Xantrex DCCB-L, DCCB-L-175, DCCB-L-250 User Guide

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Sine Wave Plus DC Conduit Box Long

DCCB-L DCCB-L-175 DCCB-L-250

Owner’s Guide

Sine Wave Plus Long DC Conduit Box

Owner’s 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.

Trademarks

Sine Wave Plus Long DC Conduit Box is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex International.

Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.

Notice of Copyright

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision

July 2004 Revision A

Part Number

973-0032-01-01 Rev A

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

Fax: 1 800 994 7828 (toll free North America)

Email: customerservice@xantrex.com

Web: www.xantrex.com

1 360 925 5097 (direct)

1 360 925 5143 (direct)

About This Guide

Purpose

The purpose of this Owner’s Guide is to provide explanations and procedures for installing the Long DC Conduit Box (DCCB-L) on a Sine Wave Inverter/charger.

Scope

The Owner’s Guide provides safety guidelines and procedures for installing the Long DC Conduit Box.

Audience

The information in this Guide is intended for the experienced electrician who need to install the Long DC Conduit Box into a power system. Only skilled personnel, such as certified electricians and certified Renewable Energy technicians should attempt installation of this equipment. Skills required include the ability to read and understand how to follow single-line wiring diagrams.

Organization

This Guide consists of two chapters.

Chapter 1, “Introduction” provides basic information about the design and purpose of the Sine Wave Plus Long DC Conduit Box.

Chapter 2, “Installation” provides installation and wiring instructions for the Sine Wave Plus Long DC Conduit Box (DCCB-L).

Warranty and Product Information is provided at the end of the manual.

973-0032-01-01 Rev A iii

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:

know, but not as serious as a caution or warning.

These notes describe things which are important for you to

Product Naming Conventions

DCCB-L refers to the Long DC Conduit Box without any factory installed wiring.

DCCB-L-175/L-250 refers to the Long DC Conduit Box with either a GJ175F or a GJ250F Circuit Breaker installed. It includes some factory-installed wiring.

DCCB-RE describes a field-installed, dual-conduit box installation intended for supporting multiple RE sources.

Long DC Conduit Box refers to all products and is used in situations where all three products are treated the same.

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Abbreviations and Acronyms

AC Alternating Current

AHJ Authority Having Jurisdiction

ASC Authorized Service Center

AWG American Wire Gauge

BSM Battery Status Meter

BTS Battery Temperature Sensor

CEC Canadian Electrical Code

CSA Canadian Standards Association

DC Direct Current

DCCB-L DC Conduit Box Long Version for the SW Plus Inverter/Charger

DCCB-L-175/L-250 A DCCB-L that includes factory-installed hardware.

PVGFP PV Ground Fault Protection

NEC National Electrical Code (US)

RE Renewable Energy

RMA Return Material Authorization

UL Underwriters Laboratory

About This Guide

Related Information

You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com.

973-0032-01-01 Rev A v

Important Safety Instructions

WARNING

This chapter contains important safety and operating instructions for the Sine Wave Plus Long DC Conduit Box (all models). Read and keep this Installation Guide for future reference.

1. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and certified Renewable Energy (RE) system installers to ensure adherence to the local and national electrical codes applicable in your installation. For a list of Xantrex Certified RE dealers, please visit our website at www.xantrexREdealers.com.

2. Before installing any components, read all instructions and cautionary markings on the Long DC Conduit Box, the batteries, and all appropriate sections of this guide.

3. The Long DC Conduit Box is designed to be permanently connected to your Sine Wave Plus inverter to prevent accidental exposure to shock hazards.

4. Do not expose the Long DC Conduit Box to rain, snow, or spray. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings.

5. Do not install the Long DC Conduit Box in a zero-clearance compartment. The Sine Wave Plus inverter that is attached may overheat. Minimum

clearance for ventilation around unit must be 12 inches (305 mm) at the end and the top.

6. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the inverter with damaged or substandard wiring.

7. To reduce the risk of electrical shock, disconnect both AC and DC power from the system before attempting any maintenance or cleaning or working on the Long DC Conduit Box.

8. The Long DC Conduit Box is provided with an equipment-grounding bar that must be connected to the inverter equipment ground and the system ground.

9. Do not store any flammable materials near the primary system panel.

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Safety

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 DCCB-L.

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.

Certifications

CSA certified to the following standards:

• UL 1741-2001 First Edition, and

• CSA C22.2 No. 107.1-01

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Contents

Important Safety Instructions

Introduction

Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Blockoff Plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Options/Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

Charge Controllers or Diversion Load Controllers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Charge Controller Installation Package - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 PV Ground Fault Protection (PVGFP-CF) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 GJ175F and GJ250F Breakers and Flag Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 CF60 Circuit Breakers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 CF-Series Breaker Mounting Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Power Distribution Blocks (PDB) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Battery Status Monitor (BSM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11 Battery Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 Battery Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 DC Negative Bus Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13

Installation

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii

Preparing for the Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Code Compliance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Installation Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Pre-installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Service Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Ventilation Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Removing and Replacing the Long DC Conduit Box Cover - - - - - - - - - - - - - - - - - - - - - - - 2–5 Installing or Removing the Blockoff Plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6 Knockout Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

Mounting the Long DC Conduit Box on the Xantrex Back Plate (XBP) - - - - - - - - - - - - - - - 2–8

Mounting on Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Installing Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Dual DCCB-L Configurations (DCCB-L-RE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

Dual DCCB-Ls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

Dual DCCB-L-175s (or L-250s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

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Contents

Charge/Load Controllers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–15 Wiring - General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–16

Grounding the Long DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–16

DC Equipment Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–17 Bonding DC Negative to Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18 Connecting to the Primary System Ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18

Connecting DC and AC Electrical System Grounds Together - - - - - - - - - - - - - - - - - - -2–19 Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–22 Master DC Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–23 Additional Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–24 Battery Cable Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–25

Wiring - Specific - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–27

Single Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–27 Single Inverter System with Renewable Energy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–28 Dual Inverter System with Renewable Energy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–29 Dual Inverter System with Multiple Renewable Energy - - - - - - - - - - - - - - - - - - - - - - - - - -2–30 Additional Accessory Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–31

Battery Status Monitor (BSM) (p/n TM500A or TM500A-NS) - - - - - - - - - - - - - - - - - -2–31

Charge Controller Wiring using the C-Series Multifunction DC Controller

and the CC PCK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–32

Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–33

Warranty and Return Information

Index

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

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Figures

Figure 1-1 Sine Wave Plus Long DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Figure 1-2 Long DC Conduit Box Dimensions (Not To Scale)- - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 Figure 1-3 The Blockoff Plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Figure 1-4 The C-Series Multi-function DC Controller Family - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 Figure 1-5 Charge Controller Installation Package (CC PCK) - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 Figure 1-6 PVGFP-CF Breakers (-1, -2, -3 and -4)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Figure 1-7 GJ Breakers and Flag Terminals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9 Figure 1-8 GJ 175F-PCK or the GJ250F-PCK- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9 Figure 1-9 CF60 Circuit Breaker- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Figure 1-10 CF-Series Mounting Plate (CFMP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Figure 1-11 Power Distribution Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Figure 1-12 Battery Status Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11 Figure 1-13 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 Figure 1-14 Battery Cable Set (BC-L2-250 or BC-L2-175)- - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 Figure 1-15 DC Negative Bus Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13 Figure 2-1 Warning Label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Figure 2-2 Space and Clearance Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Figure 2-3 Removing and Replacing the Long DC Conduit Box Top Cover- - - - - - - - - - - - - - - - - 2–5 Figure 2-4 The Blockoff Plates on the Long DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6 Figure 2-5 Knockout Locations on the Long DC Conduit Box- - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 Figure 2-6 The XBP Back Plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Figure 2-7 Mounting the Long DC Conduit Box and the SW Plus Inverter Charger on the XBP - - - 2–9 Figure 2-8 Mounting the Long DC Conduit Box and the Sine Wave Plus Inverter Charger

on Plywood - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Figure 2-9 Installing Circuit Breakers on the Long DC Conduit Box - - - - - - - - - - - - - - - - - - - - 2–12 Figure 2-10 Optional Component Locations on the Long DC Conduit Box - - - - - - - - - - - - - - - - - 2–12 Figure 2-11 Creating a DCCB-L-RE Configuration from Dual DCCB-Ls - - - - - - - - - - - - - - - - - - 2–13 Figure 2-12 Creating a DCCB-L-RE Configuration from two DCCB-L-175 (or L-250)- - - - - - - - - 2–14 Figure 2-13 Adding Charge or Diversion Load Controllers on the Long DC Conduit Box - - - - - - - 2–15 Figure 2-14 Grounding Using PVGFP-CF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20 Figure 2-15 Grounding Without PVGFP-CF- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21 Figure 2-16 Battery Connections for a Single-inverter System- - - - - - - - - - - - - - - - - - - - - - - - - - 2–25 Figure 2-17 Battery Connections for a Dual-inverter System- - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26 Figure 2-18 DC Wiring for a Single Inverter System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27 Figure 2-19 DC Wiring for a Single Inverter System with Renewable Energy - - - - - - - - - - - - - - - 2–28 Figure 2-20 DC Wiring for a Dual Inverter System with Renewable Energy - - - - - - - - - - - - - - - - 2–29

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Figures

Figure 2-21 DC Wiring for a Dual Inverters, Dual Long DC Conduit Box System with Multiple RE 2–30 Figure 2-22 Installing the BSM on the Long DC Conduit Box - - - - - - - - - - - - - - - - - - - - - - - - - -2–31 Figure 2-23 Wiring the C-Series Multifunction Charge Controllers to the Long DC Conduit Box

using the CC PCK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–32 Figure 2-24 BTS Port locations on the Sine Wave Plus Inverter - - - - - - - - - - - - - - - - - - - - - - - - -2–33 Figure 2-25 BTS Port locations on the C-Series DC Controller- - - - - - - - - - - - - - - - - - - - - - - - - -2–33 Figure 2-26 Installing the Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–34

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Tables

Table 1-1 Operational and Environmental Specifications for the Long DC Conduit Box- - - - - - - - 1–3 Table 2-1 Minimum Equipment Ground Wire and DC Disconnect Size Chart- - - - - - - - - - - - - - 2–17 Table 2-2 Recommended Battery Cable Size Versus Length - - - - - - - - - - - - - - - - - - - - - - - - - 2–22 Table 2-3 Battery Cable to Maximum Breaker/Fuse Size- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22

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xiv

Introduction

Chapter 1, “Introduction” provides basic information about the design and purpose of the Sine Wave Plus Long DC Conduit Box.

