ACCB Owner’s Guide Sine Wave Plus AC Conduit Box (ACCB) Owner’s Guide
Sine Wave Plus AC Conduit Box (ACCB) Installation Guide
About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing and operating the Sine Wave Plus AC Conduit Box (ACCB). Scope The Sine Wave Plus AC Conduit Box (ACCB) Installation Guide provides safety guidelines and procedures for installing and operating the ACCB. Audience This Guide is intended for those who need to install and operate the Sine Wave Plus AC Conduit Box.
About This Guide Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions that could result in personal injury or loss of life. CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
Important Safety Instructions WARNING This chapter contains important safety and operating instructions for Sine Wave Plus AC Conduit Boxes (ACCB). Read and keep this Sine Wave Plus AC Conduit Box (ACCB) Installation Guide for future reference. 1. Before installing the ACCB, read all instructions and cautionary markings on the ACCB and all appropriate sections of this guide. 2. Do not expose the ACCB to rain, snow, or spray. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings.
Important Safety Instructions Explosive gas precautions 1. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, you must read this guide and follow the instructions exactly before installing the ACCB. 2. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed.
Contents Important Safety Instructions 1 Installation Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2 Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 Bypass Switch Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4 Safety Plate (SP-1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents 2 Operating the ACCB The Bypass Switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operating the Bypass Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Normal Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bypass Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AC Input/Output Off - - - - - - - - - - - - - -
Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 Figure 1-11 Figure 1-12 Figure 1-13 Figure 1-14 Figure 1-26 AC Conduit Box, Front View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–2 ACCB Dimensions (not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 Safety Plate SP-1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–4 Clearance Requirements for Ventilation - -
Figures Figure 1-27 Ground Connections for an On-Grid Application with an AC Distribution Panel (sub panel) and a Generator Disconnect Breaker in the ACCB - - - - 1–31 Figure 1-28 Neutral Connections for an On-grid Application with an AC Distribution Panel and internal Generator Disconnect Breaker in the ACCB - - - - - - - - 1–32 Figure 1-29 Hot Connections for an On-Grid Application with an AC Distribution Panel and an Internal Generator Disconnect - - - - - - - - - - - - - - - - - - - - - 1–33 Figure 1-3
1 Installation Chapter 1, “Installation” provides installation and wiring instructions for the Sine Wave Plus AC Conduit Box (ACCB). The following topics are covered in this chapter.
Installation Introduction The ACCB connects to the AC side of a Sine Wave Plus inverter and accepts AC conduit runs. It protects the cable connections to the inverter and provides an inverter bypass (for a single AC source) and AC disconnect breakers. Additional circuit breakers may be added to the ACCB. Use Square D, Type QOU, DIN rail mounted breakers which can be readily purchased from most electrical suppliers.
Specifications Specifications Dimensions Weight Shipping Weight Operating Voltage Breakers: Bypass Inverter Input/Output Operating Temperature Storage Temperature Enclosure Finish Color Regulatory 15 1/8" (H) x 10 3/4" (W) x 8 7/8" (D) (384 mm x 273 mm x 225 mm) 12 pounds (5 kg) 15 pounds (7 kg) 120 Vac 60 Amp (SPST) 60 Amp (DPST) -10 to 60 °C (14 to 140 °F) -55 to +100 °C (-67 to 212 °F) Indoor rated Powdercoat White Certified by CSA to UL 1741 and CSA 107.
Installation Bypass Switch Assembly The bypass switch assembly in the ACCB is designed for 120 Vac applications and comes with two 60-amp circuit breakers (one SPST and one DPST). The breaker pair is equipped with a lockout rocker that allows only one breaker to be ON at any given time. The bypass switch allows the generator or grid to provide power to the inverter loads in the event that the inverter is disabled or removed for service.
Code Compliance Code Compliance Governing installation codes vary depending on the location and type of installation. Electrical installations must meet local and national wiring codes. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System Installers. For a list of Xantrex Certified RE dealers, please visit our website at www.XantrexREdealers.com.
