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MPPT 80-600 User Manual

1. 3 3 Normal Operation 2 27 75 eee e 3 3 Charge Stages 3 4 975 0560 01 01 Revision B xi Contents Viewing Active Faults Errors and Warnings 3 4 Faults 77 74 7440 40 400 4000000 3 6 Errors 3 7 Warnings 3 9 Viewing Fault Error and Warning Logs 3 11 Viewing Harvest Logs 3 11 Daily Logs 3 12 Monthly Logs 3 12 Yearly Logs 3 12 Equalizing Batteries 3 12 4 Troubleshooting Troubleshooting 4 2 A Specifications Electrical Specifications A 2 MPPT Voltage Range A 3 Operating Below the PV Array Voltage Full Power Range A 3 Default Battery Charging Settings
2. A 5 Mechanical Specifications A 5 Output Power Versus Ambient Temperature A 6 Accessories 22 eee 40 HH 00000 A 6 Regulatory Approvals A 7 B Xantrex XW System Control Panel Menus Using the SCP B 2 SCP Menu Map B 3 Changing Settings Using the SCP B 4 Viewing the Select Device Menu B 5 Viewing the Setup Menu B 5 The Setup Menu B 6 Configuration Settings B 7 Monitoring the Unit B 10 Home Screen B 10 Meters B 11 C Boost Charging Using Boost Charging C 2 xii 975 0560 01 01 Revision B 975 0560 01 01 Revision B Introduction Chapter 1 describes features and functions of the charge controller
3. Viewing the Setup Menu On the Select Device menu select the charge controller to view and change its settings Select Device System Settings SCP Clock Figure B 3 Selecting the unit To select the charge controller from the Select Device menu 1 Press the down arrow button to highlight XW MPPT80 xx where xx is the device number 2 Press Enter The Setup menu appears 975 0560 01 01 Revision B B 5 Xantrex XW System Control Panel Menus The Setup Menu The Setup menu allows access to he Meters screen and several other commands that control the charge controllers operation XW MPPT80 01 Setup Force Chg Equalize Mode Figure B 4 Setu Clear Faults Warnings Vien Device Info Basic Settings Bulk Disabled Operating p menu Table B 3 Setup menu Menu Item Description Meters Displays the Meters screen Harvest Logs Displays the charge controller s daily monthly and yearly performance logs See Viewing Harvest Logs on page 3 11 Force Chg Causes the current charge stage to change to the selected stage Equalize Starts or stops battery equalization Mode Sets the charge controller s operating mode Clear Faults Warnings Clears any active faults or warnings If the fault or warning condition is still present the fault or warning message could reappear View Device Info Displays the Dev Info scre
4. multi unit installation Select the device number of the charge controller from which you want to copy the setup This screen is hidden when no compatible devices are found The Copy fromcommand copies all charger settings and custom battery settings from the selected charge controller 975 0560 01 01 Revision B Configuring Device Settings NOTICE The Copy from command will not give you any indication that it has completed its task To check that the charger settings have been copied properly view some of the settings you originally configured Settings that are copied from one charge controller to another are Batt Type Batt Capacity Max Chg Rate Charge Cycle ReCharge Volts Absorb Time Default Batt Temp Batt Voltage DC Conn Custom battery settings if Custom battery type selected including Eqlz Support Eqlz Voltage Bulk Voltage Absorb Voltage Float Voltage and Batt TempComp 975 0560 01 01 Revision B Configuration Reducing Tare Loss By default the charge controller is configured to reduce tare losses at night by shutting off the auxiliary power supply To further reduce power consumption at night you can configure the charge controller to also shut off the network Xanbus power supply You can change these settings using the Adv Features menu item provided you are using an SCP with firmware version 1 03 or higher To display the tare loss settings select Advanced Set
5. Configure the charge controller using the SCP See Appendix B Xantrex XW System Control Panel Menus for an overview of the SCP or download the entire SCP Owner s Guide Document Part Number 975 0298 01 01 at www schneider electric com Before you can configure the charge controller s settings you must select the charge controller s device number in the SCP by performing the following steps 1 Onthe System Status home screen press Enter The Select Device menu opens 2 Use the arrow buttons to scroll to the charge controller and then press Enter The XW MPPT80 xx Setup menu appears where xx is the device number Viewing Basic and Advanced Settings 2 2 The charge controller has basic and advanced configuration menus The basic menu contains items you might have to view and adjust on a routine basis The advanced menu contains items intended for service personnel and one time setup such as auxiliary output and custom battery configuration To display the Advanced Settings menu item instead of the Basic Settings menu item perform the following special keypress From the Setup menu press the Enter up arrow and down arrow buttons 908 Onthe Setup menu Basic Settings disappears from the bottom of the list and Advanced Settings appears at the top of the list After configuring the charge controller help prevent unintended advanced configuration by using the combined keypress again to hide the advanced menu it
6. 2 4 Batt Type Flooded GEL AGM Custom Flooded Sets your battery type Selecting Custom allows you to adjust equalize bulk absorption and float voltage settings You can also adjust battery temperature compensation fromthe Custom Battery menu The Custom option is available only when advanced menus are displayed 975 0560 01 01 Revision B Table 2 1 Battery configuration settings SCP Device Menu Configuring Battery Characteristics and Battery Charging Item Setting Values Default Description Advanced Settings gt Batt Capacity 0 10000Ah 440Ah Sets the amp hour capacity of Charger Settings your battery bank Setting Batt CapacitytoO disables the exit current threshold mechanism used to transition from absorption to float As a result the charge controller will transition to float once the Max Absorption timer has elapsed Advanced Settings gt Max Chg Rate 1 100 100 Sets the charging current limit Charger Settings Advanced Settings gt ReCharge 24V 20 0 27 0V 25 0V Sets the voltage at which the Charger Settings Volts I charger transitions from float or 48V 40 0 54 0V 50 0V no float back to bulk or from absorption back to bulk Advanced Settings gt Absorb Time 1 480min 180min Sets the maximum time spent in Charger Settings the absorption stage Setup Force Chg Bulk Bulk Manually advances the charge Float stage to bulk float or no float No Float Ad
7. For information on See Features page 1 2 Maximum Power Point Tracking page 1 3 Fast Sweep Shade Tolerant MPPT Algorithm page 1 3 Charge Controlling page 1 4 Auxiliary Output Functions page 1 9 Introduction Features This photovoltaic charge controller tracks the maximum power point of a PV array to deliver the maximum available current for optimum charging of batteries The charge controller can be used with 24 and 48 VDC battery systems only The charge controller is designed to regulate the available power from a PV source only It is not designed to regulate power from other types of power sources The charge controller can be installed in single or multi unit configurations with a Xantrex XW Hybrid Inverter Charger or as a stand alone battery charger However it is recommended that at mininum an SCP or Xantrex Gateway be included in the system see Accessories on page A 6 for product part numbers The System Control Panel SCP provides both status information and the ability to change settings while the Gateway access via a personal computer provides status information only An SCP is required for installation of the charge controller Standard features of the charge controller include e Two or three stage charging process with manual equalization to maximize system performance and maintain expected battery life e Maximum Power Point Tracking MPPT to deliver the maximum
8. Onthe Config menu select Restore Defaults 2 Press Enter XH MPPT80 01 Meters DC Out Power 210H Time in Float 0 00 00 3 5 h 0 20kHh XH MPPT80 01 Setup Meters Harvest Logs Force Chg Equalize Disabled Vien Device Info Basic Settings 0 1kAh 5kHh 20C Float Manual0ff Thermal Derating Off 215W 2 1A 100 5V 3 7A 57 4V XW MPPT80 01 Dev Info View Fault Log View Warning Log Mode Operating Clear Faults Warnings XW MPPT80 01 Config Batt Capacity 440Ah Max Chg Rate 1007 Charge Cycle 3Stage F looded Batt Voltage 48 0V Figure B 6 Configuration menus Basic 975 0560 01 01 Revision B palqeuj pyy ye wu cT palqestd stq or SR unouyun WI MI 3234 APU Q QRLddN MX boy buzusen nata Boy z nea MITA ou 499 Q QalddH HX phessyue os UI Ad B 9 Configuration Settings uuo I8 G8lddh MX gt 51 fataq 21 gt 19 8t Taaa may 3851 fetag a661 40 PP Taaa 266 TL A egHO7 338 Bra S1 eu0pnNy uny penam XN J0 Q8LddM MX pa gesip S XOLI Lolny Idd N uaym Aluo peBueyo 9Q ULD SHOA JOH dd Z80901 deoydsa1 yeg AQ pS 2104 JOT AQ 2S 23194 quosqy A925 auroa y ng A0 9 wi 104 ziba paigeuJj woddns z ba 5nJ I8 O8LddH MX Sb 1 SOU 10 py Aad 009 081ddH my And IINA I8 G8LddH MX 35u1y S gt ppma ny 440Tenuey Any Tem XNY I O8LddH MX AQ 009 SIVA 374
9. 01 This Guide is organized into the following chapters and appendices e Chapter 1 describes features and functions of the charge controller e Chapter 2 contains information and procedures to configure the charge controller e Chapter 3 contains information about operating the charge controller e Chapter 4 contains information about identifying and resolving possible problems that might arise while using a charge controller 975 0560 01 01 Revision B jii About This Guide Conventions Used e Appendix A provides the specifications for the charge controller e Appendix B is a guide to the charge controller s monitoring and configuration menus on the Xantrex XW System Control Panel e Appendix C provides information on Boost Charging for flooded lead acid batteries in off grid applications This Guide uses the term charge controller to refer to the Xantrex XW MPPT 80 600 Solar Charge Controller This Guide uses the following conventions for conveying important safety related information A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous condition which if not avoided can result in minor or moderate injury CAUTION CAUTION wi
10. 90 80 70 60 f Output 50 Current Amps 40 195 200 205 210 215 220 225 230 235 240 Input Voltage Volts Figure A 2 Maximum expected output current versus input voltage 5000 4500 4000 3500 a S Output 2000 1500 1000 500 195 200 205 210 215 220 225 230 235 240 Input Voltage Volts Figure A 3 Maximum expected output power versus input voltage Battery Voltage 54V Battery Voltage 58V Battery Voltage 64V Power 2500 ae eea I Battery Voltage 58V Battery Voltage 64V A 4 975 0560 01 01 Revision B Default Battery Charging Settings Default Battery Charging Settings All settings in the following table are based on a 48 V nominal battery bank For a 24 V nominal battery bank divide the voltage values in this table by two Battery Type Setting Flooded Gel AGM Equalize Voltage 64 0 V n a n a ReCharge Voltage 50 0 V 50 0 V 50 0 V Bulk Voltage 57 6 V 56 8 V 57 2V Absorption Voltage 57 6 V 56 8 V 57 2V Float Voltage 54 0 V 55 2 V 53 6 V Absorption Time 360 min 360 min 360 min Batt Temp Comp 108 mV C 108 mV C 84 mV C a When Custom is selected for the battery type the default settings are based on the flooded battery type Mechanical Specifications Enclosure Type IP20 indoor ventilated aluminum sheet metal chassis with 7 8 and 1 22 22 mm and 27 76 mm knockouts and aluminum heat si
11. a boost voltage charge level that has been found to be beneficial for ensuring enough amp hours are returned to the battery bank for off grid installations For detailed information on how boost charging works and when it is recommended see Appendix C Boost Charging 975 0560 01 01 Revision B Charge Controlling The charge controller transitions to the float stage if either of the following two conditions are met e The charge current allowed by the batteries falls below the exit current threshold which is equal to 2 of the programmed battery capacity for a 500 amp hour battery bank this would be 10 amps for one minute e The charge controller has been in absorption for the programmed maximum absorption time limit The default is three hours but the time limit is programmable from one minute to eight hours Float Stage 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 voltage setting for one minute a new bulk cycle is triggered Absorption Bulk State Stat Float State Bulk Boost ale Voltage Voltage Se penne i Absorption Voltage Float Voltage x Recharge Voltage gt Boost Time Timer ihr fixed oe ee Max Absorb Time dflt 3 hrs adjustable 1 min 8 hrs sR aa a A gt Current Max C
12. a particular installation Ifthis charge controller does cause harmful interference with radio or television reception which can be determined by turning the charge controller off and on try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the charge controller and the receiver e Connect the charge controller to a different circuit from that to which the receiver is connected e Consult the dealer or an experienced radio or TV technician for help 975 0560 01 01 Revision B ix Contents Important Safety Instructions vii 1 Introduction Features 47 77 4470 eee HH HH 1 2 Maximum Power Point Tracking 1 3 Fast Sweep Shade Tolerant MPPT Algorithm 1 3 Charge Controlling 1 4 Three Stage Battery Charging 1 4 Bulk Stage 1 4 Absorption Stage 1 4 Float Stage 1 5 Two Stage Battery Charging 1 6 Battery Temperature Compensation 1 7 Equaliza
