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Xantrex XW4024-120, Operation Manual

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Xantrex XW4024-120 Operation Manual Download Page 1

Hybrid Inverter/Charger

XW Series Hybrid 
Inverter/Charger

Operation Guide

XW4024-120/240-60
XW4548-120/240-60
XW6048-120/240-60

Summary of Contents for XW4024-120

Page 1: ...Hybrid Inverter Charger XW Series Hybrid Inverter Charger Operation Guide XW4024 120 240 60 XW4548 120 240 60 XW6048 120 240 60...

Page 2: ......

Page 3: ...XW Series Inverter Charger Operation Guide...

Page 4: ...tion 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 MAN...

Page 5: ...accessories see the XW Series Inverter Charger Installation Guide Audience The Guide is intended for anyone who needs to operate configure and troubleshoot the XW Series Inverter Charger Certain conf...

Page 6: ...nd more information about Xantrex Technology Inc as well as its products and services at www xantrex com WARNING Warnings identify conditions or practices that could result in personal injury or loss...

Page 7: ...e damaged in any way If the XW Inverter Charger is damaged see the Warranty section 7 Do not disassemble the XW Inverter Charger It contains no user serviceable parts See Warranty for instructions on...

Page 8: ...ngine or batteries 4 Use caution to reduce the risk of dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion 5 Remove...

Page 9: ...ause 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...

Page 10: ...viii...

Page 11: ...g Batteries 2 4 Turning the XW Inverter Charger On and Off 2 5 Monitoring Battery Level 2 6 Reading the Display Screen 2 6 Monitoring Operation with the XW System Control Panel 2 7 XW System Control P...

Page 12: ...ry Output Settings 3 21 Trigger Source Descriptions 3 22 Multi Unit Config Menu 3 23 Setting the Device Name 3 24 Setting the Device Number 3 25 Connections Menu 3 26 Operating Without Connections 3 2...

Page 13: ...A 4 XW Inverter Charger Efficiency A 4 Inverting Efficiency Typical A 4 Charging Efficiency Typical A 5 Sell Mode Efficiency Typical A 5 Mechanical Specifications A 5 Accessories A 6 B Default Settin...

Page 14: ...xii...

Page 15: ...1 Introduction Chapter 1 Introduction describes the operational features of the XW Series Inverter Charger Topics in this chapter include Basic Features on page 1 2 Basic Operation on page 1 3...

Page 16: ...stage charging to minimize charging time Easy to configure and install systems at a competitive dollar per watt cost Optional XW Automatic Generator Start allows operation with a wide range of genera...

Page 17: ...t to turn off The current sharing imbalance for a single inverter charger does not exceed 10 per cent of the rated maximum nominal output power All non utilized inverter chargers are off line when no...

Page 18: ...r Charger has one programmable auxiliary output that is able to run a small 12 V fan or operate an external relay to perform other functions such as to remotely start a generator if the Xanbus enabled...

Page 19: ...der grid voltage range These settings should only be changed by qualified service personnel using a special software application provided by Xantrex Changing any values may compromise compliance with...

Page 20: ...ormation Panel features Buttons for XW Inverter Charger on and off control clearing faults and warnings and battery equalization Three character display to indicate power output charge current or trou...

Page 21: ...nel features Liquid crystal display that provides graphics and text describing operation and status information in real time LED fault and warning indicator Internal clock to control time dependent XW...

Page 22: ...1 8...

Page 23: ...monitoring XW Inverter Charger operation using the Inverter Information Panel or the XW System Control Panel The topics in this chapter include Monitoring Operation with the Inverter Information Pane...

Page 24: ...AC1 LED indicates the presence and status of AC source connected to the AC1 input In most installations AC1 input is from the utility grid However any AC source can be connected to the AC1 input Gen...

Page 25: ...ng the battery bank When this LED is on the display screen shows battery charging current in amps Monitoring Faults and Warnings The red Fault Warning LED indicates the presence of a fault or warning...

Page 26: ...escalate to a fault if the warning condition does not go away CAUTION Battery damage Equalization may damage your battery Consult your battery supplier for details on equalize charging for the batter...