The following topics are covered in this chapter.

For this topic: See...

“Introduction” page 1–2

“Specifications” page 1–3

“Blockoff Plates” page 1–5

“Options/Accessories” page 1–6

Introduction

The Sine Wave Plus Long DC Conduit Box (DCCB-L) connects to the DC side of the inverter and accepts DC conduit runs. The conduit box provides protection to the DC cables connected to the inverter and provides a centralized location for the DC circuit breakers and PV Ground Fault Protection (GFP) breakers. It is also designed to incorporate cabling from up to two Multi-function DC Charge Controllers, such as the Xantrex C-Series Charge Controllers, and cabling from a battery meter, such as the Xantrex Battery Status Meter.

The Long DC Conduit Box is available in three different configurations.

•The DCCB-L Basic provides an internal ground bar only and space to add additional circuit breakers; three large and six small.

•The DCCB-L-175 includes a 175 amp GJ, F-Type, circuit breaker, a DC negative bus bar and 500A/50 mV shunt, battery cables (1 set) and a ground wire connected to the ground bar.

•The DCCB-L-250 includes a 250 amp GJ, F-type, circuit breaker a DC negative bus bar and 500A/50 mV shunt, battery cables (1 set) and a ground wire connected to the ground bar.

For expandability, the Long DC Conduit Box is designed so that a second DCCBL (any model) can be added on for additional breaker spaces, wiring, room and controller mounting spaces. Dual configurations have been certified to meet UL1741-2001 (First Edition) standards when using the field-installable accessories as listed page 1–6.

Blockoff

Plates

Upper

Lower

DCCB-L includes:

❐ Front Cover ❐ Blockoff Plates (top and bottom)

B C

❐ DC Ground Bar

❐ 6CF/3GJ Mounting Plate

❐ Battery Meter Mounting Box

Figure 1-1

1–2 973-0032-01-01 Rev A

Sine Wave Plus Long DC Conduit Box

Front Cover

DCCB-L

DCCB-L-175 or DCCB-L-250 adds: F

❐ One GJ175F or GJ250F Circuit Breaker

❐ DC Negative Bus Bar and Shunt

❐ One Positive (+) Battery Cable

❐ One Negative (–) Battery Cable

❐ One length green GROUND wire

DCCB-L-175 or DCCB-L-250

Specifications

The following table provides the operational and environmental specifications for the Long DC Conduit Box (all models).

Table 1-1

Operational and Environmental Specifications for the Long DC Conduit Box

DCCB-L Basic DCCB-L-175 DCCB-L-250

Dimensions 33" (H) x 13 1/2" (W) x 8 7/8" (D)

(384 mm x 343 mm x 225 mm)

Weight 22 lbs (10 kg) 33 lbs (15 kg) 33 lbs (15 kg)

Shipping Weight

Factoryinstalled hardware

Factoryinstalled wiring

Rated Temperature

Storage Temperature

Enclosure Indoor rated, Galveneel, White,

25 lbs (11.5 kg) 36 lbs (16.5 kg) 36 lbs (16.5 kg)

• DC Ground Bar (with 12 holes, accepts #2 - 14 AWG wires)

• 6CF/3GJ Mounting Plate

• Mounting box for BSM (w cover)

None • One - Ground Wire (#4 AWG, 18",

0 to 25 °C (32 to 77 °F)

-55 to +100 °C

(-67 to 212 °F)

Powdercoat Finish

33" (H) x 13 1/2" (W) x 8 7/8" (D) (384 mm x 343 mm x 225 mm)

• DC Ground Bar (with 12 holes, accepts #2 - 14 AWG wires)

• 6CF/3GJ Mounting Plate

• Mounting box for BSM (w cover)

• DC Negative Bus Bar

• 500 A/50 mV Shunt

• GJ175F Circuit Breaker

rated to 105 °C, stranded copper) (

• One - Positive (+) Battery Cable

(#2/0 AWG, 16" Cable)

• One - Negative (–) Battery Cable

(#2/0 AWG, 30" Cable)

0 to 25 °C (32 to 77 °F)

-55 to +100 °C

(-67 to 212 °F)

Indoor rated, Galveneel, White, Powdercoat Finish

33" (H) x 13 1/2" (W) x 8 7/8" (D) (384 mm x 343 mm x 225 mm)

• DC Ground Bar (with 12 holes, accepts #2 - 14 AWG wires)

• 6CF/3GJ Mounting Plate

• Mounting box for BSM (w cover)

• DC Negative Bus Bar

• 500 A/50 mV Shunt

• GJ250F Circuit Breaker

• One - Ground Wire (#4 AWG, 18",

rated to 105 °C, stranded copper)

• One - Positive (+) Battery Cable

(#4/0 AWG, 16" Cable)

• One - Negative (–) Battery Cable

(#4/0 AWG, 30" Cable)

0 to 25 °C (32 to 77 °F)

-55 to +100 °C

(-67 to 212 °F)

Indoor rated, Galveneel, White, Powdercoat Finish

Ratings • 160 Vdc maximum (Open Circuit)

• 250 amps maximum each inverter

• 250 amps max. renewable energy

Charge Controllers

Regulatory Certified by CSA to UL 1741-2001

Accommodates: 2 Charge Controllers, 60 amps max. each

(First Edition) and CSA C22.2 No. 107.1-01

• 160 Vdc maximum (Open Circuit)

• 250 amps maximum each inverter

• 250 amps max. renewable energy

Accommodates: 2 Charge Controllers, 60 amps max. each

Certified by CSA to UL 1741-2001 (First Edition) and CSA C22.2 No. 107.1-01

• 160 Vdc maximum (Open Circuit)

• 250 amps maximum each inverter

• 250 amps max. renewable energy

Accommodates: 2 Charge Controllers, 60 amps max. each

Certified by CSA to UL 1741-2001 (First Edition) and CSA C22.2 No. 107.1-01

973-0032-01-01 Rev A 1–3

Introduction

Table 1-1

Optional hardware available at Xantrex

Operational and Environmental Specifications for the Long DC Conduit Box

DCCB-L Basic DCCB-L-175 DCCB-L-250

• Charge Controllers (60 A max ea.)

• Charge Controller Kit (CC PCK)

• Power Distribution Blocks (PDB-6 or PDB-12)

• PVGFP-CF (-1, -2, -3, -4)

• GJ175F or GJ250F Circuit Breakers

• GJ175F-PCK (includes wiring)

• GJ250F-PCK (includes wiring)

• Battery Status Meter (TM500A, TM500A-NS, and TM48)

• CF60 Circuit Breakers

• CF Mounting Plate (CFMP)

• DC Negative Bus Bar with shunt

(DCBUSBAR)

• Battery Temperature Sensor (BTS)

• BC-L2-175 (#2/0 AWG cable)

• BC-L2-250 (#4/0 AWG cable)

Inverter Side

• Charge Controllers (60 A max ea.)

• Charge Controller Kit (CC PCK)

• Power Distribution Blocks (PDB-6 or PDB-12)

• PVGFP-CF (-1, -2, -3, -4)

• GJ175F or GJ250F Circuit

Breakers

• GJ175F-PCK (includes wiring)

• GJ250F-PCK (includes wiring)

• Battery Status Meter (TM500A,

TM500A-NS, and TM48)

• CF60 Circuit Breakers

• CF Mounting Plate (CFMP)

• DC Negative Bus Bar with shunt

(DCBUSBAR)

• Battery Temperature Sensor (BTS)

• BC-L2-175 (#2/0 AWG cable)

• BC-L2-250 (#4/0 AWG cable)

DCCB-L Base

• Charge Controllers (60 A max ea.)

• Charge Controller Kit (CC PCK)

• Power Distribution Blocks (PDB-6 or PDB-12)

• PVGFP-CF (-1, -2, -3, -4)

• GJ175F or GJ250F Circuit Breakers

• GJ175F-PCK (includes wiring)

• GJ250F-PCK (includes wiring)

• Battery Status Meter (TM500A, TM500A-NS, and TM48)

• CF60 Circuit Breakers

• CF Mounting Plate (CFMP)

• DC Negative Bus Bar with shunt (DCBUSBAR)

• Battery Temperature Sensor (BTS)

• BC-L2-175 (#2/0 AWG cable)

• BC-L2-250 (#4/0 AWG cable)

Outside

Figure 1-2

0.265 x 1”

(Obround x4)

0.188”

(fits up to #8

screw x2)

Long DC Conduit Box Dimensions (Not To Scale)

1–4 973-0032-01-01 Rev A

Blockoff Plates

Upper and Lower Blockoff Plates are included to enclose the open portions of the Long DC Conduit Box chassis. In the event that an inverter is removed, the Blockoff Plates secure the enclosure to prevent accidental contact with any AC power within the Long DC Conduit Box.

Remove the Blockoff Plate (upper or lower) from its position for the inverter used in your installation. The Blockoff Plates will not be needed at all in a dual SW Plus inverter installation.