13. after system power is removed the ground fault is Ground fault corrected the GFP fuse is replaced by qualified personnel type 1 negative or positive grounded systems only and system power is restored See the Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide for more information GroundF1t2 F83 A problem with the hardware circuitry used to detect ground faults exists Contact customer service for assistance Ground fault type 2 InputoVFlt F74 Input voltage has exceeded 600 VDC Damage to the charge controller is possible so the fault will not clear until an operator Input over voltage clears it manually using the SCP fault FanoVFlt F75 Fan voltage has risen above 13 8 V The fan will cease operating but the charge controller will continue operating though it will Fan over voltage probably experience power derating The fault will not clear until an fault operator clears it manually using the SCP OutputoCFlt F78 Three fast output F71 or slow output F73 over current errors have occurred within 30 seconds Output over current fault The fault will not clear until an operator clears it manually using the SCP FanOCFlt F79 More than two Fan Errors have occurred within 30 seconds The fan Fan over current fault 3 6 will cease operating but the charge controller will continue operating though it will probably experience power derating The fault will clear itself when the operator togg
14. available power from a PV array to a bank of batteries See Maximum Power Point Tracking on page 1 3 e Integrated PV Ground Fault Protection PV GFP e Fan cooled with speed control based on internal heat sink temperature e 80 amp charging current capability e Configurable auxiliary output See Auxiliary Output Functions on page 1 9 e Three LEDs for displaying operating status On Charging Equalize and Error Warning e Input over voltage protection output over voltage protection output under voltage protection and output over current protection Warnings errors and faults are indicated by the red LED View the associated warning or error message on the SCP e Xantrex Xanbus enabled Xanbus is a network communications protocol developed by the manufacturer The charge controller is able to communicate its settings and activity to other Xanbus enabled devices such as the Xantrex XW Hybrid Inverter Charger the SCP the Xantrex XW Automated Generator Start and other charge controllers e Over temperature protection and power derating of output power when ambient temperature is high e Battery Temperature Sensor BTS to provide automatic temperature compensated voltage setpoints for battery charging If the BTS is lost or damaged you can order a replacement from the manufacturer part number 808 0232 02 975 0560 01 01 Revision B Maximum Power Point Tracking Maximum Power Point Tracking MPPT all
15. devices to enter absorption e The last Xantrex XW Hybrid Inverter Charger that is ready to exit absorption triggers all devices to exit absorption and enter float Two Stage Battery Charging No Float State The two stage charging process includes the bulk and absorption stages only There is not a float stage The relationship between charging current and battery voltage during the two stage charging process is shown in Figure 1 3 During the no float state 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 voltage setting for one minute NOTICE For more information about battery charging settings see Table 2 1 Battery configuration settings on page 2 4 and Table 2 2 Custom battery settings on page 2 6 975 0560 01 01 Revision B Charge Controlling i No Fl Bulk State ig SO 2 er gt Bulk Boost tate er Voltage Voltage u i Absorption Voltage Float Voltage Recharge Voltage Boost Timer Ihr fixed Time Max Absorb Time dflt 3 hrs adjustable 1 min 8 hrs A a alc na een gt Current Max Current Limit Absorption Exit Current Threshold 2 of programmed AH capacity gt Time Figure 1 3 Two stage battery charging cycle Battery Temperature Compensation The Battery
16. for 1 second OutpFastOCErr F71 Output current has risen above 117 5 ADC The error clears itself after 5 seconds If the error is triggered three times in a span of 30 Fast output over seconds then it must be cleared manually current error OutpSlowoCErr F73 Output current has risen above 90 0 ADC for 10 milliseconds The Slow output over current error 3 8 error clears itself after 5 seconds 975 0560 01 01 Revision B Table 3 5 Error messages Viewing Active Faults Errors and Warnings Display Text Description Error ID Definition FanOCErr F76 Fan current has risen above 1 6 A for 20 milliseconds The error clears itself when fan current falls below 1 0 A for Fan over current 1 second error InputOCErr F77 PV current has risen above 25 ADC The error clears itself after 5 seconds Input over current error Warnings Table 3 6 lists all possible warnings Warnings indicate that one ofthe charge controller s operating parameters is approaching the specified limits for the device Table 3 6 Warning messages Display Text Description WarningID Definition BattOTWrn W4 Battery temperature has risen above 50 C 122 F for 10 seconds The warning clears itself when the battery Battery over temperature falls below 45 C 113 F for 10 seconds temperature warning AmbOTWrn W5 Ambient temperature inside the charge controller has risen above 70 C 158 F for 10 second
17. the primary interface to the charge controller It must be used for setup and configuration and it is recommended to be used for monitoring and fault reporting once installation is complete Only one SCP is required to monitor multiple charge controllers NOTICE You must use an SCP with firmware version 1 05 00 or higher for full compatibility with the charge controller For information on updating your firmware contact customer service The Xantrex XW Config tool is required for upgrading The following accessories are optional Gateway 865 1055 Xanbus power supply 865 1057 XW Config 865 1155 Provides the ability to update system firmware and monitor system status See Xantrex XW Config User s Guide Part Number 975 0365 01 01 975 0560 01 01 Revision B Regulatory Approvals Regulatory Approvals Certified to UL 1741 and to CSA 107 1 and carries the c CSA us mark EMC North America e FCC Part 15 sub part B Class B e Industry Canada ICES 003 Class B CE Marked and complies with the following Low Voltage Directive 2006 95 EC per e EN50178 Electronic Equipment for Use in Power Installations EMC Directive 2004 108 EC per e EN61000 6 3 Emission standard for residential commercial and light industrial environments e EN61000 6 1 Immunity for residential commercial and light industrial environments 975 0560 01 01 Revision B A 7 A 8 Xantrex XW System Control Panel Menu
18. vary depending on the temperature around the batteries Temperature compensation can be accomplished automatically by using a BTS The BTS attaches directly to the side of one of the batteries in the bank and provides precise battery temperature information See Installing the Battery Temperature Sensor in the Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide for detailed instructions on how and where to install the BTS If a BTS is installed the charge controlling process is automatically adjusted for the battery temperature The charge controller uses the following coefficients to adjust the charging voltage e Flooded Lead Acid and Gel Type Batteries 48 V nominal 108 mV per degree Celsius e Absorbed Glass Mat AGM Type Batteries 48 V nominal 84 mV per degree Celsius If using a BTS when the battery temperature drops below 25 C 77 F the regulation voltage setting automatically increases When the temperature rises above 25 C 77 F the regulation battery voltage setting automatically decreases The temperature range where compensation is applied is between 0 C and 50 C Outside of this temperature range the compensation value is clamped at the corresponding value for either 0 C or 50 C If a BTS is not installed configure the charge controller to use one of three temperature compensated charge settings e Cold 10 C 50 F e Warm 25 C 77 F e Hot 40 C 104 F If signif
19. with the current date The charge controller stores up to 62 daily logs After 62 days the oldest daily log is overwritten To view the monthly logs go to Setup gt Harvest Logs From the Monthly Logs screen press Enter Press the down arrow button to scroll through the monthly logs starting with the current month The charge controller stores up to 24 monthly logs After 24 months the oldest monthly log is overwritten To view the yearly logs go to Setup gt Harvest Logs From the Yearly Logs screen press Enter Press the down arrow button to scroll through the yearly logs starting with the current year The charge controller stores up to 12 yearly logs After 12 years the oldest yearly log is overwritten Equalizing Batteries 3 12 Equalization charging is the process of deliberately charging a battery or battery bank at a high voltage for a set period of time Equalize charging remixes the electrolyte helps to remove sulfate buildup on the battery plates and balances the charge of individual cells Make sure to read all cautions and warnings regarding equalization charging batteries before allowing an equalization charge to occur 975 0560 01 01 Revision B Equalizing Batteries NOTICE In a system where more than one device is capable of equalizing batteries such as a system including multiple charge controllers and Xantrex XW Hybrid Inverter Chargers there is no system wide equalization command for all device
20. 15 8 VDC The error clears itself when the voltage rises above 19 0 VDC for 1 second Output under voltage immediate error OutputUVErr F11 24 V System Output voltage has fallen below 18 0 VDC The error clears itself when the voltage rises above 19 0 VDC for 1 second Output under voltage error 48 V System Output voltage has fallen below 36 0 VDC The error clears itself when the voltage rises above 38 0 VDC for 1 second AuxPSErr F26 Auxiliary power supply is not within its expected operating range The error clears itself after 1 second and the auxiliary power Auxiliary power supply will attempt to restart supply error HsOTErr F55 Heat sink temperature has risen above 90 C 194 F for 5 seconds The error clears itself when the heat sink temperature Heat sink over falls below 80 C 176 F for 30 seconds temperature error SetupErr F69 Multiple charge controllers connected to the Xanbus network have the same device number The error will clear when the operator changes the device numbers of the duplicate charge controllers The device number can be changed in the Multi Unit Config screen of the SCP OutputOVErr F70 24 V System Output voltage has risen above 33 0 VDC for 1 second The error clears itself when the voltage falls below 32 0 Output over VDC for 1 second voltage error 48 V System Output voltage has risen above 65 0 VDC for 1 second The error clears itself when the voltage falls below 64 0 VDC
21. 2 16 nighttime tare losses 2 16 no float charging stage 1 6 3 4 not charging charging stage 3 4 NOTICE definition iv 975 0560 01 01 Revision B O on charging LED 3 2 Operating mode 2 13 operating mode configuring 2 13 orange LED 3 2 output power versus ambient temperature A 6 P peak power tracking configuring 2 7 personal protection viii power supplies disabling at night 2 16 protection personal viii PV In setting 2 8 R radio reception interference ix reception interference ix ReCharge Volts setting 2 5 red LED 3 2 regulatory approvals A 7 resetting to factory defaults 2 16 B 8 Restore Defaults setting 2 16 S safety information batteries viii general vii SCP See Xantrex XW System Control Panel settings Absorb Time 2 5 Absorb Voltage 2 6 Batt Capacity 2 5 Batt Temp 2 5 Batt Type 2 4 Batt Voltage 2 4 BattTempComp 2 6 Bulk Voltage 2 6 Charge Cycle 2 5 Clear Delay 2 10 Clear Level 2 10 Copy from 2 14 DC Conn 2 4 Default Batt Temp 2 5 Dev Number 2 13 Eqlz Support 2 6 Eqlz Voltage 2 6 Equalize 2 4 F W Rev 2 13 Float Voltage 2 6 Force Chg 2 5 975 0560 01 01 Revision B Index Lo Pwr at Night 2 16 Manual Aux 2 9 Max Chg Rate 2 5 Mode 2 13 MPPT AutoTrack 2 8 MPPT Ref Volts 2 8 NetPS Night Dis 2 16 PV In 2 8 ReCharge Volts 2 5 Restore Defaults 2 16 Trig Src 2 9 Trigger Delay 2 10 Trigger Level 2 10 shade tolerance 1 3 specifications electrical A 2 mechanical A 5 S
22. 3 4 viewing active 3 5 viewing logs 3 11 exit button Xantrex XW System Control Panel B 2 F F W Rev setting 2 13 Fast Sweep 1 3 faults clear manually 3 5 disable normal operation 3 5 messages 3 6 must be manually cleared 3 5 overview 3 4 viewing active 3 5 viewing logs 3 11 faults and warnings menu 3 4 FCC information ix float charging stage 1 5 3 4 Float Voltage setting 2 6 Force Chg setting 2 5 G Gateway See Xantrex Gateway green LED 3 2 H harvest logs daily 3 12 monthly 3 12 overview 3 11 requirements 3 11 yearly 3 12 input configuring 2 7 interference radio and television reception ix IX 2 L LEDs flashing 3 2 overview 3 2 limitations on use vii Lo Pwr at Night setting 2 16 load control using auxiliary output 1 9 logs daily 3 12 error 3 11 fault 3 11 harvest 3 11 monthly 3 12 warning 3 11 yearly 3 12 M Manual Aux setting 2 9 manually advancing charge stages 2 5 clearing faults errors or warnings 3 5 Max Chg Rate setting 2 5 maximum power point tracking maximum power point curve 1 3 overview 1 3 voltage range A 3 mechanical specifications A 5 menu mapsXantrex XW System Control Panel advanced configuration menu map B 9 messages errors 3 7 faults 3 6 warnings 3 9 meters screen B 11 Mode setting 2 13 monthly logs 3 12 MPPT AutoTrack setting 2 8 MPPT Ref Volts setting 2 8 MPPT See maximum power point tracking multiple units copying settings 2 14 N NetPS Night Dis setting
