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XW Solar Charge Controller Installation
4–10 975-0239-01-01
Battery Circuit
The DC-rated fuse or circuit breaker between the battery and the XW Solar Charge
Controller must have a maximum size of 1.25 × 60 A (the maximum current rating of the
XW Solar Charge Controller). That is, the fuse or circuit breaker must be rated equal to or
above 75 A.
PV Circuit
The DC-rated fuse or circuit breaker between the PV array and the XW Solar Charge
Controller must be rated for the I
sc
of the array but will not exceed the 60 A rating.
Long-distance wire
runs
If there is a significant distance between the PV array and the XW Solar Charge Controller
or between the XW Solar Charge Controller and the battery, larger wires can be used to
reduce the voltage drop and improve performance. Refer to Table 4-4 or Table 4-5.
To use a larger size wire, use a splicer block (terminal block) approved and rated for this
application. This allows the larger cable size from the batteries to be “spliced” to the #6
AWG wire connected to the XW Solar Charge Controller. The splicer block must be
installed outside of the XW Solar Charge Controller wiring compartment.
Follow manufacturer’s recommendations for torque and mounting. Splicer blocks and
split-bolt kerneys are available from renewable energy suppliers.
Maximum one-way
distance and wire
size
Refer to Table 4-4 or Table 4-5 and find the maximum current in the left column, and the
one-way distance from the PV array to the XW Solar Charge Controller (or the distance
from the XW Solar Charge Controller to the battery) on the same line, then read the wire
size required at the top of the column.
Table 4-3
Recommended Circuit Breakers for the XW Solar Charge Controller
Xantrex Part
Number Description
865-1065 Master Pack - Qty 6, Breaker 250A, 160 Vdc, Stud Terminal, Panel
Mount, UL/CSA
865-1070 Master Pack - Qty 12, Breaker 80A, 125 Vdc, Panel Mount, UL/CSA
865-1075 Master Pack - Qty 48, Breaker 60A, 160 Vdc, Panel Mount, UL/CSA
WARNING: Equipment damage
Do not connect an array capable of delivering over 60 A I
sc
to the XW Solar Charge Controller.
Wires larger than #6 AWG can be used only to reduce power loss in the wiring.
Important:
Local and national electrical codes must be followed for determining additional
installation requirements.
Larger wire sizes may be used to improve performance, but may not be installed directly into this
Charge Controller. Use a splicer block as previously described.