See “Installing or Removing the Blockoff Plates” on page 2–6 for additional information.

Important:

single-inverter systems to use the upper mounting location for the inverter. Mounting an inverter in the lower mounting position for a single-inverter system will required sitefabricated cables.

The cable lengths provided in the DCCB-L-175/L-250 were designed for

WARNING: Shock Hazard

Be sure to disconnect all DC and AC power before removing the inverter and installing the blockoff plate.

Upper Blockoff Plate

Lower Blockoff Plate

Knockout panel (if needed)

Figure 1-3

973-0032-01-01 Rev A 1–5

The Blockoff Plates

Introduction

Options/Accessories

The following CSA-approved accessories are available through Xantrex to expand or monitor the DC side of the system.

• C-Series Multi-function DC Controllers (C35, C40, C60)

• Charge Controller Installation Package (CC PCK)

• PV Ground Fault Protection CF Breakers (PVGFP-CF-1, PVGFP-CF-2, PVGFP-CF-3, PVGFP-CF-4)

• GJ-F Series Flag Style Circuit Breakers 175A or 250A (without wiring) (GJ175F, GJ250F)

• GJ Series Flag Style Breakers 175A or 250A (with battery cables to connect second inverter) (GJ175F-PCK, and GJ250F-PCK)

• Dual-pole or Triple-pole GJ Flag Terminal Bus bars (GJ-FT2, GJ-FT3)

• CF Breaker Mounting Plate (CFMP)

• 60 Amp CF Series Circuit Breakers for loads (CF60)

• Power Distribution Blocks 6:1 and 12:1 (PDB-6 or PDB-12)

• Battery Status Meter (TM500A-NS without shunt) or (TM500A with shunt)

• Battery Temperature Sensors (BTS)

• Battery Cables for adding a second inverter (BC-L2-175 or BC-L2-250). These battery cables are the same as those included with the appropriate breaker with the GJF175-PCK or GJF250-PCK.

• DC Negative Bus Bar (DCBUSBAR)

Important:

configuration. Other components may be used, but may not allow continuous operation of the SW Plus Inverter and should be approved by the AHJ.

The components shown in this section are to be used in a DCCB-L-RE

Charge Controllers or Diversion Load Controllers

If charge control or diversion control is required, spaces are provided for mounting up to two DC controllers on the top of the DCCB-L chassis. Xantrex offers the C-Series Multi-function DC Controller to provide either charge control or diversion control.

Charge controllers not purchased from Xantrex may be used also, but might not fit the mounting holes on the top of DCCB-L. If this occurs, the non-Xantrex supplied charge controllers will need to be mounted somewhere off the DCCB-L chassis.

Any charge controllers used on this component (Xantrex and Non-Xantrex) should not exceed 60 A each (120 A total).

If more charge controllers are required, then it may be desirable to have two DCCB-Ls (any model combination) installed in a dual-configuration.

1–6 973-0032-01-01 Rev A

Options/Accessories

Figure 1-4

CM Faceplate Meter Display

CM/R Meter

Display

The C-Series Multi-function DC Controller Family

C35

Charge Controller Installation Package

The following hardware can be purchased upon request for installing the C-Series Multi-function DC Controller to the Sine Wave Plus Long DC Conduit Box. The Charge Controller add-on package (CC PCK) includes the following:

• one 48-inch white #6 AWG wire (temperature rated at 90° C),

• one 96-inch red #6 AWG wire (temperature rated at 90° C),

• one 48-inch green #10 AWG wire (temperature rated at 105° C), and

• two conduit chase nipples, two lock nuts, and two plastic bushings for 1" knockouts.

C40

C60

Figure 1-5

Charge Controller Installation Package (CC PCK)

See Figure 2-23 on page 2–32 for instructions on cutting and installing the CC PCK wiring.

973-0032-01-01 Rev A 1–7

Introduction

PV Ground Fault Protection (PVGFP-CF)

PV ground fault protection is available in up to four CF-Series breaker configurations. It’s designed to minimize the possibility of a fire resulting from ground faults in a PV array in accordance with the National Electric Code (NEC) for roof-mounting arrays on homes. Each switch is rated for 100 amps maximum per circuit and mounts directly to the breaker mounting plate. It is not designed or intended to prevent electrical shock or to be used for PV DC over-current protection. They can be used as an array disconnect.

PVGFP-CF-3

Figure 1-6

PVGFP-CF-1

Note: Wiring shown in this figure has been trimmed for visual purposes only and does not represent the actual length of wires that are attached to the breakers.

PVGFP-CF-2

PVGFP-CF Breakers (-1, -2, -3 and -4)

Each charge controller that is connected to a roof mounted PV array on a home requires a “pole” on one of the four available PV-GFV-CF configurations.

For example: If three controllers are used, one for a ground mounted PV array, one for a roof mounted PV array on a home, and one with a diversion load, only the one used for a roof-mounted array requires a ground fault pole.

CAUTION: Equipment Damage

Never install a PVGFP-CF between the diversion load and controller. Overcharging may occur during a “ground fault condition”.

GJ175F and GJ250F Breakers and Flag Terminals

GJ breakers are available in sizes 175A and 250A. The GJ175F and GJ250F breakers have single-pole “flag” terminals on them that are designed for use with lugged cables with ring terminals. These breakers can be used as a disconnect and/ or an over-current device for the inverter(s) and PDBs.

PVGFP-CF-4

1–8 973-0032-01-01 Rev A

Options/Accessories

If more than one GJ F-Series breaker is being used, they can be tied together using the double-pole or triple-pole flag terminals. The double-pole and triple-pole flag terminals are used to provide power to additional GJ175F or a GJ250F breakers that in turn can feed a PDB-6 or PDB-12. This eliminates the need for an extra cable from the battery bank.

Regular GJ breakers use “box lugs” and are intended for use with cables that do not have ring terminals. These breakers can be used in the DCCB-L, but can not use the flag terminals.

GJ Breaker

(GJ175, GJ250)

GJ F-Series Breaker

(GJ175F, GJ250F)

Dual-Pole Flag Terminal

(GJ-FT2)

Triple-Pole Flag Terminal

(GJ-FT3)

Figure 1-7

GJ Breakers and Flag Terminals

GJ250F-PCK consists of the following parts.

GJ250F Circuit Breaker

#6 (THHN) AWG, 7", Ground Wire

#4/0 AWG, 26", Positive Cable

#4/0 AWG, 20", Negative Cable

GJ175F-PCK consists of the following parts.

GJ175F Circuit Breaker

#6 (THHN) AWG, 7", Ground Wire

#2/0 AWG, 26", Positive Cable

#2/0 AWG, 20", Negative Cable

(Assembly hardware not shown.)

Figure 1-8

GJ 175F-PCK or the GJ250F-PCK

Charge controllers and other loads may use a CF60 breaker. Ensure the wiring is properly sized according to local codes.

973-0032-01-01 Rev A 1–9

Introduction

CF60 Circuit Breakers

CF-Type (60 amp/160 Vdc Open Circuit) breakers are available at Xantrex for charge controllers and other DC loads. Smaller sizes can be used if properly sized for the load. Smaller breakers can be purchased at the local, electrical supply dealer. Ensure the wiring is properly sized for the breaker according to local code.

Figure 1-9

CF60 Circuit Breaker

CF-Series Breaker Mounting Plate

The CF-Series Mounting Plate (CFMP) replaces the standard 3GJ/6CF Mounting Plate already in the DCCB-L and provides spaces for up to 10 CF-Series breakers.

Figure 1-10

CF-Series Mounting Plate (CFMP)

Power Distribution Blocks (PDB)

Two Power Distribution Blocks are available for use as a DC positive bus.

PDB-6 PDB-12

Figure 1-11

1–10 973-0032-01-01 Rev A

Power Distribution Blocks

Battery Status Monitor (BSM)

The Xantrex Battery Status Monitor (BSM) (p/n TM500A and TM500A/NS) features six data monitoring functions and three indicators including:

• State of charge/amp-hour content (full or percent of capacity)

• State of charge/voltage (real-time voltage level, historical high and low system voltage)

• Amps (real-time amps, total charging amps, total load amps)

• Amp hours removed

• Days since fully charged

• Cumulative amp hours

• Recharge indicator

• Low-voltage indicator

• Full-charge indicator

The unit is configurable for specific system or application functions such as setting the CHARGED indication parameters, battery capacity, charging efficiency, low-battery warning conditions and a recharge reminder. The BSM can monitor any battery supply from approximately 8 to 65 volts, track energy consumption, and estimate remaining battery life.

Options/Accessories

The BSM operates on 12-, 24-, or 48-volt battery systems (48-volt systems require an optional shunt board--the TM48).

The BSM (TM500A) includes a 500A/50mV shunt.

The BSM (TM500A-NS) does not include the shunt.

Figure 1-12

Battery Status Monitor

The DCCB-L-175/L-250 both include a shunt mounted to the DC negative bus bar. This shunt can be used with the TM500A/NS.

The DCCB-L will require the TM500A (with a shunt).

973-0032-01-01 Rev A 1–11

Introduction

Battery Temperature Sensors

A Battery Temperature Sensor (BTS) is provided with each SW Plus Inverter. A BTS can also be purchased separately for use with the C-Series Multi-function DC Controllers. This sensor can easily be installed in the system to ensure proper charging of the batteries based on temperature. Installing a BTS extends battery life by preventing overcharging in warm temperatures and undercharging in cold temperatures.

If more than one BTS is being used, install them adjacent to each other so that they all detect a common temperature.

Battery Cables

Figure 1-13

Battery Temperature Sensor

Xantrex offers battery cables in a variety of lengths and sizes. Consult your dealer for more specific information on size and length requirements depending on the configuration of your system.