23. 6W 57 5V State Float Harvest 206Wh 3Ah setup system Top Line Model device number Line 1 Output current to batteries Line 2 Output power battery voltage Line 3 Charge State Line 4 Output since last sleep period Figure B 8 Home screen The charge controller s Home screen features a setup arrow pointing to the Enter button and a system arrow pointing to the Exit button Pressing Enter takes you to the charge controllers Setup menu Pressing Exit takes you to the System Status screen Pressing the down arrow button takes you to the home screens for the other Xanbus enabled devices in the system 975 0560 01 01 Revision B Monitoring the Unit Meters Monitor the charge controller s operation on the Meters screen The Meters screen displays input and output power battery temperature charge stage total power production for that day and power production over the charge controller s lifetime You can select the Meters screen from the charge controller s Setup menu XW MPPT80 01 Setup XW MPPT80 01 Meters PV In Power 215W Harvest Logs PV In 2 1A 100 5V Force Chg DC Out Power 2104 Equalize Disabled DC Out 3 7A 57 4 Mode Operating 5 Time in Float 0 00 00 Clear Faults Warnings Today 3 5Ah 0 20kWh Vien Device Info Life 0 1kAh okWh Basic Settings Batt Temp 20C State Float Aux ManualOff Thermal Derating off Figure B 9 Selecting the Meters screen 975 0560 01 01 Rev
24. Charger Home Sareen A V jll Xantrex XVVIVPPT N Xantrex XVWVIVPPT Home Sareen A V Device 3 Home screen setup menu AIV I N Device g setup menu Device 7 Home sareen A V Xantrex XVVSCP menu Clock menu y 8 w Figure B 2 SCP menu map 975 0560 01 01 Revision B B 3 Xantrex XW System Control Panel Menus Table B 2 Screen and menu descriptions Screen or menu Description Startup screen Appears for a few seconds after the system starts up or when the system has been reset System Status screen Displays status information for the power system consisting of all Xanbus connected devices on a single network The System Status home screen appearance varies with the status of the inverter charger and other Xanbus enabled devices in the power system The System Status home screen features a menu arrow pointing to the Enter button Pressing Enter takes you to the Select Device menu XW MPPT Home screen Displays status information for the charge controller Select Device menu Displays a list of Xanbus enabled devices in the system including the charge controller and the SCP The length of this menu depends on how many Xanbus enabled devices are installed in the system This menu also contains the clock menu where you can set the time and date and the system settings menu where you can change system modes The System Panel Clock and S
25. LH patgeuJ PELON LN ndur 1 B8LddH MX A0 SP aber Toy 3300 uep deal yyuq yInmjaq umes EL Qaosqu AQ 0S 104 ab mpay be s rpfo amp 7991 ayay bin xey yverr fo pede 3380 s6uy 325 won papoo 4 adh 38a aby 10 G8LddH MX sho7 Area 5071 ftp uoy sho7 fitted EPAIEN 40 QRLddH HX 440 buppasoq TEAL 440Tenuey un ye0 WS 302 thea 3328 ynys HUH san UN3M0Z 0 uus r Fepo 09 09 08 peod uj wall APES YLE ang NI norz red yng 34 AS 001 YEZ Ur Ad MSIZ Od UT Ad 319394 0 031ddH MX 2202093 ADU inead 03S N Briuo3 yrun THINN Z0 lddH wouy fido gt shuy 25 uny auas yndur ums abe T UO I8 O8LddH MX OWT ITA HATA sburusan SINE aT buryeuadg apoy pargestq szrrenbg By 22 04 s607 3324 0 3323 90 sbut 35 pasueapy dnzas 10 G8lddW MX Figure B 7 Configuration menus Advanced 975 0560 01 01 Revision B Xantrex XW System Control Panel Menus Monitoring the Unit Home Screen You can monitor the charge controller s operation on the SCP by viewing the e Home Screen e Meters screen The charge controller s Home screen displays real time operational data specific to the charge controller To view the charge controller s Home screen Fromthe System Status screen press the down arrow until the charge controller s Home screen appears To return to the System Status screen Press the Exit button XW MPPT80 01 Home Output 2 9A Battery 16
26. T 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 DOCUMENT 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 CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW SCHNEIDER ELECTRIC COM Document Part Number 975 0560 0 1 01 Revision B Date January 2012 Contact Information www schneider electric com amp amp De 1 650 351 8237 1 866 519 1470 North America 1 925 245 1022 re techsupport schneider electric com France 33 0 825 012 999 fr re techsupport fr schneider electric com Deutschland 49 0 180 575 3 575 49 0 2102 404 7101 pv service de schneider electric com Espa a 34 902 101 813 34 933 055 026 es sat es schneider electric com L Italia 39 035 4151111 39 035415 3200 IT pronto contatto it schneider electric com For other country details please contact your local Schneider Electric Sales Representative or visit the Schneider Electric Web site at http www schneider electric com sites corporate en support operations local operations local operations page Information About Your System As soon as you open your product record the following information and be sure to keep your proof of purchase Serial Number Product Number Purc
27. TS reading is only shown on the Meters screen if the BTS is physically connected to the device you are viewing on the SCP All devices share BTS information but they only report the information to the SCP if they have the BTS plugged into their BTS port Navigate to the Meters screen on the SCP for the device that has the BTS connected to it 975 0560 01 01 Revision B Table 4 1 Charge controller problems Problem Possible Cause Troubleshooting Solution Thermal derating is indicated on the SCP A The charge controller is operating ina high ambient temperature environment at high power levels B The fans are not working properly A The charge controller is specified to operate at full output power up to 45 C Derating occurs at temperatures above this level B Make sure that you have not blocked the ventilation holes atthe top and bottom of the charge controller and that you have provided sufficient clearance for proper ventilation of the charge controller Check the active fault list and the historical fault log on the SCP to see if the charge controller has registered any faults or errors related to fan operation The charge controller s Error Warning red LED is on and the SCP indicates an input over voltage error F9 for the charge The PV panels are producing voltage levels that are outside the operating specifications for the charge controller This is likely due to the pane
28. Temperature Sensor BTS provides temperature compensation for battery charging With the BTS installed the charge controller adjusts charging voltage with the temperature of the battery to optimize the charge delivery and help prolong battery life The BTS also provides over temperature protection for the batteries The BTS plugs into the BTS RJ 11 port located inside the wiring compartment of the charge controller The BTS can be installed on the negative battery post positive battery post or side of the battery case See Installing the Battery Temperature Sensor in the Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide Document Part Number 975 0540 01 01 975 0560 01 01 Revision B 1 7 Introduction Figure 1 4 Battery temperature sensor If a BTS is not installed the voltage settings for charging are based on one of three temperature settings Cold Warm or Hot available on the Charger Settings menu See Configuring Battery Characteristics and Battery Charging on page 2 3 If multiple charge controllers or a complete Xantrex XW Power System with Xantrex XW Hybrid Inverter Chargers are networked together using Xanbus then only one BTS is required per battery bank All networked Xantrex XW Series devices share battery temperature information and you can connect the BTS toa charge controller or a Xantrex XW Hybrid Inverter Charger If more than one BTS is used within the system then the highest reported
29. Xantrex XW MPPT 80 600 Solar Charge Controller Operation Guide Schneider www schneider electric com E ectric Xantrex XW MPPT 80 600 Solar Charge Controller Operation Guide Schneider www schneider electric com ES Electric Trademarks Schneider Electric the Schneider Electric logo Fast Sweep Xanbus and Xantrex are trademarks or registered trademarks of the Schneider Electric group of companies Other trademarks registered trademarks and product names are the property of their respective owners and they are used herein for identification purposes only Notice of Copyright Copyright 2012 2010 Schneider Electric SA No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of Schneider Electric SA 35 rue Joseph Monier 92500 Rueil Malmaison France This documentation may be revised and content hereof changed from time to time without obligation to notify any person or entity or to organize such revisions or changes unless required to do so by prior arrangement Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING SELLER 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 MIGH
30. alize charge has been enabled via the SCP Orange but has not yet started the charge controller must complete a full bulk and absorption cycle before it can begin the equalize cycle e Flashing at a constant rate when the charge controller is performing the equalize charge to the batteries After the equalize charge has completed the LED goes dark 3 2 975 0560 01 01 Revision B Viewing Status on the SCP Viewing Status on the SCP Use the SCP to configure and view system information and operating status See Appendix B Xantrex XW System Control Panel Menus for an overview of the SCP or download the entire SCP Owner s Guide Document Part Number 975 0298 01 01 at www schneider electric com The charge controller also has three LEDs for displaying basic status regarding charging equalization and fault error and warning conditions e When in Charge Control mode the SCP displays parameters such as PV voltage battery voltage and charge current on the XW MPPT80 Home screen e When a fault or error condition exists the SCP Fault Warning light is solid and the SCP shows Fault Active on the XW MPPT80 Home screen e When a warning condition exists the SCP Fault Warning light is flashing and the SCP shows Warning Active onthe XW MPPT80 Home screen Normal Operation From the XW MPPT80 Setup Screen select Meters to view normal operation information This information is refreshed once per second Table 3 2 Normal op
31. all jewelry before performing electrical work e Install batteries in a well ventilated area to help prevent the possible buildup of explosive gases e Do not mix battery types e Do not smoke in the vicinity of a battery e Use insulated tools when working with batteries e When connecting batteries always verify proper voltage and polarity e Do not short circuit the battery e Always use proper lifting techniques when handling batteries Failure to follow these instructions will result in death or serious injury For full installation instructions and safety information see the documentation provided with the batteries Consult the MSDS for the batteries for first aid procedures emergency procedures and clean up instructions viii 975 0560 01 01 Revision B Safety FCC Information to the User This charge controller has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 ofthe FCC Rules and Industry Canada ICES 003 These limits are designed to provide reasonable protection against harmful interference when the charge controller is operated in a residential environment This charge controller generates uses and can radiate radio frequency energy and if not installed and used in accordance with the installation and operation guides could cause harmful radio frequency interference with radio communications However there is no guarantee that interference will not occur in
32. battery bank 96 nominal 48 V battery bank Auxiliary Output Dry contact switching up to 60 VDC 30 VAC 8A Charger Regulation Method Three stage bulk absorption float Two stage bulk absorption Manual equalization Tare Losses less than 1 0 W Xanbus power supply on less than 0 5 W Xanbus power supply off a Full power output below 230 V is not assured See Operating Below the PV Array Voltage Full Power Range on page A 3 for more information b These values are based on the following specifications The battery voltage is 48 V The auxiliary power supply is shut off at night See Reducing Tare Loss on page 2 16 for more information 975 0560 01 01 Revision B Electrical Specifications NOTICE e PV array voltages often exceed STC voltage specifications especially when the array is cold A voltage temperature correction factor based on the local code i e NEC 690 or CEC Section 50 ambient temperature conditions and module manufacturer specifications must be applied to the array STC Vgc to keep array voltage within specifications listed above e PV array current might exceed STC current specifications especially under intense sunlight certain atmospheric conditions or from reflections i e water snow or ice Local codes typically apply a multiplier to the PV array Is to determine maximum current for design purposes The Maximum PV Current specification a