Installation Wiring Scenarios Wiring scenarios will depend upon the configuration of the overall system (i.e., Off Grid or On Grid). Pre-installation and mounting instructions apply to all configurations. Follow the instructions from page 1–7 to page 1–17 for all installations. After the pre-installation procedures have been completed, select the wiring scenario that applies to your configuration.
Pre-installation Pre-installation WARNING Ensure that no DC voltage is being supplied to the inverter and that no AC voltage is present on the AC wiring. Failure to do so could cause serious injury or death. Location Be sure to allow sufficient space for the ACCB to be mounted directly adjacent to the inverter’s AC side. Also consider the additional weight and ventilation space requirements of the ACCB.
Installation Knockout Preparation Knockout preparation should be done before mounting either the inverter or the ACCB. 1. Remove the appropriate knockouts from the AC side of the inverter, for cabling from the ACCB terminal block to the inverter terminal block. See Figure 1-5 for the size and locations of the knockouts on the Sine Wave Plus Inverter Charger. 2. Remove the appropriate knockouts from the ACCB for wire runs from utility and/or inverter panels, a generator, and/or additional inverters.
Pre-installation Knockout Locations for four additional circuit breakers Figure 1-6 Knockouts on ACCB Top Cover for Additional Circuit Breakers Accessory Cable Slots Two slots on the top and bottom of the ACCB base are provided to route the cables for the Inverter Stacking Cable - Series (ISC-S) and the remote Inverter Control Module (ICM) if used. These slots are covered by small hole plugs if these accessories are not used.
Installation See below for location of knockouts on vented end.
Pre-installation Removing and Replacing the ACCB Cover Remove the top cover to install additional breakers and to connect the AC wiring of the inverter to the ACCB. See Figure 1-8 for the locations of screws and cover tabs. To remove the ACCB cover: 1. Remove the three #12 Phillips screws and lock washers from the front of the cover and the two #8 Phillips head, Sems screws from the top and bottom of the cover. Place the loose screws and washers somewhere safe where they will not be lost. 2.
Installation Remove these #8 Phillips head, Sems screws and washers from the top and bottom of the chassis. When replaced, torque to 19-21 in-lbs. Remove these #12 Phillips screws and lock washers from the front of the chassis. When replaced, torque to 26-28 in-lbs.
Pre-installation Installing Additional Breakers If additional AC circuit breakers are to be installed for specific AC loads or a generator disconnect, then install them per the manufacturer’s instructions in the space to the left of the inverter bypass and AC disconnect breakers. Note: The ACCB DIN-Rail accepts Square-D, Type QOU circuit breakers. To install additional Square-D, Type QOU, circuit breakers: 1. Remove the top cover as described on page 1–11. 2.
Installation Mounting the ACCB to the Inverter Important: Ensure that the factory installed cables in the ACCB are not pinched, crushed, removed, or damaged during the installation to the inverter. To install the ACCB on the inverter: 1. Mount the inverter into place, either wall-mounted or shelf-mounted, and secure with appropriate lag bolts. See the Sine Wave Plus Inverter/Charger Owner’s Manual for specific mounting instructions for the inverter. 2.
Pre-Wiring Preparation Pre-Wiring Preparation The ACCB is pre-wired at the factory and ready for connection to the Sine Wave Plus Inverter/Charger. The factory-installed wires are labeled to assist with the installation procedure. WARNING: Electrical Hazard Do not remove or alter in any way the pre-installed factory wiring. Any changes can result in personal injury and/or equipment damage, and will void your warranty.
Installation The distribution blocks in the ACCB AC terminal block accept the following gauge wires. • • The 1:1 distribution blocks accept #2/0 - 14 AWG. The 1:4 distribution blocks accept #2/0 - 14 AWG on the single terminal and #4-14 AWG on the quad terminals. The ground bar in the ACCB accepts #4 to 14 AWG wires.