Page 27: ...gle unit installation when the XW Inverter Charger is turned off using the On Off button Xanbus network power is lost When Xanbus network power is lost network connected accessories such as the Automa...

Page 28: ...information about the operational state of the XW Inverter Charger Output power in kilowatts when the XW Inverter Charger is inverting and the kW LED is lit Battery charger current when the XW Invert...

Page 29: ...cates a device has a fault or warning condition and requires attention The light flashes when a warning occurs and turns on steadily when a fault occurs 2 Enter button confirms selection of a menu ite...

Page 30: ...puts the entire XW power system including Charge Controllers into Standby mode In Standby mode the XW Inverter Chargers stop passing AC input through to the loads and Stb is displayed on Inverter Info...

Page 31: ...System Status Screen on page 2 11 Figure 2 3 System Control Panel Top Level Screens Startup screen System Status screen System Status Select Device menu Select Device XW Inverter Charger Home screen X...

Page 32: ...ces in the system including the XW Inverter Charger and the System Control Panel The Select Device menu is where you can access the Setup menus for each device in the system The length of the Select D...

Page 33: ...een press the down arrow button until the XW Inverter Charger Home screen appears Figure 2 4 Selecting a Device Setup Menu Select Device menu Select Device XW6048 XW6048 00 Setup Meters Enabled Disabl...

Page 34: ...es from qualified AC input from the utility grid or a generator The charge state is in transition to either Bulk Absorption Float or Equalize AC input is also passed through to the load while charging...

Page 35: ...ile still maintaining a charged battery bank No power is sold to the utility in this mode The XW Inverter Charger uses stored DC capacity to support the grid until the total AC load current grid plus...

Page 36: ...the XW Inverter Charger to the loads The batteries are not being charged in this state Equalize Equalization has been turned on and the XW Inverter Charger is equalizing the batteries after completin...

Page 37: ...lt Amps AC2 is assumed to be connected to a generator but can be connected to any other 240 Vac source AC2 in L1 AC input voltage and current supplied to the inverter charger from the AC2 L1 input Thi...

Page 38: ...2 16...

Page 39: ...nfiguration explains how to navigate through the XW System Control Panel menus and configure the XW Inverter Charger Topics in this chapter include Using the XW System Control Panel on page 3 2 Using...

Page 40: ...Highlight the XW Inverter Charger device name and press Enter WARNING Risk of fire and shock hazard The following information is for qualified installation service personnel only Incorrect configurati...

Page 41: ...features such as Peak Load Shaving and Grid Sell mode See Grid Support Settings on page 3 17 To allow Grid Support to function after battery charging has completed it is recommended to set the Charge...

Page 42: ...ing customizing the default model name of the inverter charger and setting its network device number Setting the device number is important when multiple XW Inverter Chargers are on the Xanbus network...

Page 43: ...et value appears with an asterisk beside it 4 Press Enter to select the value 5 If you have another setting to change return to step 1 Or If you have no more settings to change press Exit until the Sy...

Page 44: ...00AM 12 00AM ManualOff ActHi LowBattV 42V 1sec 48V 1sec XW6048 00 SplitPhMstr HouseBatt1 ACLoad1 Grid1 Gen1 Disabled 10A XW6048 01 XW6048 00 Basic Batt Type Flooded 440Ah 100 2 Stage 50V AC1 60A 60A...

Page 45: ...the Low Batt Cut Out setting for inverter operation to resume High Batt Cut Out High Batt Cut Out sets the maximum battery voltage at which the inverter will operate If the battery voltage exceeds thi...

Page 46: ...ger has a no load power draw of about 28 watts Enabling Search mode reduces this power draw to less than 8 watts When to set up Search mode The Search mode feature on the inverter is only valuable if...

Page 47: ...ers include video recorders coffee makers with brew timers refrigerators and freezers with defrost timers Examples of devices that need power 24 hours a day include telephone answering machines alarm...