33. bove includes the 125 multiplier required by the NEC and the CEC Accordingly the PV array STC I cannot exceed 28 A MPPT Voltage Range The charge controller s Maximum Power Point Tracking MPPT algorithm maximizes the output energy of PV arrays as long as the operating voltage is within the MPPT operational window Make sure that the PV arrays used in the system operate within the MPPT operational window The MPPT operational window are shown below Charging Max Power Point Tracking Vpv 195V 230V 510V 550V 600V Min Operating Voltage Min Starting Voltage Max Operating Voltage Note Max Voc 600 V Input current limit 35 A array lsc including 125 code multiplier Output current limit 80 A Figure A 1 MPPT operational window Operating Below the PV Array Voltage Full Power Range When the charge controller is operating on a 48 V battery bank and a PV array where the MPP is below 230 V full output power is not assured Figure A 2 and Figure A 3 show the maximum output current and maximum output power that can be produced when the charge controller is operating below 230 V The actual amount of current and power that your charge controller can produce below 230 V will depend on the actual battery voltage and the amount of solar power available from your panels Full output current is available on 24 V battery systems across the entire input voltage operating range 975 0560 01 01 Revision B A 3 Specifications
34. ds The warning clears itself when the voltage falls below 61 0 VDC for 10 seconds HsOTWrn Heat sink over temperature warning W35 5 PV Input Voltage 560 500 Figure 3 2 Heat sink temperature has risen above 85 C 185 F for 10 seconds The warning clears itself when the heat sink temperature falls below 80 C 176 F for 10 seconds Vpv Error Level u Vpv Clear Level 50 40 30 20 10 0 10 20 30 40 50 60 70 80 Heat Sink Temperature Celsius Over voltage protection 975 0560 01 01 Revision B Viewing Fault Error and Warning Logs Viewing Fault Error and Warning Logs The SCP displays fault error and warning logs stored on the charge controller Table 3 7 History menu items SCP Device Menu Item Description Setup gt View Fault Log Displays a log of the faults and errors View Device Info Setup gt View Device Info View Warning Log Displays a log of the warnings e To view the fault and error logs go to Setup gt View Device Info gt View Fault Log e To view the warning logs go to Setup gt View Device Info gt View Warning Log Press the down arrow to view all the entries in the log The entries are listed chronologically with the most recent fault error or warning at the top of the list The fault error or warning number date and time are displayed Press Enter to view details for a particular entry including the name The t
35. e and configure the auxiliary output for your application The charge controller s auxiliary output can be configured 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 The charge controller s auxiliary output can be configured to trigger a small DC fan to clear a battery compartment of harmful gases The charge controller s auxiliary output must be configured to activate when flooded batteries reach their gassing voltage 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 error condition 975 0560 01 01 Revision B 1 9 975 0560 01 01 Revision B Configuration Chapter 2 contains information and procedures to configure the charge controller For information on See Configuring the Unit page 2 2 Configuring Battery Characteristics and Battery Charging page 2 3 Configuring Peak Power Tracking page 2 7 Configuring the Auxiliary Output page 2 8 Configuring Device Settings page 2 13 Reducing Tare Loss page 2 16 Resetting to Factory Defaults page 2 16 Configuration Configuring the Unit Selecting a Unit
36. een displays Clear Temperature Level in degrees Celsius This setting is hidden if the trigger source is set to an error warning or fault Clear Delay 0 600s 1s Sets how long in seconds the trigger condition must remain inactive before the auxiliary output turns off This setting is hidden if the trigger source is set to an error warning or fault NOTICE If the selected trigger source is LowBattV or HighBattv changing the Batt Voltage setting will reset the Trigger Level and Clear Level settings to their default values 2 10 975 0560 01 01 Revision B Configuring the Auxiliary Output Trigger Source Descriptions Configurable trigger sources are described below The text in parentheses indicates how the trigger source appears on the SCP The remaining trigger sources are errors warnings and faults that are not configurable See their descriptions in Table 3 6 Warning messages on page 3 9 Low battery voltage LowBattv Activates the auxiliary output when the battery voltage falls below the trigger setting for the trigger delay time Deactivates the auxiliary output when the battery voltage rises above the clear setting for the clear delay time Use this setting if you want the auxiliary output to control a relay to disconnect loads from a battery that is nearly discharged or to activate a low battery voltage alarm such as a buzzer or light High battery voltage HighBattv Activates the a
37. ems 975 0560 01 01 Revision B Configuring Battery Characteristics and Battery Charging Modifying Configurable Settings Configurable settings are identified by square brackets around the values along the right side of the screen To select and change a configurable setting 1 Onthe menu press the up arrow or down arrow button to highlight the setting you want to change Press Enter to highlight the current value of the setting Press the up arrow or the down arrow button to change the value Hold down the button to scroll through a large range of values quickly The previously set value appears with an asterisk beside it 4 Press Enter to select the value Configuring Battery Characteristics and Battery Charging AWARNING HAZARD OF FIRE AND EXPLOSION Battery charging settings must be configured by qualified personnel in accordance with the battery manufacturer s recommended charging instructions Failure to follow these instructions can result in death or serious injury CAUTION BATTERY DAMAGE The charge controller is incapable of determining battery type and cannot warn against or disallow incorrect settings Carefully check the settings for bulk absorption float and equalization charge against the battery specifications Incorrect settings can damage the battery or shorten battery life Failure to follow these instructions can result in equipment damage From various menus in t
38. en On the Dev Info screen you can view the warning fault and event logs Basic Settings B 6 Displays the charge controller s basic or advanced configuration settings To change to advanced settings press the Enter up arrow and down arrow buttons simultaneously 975 0560 01 01 Revision B Configuration Settings Configuration Settings Basic menu Advanced menu The configuration settings can be viewed in basic and advanced formats The basic menu contains items you might have to view and adjust on a routine basis The advanced menu contains items intended for service personnel and one time setup such as auxiliary output and custom battery configuration To display the Advanced Settings menu item instead ofthe Basic Settings menu item perform the following special keypress From the Setup menu press the Enter up arrow and down arrow buttons simultaneously Onthe Setup menu Basic Settings disappears from the bottom of the list and Advanced Settings appears at the top of the list After configuring the charge controller help prevent unintended advanced configuration by using the combined keypress again to hide the advanced menu items NOTICE e This keypress displays advanced settings for every device in the system e After performing the keypress Advanced Settings appears at the top of the Setup menu When the keypress is performed again the Setup menu displays Basic Settings as the last ite
39. eration information Meters screen Display Description PV In Power Measured input power PV In Measured input voltage and current DC Out Power Power being produced by the charge controller now DC Out Measured output voltage and output current Time in Float Elapsed time that the charge controller has been in float in hh mm ss format 00 00 00 Today Accumulated amp hours and kilowatt hours produced today by the charge controller Life Lifetime accumulated amp hours and kilowatt hours produced by the charge controller Batt Temp Battery temperature detected by the BTS If a BTS is not connected then no value is shown State Charge stage See Table 3 3 on page 3 4 Aux Auxiliary output state See Table 2 4 on page 2 9 Thermal Derating Indicates whether the charge controller is derating output power due to high operating temperatures See Figure A 4 on page A 6 975 0560 01 01 Revision B 3 3 Operation Charge Stages The charge stages displayed on the SCP are described in Table 3 3 The charge states are displayed under State on the Meters Screen Table 3 3 Charge stages Text Description Bulk Batteries are charging at the maximum current available from the charge controller If the charge controller shuts down because of low input PV voltage then charging will resume in bulk mode This means the charge controller starts in bulk at the beginning of every day regardless o
40. f a problem Table 3 5 Error messages Display Text Description Error ID Definition CapOTErr F2 Output capacitor temperature has risen above 100 C 212 F for 5 seconds The error clears itself when the capacitor temperature Capacitor over falls below 90 C 194 F for 30 seconds This error should not temperature error normally occur If it is triggered multiple times the charge controller must be serviced BattOTErr F4 Battery temperature has risen above 60 C 140 F for 30 seconds The error clears itself when the battery temperature Battery over falls below 55 C 131 F for 30 seconds temperature error AmbOTErr F5 Ambient temperature inside the charge controller has risen above Ambient over temperature error 975 0560 01 01 Revision B 80 C 176 F for 5 seconds The error clears itself when the ambient temperature falls below 65 C 149 F for 30 seconds 3 7 Operation Table 3 5 Error messages Display Text Description Error ID Definition InputoVErr F9 Input voltage has exceeded the input over voltage shut off value which is dependent upon temperature measured on the heatsink Input over voltage Vin High Threshold in Figure 3 2 on page 3 10 The error clears error itself when the input voltage falls below the input over voltage restart value Vin Restart Threshold in Figure 3 2 on page 3 10 OutputUVImmErr F10 Output voltage has fallen below
41. f the battery voltage If the batteries are fully charged the bulk absorption cycle finishes after a short period and the charge controller transitions to float no float depending on charge cycle configuration Absorb After transitioning from bulk mode the charge controller holds the battery voltage at the absorption voltage setting and the charge current gradually declines as the battery capacity is restored The charge controller stops absorption charging when one of two conditions are met as described in Absorption Stage on page 1 4 Float Battery voltage is held at the float voltage setting When the battery voltage drops below the ReCharge Volts setting for a cumulative period of one minute a new bulk charge cycle is triggered No Float The charge controller does not output any power during this stage When the battery voltage drops below the ReCharge Volts setting for a cumulative period of one minute a new bulk cycle is triggered Equalize A deliberate overcharge designed to return each battery cell to optimum condition by reducing sulfation and stratification in the battery An equalization charge lasts one hour Not Charging No charging is occurring because the input power from the PV array has fallen below the minimum PV array operating voltage as specified in Electrical Specifications on page A 2 Viewing Active Faults Errors and Warnings 3 4 When a fault error or warni
42. hased From Purchase Date About This Guide Purpose Scope Audience Organization This Guide provides explanations and procedures for configuring operating and troubleshooting the Schneider Electric Xantrex XW MPPT 80 600 Solar Charge Controller This Guide provides safety guidelines as well as information about operating configuring and troubleshooting the charge controller It does not provide details about particular brands of photovoltaic PV panels or batteries This Guide is intended for anyone who operates the charge controller Operators must be familiar with all the safety regulations pertaining to operating high voltage equipment as dictated by local code Operators must also have a complete understanding of this product s features and functions Only qualified personnel should perform the installation configuration commissioning and maintenance of the charge controller Qualified personnel have training knowledge and experience in e Installing electrical equipment and PV power systems up to 1000 V e Applying all applicable installation codes e Analyzing and reducing the hazards involved in performing electrical work e Selecting and using personal protective equipment Do not use this charge controller unless it has been installed by qualified personnel in accordance with the instructions in the Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide Document Part Number 975 0540 01
