

nits can be mounted side by side or side mounted against an XW

(part number 865-1015). For more

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150 mm (6 inches) on top and side(s)

Mounting

Figure 2-1

Minimum Clearance Requirements

Removing the Wiring Terminals Cover

Before mounting, remove the wiring terminals cover to access the mounting holes and the wiring terminals. The wiring terminals cover is secured with two Phillips #8-32 × 2 ½-inch screws on the front cover of the unit. See Figure 2-2.

Figure 2-2

Removing the Wiring Terminals Cover

Removing Knockouts

Six dual and two single knockouts are provided for routing battery, PV array, BTS, and network cables into the Charge Controller. Use bushings or conduits to protect the wiring from damage from rough edges around the knockout holes.

When removing knockouts, ensure that no metal shavings or fragments fall into the wiring compartment.

Remove screws to access the wiring terminals.

Important:

knockouts provided for conduit entry.

975-0283-01-01 2–5

Do not drill, cut, or punch holes in the Charge Controller. Use only the

Installation

Keyhole slot for wall mounting

73 (2 7/8)

Figure 2-3

KNOCKOUT

27.78 (1 1/16)

280 (11)

368 (14 1/2)

Ø 6.35

(1/4)

60 (2 3/8)

14 (9/16)

138 (5 7/16)

26.5 (1)

Dimensions and Knockout Locations

DUAL KNOCKOUT

34.52 (1 3/16) & 27.78 (1 1/16) 2 PL

323 (12 3/4)

Additional mounting holes

53 (2 1/16)

118 (4 5/8)

146 (5 3/4)

All measurements in mm (in.)

Single knockouts intended for BTS and network cables

DUAL KNOCKOUT

34.52 (1 3/16) & 27.78 (1 1/16) 2 PL

KNOCKOUT

27.78 (1 1/16)

DUAL KNOCKOUT

34.52 (1 3/16) & 27.78 (1 1/16)

26.47 (1)

31.50 (1¼)

20.20 (¾)

50.00 (2) 50.80 (2)

25.9 (1)

26.47 (1)

25.0 (1)

50.80 (2)

50.00 (2)

All measurements in mm (in.)

Figure 2-4

Knockout Dimensions

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Mounting the Charge Controller

The Charge Controller is vertically mounted using three #10 × ½-inch or #12 × ½inch pan-head screws.

To mount the Charge Controller:

1. Remove the wiring terminals cover.

2. Mark the location of the keyhole slot on the wall.

3. Secure the top mounting screw in the location marked. Leave the screw head backed out approximately ¼ inch (6 mm).

4. Place the controller onto the screw and pull it down into the keyhole slot.

5. Insert two screws in the two mounting holes provided to secure the unit to the wall.

6. Provide strain-relief clamps or conduit to prevent damage to the circuit board and terminal block from pulling on the wires.

¼"

Mounting

Figure 2-5

Place keyhole slot over the mounting screw.

Secure with two more screws.

Mounting the Solar Charge Controller

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Installation

Grounding

The Charge Controller is designe d to work only with negative-grounded electrical systems. Grounding for both PV and battery circuits is provided inside the wiring compartment. Each ground connection can accommodate up to #6 AWG wire size.

A fuse rated at 1 A, 600 V (accessible from inside the wiring compartment) grounds the negative conductor of the PV array and provides PV ground-fault protection (PV-GFP). Replace with Littelfuse KLKD 1 or equivalent.

Important:

installations with multiple parallel Charge Controllers. Before mounting and connecting the Charge Controllers, remove the PV-GFP fuse from each unit except one.

Only one Charge Controller is to have the PV-GFP fuse installed in

WARNING: Shock hazard

Do not connect the battery negative to ground. NEC requirements specify that the battery negative ground must be done only through the 1A PV-GFP fuse. Bonding the battery negative to ground disables PV ground-fault protection and causes improper unit operation. The battery compartment must only be grounded if it is metal. See Figure 2-9 on page 2–13 for correct routing of the battery negative.