For dual configurations, Xantrex offers two sets of precut cables that are specifically designed to accommodate adding the second inverter.

• The BC-L2-175 provides a pair of #2/0 AWG battery cables.

• The BC-L2-250 provides a pair of #4/0 AWG battery cables.

B A

Posistive Cables are 26" (66 cm)

Negative Cables are 20" (51 cm)

BC-L2-250 shown.

Figure 1-14

1–12 973-0032-01-01 Rev A

Battery Cable Set (BC-L2-250 or BC-L2-175)

DC Negative Bus Bar

Xantrex has custom-designed a DC Negative Bus Bar. The DC Negative Bus Bar (p/n DCBUSBAR) comes with a 500 A/50 mV shunt and is factory-installed in the DCCB-L-175 and DCCB-L-250. It can also be purchased separately and fieldinstalled at a later time, either to convert a single DCCB-L into a dual-RE configuration or to add to a DCCB-L (basic model).

1 1/2" (1.27 cm)

A A A

7" (17.78 cm)

AAAA

C C C C C

Options/Accessories

Figure 1-15

DC Negative Bus Bar

Important:

provided with this kit needs to be color-coated for code compliance, electrical tape or nonconductive paint may be used.

#1/4-20 stainless steel, hex head, cap screws with stainless steel flat washers.

#5/16-18 stainless steel, hex head, cap screws with stainless steel flat washers

#10-32 threaded holes

500 A/50 mV Shunt

Standoff with #1/4-20 screw and washer

The standoff provided in this kit is only available in red. If the standoff

973-0032-01-01 Rev A 1–13

1–14

Installation

Chapter 2, “Installation” provides installation and wiring instructions for the Sine Wave Plus Long DC Conduit Box (DCCB-L).

The following topics are covered in this chapter.

For this topic: See...

“Preparing for the Installation” page 2–2

“Pre-installation” page 2–3

“Mounting” page 2–8

“Installing Accessories” page 2–11

“Wiring - General” page 2–16

“Wiring - Specific” page 2–27

“Single Inverter System” page 2–27

“Single Inverter System with Renewable Energy” page 2–28

“Dual Inverter System with Renewable Energy” page 2–29

“Dual Inverter System with Multiple Renewable Energy”

page 2–30

Installation

Preparing for the Installation

Code Compliance

Governing installation codes vary depending on the location and type of installation. Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System Installers to ensure adherence to the local and national electrical codes applicable in your application.

Important:

starting this installation.

Be sure to obtain the appropriate permits, if necessary, prior to

Installation Tools and Materials

Tools Required The following tools may be required for installing this equipment.

❐ Wire strippers ❐ Assorted open-end wrenches or socket wrench and fittings ❐ Torque wrench ❐ Electrical tape ❐ Multimeter (AC/DC volts, frequency) ❐ Assorted Phillips screwdrivers ❐ Slotted screwdriver ❐ Level ❐ Utility knife

Hardware / Materials Required

The following materials may be required for completing this installation.

❐ Conduits (flexible conduit recommended), bushings, and appropriate fittings

for wire runs. See “Service Planning” on page 2–3.

❐ DC fuses and/or DC disconnects ❐ Electrical wire of appropriate size and length and wire nuts ❐ Battery cables and battery cable lugs (depending on the type of battery

cables used)

❐ Breaker panel(s) ❐ Power Distribution Block (optional) ❐ Ground busses, bars, and/or rods ❐ Six appropriately sized wood screws and/or lagbolts and washers (for

plywood mounting)

2–2 973-0032-01-01 Rev A

Pre-installation

WARNING: Shock Hazard

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. A warning label is provided to inform all personnel that multiple sources of power are available inside. This label should be installed on the outside cover to be clearly visible. Ensure all sources are OFF or disconnected before servicing.

Location

Service Planning

WARNING

PN 3550

ELECTRICAL SHOCK

HAZARD

THIS ELECTRICAL SYSTEM IS EQUIPPED WITH A DC TO AC P O WE R INV ERTE R. DISCO NNE CT THE

DC AND AC SOURCES BEFORE SERVICING.

Figure 2-1

Be sure to allow sufficient space for the Long DC Conduit Box to be mounted directly adjacent to the inverter’s DC side. Be sure to leave room for expansion if necessary. Also consider the additional weight and ventilation space requirements of the Long DC Conduit Box and another components (such as the ACCB-L) that will be mounted with the SW Plus Inverter.

If for any reason the inverter may need service or needs to be removed from the position where it’s mounted, the following recommendations should be considered to make this task easier.

Warning Label

To make servicing the inverter easier to accomplish:

• Use flexible conduit.

• When mounting the components such as the ACCB-L or DCCB-L next to the inverter, bias the mounting screws away from the inverter. This will allow "sliding" room within the mounting holes, so that the ends can slide apart without being removed from their mounted position.

Figure 2-8, “Mounting the Long DC Conduit Box and the Sine Wave Plus Inverter Charger on Plywood” on page 2–10 for details.

973-0032-01-01 Rev A 2–3

Installation

Ventilation Requirements

Minimum clearance for ventilation around Long DC Conduit Box must be at least 12 inches (305 mm) at the end and at the top. The minimum clearance is needed to prevent recirculating hot air from the inverter’s exhaust (DC side) from going back into the inverter’s intake (AC side).

Please refer to the Sine Wave Plus Inverter/Charger Owner’s Guide for additional location considerations.

12” (305 mm) Minimum Required

Figure 2-2

Shock Hazard Warning Label

Space and Clearance Requirements

WARNING

ELECTRICAL SHOCK

HAZARD

THIS ELECTRICAL SYSTEM IS EQUIPPED WITH A DC TO AC POWER INVERTER. DISCONNECT THE DC AND AC SOURCES BEFORE SERVICING.

PN 3550

12” (305 mm) Minimum Required

2–4 973-0032-01-01 Rev A

Removing and Replacing the Long DC Conduit Box Cover

Remove the top cover to install additional breakers and to connect the DC wiring of the inverter to the Long DC Conduit Box.

Remove these 3 #8 phillips screws from the top of the cover.

Slide these 3 cover tabs into the cover slots on the SW Plus Inverter.

Pre-installation

Replace these screws and torque to 19-21 in lbs.

Only remove this screw if you are going to install a Battery Status Meter.

Slide these 3 cover tabs into the cover slots on the 2nd SW Plus Inverter (if used).

Figure 2-3

Remove these 8 #12 phillips screws from the front of the cover.

Replace these screws and torque to 26-28 in lbs.

Remove these 3 #8 phillips screws from the bottom of the cover.

Replace these screws and torque to 19-21 in lb

Removing and Replacing the Long DC Conduit Box Top Cover

973-0032-01-01 Rev A 2–5

Installation

Installing or Removing the Blockoff Plates

The unit is shipped with both upper and lower blockoff plates installed. If you are installing a single-inverter system, remove the upper blockoff plate only. If you are installing a dual-inverter system, then remove the lower blockoff plate as well.

If a TX Autotransformer will be installed, then remove the rectangular knockout in the lower blockoff plate, but leave the blockoff plate installed. The two bottom screws that hold the lower blockoff plate may need to be removed to ensure a tight fit between the TX and Long DC Conduit Box.

Store the blockoff plates (if removed) in a safe place, where they can be easily retrieved and reinstalled in the event that the inverter is removed for service. This will prevent accidental contact with potentially live and lethal circuits.

WARNING: Shock Hazard

Be sure to disconnect all DC and AC power before removing the inverter and installing the blockoff plate.

Align holes on Blockoff Plate behind the mounting holes provided on the Long DC Conduit Box

Secure with hardware provided.

Figure 2-4

2–6 973-0032-01-01 Rev A

The Blockoff Plates on the Long DC Conduit Box

Knockout Preparation

Knockout preparation should be done before mounting either the inverter or the Long DC Conduit Box.

To prepare the knockouts:

1. Remove the appropriate knockouts from the Long DC Conduit Box for wire

2. If additional CF- or GJ-type circuit breakers are to be added to the Long DC

3. Ensure that there are no metal shavings in the Long DC Conduit Box or

4. Install bushings in knockouts to protect the wires from damage.

Pre-installation

runs from the battery bank, Renewable Energy sources and/or DC Generator, and Multi-function DC Charge Controllers (if used).

Conduit Box, remove one knockout on the circuit breaker mounting plate for each additional circuit breaker to be installed.

inverter before proceeding with the rest of the installation.

3/4 and 1” Dual Knockouts (x4)

(two are not visible behind BSM mounting box in this illustration)

2” Knockouts (x2)

Knockout panel for CF- or GJ-type breakers

2 and 2 ½” Dual Knockouts (x2)

3/4 and 1” Dual Knockouts (x3)

Bottom

Important:

If larger knockouts are required, an electricians knockout punch

may be used for larger size knockout holes if necessary.

Base

Outside Wall

2” Knockouts (x3)

Lower

Blockoff Plate

One Rectangular

Knockout only

Top

3/4 and 1” Dual Knockouts (x13)

Figure 2-5

½” Knockout (x3)

2 and 2 ½” Dual Knockouts (x2)*

2” Knockouts (x1)*

3/4 and 1” Dual Knockouts (x5)

Knockout Locations on the Long DC Conduit Box

*The 2” Knockouts on the outside wall are spaced 1 5/8” off the mounting surface (wall). This allows the use of 1 5/8” conduit mounting strut (aka Unistrut) to provide secure mounting for the large battery cable conduits. If using the XBP, a 1” spacer will be required.