Page 48: ...DC output current for different models is XW4024 150 Adc XW4548 85 Adc XW6048 100 Adc Charge Cycle Sets the charging method 3 Stage Bulk Absorption Float and 2 Stage Bulk Absorption NoFloat Default Ba...

Page 49: ...ess to maintain the batteries Whenever AC power that is within the range of the inverter s settings is present at the inverter s input it passes power through to the connected load and begins charging...

Page 50: ...charge the batteries 2 Stage mode increases efficiency of utility connected systems by reducing the amount of power consumed by the inverter and batteries compared to when the battery is continuously...

Page 51: ...Cycle Bulk Stage Absorption Stage NoFloat Stage DC Voltage DC Current Time Charging Started Increased Voltage Bulk Absorption Volts Setting Absorption Time Constant Voltage Max Charge Rate Setting Co...

Page 52: ...at is in Float Absorption Bulk or Equalize stage at the Chg Block Start time charging on AC1 stops immediately and the charger enters an idle state identical to No Float see 2 Stage on page 3 12 When...

Page 53: ...etting a custom battery type Important All settings for configuring a custom battery type are based on the default settings for a Flooded battery type Table 3 4 Custom Battery Settings menu items Item...

Page 54: ...distribution panel The XW Inverter Charger limits the maximum input current to this setting by derating its charging current If the connected loads exceed the AC1 breaker setting the AC breaker trips...

Page 55: ...ge For more information see Islanding Protection on page 1 5 Table 3 6 Grid Support Settings menu Item Description Grid Supp Volts Sets the level to which the batteries will be discharged when the inv...

Page 56: ...ternal DC sources power is then drawn from the utility to support the load However if the local load demand is less than the power available from external DC sources the net excess power from the exte...

Page 57: ...a surcharge The XW Inverter Charger can be configured using the Load Shave Start Load Shave Stop and Charger Block settings to overcome these peak charges by using utility power to charge the battery...

Page 58: ...ttery Cut Out setting To further ensure the batteries are able to support the loads an additional source of power solar wind or hydroelectric is recommended Depending upon the capacity of the system c...

Page 59: ...m Note Running and Start up Peak currents are limited to the maximum current limits of the inverter Table 3 7 Gen Support Menu Values Setting Description GenSupp Mode Turns the Generator Support featu...

Page 60: ...ctivating a vent fan to disperse hydrogen from the battery compartment when the batteries reach their gassing voltage Low Batt Temp Activates the Auxiliary Output when the battery temperature falls be...

Page 61: ...y places the XW Inverter Charger in Standby mode When entering the Multi Unit Config menu the unit also identifies itself by flashing all front panel lights After exiting the Multi Unit Config menu th...

Page 62: ...i Unit Config menu 3 Select Dev Name 4 Press Enter The last letter of the XW Inverter Charger name is highlighted 5 Begin customizing the device name To change the character press the up or down arrow...

Page 63: ...r to a value other than 00 00 is a factory default value and can be used to indicate a Restore Defaults command was successfully performed if the value was previously different To set the XW Inverter...

Page 64: ...one of the units is set with a different DC connection a system configuration fault F66 occurs Although the XW Power System does support multiple XW Inverter Chargers connected to multiple battery ba...

Page 65: ...ssary configuration step as the system will still operate with the default settings Using None where no AC source is used only serves as a label in this case and does not modify the behavior of a unit...

Page 66: ...to factory default settings After using the Restore Defaults command the XW Inverter Charger is no longer configured for the power system To restore XW Inverter Charger default settings 1 On the Advan...

Page 67: ...4 Troubleshooting Chapter 4 Troubleshooting contains information and procedures for solving possible problems with the XW Inverter Charger...

Page 68: ...ould include the following as well as any other information asked for on page page WA 4 Loads the XW Inverter Charger was running or attempting to run Battery condition at the time of failure voltage...

Page 69: ...esistive loads usually generate heat in order to accomplish their tasks Toasters coffee pots and incandescent lights are typical resistive loads It is usually impractical to run larger resistive loads...

Page 70: ...power supplies that do not present a load until line voltage is available When this occurs each unit waits for the other to begin To drive these loads either a small companion load like a light bulb...