This symbol identifies the protective conductor



Ground fault protection fuse (behind wiring terminals)

(grounding) connection.

Chassis ground terminals (2)

Figure 2-6

Charge Controller Safety Ground Connector

WARNING: Shock and fire hazard

Fuses must only be replaced by qualified service personnel, such as a certified electrician or technician. For continued protection again risk of fire, replace only with the same type and rating of fuse.

WARNING: Shock hazard

Disconnect PV and battery circuits before removing the grounding connections or before removing or installing the PV-GFP fuse. Wait at least 5 minutes for the internal circuitry to discharge before servicing the unit.

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Wiring

Important:

equipment should only be performed by a qualified electrician or a Certified Renewable Energy (RE) System Installer.

Installations must meet all local electrical codes. Installations of this

WARNING: Shock hazard

Disconnect PV and battery circuits before wiring.

DC Terminal Connector Locations

Terminal connectors for DC wiring are located inside the wiring compartment. The labels above the DC wiring terminals and inside the wiring compartment identify all the connection points. See Figure 2-7.

CONNECTIONS DIAGRAM

TERMINAL TORQUE REQUIREMENTS

15lbf.in (1.7 Nm) FOR #14- 10 AWG WI RE

18lbf.in (2.0 Nm) FOR #8 AWG WI RE 20lbf.in (2.2 Nm) FOR #6 AWG WI RE

BATTERY

PV PV

AUX

BTS

XANBUS

Figure 2-7

DC Connection Terminals

Wire Size and Over-current Protection Requirements

The wiring, over-current protection devices (fuses and circuit breakers), and installation methods used must conform to all national and local electrical code requirements.

Wiring must be protected from physical damage with conduit or a strain relief clamp.

To preserve signal integrity on communication cables, the BTS, auxiliary output, and network cables must pass through a different conduit than the conduits used for PV wiring and battery cables. You should pull the BTS cable through the conduit first as the connector may not fit if other wires have been pulled first.

Current Rating

The Charge Controller PV inpu t is rated for 60 A maximum Isc. Since PV outputs can vary due to the array size or sunlight angle, the safe minimum wire size must be chosen for maximum array short-circuit current. Consult PV array manufacturer specifications.

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Installation

Minimum Wire Gauge

For installations where the PV array output is the maximum allowable 60 A Isc, the minimum allowable wire gauge is #6 AWG (13.3 mm 90 °C (194 °F) insulation rating. This wire gauge is determined by electrical code requirements regarding conduit knockout sizes, wire bending radius, and space available within the Charge Controller wiring compartment.

No crimp-on terminals or lugs are required.

Over-current Protection

Over-current protection must be installed to protect the Charge Controller from short circuits and to provide a means of disconnecting the Charge Controller.

Battery Circuit

The NEC requires the battery circuit to be protected with a device rated for 125% of the rating of the circuit. The DC-rated fuse or circuit breaker between the battery and the Charge Controller must have a maximum size of 1.25 × 60 A (the maximum current rating of the Charge Controller). That is, the fuse or circuit breaker must be rated equal to or above 75 A.

PV Circuit

A PV disconnect device between the PV array and the Charge Controller must be rated for the I

of the array but will not exceed the 60 A rating.

) copper wire with a

Long-distance wire runs

If there is a significant distance between the PV array and the Charge Controller or between the Charge Controller and the battery, larger wires can be used to reduce the voltage drop and improve performance. Refer to Table 2-8.

WARNING: Equipment damage

Do not connect an array capable of delivering over 60 A Isc to the Charge Controller. Wires larger than #6 AWG can be used only to reduce power loss in the wiring.

To use a larger size wire, use a splicer block (terminal block) approved and rated for this application. This allows the larger cable size from the batteries to be “spliced” to the #6 AWG wire connected to the Charge Controller. The splicer block must be installed outside of the Charge Controller wiring compartment.

Follow manufacturer’s reco mmendations for torque and mounti ng. Splicer blocks and split-bolt kerneys are available from renewable energy suppliers.

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