Solar Xantrex 784-0110 Installation Manual

The Solar Xantrex 784-0110 is a high-performance solar charge controller designed for off-grid and backup power systems. It features advanced MPPT (Maximum Power Point Tracking) technology, multiple battery type compatibility, comprehensive system monitoring, and robust protection mechanisms. This manual covers safety precautions, installation procedures, configuration, operation, and maintenance guidelines to ensure optimal and safe system performance.

1. Safety Warnings & Precautions 2. Product Overview & Features 3. Unpacking & Inspection 4. Mounting the Controller 5. Electrical Connections 6. Initial Configuration & Setup 7. Operation & Monitoring 8. System Specifications 9. Troubleshooting 10. Maintenance & Warranty

Safety Warnings & Precautions

Installation must be performed by a qualified technician in accordance with all local and national electrical codes. Failure to follow safety instructions may result in fire, electric shock, equipment damage, or personal injury.

Disconnect All Power: Ensure all AC and DC power sources (solar array, battery, grid) are disconnected before beginning installation.
Battery Safety: Batteries contain corrosive acid and can produce explosive gases. Install in a well-ventilated area, wear protective gear, and avoid sparks or flames.
Correct Wiring: Use copper conductors of the correct gauge as specified. Ensure all connections are tight and secure to prevent overheating.
Fusing: Install appropriately rated fuses or circuit breakers on all power conductors (PV+, Battery+) as close to the source as possible.
Lightning Protection: Install surge protection devices on PV and AC lines if in an area prone to lightning strikes.

DANGER! Risk of electric shock and arc flash. High-voltage DC from solar panels is present even when the controller is off. Handle with extreme care.

Product Overview & Features

The Xantrex 784-0110 is an MPPT solar charge controller that maximizes energy harvest from your photovoltaic (PV) array to charge battery banks efficiently.

Feature	Description
MPPT Technology	Increases energy harvest by up to 30% compared to PWM controllers.
Battery Compatibility	Sealed, Gel, Flooded, and Lithium (LiFePO4) battery profiles.
Maximum PV Input	150V DC, 60A maximum charge current.
Communication	RS-232 and Ethernet ports for system monitoring and firmware updates.
LCD Display	Backlit display for real-time system data (Volts, Amps, kWh, status).
Protections	Over-temperature, short-circuit, reverse polarity, over-voltage, and battery over-charge protection.
Load Control	Programmable DC load output with timer and low-voltage disconnect (LVD).
Temperature Sensor	Included battery temperature sensor for optimized charging voltage compensation.

Unpacking & Inspection

Carefully unpack the controller and verify all components are present and undamaged.

Contents: Xantrex 784-0110 Controller, Mounting Bracket Kit, Battery Temperature Sensor, Communication Cable, User Manual.
Inspection: Check the unit for any signs of physical damage from shipping (cracks, dents, loose parts).
Documentation: Review this manual and all safety labels on the device before proceeding.

CAUTION! Do not install a damaged unit. Contact your supplier immediately if any components are missing or defective.

Mounting the Controller

Select an appropriate location for installation.

Location: Mount in a clean, dry, well-ventilated area protected from direct sunlight, rain, and excessive heat/cold. Allow at least 6 inches of clearance around the unit for airflow.
Surface: Mount on a vertical, non-combustible surface using the provided bracket.
Mounting: Secure the mounting bracket to the wall using appropriate hardware. Slide the controller onto the bracket until it clicks into place.

WARNING! Do not mount near flammable materials or in a sealed enclosure. The controller dissipates heat during operation.

Electrical Connections

Sequence is Critical: Always make connections in the following order to prevent damage.

Ground Connection: Connect the chassis ground terminal to the system ground busbar using a copper conductor.
Battery Connection: Connect the BATTERY (+) and BATTERY (-) terminals to the corresponding battery bank terminals. Ensure polarity is correct.
PV Array Connection: Connect the PV (+) and PV (-) terminals from the solar array. Verify PV open-circuit voltage is below 150V DC before connecting.
Load Connection (Optional): Connect the LOAD (+) and LOAD (-) terminals to your DC load distribution panel.
Temperature Sensor: Plug the sensor into the designated port and attach the probe to the battery terminal.
Communication (Optional): Connect the RS-232 or Ethernet cable for remote monitoring.