43. he PV and battery disconnects and then confirm that the SCP resumes operation Contact customer service if the problem is not resolved 4 3 44 975 0560 01 01 Revision B Specifications Appendix A provides the specifications for the charge controller For information on See Electrical Specifications page A 2 Default Battery Charging Settings page A 5 Mechanical Specifications page A 5 Output Power Versus Ambient Temperature page A 6 Accessories page A 6 Regulatory Approvals page A 7 All specifications are subject to change without notice Specifications Electrical Specifications Maximum PV Array Open Circuit Voltage 600 VDC PV Array Voltage Operating Range 195 to 550 VDC PV Array Voltage Full Power Range 230 to 550 VDC Maximum Power Point Tracking Range 195 to 510 VDC PV Input Start Voltage 230 VDC Maximum Operating Current 23A Maximum Array Short Circuit Current at STC 28 A Absolute Maximum Array Short Circuit Current 35 A Under Any Conditions See the Notice on the next page for more information Nominal Battery Voltages 24 and 48 VDC Default is 48 V Battery Voltage Operating Range 16 to 67 VDC Maximum Charging Current 80 A Maximum Charging Power 2560 W nominal 24 V battery bank 4800 W nominal 48 V battery bank Maximum Power Conversion Efficiency 94 nominal 24 V
44. he SCP you can e Enable battery equalization e Configure your battery type voltage and amp hour capacity e Configure a custom battery type by adjusting settings for each battery charge stage and fine tuning temperature compensated charging e Monitor battery temperature 975 0560 01 01 Revision B 2 3 Configuration Table 2 1 Battery configuration settings SCP Device Menu Item Table 2 1 describes the settings available for the charge controller s battery configuration Setting Values Default Description Setup Equalize Disabled Enabled Disabled Enables or disables battery equalization If the battery type is set to GEL or AGM this setting is not displayed Advanced Settings gt Multi Unit Config gt Connections DC Conn BattBank1 Batt Bankx BattBank1 Sets the battery bank connected to the charge controller This is important for networked installations where multiple devices must coordinate their activity around common DC conneclions Advanced Settings gt Charger Settings Batt Voltage 24V 48V 48V Sets your nominal battery voltage Select the nominal voltage level that matches your system s battery voltage Changing the battery voltage willreset Trigger Level and Clear Level to their default values for the auxiliary output if Trig Src is set to LowBattV or HighBattVv see Table 2 4 on page 2 9 Advanced Settings gt Charger Settings
45. he charge controller and is also available at www schneider electric com You can find more information about Schneider Electric as well as its products and services at www schneider electric com 975 0560 01 01 Revision B vi Important Safety Instructions This Guide contains important safety instructions that must be followed during the installation and maintenance of the charge controller Make sure you read understand and save these safety instructions 4 DANGER HAZARD OF SHOCK BURN FIRE AND EXPLOSION e The charge controller must be installed and serviced only by qualified personnel equipped with appropriate personal protective equipment and following safe electrical work practices e The charge controller is energized from multiple sources Before removing the covers consult the system diagram to identify all sources de energize lock out and tag out and wait for two minutes for internal capacitors to discharge to a safe voltage e Before servicing the charge controller test using a meter rated at least 1000 VDC to make sure all circuits are de energized e The charge controller is provided with integral PV ground fault protection Normally grounded conductors could be ungrounded and energized when a ground fault is indicated The integral ground fault detection fuse is located under the wiring compartment cover Disconnect all sources of power before opening the cover Failure to follow these instructions will re
46. icant seasonal variations are common in your area change the settings multiple times during the year for optimal battery charging Configuring Peak Power Tracking You can disable automatic maximum power point tracking and configure the reference voltage level from which the charge controller operates Configuring the reference voltage is not required for normal operation but it can be useful for testing purposes 1 For 24 V battery systems divide these coefficients by two 975 0560 01 01 Revision B 2 7 Configuration Table 2 3 Peak power tracking settings SCP Device Menu Item Setting Values Default Description Advanced Settings gt MPPT AutoTrack Disabled Enabled Enables or disables MPPT Input Settings Enabled Advanced Settings gt MPPT Ref Volts 195 600V N A When tracking is set to Input Settings Disabled you can select the reference voltage from which the charge controller operates When tracking is set to Enabled the reference voltage updates to reflect tracking activity Advanced Settings gt PV In SolarArray SolarArray1 Sets the input connection for the Multi Unit Config gt 1 16 charge controller Connections Configuring the Auxiliany Output 2 8 Use the Aux Settings menu item to enable and configure the auxiliary output You can use the auxiliary output to operate a relay indicator light vent fan alarm or any other required function See Auxiliary Output Fu
47. ig Src is set to LowBattV or HighBattyv then changing battery voltage see Table 2 1 on page 2 4 will reset Trigger Level and Clear Level to their default values For a description of the non configurable faults errors and warnings that you can setfor Trig Src see Table 3 4 Fault messages on page 3 6 Table 3 5 Error messages on page 3 7 and Table 3 6 Warning messages on page 3 9 2 9 Configuration Table 2 4 Aux menu settings Setting Values Default Description Trigger Depends on Trigger Source Sets the battery or array voltage to activate the auxiliary Level see Table 2 5 output Ifthe selected trigger source is HighBattTemp LowBattTemp Or HighHsTemp this screen displays Trigger Temperature Level in degrees Celsius Changing Trigger Level while the auxiliary output is already in the triggered state resets the auxiliary output This setting is hidden if the trigger source is set to an error warning or fault Trigger 0 600s 1s Sets how long in seconds the selected trigger Delay source must be active before the auxiliary output activates This can avoid unnecessary triggering by momentary loads This setting is hidden if the trigger source is set to an error warning or fault Clear Level Depends on Trigger Source Sets the battery or array voltage to turn off the auxiliary see Table 2 5 output Ifthe selected trigger source is HighBattTemp LowBattTemp Or HighHsTemp this scr
48. is setting can be used to trigger an alarm Fault Fault Activates the auxiliary output when any error warning or fault occurs This trigger source is not configurable Trigger Source Configurable Ranges This table contains the available configuration ranges and default settings for configurable trigger sources The units vary according to the trigger source selected If the selected trigger source is based on a battery voltage the range also varies according to the nominal battery voltage of your system NOTICE Changing the trigger level resets the auxiliary output If an auxiliary output trigger is active changing the trigger level will clear the trigger Table 2 5 Trigger source configuration ranges Default Trigger Source Range Trigger Default Clear Low battery voltage 24V 18 26V 22V 24V LowBat tv 48V 36 52V 44V 48V High battery voltage 24V 24 32V 28V 26V HighBattv 48V 48 64V 56V 52V Low array voltage 10 600V 190V 195V LowArrayV High array voltage 190 600V 575V 500V HighArrayV Low battery temperature 20 0 10 0 C 10 0 C 5 0 C LowBatt Temp High battery temperature 30 0 60 0 C 45 0 C 40 0 C HighBattTemp High heat sink 20 95 C 90 C 85 C temperature HighHsTemp 975 0560 01 01 Revision B Configuring Device Settings Configuring Device Settings From various menus you can change the operating mode of the charge controller and view the cha
49. ision B B 11 975 0560 01 01 Revision B Boost Charging Appendix C provides information on Boost Charging for flooded lead acid batteries in off grid applications Boost Charging Using Boost Charging Boost charging allows for better utilization of flooded lead acid batteries under moderate cycling in off grid applications Boost charging encourages a short duration charging voltage above the gassing voltage at the beginning of the absorption charge state Testing has shown that boost charging improves battery performance by providing a regular mixing of the liquid electrolyte Boost charging specifically discourages capacity robbing acid stratification and plate sulfation Boost mode charging can be enabled by selecting the custom battery type and then setting the bulk voltage higher than the absorption voltage The multi stage charge algorithm then attempts to use the higher bulk voltage for the first hour of the absorption stage unless interrupted by the max absorption timer or exit current threshold mechanism 1 Boost charging encourages gassing of flooded lead acid batteries AWARNING HAZARD OF EXPLOSION Boost charging generates explosive gases which might escape from the battery Always make sure battery ventilation is adequate Failure to follow these instructions can result in death or serious injury 2 Boost charging is NOT recommended for AGM GEL or any other electrolyte limited and or valve
50. larm when the PV array voltage exceeds the trigger setting the charge controller s maximum operating voltage is 550 VDC Low battery temperature LowBattTemp Activates the auxiliary output when the battery temperature falls below the trigger setting for the trigger delay time Deactivates the auxiliary output when the battery temperature rises above the clear setting for the clear delay time Battery temperature is measured with a BTS Do not use this setting if a BTS is not installed With this setting the auxiliary output can turn on an indicator alarm if the batteries are too cold A battery with frozen electrolyte will not accept a charge 975 0560 01 01 Revision B 2741 Configuration High battery temperature HighBattTemp Activates the auxiliary output when the battery temperature rises above the trigger setting for the trigger delay time Deactivates the auxiliary output when the battery temperature falls below the clear setting for the clear delay time Battery temperature is measured with a BTS Do not use this setting if aBTS is not installed With this setting the auxiliary output can turn on a fan to cool the battery compartment High heat sink temperature HighHsTemp Activates the auxiliary output when the charge controller s heat sink temperature rises above the trigger setting for the trigger delay time Deactivates the auxiliary output when the heat sink temperature falls below the clear setting for the clear delay time Th
51. le custom battery settings To access the menu go to Advanced Settings gt Charger Settings gt Custom Settings Table 2 2 Custom battery settings Setting Values Default Description Eqlz Support Enabled Disabled Enabled Enables or disables equalization for the custom battery Eqlz Voltage 24V 27 0 32 0V 32 0V Sets the equalization voltage consult your battery manufacturer for equalization voltage setting 48V 54 0 64 0V 64 0V This screen is hidden if Eqlz Support is disabled Bulk Voltage 24V 20 0 32 0V 28 8V Sets the bulk voltage for a custom battery 48V 40 0 64 0V 57 6V Absorb Voltage 24V 20 0 32 0V 28 8V Sets the absorption voltage for a custom battery 48V 40 0 64 0V 57 6V Float Voltage 24V 20 0 32 0V 27 0V Sets the float voltage for a custom battery 48V 40 0 64 0V 54 0V BattTempComp 24V 90 OmV degC 54mV Sets the battery temperature compensation for a custom battery This setting is the reference that 48V 180 OmV degC 108mV C 2 6 the BTS uses to adjust the charging voltage when the temperature falls above or below 25 C See Battery Temperature Compensation on page 2 7 See Default Battery Charging Settings on page A 5 for default settings for standard battery types 975 0560 01 01 Revision B Configuring Peak Power Tracking Battery Temperature Compensation When battery charging voltages are compensated based on temperature the charge voltage will
52. les power to the charge controller 975 0560 01 01 Revision B Table 3 4 Fault messages Viewing Active Faults Errors and Warnings Display Text Description Fault ID Definition FanUVFlt F80 Fan voltage has fallen below 3 5 V The fan will cease operating but the charge controller will continue operating though it will Fan under voltage probably experience power derating The fault will not clear until an fault operator clears it manually using the SCP FanUCFlt F81 Fan current has fallen below 0 5 A for 100 milliseconds The fan will cease operating but the charge controller will continue operating Fan under current though it will probably experience power derating The fault will not fault clear until an operator clears it manually using the SCP NetPSFlt F82 e A short circuit or an overload condition has been detected on Network power supply fault Errors the Xanbus network power supply e An over voltage event has been detected on the Xanbus network power supply The network power supply will be turned off and loss of Xanbus communication is possible The fault will not clear until an operator clears it manually The operator might have to power cycle the charge controller if no other devices are present on the Xanbus network to provide network power to run the SCP Table 3 5 lists all possible errors Errors are situations where the charge controller has stopped itself from operating because o