973-0032-01-01 Rev A 2–7

Installation

Mounting

The Long DC Conduit Box is designed to mount directly to the DC side of a SW Plus inverter. The SW Plus inverter can weigh up to 136 lbs (62 kg). The DCCBL weighs up to 17 lbs (8 kg). Ensure the supporting surface is strong enough to hold twice the total weight being installed. Remember to include the weight of any other accessory, such as the AC conduit box and/or controllers, when considering the strength of the support surface.

Xantrex provides a steel back plate (XBP) that provides the additional support. A sheet of 3/4" plywood could also provide adequate support.

Mounting the Long DC Conduit Box on the Xantrex Back Plate (XBP)

A two-piece steel, back plate is available for providing extra support to the mounting surface. The back plate comes with mounting hooks that can be attached to the panel to hang the components on as they’re installed. If two Long DC Conduit Boxs are to be installed, an additional back plate (XBP-DC) is available to provide the extra support required.

Pass through holes for conduits running through the back of the back plate

Hand Holds for installing

Pass through holes for conduits running through the back of the back plate

Figure 2-6

XBP Left Side

The XBP Back Plate

To mount the Long DC Conduit Box on the Back Plate (XBP):

1. Install the mounting hook (if used) onto the back plate in the position indicated in Figure 2-6.

2. Mount the back plate according to the instructions provided with the XBP Installation Instructions.

46”

(117 cm)

XBP Right Side

Mounting Hook for 1st DCCB-L

XBP-DC

13 1/2”

(34 cm)

Mounting Hook for 2nd DCCB-L

35”

(89 cm)

Side View

2–8 973-0032-01-01 Rev A

Mounting

3. Lift the inverter and place the mounting rail holes directly over the mounting hooks on the panel and lower into place.

4. Next, lift the Long DC Conduit Box and place it over the mounting hook for the DCCB-L and into the hole on the mounting rail.

Important:

rails. If you can not see the hooks, the unit is not installed properly and will not be secure to the wall.

5. Secure the inverter to the panel using the ten of the ¼-20 phillips screws provided with the back plate hardware kit. Torque to 76 in-lbs.

6. Push the Long DC Conduit Box as close to the inverter as it will possibly go and secure it to the panel using four of the ¼-20 phillips screws provided with the back plate hardware kit. Torque to 76 in-lbs.

IMPORTANT: Be sure to consult local electrical and building codes for additional mounting requirements.

Mounting hook from backplate for Long DC Conduit Box

Ensure the mounting hooks are visible through the holes in the mounting

Be sure the mounting hooks are visible in the mounting rail holes

Secure the inverter and Long DC Conduit Box to the backplate with twelve ¼-20 phillips screws provided with the back plate.

Figure 2-7

Mounting the Long DC Conduit Box and the SW Plus Inverter Charger on the XBP

973-0032-01-01 Rev A 2–9

Installation

Mounting on Plywood

To install the Long DC Conduit Box on plywood:

1. Mount the inverter into place and secured with appropriate lag bolts.

2. Line up the Long DC Conduit Box at the DC end of the inverter, so that the

3. Secure the Long DC Conduit Box in place with six #10 wood screws of an

4. Leave the top cover off the Long DC Conduit Box to proceed with wire

mounting rails are aligned together and the Long DC Conduit Box base is as close to the inverter as possible. The gap between the Long DC Conduit Box and the inverter should be no more than 1/16 inch.

appropriate length (or lag bolts) in the six mounting and keyhole slots on the mounting rails of the Long DC Conduit Box. Bias the screws away from the inverter.

connections.

Mounting Rails

Mounting holes and keyhole slots for Long DC Conduit Box

Long DC Conduit Box Base with top cover removed

Bias the screws (top and bottom) away from the inverter for easier removal if necessary

Mounting holes and keyhole slots for Long DC Conduit Box

Figure 2-8

2–10 973-0032-01-01 Rev A

Mounting the Long DC Conduit Box and the Sine Wave Plus Inverter Charger on Plywood

Installing Accessories

Additional components may be required depending on the desired installation. Be sure to consult NEC/CEC regulations to ensure all installations meet code requirements.

GJ-Series Breakers Space is provided for up to three GJ-Series Breakers for over-current protection.

Use either regular GJ-Series or GJ F-Series depending on the type of lugs used on the battery cables.

Flag Terminals If more than one GJ F-Type breaker is being used, they can be tied together using

the dual-pole or triple-pole flag terminals. Regular GJ breakers can not use flag terminals.

Both kinds of breakers can be used as a disconnect and/or an over-current device for the inverter(s) and the optional PDBs.

PVGFP-CF or CF60 Space is provided for up to six additional CF-Series Breakers for PV ground fault

protection (PVGFP-CF) or load protection (CF60).

To mount the GJ-Series or CF-Series Breakers:

1. Place the circuit breaker behind the mounting plate in the position of the knockout that was removed.

2. Align the hole of the circuit breaker with the hole in the mounting plate.

3. Insert the mounting screw from the front of the mounting plate. Tighten to the torque value indicated on the side of the breaker.

Power Distribution Blocks (PDB)

CF Mounting Plate (CFMP)

Important:

the Breaker Mounting plate.

Ensure the position of the breaker lines up with the knockout removed in

CAUTION: Fire Hazard

Ensure the size of the breaker meets NEC/CEC requirements and is not oversized for the wire/cable used.

Install the PDB (if used) on the back wall of the Long DC Conduit Box chassis. Mounting holes are provided. PDBs are available in 6:1 and 12:1 sizes.

A separate mounting plate can be used if only CF breakers will be used. This mounting plate has 10 positions for CF-type Breakers. The CF Mounting replaces the existing mounting plate in the chassis.

To install the CFMP:

1. Remove the four nuts on the mounting screws holding the original mounting plate in place. See Figure 2-10 on page 2–12.

2. Slide the original mounting plate toward the back of the chassis away from the screws and remove it.

3. Slide the new CFMP into place and replace the nuts.

4. Tighten to 31 in-lbs.

973-0032-01-01 Rev A 2–11

Installation

To install GJ or CF Circuit Breakers:

1. Place the breaker behind the mounting plate.

2. Inserting mounting screws into mounting holes from top, or front, of mounting plate.

3. Tighten to 20-25 in-lb.

Breaker Enlargement

DCCB-L

Figure 2-9

Installing Circuit Breakers on the Long DC Conduit Box

Battery Status Meter

Power Distribution Block

GJ F-type Breakers

Triple Flag Terminal

PVGFP-CF or CF-Type Breakers

(PVGFP-CF -4 shown)

DC Negative Bus Bar and Shunt*

*Tighten the 10-32 phillips screws to 31 in-lbs when field-installing. Callout “C” in Figure 1-15 on page 1–13.

**Tighten the 1/4 x 20 phillips screws to 76 in-lbs when fieldinstalling. Callout “A” in Figure 1-15 on page 1–13.

To install the CFMP:

1. Loosen the four nuts on the mounting

2. Slide the original mounting plate toward

3. Slide the new CFMP into place and

4. Tighten to 31 in-lbs.

screws holding the original mounting plate in place (as shown above).

the back of the chassis away from the screws and remove it.

tighten the nuts.

Figure 2-10

Optional Component Locations on the Long DC Conduit Box

2–12 973-0032-01-01 Rev A

Dual DCCB-L Configurations (DCCB-L-RE)

If additional breakers or other accessories are needed, dual-DCCB-Ls can be installed and organized into a DCCB-L-RE configuration. The DCCB-L-RE is a CSA approved, field-installable configuration when used with the factory installed hardware and wiring, and optional hardware as shown in Table 1-1. In this configuration, some hardware components may need to be installed, or mounted, onto the second Long DC Conduit Box prior to wiring. The following section provides a basic list of additional hardware that may be needed. Consult the local codes for specific requirements.

Dual DCCB-Ls

Important:

The components shown in this section are approved by CSA to be used in a DCCB-L-RE configuration. Other components may be used, but may not allow continuous, full power, operation of the inverter and should be approved by the AHJ.

Dual Configurations can be created from the following combinations of DCCB-L models:

• two DCCB-L Basics

• one DCCB-L-175 (or L250) and one DCCB-L Basic

• one DCCB-L-175 (or L250) and one DCCB-L-175 (or L-250)

If creating a dual-configuration with two DCCB-Ls (basic models), the following components can be added.

Circuit Breakers

Up to three GJ circuit breakers and six CF-type circuit breakers can be installed using the standard breaker mounting plate. Bond the larger

GJxxxF breakers together with the dual or triple flag terminals as required.

Power Distribution Block(s) (PDB)

Space is provided for a PDB-6 or a PDB-12, if needed.

CF Mounting Plate (CFMP)

The standard breaker mounting plate can be replaced with the CFMP. This provides space for up to 11 CF-type breakers. Remove the appropriate number of knockouts and install the desired number, type(s) and size(s) of breaker(s) on the CFMP.

A DC Negative Bus Bar can be added for Negative Bonding.

Negative Bonding Jumper

A battery cable (BC 1.5-2/0 or BC1.5-4/0) can be installed on the negative bus bar to tie the two bus bars together. Cable size will depend on the overall size of the system to be installed.

DCCB-L

Figure 2-11

DCCB-L

Creating a DCCB-L-RE Configuration from Dual DCCB-Ls

973-0032-01-01 Rev A 2–13

Installation

Dual DCCB-L-175s (or L-250s)

It is also possible to add a second DCCB-L-175 or DCCB-L-250 to the end of an existing DCCB-L-175 or DCCB-L-250 to create the dual DC end shown in Figure 2-12. Minor reconfiguring of the factory installed 175A or 250A breaker and associated cables will be necessary.

To prepare the second DCCB-L-175 (or DCCB-L-250) for use as the second DC end, the following steps will be necessary.