Page 71: ...n Release or reset the Remote Power Off switch No AC power output INVERT LED is on with no Fault Warning LED Open AC output breakers or fuses and bad output wire connections Check the Load VAC status...

Page 72: ...of the bulb Fluorescent bulbs work the opposite of incandescent light bulbs If the inverter is set to detect a 30 watt load and a 40 watt fluorescent is switched on the inverter will not detect it Th...

Page 73: ...e utility but when it does disconnect there will be a 5 minute delay minimum before re entering a grid interactive mode During this 5 minute delay all other modes of operation will be available assumi...

Page 74: ...e charger 2 Disable Charger Block if you need to override this feature 3 Check the Load Shave settings If the load draw from the grid exceeds the Load Shave Amps setting the charger will not operate 4...

Page 75: ...or equalization has finished Fault LED flashes and AC output drops momentarily Cold temperature around batteries with battery temperature sensor BTS installed may be causing unit to reach High Batt Cu...

Page 76: ...d time that the warning appeared If several warning messages occur before you can acknowledge or clear them they are displayed together on a warning list This list contains messages from every Xanbus...

Page 77: ...sing the Enter button on the System Control Panel for Yes and the Exit button for No Refer to the System Control Panel Owner s Guide for more information Table 4 2 Warning Messages Warning Number Syst...

Page 78: ...Automatic Battery Over Temperature Warning Battery temperature is over 50 C Check battery voltage and battery cable connections Stop charging if necessary Check for excessive ambient temperature and...

Page 79: ...Rate setting W58 FET2 Over Temperature Automatic See W57 See W57 W63 AC Overload Automatic Excessive load on the AC output Check for loads above the inverter s capacity Turn off some loads if necessar...

Page 80: ...tomatic Battery Temperature Sensor Shorted Replace battery temperature sensor W500 Lost network connection Automatic Lost network connection Check network cables W501 Inv Chg is trying to fix a memory...

Page 81: ...t list This list contains messages from every Xanbus enabled device not just the XW Inverter Charger You can select a message and view its details from the fault list To view a message from a fault li...

Page 82: ...exists the fault message reappears correcting the condition that caused the fault Escalating automatic faults Clear automatically if the fault condition goes away just like an automatic fault However...

Page 83: ...ve states charging peak load shaving sell gen support the unit goes into AC bypass mode until the temperature returns to the nominal value If the unit is not in AC bypass it shuts down until the tempe...

Page 84: ...t clears when voltage rises above the AC1 Lo Volt setting If fault persists check AC input voltage Check and adjust AC input low voltage setting F4 AC1 Input L1 Over Voltage Automatic AC1 over voltage...

Page 85: ...g If fault persists check AC input voltage Check and adjust AC input high voltage settings F12 AC2 Input L1 Under Voltage Automatic AC2 under voltage shutdown at the AC2 Lo Volt setting Fault clears w...

Page 86: ...s bad or an AC source was wired directly to the AC output See F17 F20 Relay s Welded Manual AC2 L2 transfer relay is bad or an AC source was wired directly to the AC output See F17 F21 Relay s Welded...

Page 87: ...ference between L1 and L2 See F23 F30 AI L1L2 Over Voltage Automatic Over voltage anti islanding fast disconnect 270 V See F23 F31 AI L1 Over Voltage Automatic Over voltage anti islanding slow disconn...

Page 88: ...ng Auto Fault Must occur 3 times in 30 seconds before becoming a manual fault Auxiliary power supply over voltage shutdown Clear the fault and attempt restart If problem persists call customer service...

Page 89: ...See F47 F49 DC Over Voltage Automatic DC over voltage shutdown Occurs if DC voltage is above 32 Vdc 24 V or 70 Vdc 48 V Clear the fault and attempt restart Ensure battery voltage is below 29 Vdc 24 V...

Page 90: ...to check the fan If the fan has failed have the inverter serviced Increase clearance around the inverter or unclog the fan air intake Lower the Max Charge Rate setting F58 FET2 Over Temperature Shutd...