Pre-Wiring Preparation Bypass Switch Assembly AC Terminal Block Factory-installed NEUTRAL Wire (labeled TO INV AC1 NEU OR AC2 NEU) DIN Rail Factory-installed Hot OUT Wire (labeled TO INV - OUT) Factory-installed Hot IN Wire (labeled TO INV AC1 GRID OR AC2 GEN) Factory-installed Ground Wire Ground Bar Figure 1-12 ACCB Internal Components and Factory-installed Wiring Bypass Switch Assembly includes: two 60-amp circuit breakers and a lockout rocker NEU - Neutral In/Out AC OUT - TO LOADS AC IN - FROM GR
Installation Wiring for Off-Grid Applications Using an AC Distribution Panel and an External Generator Disconnect The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off-grid application using an AC distribution panel for the outputs and a 120 Vac generator for input. Wiring instructions are provided for making ground connections first (page 1–19), neutral connections second (page 1–20), and hot connections last (page 1–21).
Wiring for Off-Grid Applications Using an AC Distribution Panel and an External Generator Disconnect To make the ground connections: 1. Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel. See the Sine Wave Plus Inverter/ Charger Owner’s Manual for information regarding preparing the primary system ground. 2.
Installation To make the neutral connections: 1. Create only one neutral-to-ground bond in the system. In this case, it would be in the main AC distribution panel. Important: Ensure there is only one neutral-to-ground bond in the entire system. See the Sine Wave Plus Inverter/Charger Owner’s Manual for additional information regarding the neutral-to-ground bond requirements. 2. Connect the neutral (white) wire from neutral bar in the AC distribution panel to one of the neutral terminals in the ACCB. 3.
Wiring for Off-Grid Applications Using an AC Distribution Panel and an External Generator Disconnect To make the hot connections: 1. Connect the factory-installed hot (black) wire from the Inverter Input Breaker in the ACCB to the AC2 GEN terminal in the inverter. 2. Connect the factory-installed hot wire (black) from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter. 3. Connect a HOT (Black) wire AC OUT in the ACCB to the HOT IN in the AC Distribution Panel. 4.
Installation Wiring for Off-Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off-grid application using an AC distribution panel for the outputs and a 120 Vac generator for input. This diagram also includes the use of a generator disconnect breaker in the ACCB.
Wiring for Off-Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect To make the ground connections: 1. Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel. See the Sine Wave Plus Inverter/ Charger Owner’s Manual for information regarding preparing the primary system ground. 2.
Installation To make the neutral connections: 1. Create only one neutral-to-ground bond in the system. In this case, it would be in the main AC distribution panel. Important: Ensure there is only one neutral-to-ground bond in the entire system. See the Sine Wave Plus Inverter/Charger Owner’s Manual for additional information regarding the neutral-to-ground bond requirements. 2. Connect the neutral (white) wire from the neutral bar in the AC distirbution palen to one of the neutral terminals in the ACCB.
Wiring for Off-Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect To make the hot connections: 1. Connect the factory-installed hot (black) wire from the Inverter Input Breaker in the ACCB to the AC2 GEN terminal in the inverter. 2. Connect the factory-installed hot wire (black) from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter. 3. Connect a hot (black) wire from the AC OUT in the ACCB to the HOT IN on the AC distribution panel. 4.
Installation Wiring for Off-Grid Applications Using Additional Circuit Breakers in the ACCB Only The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off-grid application using additional circuit breakers in the ACCB for the outputs and a 120 Vac generator for input. This diagram also includes the use of a generator disconnect breaker in the ACCB.
Wiring for Off-Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the ground connections: 1. Prepare the primary system ground and, routing it through one of the knockouts prepared in the ACCB, connect it to the ground bar in the ACCB. See the Sine Wave Plus Inverter/Charger Owner’s Manual for information regarding preparing the primary system ground. 2. Connect the factory-installed ground wire (green) in the ACCB to the AC ground bar in the inverter. 3.