IMPORTANT: Torque all terminal screws to the specified value (typically 20-25 in-lbs). Use ring terminals on all wires.

Initial Configuration & Setup

Power on the system and configure the controller via the LCD interface.

Power Up: The controller will initialize. The LCD will light up and display the main status screen.
Enter Menu: Press the "MENU" button. Navigate using the arrow keys.
Set Battery Type: Navigate to BATTERY > TYPE. Select the correct chemistry for your bank (e.g., FLOODED, GEL, LITHIUM).
Set Charge Parameters: For flooded batteries, set Absorption Voltage (typically 14.4V-14.6V for 12V system) and Float Voltage (typically 13.5V-13.8V). Use preset values for other types.
Set Load Control: Configure the DC load output mode (e.g., ON/OFF, Timer, Dusk-to-Dawn) and Low Voltage Disconnect (LVD) level.
Set System Voltage: Ensure the SYSTEM VOLTAGE is set correctly (12V, 24V, or 48V).
Exit & Save: Press "ENTER" to save settings, then "ESC" to return to the main screen.

Tip: Consult your battery manufacturer's datasheet for optimal charge voltage settings.

Operation & Monitoring

The LCD display provides real-time system information.

Main Screen: Displays Battery Voltage, Charge Current (from PV), Load Current, Battery State of Charge (%), and daily harvested energy (kWh).
Fault Indicators: The display will show warning icons for faults (e.g., High Temp, PV Over Voltage, Battery Low).
Charging Stages: The controller automatically manages Bulk, Absorption, and Float stages. The current stage is indicated on screen.
Remote Monitoring: Use the Xantrex Connect software (via Ethernet) or third-party monitoring platforms to view data logs and system performance over time.

System Specifications

Model: Xantrex 784-0110
Rated Battery Voltage: 12/24/48V DC Auto-select
Maximum PV Input Power: 12V: 800W, 24V: 1600W, 48V: 3200W
Maximum PV Open Circuit Voltage: 150V DC
Maximum Charge Current: 60A
Maximum Load Current: 20A
MPPT Tracking Efficiency: > 99%
Operating Temperature: -30°C to +60°C (-22°F to +140°F)
Enclosure Rating: IP32 (Indoor use)
Communication: RS-232, Ethernet (10/100)
Dimensions (HxWxD): 12.2 x 8.3 x 3.5 in (310 x 210 x 90 mm)

Troubleshooting

Symptom	Possible Cause	Corrective Action
No display, unit dead	No battery power; blown fuse; reverse polarity.	Verify battery voltage at terminals; check battery fuse; disconnect and correct polarity if reversed.
Not charging (0A)	PV voltage too low/high; night time; faulty connection.	Check PV open-circuit voltage is between startup and 150V; inspect all PV connections and fuses.
Battery over-voltage fault	Battery voltage setting too high; faulty battery sensor.	Verify battery type and charge voltage settings; ensure temperature sensor is connected properly.
Controller overheating	Insufficient ventilation; ambient temperature too high; overload.	Ensure adequate clearance; relocate to a cooler area; verify PV input power is within limits.
Load output not working	Load disabled; LVD triggered; blown load fuse.	Check load settings in menu; check battery voltage (if low, LVD is active); inspect load fuse.
Communication failure	Incorrect cable; software not configured; faulty port.	Use correct RS-232/Ethernet cable; verify COM port settings in software; try a different port.

Reset: To perform a factory reset, navigate to MENU > SYSTEM > FACTORY RESET. Warning: This will erase all custom settings.

Maintenance & Warranty

Maintenance: The controller requires minimal maintenance. Periodically:

Check all electrical connections for tightness and signs of corrosion.
Clean the exterior and ventilation slots with a dry, soft cloth to prevent dust buildup.
Verify system performance data matches expectations.

Warranty: The Xantrex 784-0110 is covered by a limited warranty for 5 years from the date of purchase. The warranty covers defects in materials and workmanship. It does not cover damage from misuse, improper installation, lightning, or unauthorized modification. For warranty service, contact Xantrex Technical Support with your proof of purchase.

Support:
Website: www.xantrex.com
Technical Support: 1-800-xxx-xxxx
Email: [email protected]