1st DCCB-L-175 (or L-250)

2nd DCCB-L-175 (or L-250)

To convert a DCCB-L-175 or DCCB-L-250 to a Dual Configuration:

1. Remove the DC breaker, positive cable, and negative cable from the second DC end.

2. If more than 6 CF breakers are needed in the second DC end, remove the original GJ/CF breaker mounting plate in the second DC end

and replace it with a CFMP.

3. Install the DC breaker (removed in step 1) in the first DC end adjacent to the inverter breakers. This new breaker will be used as the DC main bus overcurrent device/disconnect for charge controllers, other DC sources, and DC loads.

4. If needed, install a Power Distribution block

(PDB-6 or PDB-12) in the second DC end.

5. Connect the DC positive cable (removed during

step 1) to the DC main bus breaker (installed in step 3) and connect it to the PDB (Installed in step 4). Note: one end of the cable will need to

be cut to length to fit into the PDB and a 2" chase bushing will be needed.

6. Use the negative cable (removed during step 1)

as the negative bonding jumper between both DC negative bus bars in each DC end. Note:

This cable can be used “as is” or cut to the required length if the appropriate crimper/lug is available or a Xantrex 18” cable may be purchased (p/n BC1.5B-2/0 or BC1.5B-4/0). A 2" chase bushing will also be needed.

7. Connect the #4 AWG ground wire from the

second DC end equipment grounding bar to the first DC end equipment grounding bar.

Figure 2-12

Creating a DCCB-L-RE Configuration from two DCCB-L-175 (or L-250)

2–14 973-0032-01-01 Rev A

Charge/Load Controllers

Each Long DC Conduit Box accommodates up to two C-Series Multi-function DC controllers on the top of it’s chassis. If installing charge or diversion load controllers, install them at this time according to the manufacturer’s instructions.

If using C-Series Multi-function DC Controllers, the CC PCK provides the necessary bushings, conduit, and wiring to install one controller.

Mount up to 2 Charge/Diversion Load controllers on the top of each Long DC Conduit Box.

Charge/Load Controllers

Figure 2-13

973-0032-01-01 Rev A 2–15

Adding Charge or Diversion Load Controllers on the Long DC Conduit Box

Important:

model) may restrict airflow enough to cause the inverter to over-heat. Only use two charge controllers (maximum 60 amps DC each) per DCCB-L (any model). Installing more than two charge controllers per DCCB-L is not approved by CSA.

Installing more than two charge controllers in the same DCCB-L (any

Installation

Wiring - General

WARNING: Shock Hazard

Although the DC electrical system may be “low voltage”, significant hazards may still be present, particularly from short-circuits of the battery system. Inverter systems, by their nature, involve power from multiple sources (e.g., inverter, generator, utility, batteries, and solar arrays) that add hazards and complexity that can be very challenging.

CAUTION

The battery negative connection is only grounded at one point. This is usually the chassis bonding lug to the DC negative bus or bonded using the PVGFP-CF assembly.

CAUTION: Equipment Damage

When making your DC connections, ensure there is nothing between the cable terminal/ lug and the terminal surface (i.e., washers, anti-oxidant paste etc.). Overheating of the terminal may occur.

Grounding the Long DC Conduit Box

The Long DC Conduit Box is used to ground the DC system. The purpose of grounding is to maintain all DC equipment at the same “ground” potential to avoid a shock hazard. It also provides a low impedance connection to shunt fault currents to earth.

The following points should be taken into consideration when planning how to properly ground the DC system, whether or not you’re installing a new system or integrating new parts into an older system.

• DC Equipment Grounding

• Bonding DC Negative to Ground

• Connecting to the Primary grounding system

• Connecting DC and AC electrical system grounds together

Important:

installations must comply with national and local codes and ordinances. Consult local and/ or national codes to ensure that proper grounding techniques are being employed and that the desired installation will meet all the code requirements when inspected. It is the responsibility of the installer to ensure the system meets all electrical codes for that jurisdiction. The following information is provided as a guide and is not intended to override applicable codes/requirements.

The grounding requirements vary by county and by application. All

2–16 973-0032-01-01 Rev A

Wiring - General

Important:

which is the normal configuration in most DC systems. If your system requires a positive ground, the information below will differ on what conductors are grounded and which are not. Consult the NEC/CEC regulations for positive grounding requirements.

DC Equipment Grounding

All DC components that have non-current carrying exposed metal parts require appropriate grounding. The Long DC Conduit Box provides the DC ground bar which will allow you to connect all the exposed metal chassis of the various DC components to the same point. The DC equipment will need to be connected to the DC ground bar using appropriately sized wires, referred to as equipment grounding conductors. Connecting these equipment grounding conductors to the DC ground bar will tie them together at the same voltage potential and provide a path to ground through the grounding electrode conductor. This reduces the possibility for electric shock and also provides a path for fault currents to flow through to blow fuses or trip circuit breakers. If two Long DC Conduit Boxes are used, ensure both DC ground bars are connected together using an appropriately sized equipment grounding conductor.

Equipment Grounding Conductor size

The equipment grounding conductor must have adequate ampacity and low enough impedance to cause the overcurrent device (fuse or circuit breaker) to open on the supply side in case an ungrounded conductor comes in contact with any exposed metal part of the DC system or equipment.

The information in this section is based on a negative grounded DC system

In the United States, homes that have roof-mounted photovoltaic arrays are required to have ground-fault protection. In a DC system where there is groundfault protection equipment, the size of the equipment grounding conductor should be coordinated with the size of the over-current devices for the DC equipment involved, as shown in Table 2-1. This table determines the minimum wire size of copper conductor you require, which is based on the size of the circuit breaker protecting the equipment that you are using in the DC system. This table also provides guidance on the torque requirements needed when attaching the corresponding wire to the ground bus bar.

Table 2-1

Battery DC Disconnect Size

60 Amp #10 AWG 35 in-lb

175 Amp #6 AWG 45 in-lb

250 Amp #4 AWG 50 in-lb

Minimum Equipment Ground Wire and DC Disconnect Size Chart

Minimum Size of Copper Ground Wire

DCCB Ground Lug Wire Torque Spec

In DC systems not required to use ground-fault protection equipment, the size of the equipment grounding conductor is required to be sized for 125 percent of the photovoltaic-originated short-circuit currents in that circuit. Consult PV array specifications and the NEC/CEC for proper wire sizes.

973-0032-01-01 Rev A 2–17

Installation

Important:

size (i.e. voltage drop, increased surge requirements), the DC Equipment Grounding Conductors shall be increased in size proportionately according to circular mil area of the ungrounded conductors.

Per the NEC, where ungrounded conductors (DC Positive) are increased in

Bonding DC Negative to Ground

The current carrying grounded conductors (DC negative) and the Equipment Grounding Conductors (green ground wires, equipment grounds) shall be tied or “bonded” together at a single point in the DC System. This connection is made with an appropriately sized wire as shown on Figure 2-15 on page 2–21, referred to as the Main Bonding Jumper. When an ungrounded conductor (DC positive) touches the grounding system, current will flow to the common grounding point (DC Ground Bar) through the Main Bonding Jumper to the grounded conductor (DC negative) and back to the source. This will cause the over-current protection device to open, which will stop the flow of current, protecting the system. In DC systems where there is a requirement to have a ground-fault protection device (PVGFP-CF) as shown on Figure 2-14 on page 2–20, it will effectively be the single point connection between the DC negative and the common grounding point (DC Ground Bar). In this application, if a DC ground-fault is detected, the ground-fault protection device will open and switch the grounding system from a low impedance, DC negative-to-ground bond to a high-impedance bond that will limit fault currents to a safe level.

Bonding location This single connection point or DC negative to ground “bond” is usually located

in the over-current protection device enclosure (Long DC Conduit Box). The DC bond should not be done at the inverter. Codes do not generally allow this because the inverter is considered a “serviceable” item that may be removed from the system, in which case, the ground bond would be broken.

Size of the bonding jumper

For DC systems, the size of the bonding jumper that is used to bond the DC negative to the DC ground bar shall not be smaller than the size of the DC grounding electrode conductor used, which is the conductor that connects the DC ground bar to the primary system ground.

Connecting to the Primary System Ground

The common grounding point (DC Ground Bar) in the Long DC Conduit Box will need to be grounded to the Primary System Ground. The Primary System Ground is normally referred to as the grounding electrode or rod and usually is a copperplated rod usually 5/8 inch round by 8 feet long and driven into the earth. It is also common to use copper wire placed in the concrete foundation of the building as a grounding system. Either method may be acceptable, but the local code will prevail. Connection to the Primary System Ground (ground rod/grounding electrode system) from the DC Ground Bar is done by the DC Grounding Electrode Conductor. The DC Grounding Electrode Conductor normally only carries current when there is a ground fault.

2–18 973-0032-01-01 Rev A

Wiring - General

DC Grounding Electrode Conductor Size

The size for the DC Grounding Electrode Conductor when it is the DC systems sole connection to the Primary System Ground is not required to be larger than 6 AWG copper wire. It is recommended that the size of the DC Grounding Electrode Conductor should be larger than the NEC/CEC minimum requirements when installing power sources such as inverter/chargers, generators or for lightning protection.

WARNING: Explosion Hazard

Under no circumstance should a gas pipe or gas line be used for grounding purposes.

Connecting DC and AC Electrical System Grounds Together

Inherently, Xantrex inverter systems have two separate electrical systems, a DC system and an AC system. This means the grounding consideration for both systems need to be accounted for and that the two electrical systems should be connected to a grounded, permanent wiring system with the AC and DC grounds common to each other.