Installation To make the neutral connections: 1. Create only one neutral-to-ground bond in the system. In this case, it would be in the ACCB. Important: Ensure there is only one neutral-to-ground bond in the entire system. See the Sine Wave Plus Inverter/Charger Owner’s Manual for additional information regarding the neutral-to-ground bond requirements. 2. Connect the factory-installed neutral wire (white) in the ACCB to the NEU2 terminal in the inverter. 3.
Wiring for Off-Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the hot connections: 1. Connect the factory-installed hot (black) wire from the Inverter Input Breaker in the ACCB to the AC2 GEN terminal in the inverter 2. Connect the factory-installed hot wire (black) from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter. 3. Connect another hot (black) wire from the generator disconnect breaker to the AC IN terminal in the ACCB.
Installation Wiring for On-Grid Applications Using an AC Distribution Panel and an Internal Generator Disconnect Breaker The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an on-grid application using an AC distribution panel for the outputs and a 120 Vac generator for input. This diagram also uses an internal generator disconnect breaker in the ACCB.
Wiring for On-Grid Applications Using an AC Distribution Panel To make the ground connections: 1. Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel. See the Sine Wave Plus Inverter/ Charger Owner’s Manual for information regarding preparing the primary system ground. 2. Connect a ground wire (green) from the main AC distribution panel to the ground bar in the sub panel. 3.
Installation To make the neutral connections: 1. Ensure there is only one neutral-to-ground bond in the system. In this case, it would be in the main AC distribution panel. Important: Ensure there is only one neutral-to-ground bond in the entire system. See the Sine Wave Plus Inverter/Charger Owner’s Manual for additional information regarding the neutral-to-ground bond requirements. 2.
Wiring for On-Grid Applications Using an AC Distribution Panel To make the hot connections: 1. Connect the factory-installed hot (black) wire from the Inverter Input Breaker in the ACCB to the AC1 GRID terminal in the inverter 2. Connect the factory-installed hot wire (black) from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter. 3. Connect the hot (black) wire from the main AC distribution panel to the AC IN terminal in the ACCB. 4.
Installation Wiring for On-Grid Applications Using Additional Circuit Breakers in the ACCB Only The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an on-grid application using an AC distribution panel for the outputs and a 120 Vac generator for input. This diagram also uses an internal generator disconnect breaker in the ACCB.
Wiring for On-Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the ground connections: 1. Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel. See the Sine Wave Plus Inverter/ Charger Owner’s Manual for information regarding preparing the primary system ground. 2.
Installation To make the neutral connections: 1. Ensure there is only one neutral-to-ground bond in the system. In this case, it would be in the main AC distribution panel. Important: Ensure there is only one neutral-to-ground bond in the entire system. See the Sine Wave Plus Inverter/Charger Owner’s Manual for additional information regarding the neutral-to-ground bond requirements. 2.
Wiring for On-Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the hot connections: 1. Connect the factory-installed hot (black) wire from the Inverter Input Breaker in the ACCB to the AC1 GRID terminal in the inverter 2. Connect the factory-installed hot wire (black) from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter. 3. Connect the hot (black) wire from the main AC distribution panel to the AC IN terminal in the ACCB. 4.
Installation Additional Accessory Wiring If you have any of the following accessories connected (or to be connected) to your inverter, then you will also need to pass their connecting cables through the ACCB to the AC side of the inverter: • • • • Generator Start Module (GSM) for automatic generator control Auxiliary Load Module (ALM) for controlling auxiliary loads such as alarms, water pumps or ventilator fans Emergency Power Off (EPO) switch, Inverter Control Module (ICM), or an Inverter Communication
Wiring for Dual Inverter Configurations Wiring for Dual Inverter Configurations Series stacked Sine Wave Plus inverters with ACCBs installed are wired essentially the same as single inverters, with the following differences. Installing the ISC-S Cable The ISC-S cable must be run through one of the ISC-S/ICM cable slots provided on the sides of the ACCB (see Figure 1-7 on page 1–10). The cable slots are blocked with hole plugs. These hole plugs must be removed before inserting the ISC-S cable.