53. ls experiencing extreme cold temperatures for the region This condition will correct itself when the panels warm up and the voltage decreases to within operating specifications If it occurs regularly then the installation likely has too many PV panels in series and might need reconfiguration to lower the controller voltage to the charge controller See Electrical Specifications on page A 2 for details on the charge controller s operating range The charge The charge controller is outputting No problem This is intended controller s On Charging green LED is flashing charge current operation See Viewing Status Information on the Charge Controller on page 3 2 for LED status information The SCP turns off completely after The SCP is powered by the output of the charge controller and it has been See Reducing Tare Loss on page 2 16 for more information on sunset configured to turn off the Xanbus disabling certain power supplies at power supply during the night night to reduce night time tare losses The charge The network power supply fault F82 Remove power to the charge controller s Error Warning red LED is on and the SCP is blank on page 3 7 has been triggered and has disrupted power to the SCP 975 0560 01 01 Revision B controller by opening the PV and battery disconnects long enough for the red and green LEDs to turn off Restore power by closing t
54. m on the menu The charge controller s Config menu contain sub menus for configuring e Multiple unit operation e Charger and battery settings e Input settings e Auxiliary output settings To view the Config menu From the Setup menu with Basic Settings or Advanced Settings highlighted press Enter XW MPPT80 01 Setup XW MPPT80 01 Config Charger Settings Meters p Input Settings Harvest Logs Aux Settings Force Chg Copy from MPPT80 02 Equalize Disabled I Multi Unit Config Mode Operating Restore Defaults Clear Faults Harnings dv Features View Device Info Figure B 5 Selecting the configure menu 975 0560 01 01 Revision B B 7 Xantrex XW System Control Panel Menus B 8 For a map of all configuration menus see Figure B 7 on page B 9 Configurable settings are identified by square brackets around the values along the right side of the screen To select and change a configurable setting 1 Onthe menu press the up arrow or down arrow button to highlight the setting you want to change 2 Press Enter to highlight the current value of the setting 3 Press the up arrow or the down arrow button to change the value Hold down the button to scroll through a large range of values quickly The previously set value appears with an asterisk beside it 4 Press Enter to select the value To restore the charge controller s default settings 1
55. mation about identifying and resolving possible problems that might arise while using a charge controller Troubleshooting Troubleshooting Table 4 1 lists possible problems that might arise when using the charge controller Table 4 1 Charge controller problems Problem Possible Cause Solution Battery voltage is exceeding bulk and float settings in cold weather and not reaching settings in hot weather The BTS is compensating charging voltages based on battery temperature No problem This is the intended operation The charge controller s Error Warning red LED is on or flashing An active fault error or warning is present on the charge controller See Viewing Active Faults Errors and Warnings on page 3 4 to determine which alarm is active on the charge controller The tables in this section provide detailed information on why various alarms could be occuring on the charge controller Battery equalization was enabled but did not occur The charge controller must complete a bulk absorption cycle before it can initate an equalization cycle See Equalizing Batteries on page 3 12 for information on equalization charging See Viewing Status Information on the Charge Controller on page 3 2 for information on determining the status of the equalization cycle BTS information does not show up on the charge controller s Meters screen on the SCP 4 2 The B
56. n 3 3 system home screen B 4 up arrow button B 2 warning messages 3 9 XW MPPT80 600 home screen B 10 Y yearly logs viewing 3 12 IX 4 975 0560 01 01 Revision B Schneider Electric www schneider electric com lt Ded North America 1 650 351 8237 1 866 519 1470 1 925 245 1022 re techsupport schneider electric com France 33 0 825 012 999 fr re techsupport fr schneider electric com Deutschland 49 0 180 575 3 575 49 0 2102 404 7101 pv service de schneider electric com Espa a 34 902 101 813 34 933 055 026 es sat es schneider electric com L Italia 39 035 4151111 39 035415 3200 IT pronto contatto it schneider electric com For other country details please contact your local Schneider Electric Sales Representative or visit the Schneider Electric website at http www schneider electric com sites corporate en support operations local operations local operations page 975 0560 01 01 Revision B Soligent YOUR 1 b959w9 9 dwi DISTRIBUTOR SOLIGENT 800 967 6917 Printed in India www soligent net
57. nctions on page 1 9 For configurable trigger sources you can define trigger level trigger delay clear level and clear delay settings Non configurable trigger sources include errors warnings and faults 975 0560 01 01 Revision B Configuring the Auxiliary Output To display the Aux menu auxiliary settings select Advanced Settings gt Aux Settings Table 2 4 Aux menu settings Setting Values Default Description Manual Aux ManualOff ManualOff Sets the operating mode for the auxiliary output When ManualOn set to Automatic the auxiliary output will operate Automatic according to the selected trigger source You can toggle the auxiliary relay between NC and NO at any time by selecting ManualOn or ManualOff Note The remaining settings in thi s table are only visible when Manual Aux is set to Automatic Trig Src Configurable LowBattV HighBattV LowArrayV HighArrayV LowBattTemp HighBattTemp HighHs Temp Not configurable Fault GroundFlt1 GroundFit2 InputOVFIt InputOVErr InputOVWrn OutputOVErr OutputOVWrn OutputOCErr BattOTErr BattOTWrn BattUTWrn HsOTErr HsOTWrn AmbOTErr AmbOTWrn CapOTErr FanErr Fanrlt OutputUVErr OutputUVWrn InputOCErr OutputOCFIt NetPSFIt 975 0560 01 01 Revision B LowBattV Sets the desired condition to activate the auxiliary output Changing Trig Src while the auxiliary output is already in the triggered state resets the auxiliary output If Tr
58. nds equalization Failure to follow these instructions can result in equipment damage CAUTION DC LOAD EQUIPMENT DAMAGE Equalization voltage could be as high as 32 V for 24 V systems or 64 V for 48 V systems and might damage some types of DC load equipment connected to the battery Disconnect any loads that are not rated to withstand the applicable equalization voltage Failure to follow these instructions can result in equipment damage 975 0560 01 01 Revision B 3 13 Operation 3 14 NOTICE The Xantrex XW Hybrid Inverter Charger and PDP will not be damaged by equalization voltage and do not need to be disconnected during equalization Follow the battery manufacturer s recommendations for equalizing your batteries As a guide a heavily used flooded battery might need to be equalized once a month while a battery in light service might only need to be equalized every two to four months The equalization process lasts one hour When the equalization period has expired the charge controller will return to either the float or no float charge stage To enable battery equalization 1 Onthe Setup menu screen scroll to Equalize and then press Enter 2 Change the setting to Enabled The charge controller goes back to the bulk stage and goes through bulk and absorption before entering the equalization stage The full charge cycle makes sure the batteries are fully charged before an equaliza
59. ng occurs a message is displayed on the SCP You can also view active faults errors and warnings from the System Settings menu Warning messages indicate a problem that could affect normal operation The charge controller s red LED flashes when there is a warning condition The SCP Fault Warning light flashes red and the warning message is displayed on the SCP Normal operation continues until the warning escalates to a fault or error condition Fault messages indicate a fault or error condition The charge controller s red LED is solid when there is a fault or error condition The SCP Fault Warning light is solid red and the fault message is displayed on the SCP When a fault or error occurs MPPT and charging functions could be disabled 975 0560 01 01 Revision B Viewing Active Faults Errors and Warnings The following faults do not disable normal operation Fan over voltage Fan over current Fan under voltage Fan under current Network power supply Most warnings errors and faults clear automatically once the condition that caused them goes away However the following faults must be cleared manually Auxiliary power supply Ground fault protection Input over voltage Output over current Fan over voltage Fan over current Fan under voltage Fan under current Network power supply To view the complete list of active faults errors and warnings 1 Onthe Select Device menu scroll to System Settings and then p
60. nk Maximum and Minimum Wire Size in Conduit 6 AWG to 14 AWG 13 5 to 2 5 mm Maximum and Minimum Wire Size Rating of PV Terminal Block 6 AWG to 14 AWG 13 5 to 2 5 mm Maximum and Minimum Wire Size Rating of Battery Terminal Block 2 AWG to 14 AWG 35 to 2 5 mm Wire Size Rating of Auxiliary Output Connector 16 AWG 1 5 mm Operating Temperature Range derate above 45 C 4 to 149 F 20 to 65 C output power to be derated linearly to zero at 65 C Storage Temperature 40 to 185 F 40 to 85 C Altitude Limit operating Sea level to 6 500 feet approximately 2000 m Dimensions H x W x D 30 x 8 5 8 x 8 5 8 760 x 220 x 220 mm Mounting Vertical wall mount Weight charge controller only 29 8 Ib 13 5 kg Weight shipping 975 0560 01 01 Revision B 38 3 Ib 17 4 kg Specifications Output Power Versus Ambient Temperature Accessories A 6 Once the charge controller s heat sink reaches maximum full power operating temperature the charge controller reduces its power output to ensure component ratings are not exceeded Maximum Output Power W 20 10 0 10 20 30 40 50 60 Ambient Temp C in Still Air Figure A 4 Output power vs ambient temperature The SCP 865 1050 is required for installation of the charge controller and it is strongly recommended for continued operation of the charge controller It is
61. ows 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 voltage of the array to find the maximum power point Input power is measured and compared to the amount of input power harvested atthe previous operating voltage The next adjustment to the operating voltage is dependent upon whether the charge controller harvested more or less power than it did at the previous operating voltage The algorithm is implemented by applying a variable load on the array shown by the power curve solid line in Figure 1 1 until it finds the peak power the point at which the combination of the operating voltage and current is maximized as indicated by MPP in Figure 1 1 The charge controller will continue adjusting the operating voltage to stay on the maximum power point This is necessary as MPP changes throughout the day due to panel temperature panel shading and sunlight intensity The adjustments happen without interruption of output power flow to the batteries l 1 1 l lt 1 i 7 9 l I T I l T I l I T I 1 MPP 0 10 20 50 60 Vmp70 80Voc 90 30 40 Voltage V Volts V Curve Current vs Voltage Power Curve Power vs Voltage Figure 1 1 Maximum power point c
62. regulated sealed battery application 3 Boost charging could result in higher than normal water consumption However the benefits of boost charging are likely to be greater than the extra watering effort Check battery water levels at least once per month 4 Boost charging has maximum benefit when used on batteries that experience moderate cycling An unoccupied cottage for example where batteries are full the majority of the time might not benefit from boost charging especially if battery watering is difficult 975 0560 01 01 Revision B Index A abbreviations v Absorb Time setting 2 5 Absorb Voltage setting 2 6 absorption charging stage 1 4 3 4 accessories A 6 acronyms v advanced settings menu map B 9 viewing 2 2 alarm using auxiliary output 1 9 ambient temperature versus output power A 6 amp hour capacity batteries 2 5 auxiliary output alarm application 1 9 configuring 2 8 load control application 1 9 overview 1 9 trigger source configurable ranges 2 12 trigger source descriptions 2 11 vent fan application 1 9 B Batt Capacity setting 2 5 Batt Temp setting 2 5 Batt Type setting 2 4 Batt Voltage setting 2 4 batteries amp hour capacity 2 5 boost charging C 2 configuring 2 3 custom 2 6 default charger settings A 5 equalization See equalization safety information viii stopping equalization manually 3 14 battery temperature compensation BTS not connected 2 5 overview 1 7 2 7 battery temperature sensor 1 7 Bat