The NEC has provided two requirements, either using a single grounding electrode or using multiple grounding electrodes, when both DC and AC electrical systems are together:

1. Single grounding electrode: The DC grounding electrode conductor and AC grounding electrode conductor will be connected to a single grounding electrode. or,

2. Multiple grounding electrodes: The DC grounding electrode conductor will be connected between the DC grounding point to a separate DC grounding electrode. The DC grounding electrode will be connected to the AC grounding electrode to make a grounding electrode system. The conductor that connects the two ground electrodes will be no smaller than the largest grounding electrode conductor used – either AC or DC.

973-0032-01-01 Rev A 2–19

Installation

Figure 2-14

2–20 973-0032-01-01 Rev A

Grounding Using PVGFP-CF

Wiring - General

Figure 2-15

973-0032-01-01 Rev A 2–21

Grounding Without PVGFP-CF

Installation

Over-current Protection

For safety and compliance with regulations, battery overcurrent protection is required. Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability.

Table 2-2

Recommended Battery Cable Size Versus Length

Maximum

Inverter Model

Continuous DC amps

2524 134 167 #2/0 AWG

2548 67 84 #2/0 AWG

4024 214 267 #4/0 AWG

4048 107 134 #2/0 AWG

5548 147 184 #4/0 AWG

a. “Maximum Continuous DC amps”, as shown in this table, is based on low

battery voltage with an efficiency of 85%.

b. “NEC amps”, as shown in this table, is based on low battery voltage, an

efficiency of 85%, and a 125% NEC derating.

NEC

amps

Up to 5 Feet

One-way

(67.4 mm

(107 mm

(67.4 mm

(107 mm

)

Up to 10 Feet One-way

#4/0 AWG

(107 mm2)

#4/0 AWG

(107 mm2)

#4/0 AWG x 2

(107 mm2 x 2)

#4/0 AWG

(107 mm2)

#4/0 AWG x 2

(107 mm2 x 2)

Up to 15 Feet One-way

Not Recommended

#4/0 AWG x 2

(107 mm2 x 2)

Not Recommended

After selecting battery cables based on the distance from the battery bank to the inverter, add battery overcurrent protection in the battery cable line, based on Table 2-3. This table will help you to determine your maximum breaker/fuse size based on the cable size you selected previously.

Table 2-3

Cable Size Required

#2/0 (00) AWG 175 Amps 175 Amps 265 Amps

#4/0 (0000) AWG 250 Amps 250 Amps 360 Amps

Battery Cable to Maximum Breaker/Fuse Size

Maximum Rating in Conduit

a. The term “free air” is defined by the NEC/CEC as cabling that is not

enclosed in a conduit or a raceway. Cables enclosed in conduit or raceways have substantially lower continuous current carrying ability due to heating factors.

b. The NEC/CEC allows rounding to the next highest standard fuse size

from the cable rating (i.e., 150 amp cable size rounds up to a standard 175 amp size).

Breaker/Fuse

Size

Rating in “Free Air”

Maximum Breaker/Fuse

Size

300 Amps

400 Amps

2–22 973-0032-01-01 Rev A

Master DC Disconnect

The DCCB-L has been designed for the use of a DC main breaker as a master disconnect for charge controllers, DC loads, and other DC sources. The same disconnect(s) used for the inverter(s) should not be used as a controller and/or DC load disconnect. Instead, an independent disconnect for a DC bus is recommended to allow controllers and/or DC loads to operate when an inverter has been disconnected or vise versa (see Figure 2-21 on page 2–30).

A CF60 may be used as a 60A DC bus disconnect using a 1" breaker slot and a GJ175F or GJ250F can be used as a 175A or 250A DC bus disconnect using a

1.5" breaker slot. The use of a main DC disconnect can help comply with the intent of the NEC’s "six hand throw requirement" to disable an electrical system within six motions of the hand.

Some wind and water turbines, along with their controllers, may need to be wired directly to the battery bank or on a dedicated line to prevent from being inadvertently disconnected and causing a damaging, over-speed condition. Consult your turbine manufacturer's instructions for a wiring schematic and to determine if the turbine is fail-safe with loss of connection to the battery.

Wiring - General

CAUTION: Equipment Damage

Do not allow any device to be wired so that an inverter will be exposed to the open circuit voltage if any disconnects are opened. If the voltage is high enough it may damage the inverter and would not be covered under warranty.

973-0032-01-01 Rev A 2–23

Installation

Additional Over-current Protection

Depending on individual installation requirements, additional over-current devices (fuses or circuit breakers) may be desirable and/or required. The GJ F breakers used on DCCB-L models can be used both as a disconnect and an overcurrent device if inverter is overloaded or has an internal fault. However, additional over-current devices may be required.

Near battery bank The GJ F breakers will not provide over-current protection if there is a wiring

fault between the battery bank and the breaker(s). It may be desirable to add an over-current device adjacent to the battery bank positive terminal particularly if metallic (conductive) conduits are used. Non-metallic (PVC etc.) conduits may negate this risk and need.

When using triple flag terminals

Large Loads or Diversion Loads

Charge Controllers Charge controllers should be connected to a dedicated breaker that will allow

When using the triple flag terminals for the GJ F breakers, additional steps may be required to prevent over loading of the battery cables in the event of one cable is removed or becomes inadvertently disconnected. Use of the triple flag terminal on dual inverters will functionally "parallel" the battery cable conductors. This is permitted by the NEC 310.4 for cable 1/0 and larger. Specialized lugs are required to connect multiple parallel conductors into a common single conductor.

In addition, the dual-pole and triple-pole flag terminals when used on systems with large diversion loads and/or DC loads with inverters operating at full load could theoretically exceed the rated capacity of the conductors between the battery bank and the dual-pole or triple-pole flag terminal attached on the GJ F breakers thus requiring an additional over-current device. If the battery bank can not provide this level of current (+500 Adc for #4/0 AWG cable) for a theoretical continuous load (greater than 3 hours), then a over-current device sized specifically for the paralleled cable assembly may not be required.

them to function while the inverter breaker is in the off position. Connecting the "battery terminal" on charge controllers to the inverter side connection of a GJ F breaker will operate but is not recommended.

2–24 973-0032-01-01 Rev A

Battery Cable Connection

Connect the battery cables for a single-inverter system as shown in Figure 2-16.

Wiring - General

Important:

battery cables) to be marked with white tape or heat shrink on their ends to visibly show correct polarity to prevent reverse polarity and shorting.

NEC requires all grounded conductors larger than #6 AWG (such as

Figure 2-16

973-0032-01-01 Rev A 2–25

Battery Connections for a Single-inverter System

Installation

Connect the battery cables for a dual-inverter system as shown in Figure 2-17.

Important:

battery cables) to be marked with white tape or heat shrink on their ends to visibly show correct polarity to prevent reverse polarity and shorting.

NEC requires all grounded conductors larger than #6 AWG (such as

Figure 2-17

2–26 973-0032-01-01 Rev A

Battery Connections for a Dual-inverter System

Wiring - Specific

The following four diagrams illustrate how to make all the ground connections, battery connections, controller connections, and renewable energy connections for the basic configurations. They include:

• Single inverter systems with no renewable energy

• Single inverter systems with renewable energy

• Dual inverters with renewable energy

• Dual inverters with multiple renewable energy.

These diagrams are basic examples only and may vary depending upon your specific installation. Ensure appropriate local electrical codes are followed at all times.

Single Inverter System

The following example diagram illustrates the proper DC wiring for a basic, single-inverter system.

Wiring - Specific

Figure 2-18

973-0032-01-01 Rev A 2–27

DC Wiring for a Single Inverter System

Installation

Single Inverter System with Renewable Energy

The following example diagram illustrates the proper DC wiring for a single inverter system with renewable energy.

Figure 2-19

2–28 973-0032-01-01 Rev A

DC Wiring for a Single Inverter System with Renewable Energy

Dual Inverter System with Renewable Energy

The following example diagram illustrates the proper DC wiring for a dual inverter system with renewable energy.

Wiring - Specific

Figure 2-20

973-0032-01-01 Rev A 2–29

DC Wiring for a Dual Inverter System with Renewable Energy

Installation

Dual Inverter System with Multiple Renewable Energy

The following example diagram illustrates the proper DC wiring for a dual inverter system with dual DCCB-Ls and multiple renewable energy.

Figure 2-21

2–30 973-0032-01-01 Rev A

DC Wiring for a Dual Inverters, Dual Long DC Conduit Box System with Multiple RE

Additional Accessory Wiring

Install additional accessories at this time, such as the Battery Status Monitor (BSM) (p/n TM500A and TM500A-NS) and Battery Temperature Sensors.

Battery Status Monitor (BSM) (p/n TM500A or TM500A-NS)

To install the BSM on the Long DC Conduit Box:

1. Remove the cover plate from the BSM Mounting Box.

2. Install the shunt board from the BSM to the shunt in the DCCB-L.

3. Secure the BSM to the mounting box.

4. Connect the BSM communications cable to the back of the BSM.

5. Connect the other end of the BSM communications cable to the port on the shunt.

Wiring - Specific

Remove the phillips screw to remove

cover plate from the mounting box.

Install the 2 amp, 250 Vac, 3AG style in-line fuse that’s provided with the BSM.

Install the shunt board from the BSM

to the shunt in the DCCB-L.

Plastic Push

Rivets (4x)

BSM Mounting Bracket

Figure 2-22

Enlargement of Back of BSM

Installing the BSM on the Long DC Conduit Box

See the Installation and Operator’s Guide for the BSM (TM500A) for additional information.

Place the mounting bracket over the

mounting box and secure with the four plastic push rivets provided with the Long DC Conduit Box. The rivets will snap into place when pressed into the holes.

Install the bushing provided in the hole in the mounting box to protect the communications cable.

Connect the J1 communications cable to the back of the BSM and route it through the hole in the back of the mounting box.

Place the faceplate of the BSM over the mounting bracket and snap into place.