Page 91: ...F67 Watchdog Error Manual Service required F68 Transformer Over Temperature Automatic The transformer temperature is over 140 C The fault clears when the transformer temperature falls to 125 C Ensure...

Page 92: ...4 26...

Page 93: ...A Specifications Appendix A Specifications provides the electrical and environmental specifications for the XW Inverter Charger...

Page 94: ...quency Range Bypass Charge Mode 55 65 Hz default 44 70 Hz allowable AC1 voltage range Sell Modea automatically adjusts when entering Sell Mode a This unit or system is provided with fixed trip limits...

Page 95: ...operate at high power is limited by temperature When large loads are run the inverter s temperature increases At the point where more heat is created in the inverter than can be dissipated its ability...

Page 96: ...re maximum component ratings are not exceeded XW Inverter Charger Efficiency Inverting Efficiency Typical Figure A 2 Output Power Versus Ambient Temperature XW Series Power Derating 0 1000 2000 3000 4...

Page 97: ...2000 Ah Non Volatile Memory Yes Display Panel Status LEDs indicate AC In status faults warnings equalize mode battery level Three character display indicates output power or charge current fault warni...

Page 98: ...5 lb 57 kg 115 lb 52 kg 115 lb 52 kg Shipping Weight 132 lb 60 kg 122 lb 55 kg 122 lb 55 kg Accessory Part Number Power Distribution Panel 865 1015 Conduit Box 865 1025 Inverter 2 Connection Kit 865 1...

Page 99: ...B Default Settings Appendix B contains the default configuration settings and ranges for the XW Inverter Charger Configuration settings can be viewed and changed using the XW System Control Panel...

Page 100: ...048 00 Multi XW6048 00 Gen XW6048 00 Aux XW6048 00 Grid XW6048 00 Chg Custom Settings XW6048 00 Adv Connections 44V 10s 70V 50W 2s Disabled 64 0V 57 6V 57 6V 54 0V 108mV C Flooded 440Ah 100 2 Stage Wa...

Page 101: ...earch Watts 50W 25 255W 5W Search Delay 2s 1 25s 1s Item Default Setting Range Step Size 24 V 48 V 24 V 48 V Batt Type Flooded Flooded Gel AGM Custom n a Batt Capacity 440Ah 50 2000Ah 1Ah Max Chg Rate...

Page 102: ...M 57 6V 56 8V Gel 57 2V AGM 20 0 32 0V 40 0 64 0V 0 1V Float Voltage 27V 27 6V Gel 26 8V AGM 54 0V 55 2V Gel 53 6V AGM 20 0 32 0V 40 0 64 0V 0 1V Absorb Time 180min 180min 1 480min 1min Batt Temp Comp...

Page 103: ...estricted to the selected AC1 breaker size 1A Load Shave Amps 48A 0 48A 1A Load Shave Startb b When Load Shaving is enabled if Load Shave Start and Load Shave Stop are set to the same time the XW Inve...

Page 104: ...vel and Clear Delay do not appear if Trig ger Src is set to Fault 22 0V 44 0V 10 0 26 0V 20 0 52 0V 0 1 Trigger Level HighBattV 28 0V 56 0V 24 0 32 0V 48 0 64 0V 0 1 Trigger Level HighBattTemp 45 0 C...

Page 105: ...m repaired products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface...

Page 106: ...IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWIS...

Page 107: ...ed during work hours A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of t...

Page 108: ...location __________________________________ p Length of time inverter has been installed __________________________________ p Battery battery bank size __________________________________ p Battery ty...

Page 109: ...ttings B 6 description 3 26 custom battery menu 3 15 default settings B 4 Customer Service preparing to call WA 4 D default settings restoring 3 28 device home screen 2 11 Down arrow button 2 7 E ener...

Page 110: ...0 restore default settings 3 28 S safety instructions vi SCP device menu 2 10 features 1 7 2 7 select device menu 2 10 system status screen 2 11 search mode 2 13 3 3 3 7 3 8 sell mode 2 13 3 17 serial...

Page 111: ......

Page 112: ...Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 975 0240 01 01 Printed i...

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