63. ress Enter The System Settings menu opens Scroll to View Fault List of View Warning List and then press Enter The fault error or warning menu opens Press the down button to view additional fault error or warning messages If there are no active faults errors or warnings no Messages are displayed To manually clear a fault error or warning 1 975 0560 01 01 Revision B Onthe Select Device menu scroll to System Settings and then press Enter The System Settings menu opens Scroll to Clear All Flts Wrns and then press Enter 1 Additional steps are required for a ground fault See GroundFlt1 in Table 3 4 3 5 Operation Faults Table 3 4 lists all possible faults Faults are conditions that indicate that the charge controller might have incurred permanent damage or that user intervention is required before the charge controller will operate again If one of these faults occur the charge controller might also need to be serviced before it can be fully operational again Table 3 4 Fault messages Display Text Description Fault ID Definition AuxPSFlt F54 More than two auxiliary power supply errors F26 have occurred A within one minute Auxiliary power supply fault Damage to the charge controller is possible so the fault will not clear until an operator clears it manually using the SCP GroundFlt1 F56 A PV ground fault has been detected The ground fault message clears
64. rge controller s device number These activities might be necessary when performing service or diagnostics as well as when adding another Xanbus enabled device to the system Table 2 6 Device settings SCP Menu Item Setting Values Default Description Setup Mode Operating Operating Operating is the normal mode Standby for the charge controller Standby disables the charge controller so that it cannot charge The charge controller still draws some power from the battery to operate Advanced Settings gt Dev Number 00 to 31 00 Displays the device number Multi Unit Config for the charge controller This number is set when the charge controller is commissioned and uniquely identifies devices of the same type charge controllers inverter chargers control panels and so on ina networked installation Select Device gt F W Rev 1 00 00 BN 5 N A N A Firmware version and System Settings gt firmware build number View Device Info 975 0560 01 01 Revision B 2 13 Configuration A WARNING HAZARD OF FIRE AND EXPLOSION Do not use the Copy from command to copy settings unless the battery banks are identical same size type and so on Failure to follow these instructions can result in death or serious injury SCP Menu Item Setting Values Default Description Advanced Settings Copy from All available 01 Enables one step device configuration of a new numbers charge controller in a
65. s Appendix B is a guide to the charge controller s monitoring and configuration menus on the Xantrex XW System Control Panel For information on See Using the SCP page B 2 The Setup Menu page B 6 Configuration Settings page B 7 Monitoring the Unit page B 10 975 0560 01 01 Revision B Xantrex XW System Control Panel Menus Using the SCP The charge controller is configured using the SCP The SCP has four buttons for navigating between screens and menus and configuring the charge controller See Figure B 1 and Table B 1 Fault Warningl O Standby Figure B 1 SCP Table B 1 SCP navigation buttons Number Button Function 1 Enter e Confirms selection of a menu item e Displays the next screen 2 Up arrow e Scrolls up one line of text e Increases a selected value e Displays the previous Device Home screen 3 Down arrow e Scrolls down one line of text e Decreases a selected value e Displays the next Device Home screen 4 Exit e Cancels selection of a menu item e Displays the previous screen B 2 975 0560 01 01 Revision B Using the SCP SCP Menu Map Figure B 2 shows how the SCP screens and menus are organized The screens and menus are described in Table B 2 Poner Up Startup screen o Select device from list and Aly u System Settings menu N Xantrex XVVIrverte Charger Setup menu k Xantrex XVWIrverte
66. s The warning clears itself when the Ambient over ambient temperature falls below 65 C 149 F for 10 seconds temperature warning BattUTWrn w9 Battery temperature has fallen below 20 C 4 F for 10 seconds The warning clears itself when the battery temperature rises above Battery under 10 C 14 F for 10 seconds temperature warning Input over W11 This warning follows the same curve as the Input over voltage voltage warning error but it triggers 10 V lower The warning clears itself when the ImputOVWrn voltage falls to the input over voltage restart value 15 V for 1 975 0560 01 01 Revision B second The input over voltage restart value is Vin Restart Threshold in Figure 3 2 on page 3 10 3 9 Operation Table 3 6 Warning messages Display Text Description WarningID Definition OutputUVWrn W12 24 V System Output voltage has fallen below 20 0 VDC for Output under voltage warning 10 seconds The warning clears itself when the voltage rises above 21 0 VDC for 10 seconds 48 V System Output voltage has fallen below 40 0 VDC for 10 seconds The warning clears itself when the voltage rises above 42 0 VDC for 10 seconds OutputoVWrn Output over voltage warning W34 24 V System Output voltage has risen above 31 5 VDC for 10 seconds The warning clears itself when the voltage falls below 30 5 VDC for 10 seconds 48 V System Output voltage has risen above 63 0 VDC for 10 secon
67. s To equalize with multiple devices each would have to be enabled individually Alternatively equalization can be performed using only one device During the equalization process one device applies the equalization charge while the other devices continue to operate in synchronized charge mode typically in float three stage charging or no float two stage charging A WARNING HAZARD OF EXPLOSION Equalization charging generates explosive gases which might escape from the battery Make sure adequate ventilation is provided Never leave a battery unattended during equalization Follow the battery manufacturer s recommended actions for determining the appropriate point at which to stop the equalization process for example by monitoring electrolyte specific gravity Failure to follow these instructions can result in death or serious injury CAUTION BATTERY DAMAGE Never equalize a battery more than necessary Equalization can damage your batteries if performed too frequently or done improperly Always check electrolyte level before and after equalization Fill with distilled water according to the battery manufacturer s recommendation The charge controller enables equalization only when the battery type is set to Flooded Equalize mode is disabled if you have selected GEL and AGM as the battery type As a general rule do not equalize a battery unless there are provisions to add water to it and the manufacturer recomme
68. sult in death or serious injury AWARNING LIMITATIONS ON USE Do not use the charge controller with life support equipment or other medical equipment or devices Failure to follow these instructions can result in death or serious injury A WARNING HAZARD OF ELECTRIC SHOCK For installation indoors only Do not expose the charge controller to rain snow dust or liquids of any type Failure to follow these instructions can result in death or serious injury 975 0560 01 01 Revision B vii Safety Personal Protection Follow these instructions to help protect yourself while working with the charge controller 4 DANGER HAZARD OF ELECTRIC SHOCK AND BURN Thoroughly inspect the charge controller prior to energizing Verify that no tools or materials have been inadvertently left behind Failure to follow these instructions will result in death or serious injury Installation personnel must be equipped with adequately rated personal protective equipment as per local safety regulations and applicable workplace safety procedures Battery Safety Information 4 DANGER HAZARD OF ELECTRIC SHOCK BURN FIRE AND EXPLOSION Batteries contain corrosive electrolyte and can give off explosive gases Battery circuits present a shock and energy hazard Observe proper precautions when working with batteries and battery circuits including e Always wear eye protection when working with batteries e Remove
69. sults 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 2 on page 1 5 During the bulk stage the charge controller operates in constant current mode delivering the maximum current to the batteries or the maximum current available if the PV does not have enough power to provide maximum current Once the battery voltage reaches the absorption voltage setting the charge controller transitions to the absorption stage During the absorption stage the charge controller begins operating in constant voltage mode and the current falls gradually as the amp hours are returned to the battery The voltage limit used for the first 60 minutes of this stage is the bulk voltage setting The voltage limit used for the remaining time in this stage is the absorption voltage setting By default the bulk voltage setting and the absorption voltage setting are the same for all battery types The default voltage limit settings bulk and absorption can be adjusted if the battery type is set to Custom see Setting a Custom Battery Type on page 2 6 For flooded lead acid batteries only you can use a custom charging scheme which sets the bulk voltage higher than the absorption voltage The result of this is
70. tTempComp setting 2 6 boost charging C 2 bulk charging stage 1 4 3 4 Bulk Voltage setting 2 6 975 0560 01 01 Revision B C CAUTION definition iv charge controlling absorption charging stage 1 4 3 4 boost charging C 2 bulk charging stage 1 4 3 4 charging current 1 4 equalize charging stage 3 4 float charging stage 1 5 3 4 manually advance stages 2 5 no charge charging stage 3 4 no float charging stage 1 6 3 4 overview 1 4 three stage diagram 1 5 three stage overview 1 4 two stage diagram 1 7 two stage overview 1 6 Charge Cycle setting 2 5 charge stages 3 4 charger settings default A 5 Clear Delay setting 2 10 Clear Level setting 2 10 configurable settings modifying 2 3 Copy from setting 2 14 copying settings 2 14 custom batteries setting 2 6 D daily logs 3 12 DANGER definition iv DC Conn setting 2 4 Default Batt Temp setting 2 5 default settings resetting to 2 16 B 8 Dev Number setting 2 13 device settings 2 13 disabling power supplies at night 2 16 down arrow button Xantrex XW System Control Panel B 2 E electrical specifications A 2 enter button Xantrex XW System Control Panel B 2 Eqlz Support setting 2 6 Eqlz Voltage setting 2 6 IX 1 Index equalization charging stage 3 4 determining when complete 3 14 enabling 3 14 overview 1 8 3 12 stopping manually 3 14 equalize LED 3 2 Equalize setting 2 4 error warning LED 3 2 errors clear manually 3 5 messages 3 7 overview
71. tandby mode 2 13 status information charge stages 3 4 LEDs 3 2 normal operation 3 3 unit 3 2 Xantrex XW System Control Panel 3 3 stopping battery equalization 3 14 T tare losses reducing 2 16 television reception interference ix three stage charge controlling diagram 1 5 overview 1 4 Trig Src setting 2 9 Trigger Delay setting 2 10 Trigger Level setting 2 10 trigger source configurable ranges 2 12 descriptions 2 11 troubleshooting 4 2 two stage charge controlling diagram 1 7 overview 1 6 U up arrow button Xantrex XW System Control Panel B 2 V vent fan using auxiliary output 1 9 IX 3 Index w WARNING definition iv warnings clear manually 3 5 messages 3 9 overview 3 4 viewing active 3 5 viewing logs 3 11 x Xantrex Gateway 1 2 Xantrex Xanbus disabling at night 2 16 Xantrex XW System Control Panel advanced settings display 2 2 auxiliary output configuration 2 8 basic configuration menu map B 8 basic settings 2 2 battery configuration 2 3 buttons B 2 changing settings B 4 configurable settings 2 3 custom battery type settings 2 6 device settings configuration 2 13 disabling power supplies at night 2 16 down arrow button B 2 enter button B 2 error messages 3 7 exit button B 2 fault messages 3 6 input configuration 2 7 meters screen B 11 operating mode configuration 2 13 peak power tracking configuration 2 7 reducing tare losses 2 16 selecting a unit 2 2 startup screen B 4 status informatio
72. temperature from all of the units with an attached BTS will be used as the battery temperature for the temperature compensation value of the battery charge algorithm Equalization Charging The charge controller can provide the battery bank with an equalization 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 CAUTION BATTERY DAMAGE To avoid damaging your batteries be sure to read understand and follow all cautions and warnings concerning equalization charging For more information see Equalizing Batteries on page 3 12 Failure to follow these instructions can result in equipment damage 1 8 975 0560 01 01 Revision B Auxiliary Output Functions Auxiliary Output Functions Load Control Vent Fan Alarms The charge controller has a set of auxiliary relay contacts one normally opened NO and one normally closed NC that can be used 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 trigger under only one condition at a time See Configuring the Auxiliary Output on page 2 8 for information about auxiliary output trigger sources and how to enabl
73. thout the exclamation symbol indicates a potentially hazardous situation which if not avoided can result in equipment damage NOTICE NOTICE indicates important information that you need to read carefully 975 0560 01 01 Revision B About This Guide Abbreviations and Acronyms CEC Canadian Electric Code CSA Canadian Standards Association DC Direct Current FCC Federal Communications Commission GFP Ground Fault Protection IMP Current at maximum power per STC Isc Short circuit current rating of an PV panel under STC LCD Liquid Crystal Display LED Light Emitting Diode MPP Maximum Power Point MPPT Maximum Power Point Tracking MSDS Material Safety Data Sheet NFPA National Fire Protection Association PDP Xantrex XW Power Distribution Panel PV Photovoltaic SCP System Control Panel STC Standard Test Conditions specific to photovoltaic panels 1000 W m light spectrum AM 1 5 and 25 C panel nameplate ratings are based on STC and may be exceeded under other conditions UL Underwriters Laboratories VAC Volts AC VDC Volts DC VMP Voltage at maximum power per STC Voc Open circuit voltage rating of a PV panel under STC Related Information You can find information about installing the charge controller in the Xantrex XW MPPT 80 600 Solar Charge Controller Installation Guide Document Part Number 975 0540 01 01 It is provided with t