Installation Installing the Safety Plate The purpose of the Safety Plate (SP-1) is to prevent accidental contact with any live circuits or wires within the AC Conduit Box. The Safety Plate only needs to be installed in the event that the Sine Wave Plus is removed. The Safety Plate (SP-1) covers the open end of AC Conduit Box on the inverter side. It attaches to the base of the conduit box and is secured by the Sems screws that attach the top cover.
Installing the Safety Plate Top Cover AC Co nd ui t B ox Safety Plate Ensure the top cover tabs protrude through the cover tab slots. AC Co nd uit Replace the #8 Sems screw from the top of the chassis. Bo x Replace the #8 Sems screw from the bottom of the chassis.
1–42
2 Operating the ACCB Chapter 2, “Operating the ACCB” describes the different modes and operation of the Bypass Switch on the ACCB. The following topics are covered in this chapter.
Operating the ACCB The Bypass Switch During normal operation (Figure 2-2 on page 2–3), AC power passes from the external AC source (generator or grid) through the inverter to the AC loads. The inverter monitors the incoming power and can keep the batteries charged. When external sources of AC power are not available, the inverter switches to external DC power (e.g., batteries, generator, solar, wind, hydro fuel cell) and continues to power the load.
Operating the Bypass Switch Normal Operation Inverter AC power passes through the inverter to the load (Figure 2-2). In this configuration, power passes through the inverter to the connected load. When external AC power is not available, power from the external DC source is used by the inverter to power the AC loads.
Operating the ACCB AC Input/Output Off No power to the load or charger (Figure 2-4). In this configuration, power from both the external sources of AC and the inverter is removed from the loads. This allows the inverter, the connected loads, or any other installed equipment beyond the ACCB to be serviced.
Warranty and Product Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your Sine Wave Plus AC Conduit Box. This warranty lasts for a Warranty Period of two (2) years from the date of purchase at point of sale to you, the original end user customer. This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period.
Warranty and Product Information Proof of purchase may be in any one of the following forms: • The dated purchase receipt from the original purchase of the product at point of sale to the end user, or • The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status, or • The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the product or costs rel
Return Material Authorization Policy Warning: Limitations On Use Please refer to your product manual for limitations on uses of the product. SPECIFICALLY, PLEASE NOTE THAT THE SINE WAVE PLUS AC CONDUIT BOX SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES.
Warranty and Product Information Out of Warranty Service If the warranty period for your Sine Wave Plus AC Conduit Box has expired, if the unit was damaged by misuse or incorrect installation, if other conditions of the warranty have not been met, or if no dated proof of purchase is available, your inverter may be serviced or replaced for a flat fee.
Index A I abbreviations and acronyms iv AC conduit box (ACCB) introduction 1–2 specifications 1–3 AC load breakers 1–13 AC wiring for dual inverters 1–39 additional accessory wiring 1–38 additional breakers in the ACCB 1–13 Auxiliary Load Module (ALM), wiring for 1–38 Information about Your System form WA–4 installation additional breakers in ACCB 1–13 codes 1–5 knockout preparation 1–8 materials 1–5 removing cover 1–12 tools 1–5 inverter purchase date WA–4 Inverter Communications Adapter (ICA), wiring f
Index R return material authorization (RMA) policy WA–3 return procedure under warranty WA–3 RMA number WA–4 S safety instructions v–vi Safety Plate (SP-1) 1–40 series stacked inverters, see dual inverters specifications for the ACCB 1–3 T telephone number for Customer Service WA–1 tools required for installation 1–5 W warranty out of warranty service WA–4 return material authorization policy WA–3 return under warranty WA–3 terms and conditions WA–1 wiring additional accessories 1–38 grounding the ACCB
Xantrex Technology Inc. 360 435 8826 Tel 360 435 3547 Fax 800 670 0707 Toll Free North America customerservice@xantrex.com www.xantrex.