74. tings gt Adv Features Table 2 7 Tare loss settings Setting Values Default Description NetPS Night Dis Enabled Disabled Enables or disables the network power supply Xanbus Disabled nighttime disconnect If your system does not require Xanbus communication during the night then set it to Enabled to reduce power consumption The power supply will automatically turn off two hours after sunset and then turn on again at sunrise If your system requires Xanbus communication during the night then leave it set to Disabled Lo Pwr at Night Enabled Enabled Enables or disables the auxiliary power supply nighttime Disabled disconnect Leaving the setting as Enabled reduces tare losses during the night See Electrical Specifications on page A 2 for exact specifications a SCP with firmware version 1 03 or newer only Resetting to Factory Defaults From the Advanced Settings menu item you can restore factory default settings Table 2 8 Resetting to factory defaults setting Setting Values Default Description Restore Defaults N A N A Returns configurable settings to factory defaults You will be prompted with a warning asking you to confirm that you want to restore defaults Press Enter to continue The following are reset e Configurable battery charger settings e Configurable auxiliary output settings e Configurable input settings 2 16 975 0560 01 01 Revision B 975 0560 01 01 Re
75. tion Charging 1 8 Auxiliary Output Functions 1 9 2 Configuration Configuring the Unit 2 2 Selecting a Unit 2 2 Viewing Basic and Advanced Settings 2 2 Modifying Configurable Settings 2 3 Configuring Battery Characteristics and Battery Charging 2 3 Setting a Custom Battery Type 2 6 Battery Temperature Compensation 2 7 Configuring Peak Power Tracking 2 7 Configuring the Auxiliary Output 2 8 Trigger Source Descriptions 2 11 Trigger Source Configurable Ranges 2 12 Configuring Device Settings 2 13 Reducing Tare Loss ee eee 2 16 Resetting to Factory Defaults 2 16 3 Operation Viewing Status Information on the Charge Controller 3 2 Viewing Status on the SCP
76. tion is attempted The charge controller applies the equalization charge for one hour You can stop the equalization process manually at any time by changing the setting to Disabled The one hour equalization timer will continue to run even if there is insufficient power from the PV array to support this charge mode To determine when battery equalization is complete Follow the battery manufacturer s recommendations for equalizing the batteries These recommendations will include methods such as monitoring the specific gravity SG of the electrolyte using a battery hygrometer and stopping the equalization when the SG has stopped increasing e If the recommended point is reached before the automatic one hour equalization timer runs out then manually stop the equalization by changing the setting to Disabled e Ifthe recommended point is not reached after one hour the charge controller will automatically exit the equalization stage You can re start equalization by following the process above and continue equalizing until the battery manufacturer s recommendation is met To manually stop battery equalization On the Setup Menu scroll to Equalize and then press Enter 2 Change the setting to Disabled Equalization stops and the charge controller goes to either the float or no float stage depending on the charge mode selected 975 0560 01 01 Revision B 975 0560 01 01 Revision B Troubleshooting Chapter 4 contains infor
77. urrent Limit Absorption Exit Current Threshold 2 of programmed AH capacity gt Time Figure 1 2 Three stage battery charging cycle a The charging cycle ofthe charge controller might differ from the curves shown above due to the amount of solar energy available and any DC loads present on the battery system during charge 975 0560 01 01 Revision B 1 5 Introduction NOTICE This notice is applicable to Figure 1 2 and Figure 1 3 e When the charge cycle is interrupted the charge controller will resume charging at the beginning of the multi stage algorithm e The exit current threshold mechanism can be disabled by setting the amp hour capacity to 0 In this case absorption will only exit when the absorption timer expires e Charge current during the equalize state an optional state not shown in the figures is normally limited to 10 of the programmed amp hour capacity setting If this setting is programmed to O Ah the charge current during equalize is limited to what is programmed for the maximum current limit of the charge controller default is 80 A e Synchronized charge states are active when more than one charging device the charge controller or Xantrex XW Hybrid Inverter Charger is connected in the battery system and a common Xanbus network e The first charging device to enter bulk causes all other devices to enter bulk e he first charging device to enter absorption causes all other
78. urve Fast Sweep Shade Tolerant MPPT Algorithm The charge controller has a Fast Sweep MPPT algorithm that frequently conducts a very fast sweep of the full operational array voltage window to dynamically determine the array s maximum power point This feature helps deliver consistently high energy harvest for the system including when the array is partially shaded For more information on shade tolerant MPPT optimization see the white paper Photovoltaic String Inverters and Shade Tolerant Maximum Power Point Tracking Toward Optimal Harvest Efficiency and Maximum ROI available at http www se renbu docs com SEShadeTolerantWP pdf 975 0560 01 01 Revision B 1 3 Introduction Charge Controlling The charge controller can regulate PV array current at an appropriate level for 24 or 48 V batteries It produces up to 80 amps of charging current for both battery voltages up to 2560 watts 24 V or 4800 watts 48 V The charge controller controls how the batteries are charged by 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 absorption or float 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 Three Stage Battery Charging Bulk Stage Absorption Stage The three stage battery charging process re
79. uxiliary output when the battery voltage rises above the trigger setting for the trigger delay time Deactivates the auxiliary output when the battery voltage falls below the clear setting for the clear delay time This setting is useful for e Installations that have another external charging source such as a wind generator or hydro generator connected directly to the batteries The charge controllers auxiliary output can control a relay to disconnect the external charging source from the battery when the battery is close to being overcharged or control a relay to turn on a diversion load e Activating a high battery voltage alarm such as a buzzer or light e Activating a vent fan to disperse hydrogen from the battery compartment when the batteries reach their gassing voltage Low array voltage LowArrayv Activates the auxiliary output when the PV array voltage falls below the trigger setting for the trigger delay time Deactivates the auxiliary output when the PV array voltage rises above the clear setting for the clear delay time High array voltage HighArrayv Activates the auxiliary output when the PV array voltage rises above the trigger setting for the trigger delay time Deactivates the auxiliary output when the PV array voltage falls below the clear setting for the clear delay time Use this setting if you want the auxiliary output to control a series latching relay to disconnect the PV array from the charge controller or trigger an a
80. vanced Settings gt Default Batt Cold Warm Sets the default battery Charger Settings Temp Warm temperature for compensation Hot when a BTS is not connected Cold is suitable for temperatures around 10 C 50 F warm for 25 C 77 F and Hot for 40 C 104 F This screen appears only when a BTS is not connected Setup gt Batt Temp 40 65 C n a Shows the battery temperature Meters in Celsius detected by the BTS This screen appears only when a BTS is connected Advanced Settings gt Charge Cycle 3Stage 3Stage Sets the charging cycle three Charger Settings 2StgNoFloat stage bulk absorption float or 975 0560 01 01 Revision B two stage bulk absorption no float 2 5 Configuration Setting a Custom Battery Type The Custom Settings menu item allows you to adjust charging and equalization voltage for batteries whose specifications fall outside of the default settings for the battery types that the charge controller offers You can also adjust the temperature compensation constant for the BTS from the Custom Settings menu item NOTICE e Setting the battery type to Custom is possible only when the Advanced Settings menu item is displayed e The Custom Battery menu is displayed only when the battery type is set to Custom e All settings for configuring a custom battery type are based on the default settings for a flooded battery type The following table describes the availab
81. vision B Operation Chapter 3 contains information about operating the charge controller For Information on See Viewing Status Information on the Charge Controller page 3 3 Viewing Status on the SCP page 3 3 Viewing Active Faults Errors and Warnings page 3 4 Viewing Fault Error and Warning Logs page 3 11 Viewing Harvest Logs page 3 11 Equalizing Batteries page 3 12 3 1 Operation Viewing Status Information on the Charge Controller The charge controller has three LEDs for displaying basic operating information They are On Charging green Error Warning red and Equalize orange On O Charging Error O A Warning Equalize Figure 3 1 Charge controller status LEDs Table 3 1 Charge controller status LEDs LED Description On e Solid when the charge controller is connected to a battery Charging providing visual feedback that the charge controller is powered Green on e Flashing at a variable rate when the charge controller is charging a battery Slow flashing indicates a low charge rate and fast flashing indicates a faster charge rate Error e Solid when the charge controller has detected an error or fault Warning condition Red e Flashing at a constant rate when the charge controller has detected a warning condition View the error fault or warning and its description on the SCP Equalize e Solid when an equ
82. wenty most recent entries are stored Viewing Harvest Logs The SCP displays the daily monthly and yearly performance logs stored on the charge controller NOTICE To record monthly and yearly logs the charge controller must be connected to a Xanbus network real time clock source If you want monthly and yearly logs to be created and stored make sure the charge controller is attached to the Xanbus network with one of the following e Xantrex XW Hybrid Inverter Charger e SCP e Gateway 975 0560 01 01 Revision B 3 47 Operation Table 3 8 Harvest logs menu items SCP Device Menu Item Description Setup gt Daily Logs Displays a log of the charge controller s amp hour and Harvest Logs kilowatt hour production for the day as well as the peak power output and time in float for the day Setup gt Harvest Logs Monthly Logs Displays a log of the aggregate total for amp hours and kilowatt hours produced during the month as well as the peak power output and time in float for the month Setup gt Harvest Logs Daily Logs Monthly Logs Yearly Logs Yearly Logs Displays a log of the aggregate total for amp hours and kilowatt hours produced during the year as well as the peak power output and time in float for the year To view the daily logs go to Setup gt Harvest Logs From the Daily Logs screen press Enter Press the down arrow button to scroll through the daily logs starting
83. ystem Settings menu items are available from the Select Device menu regardless of the number of Xanbus enabled devices installed XW MPPT Setup menu Displays status information and changeable settings Changeable settings are identified by square brackets around values in the right hand column Changing Settings Using the SCP B 4 To change a charge controller s setting use the buttons on the SCP to perform three basic steps View the Select Device menu 2 Select the charge controller from the Select Device menu Select and adjust a changeable setting on the charge controllers Setup menu See page B 8 Each of these three steps is described in detail in the following sections NOTICE You can also view the charge controllers Setup menu by pressing Enter from the charge controller s home screen See Home Screen on page B 10 975 0560 01 01 Revision B Using the SCP Viewing the Select Device Menu The Select Device menu is where you select a Xanbus enabled device to monitor or configure The number of items on the Select Device menu depends on how many devices are installed in your Xanbus system To view the Select Device menu Onthe System Status screen press Enter NOTICE You can identify the System Status home screen by the menu arrow in the bottom left corner of the screen The menu arrow indicates the Enter button on the SCP which you press to view the Select Device menu

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