Route the other end of the communi-

cations cable to the current shunt board installed on the DC negative bus bar.

973-0032-01-01 Rev A 2–31

Installation

Charge Controller Wiring using the C-Series Multifunction DC Controller and the CC PCK

The Charge Controller add-on package (CC PCK) includes the following hardware to facilitate wiring one C-Series Multifunction DC Controller to the Long DC Conduit Box:

• two conduit chase nipples, two lock nuts, and two plastic bushings for 1" knockouts,

• one 48-inch white #6 AWG wire (temperature rated at 90° C),

• one 96-inch red #6 AWG wire (temperature rated at 90° C), and

• one 48-inch green #10 AWG wire (temperature rated at 105° C).

Follow the procedure below to prepare the units and install the wires.

To prepare the units for wiring:

Remove two 1” knockouts in the bottom of the

controller. (Step not shown in illustration).

Remove two corresponding 1” knockout s in the top of the DCCB-L (Step not shown in illustration).

Align the knockouts in the controller over the

knockouts in the DCCB-L and install the conduit chase nipples, bushings, and lock nuts. (Step not shown in illustration).

Cut the 96-inch red #6 AWG wire into two pieces (length to depend on the placement of the circuit breakers). (Step not shown in illustration.)

Overcurrent Protection

Figure 2-23

PV Array/Load Disconnect

Wiring the C-Series Multifunction Charge Controllers to the Long DC Conduit Box

To connect the wiring:

Connect one end of the green ground wire (#10 AWG) to the chassis ground in the controller. Route the other end to the DC ground bar in the DCCB-L.

Connect one end of the white wire (#6 AWG) to one of the common negatives in the controller. Route the other end to the DC Negative Bus Bar.

Connect one of the pieces of red #6 AWG wire to the Battery Positive terminal in the Controller and the other end to the top of the CF Circuit Breaker for the over-current protection.

Connect the other piece of red #6 AWG wire to the

PV/Load Positive terminal in the Controller and the other end to the top of the CF Circuit Breaker for the PV or Load Disconnect. If PVGFP is required, then substitute the CF Circuit Breaker for the Load with a PVGFP-CF.

Repeat for each controller to be installed.

using the CC PCK

2–32 973-0032-01-01 Rev A

Battery Temperature Sensor

If you have a BTS connected to your battery, then you will need to pass its connecting wire through the Long DC Conduit Box to the DC side of the inverter (see Figure 2-24).

If you have a BTS connected to your C-Series Multi-function DC controller, you can also run that wire through the Long DC Conduit Box.

To run the BTS through the Long DC Conduit Box:

1. Secure the BTS to a battery in the battery box. Connect multiple sensors to one battery in a centralized location that will give the best representation of all the batteries temperatures.

2. Run the BTS cable(s) through the DC cable conduit.

3. Connect the cable(s) to the inverter’s Battery Temperature Sensor Ports or the C-Series Battery Temperature Ports.

See your inverter manual and BTS manual for further information about the installation of this accessory.

Wiring - Specific

Positive (+) Battery Cable Terminal

Figure 2-24

Negative (–) Battery Cable Terminal

Battery Temperature Sensor Port

Chassis Ground Lug

BTS Port locations on the Sine Wave Plus Inverter

Battery Temperature Sensor Port

Figure 2-25

973-0032-01-01 Rev A 2–33

BTS Port locations on the C-Series DC Controller

Installation

Battery Temperature Sensor Cable. Can also be routed to DC Controller.

Figure 2-26

Installing the Battery Temperature Sensor

This completes the basic wiring for the Long DC Conduit Box. Once all wiring is complete, refer to the Sine Wave Plus Owner’s Manual for functional test, configuration, and operational instructions.

2–34 973-0032-01-01 Rev A

Warranty and Return 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 Long DC Conduit Box. This warranty period lasts for two years from the date of purchase at the point of sale to you, the original end user customer. You require proof of purchase to make warranty claims.

This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period. Subsequent owners also require proof of purchase.

What will Xantrex do? Xantrex will, at its option, repair or replace the defective product free of charge,

provided that you notify Xantrex of the product defect within the Warranty Period, and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty.

Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building replacement products. Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement. If Xantrex repairs or replaces a product, its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer, whichever is greater. All replaced products and all parts removed from repaired products become the property of Xantrex.

Xantrex covers both parts and labor necessary to repair the product, and return shipment to the customer via a Xantrex-selected non-expedited surface freight within the contiguous United States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada.

How do you get service? If your product requires troubleshooting or warranty service, contact your merchant. If

you are unable to contact your merchant, or the merchant is unable to provide service, contact Xantrex directly at:

Telephone: 1 800 670 0707 (toll free North America)

1 360 925 5097 (direct)

Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct)

Email: customerservice@xantrex.com

Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired at one of these facilities.

What proof of purchase is required? In any warranty claim, dated proof of purchase must accompany the

product and the product must not have been disassembled or modified without prior written authorization by Xantrex.

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

973-0032-01-01 Rev A WA–1

Warranty and Return

What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the

product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to:

a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either inter-

nally or externally, or damaged from improper use or use in an unsuitable environment;

b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations, or input voltage

that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes;

c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter

"ASCs");

d) the product if it is used as a component part of a product expressly warranted by another manufacturer;

e) the product if its original identification (trade-mark, serial number) markings have been defaced, altered, or

removed.

Disclaimer

Product

THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.

IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT.

Exclusions

If this product is a consumer product, federal law does not allow an exclusion of implied warranties. To the extent you are entitled to implied warranties under federal law, to the extent permitted by applicable law they are limited to the duration of this Limited Warranty. Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you. This Limited Warranty gives you specific legal rights. You may have other rights which may vary from state to state or province to province.

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 LONG DC CONDUIT BOX SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX MEDICAL EQUIPMENT OR DEVICES.

Please note that the Sine Wave Plus Long DC Conduit Box is not intended for use as an uninterruptible power supply and Xantrex makes no warranty or representation in connection with any use of the product for such purposes.

WA–2 973-0032-01-01 Rev A

SINE WAVE PLUS LONG DC CONDUIT BOX IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER

Warranty and Return

Return Material Authorization Policy

Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory "Ship To" address. Products must also be shipped prepaid. Product shipments will be refused and returned at your expense if they are unauthorized, returned without an RMA number clearly marked on the outside of the shipping box, if they are shipped collect, or if they are shipped to the wrong location.

When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be prepared to supply:

• The serial number of your product

• Information about the installation and use of the unit

• Information about the failure and/or reason for the return

• A copy of your dated proof of purchase

Record these details in on page WA–4.

Return Procedure

1. Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging.

2. Include the following:

• The RMA number supplied by Xantrex Technology, Inc. clearly marked on the outside of the box.

• A return address where the unit can be shipped. Post office boxes are not acceptable.

• A contact telephone number where you can be reached during work hours.

• A brief description of the problem.

3. Ship the unit prepaid to the address provided by your Xantrex customer service representative.

If you are returning a product from outside of the USA or Canada In addition to the above, you MUST

include return freight funds and are fully responsible for all documents, duties, tariffs, and deposits.

If you are returning a product to a Xantrex Authorized Service Center (ASC)A Xantrex return material

authorization (RMA) number is not required. However, you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that may apply to that particular facility.

Out of Warranty Service

If the warranty period for your Sine Wave Plus Long DC 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.

To return your Sine Wave Plus Long DC Conduit Box for out of warranty service, contact Xantrex Customer Service for a Return Material Authorization (RMA) number and follow the other steps outlined in “Return Procedure” on page WA–3.

Payment options such as credit card or money order will be explained by the Customer Service Representative. In cases where the minimum flat fee does not apply, as with incomplete units or units with excessive damage, an additional fee will be charged. If applicable, you will be contacted by Customer Service once your unit has been received.

973-0032-01-01 Rev A WA–3

Warranty and Return

Information About Your System

As soon as you open your Sine Wave Plus Long DC Conduit Box package, record the following information and be sure to keep your proof of purchase.

❐ Serial Number ❐ Purchased From ❐ Purchase Date

If you need to contact Customer Service, please record the following details before calling. This information will help our representatives give you better service.

❐ Type of installation (e.g. RV, truck, residential) ❐ Length of time inverter has been installed ❐ Battery/battery bank size ❐ Battery type (e.g. flooded, sealed gel cell, AGM) ❐ DC wiring size and length ❐ Alarm sounding? ❐ Description of indicators on front panel ❐ Appliances operating when problem occurred ❐ Description of problem

_________________________________

__________________________________

______________________________________________________________________________________

WA–4 973-0032-01-01 Rev A

Index

abbreviations and acronyms v Accessories 2–11 Accessory Wiring 2–31 additional accessory wiring 2–33

Battery Status Monitor 2–31 Battery Temperature Sensor 2–33 Battery Temperature Sensor (BTS) 2–33 Blockoff Plates 2–6 Bonding DC Negative to Ground 2–18 Bonding location 2–18

CF Mounting Plate (CFMP) 2–11 CF60 2–11 Charge/Load Controllers 2–15 Connecting DC and AC Electrical System Grounds

Together

Customer Service

preparing to call

2–19

WA–4

DC conduit box

introduction

DC Equipment Grounding 2–17 DC Grounding Electrode Conductor Size 2–19 DCCB-L-RE 2–13 Dual DCCB-L Configurations 2–13

1–2

Information about Your System form WA–4 installation

codes

2–2

knockout preparation 2–7 materials 2–2 tools 2–2

inverter

purchase date serial number WA–4

WA–4

Knockout Preparation 2–7 knockouts

preparation

2–7

Master DC Disconnect 2–23 materials required for installation 2–2 Mounting 2–8

overcurrent protection, requirements 2–22

Power Distribution Blocks (PDB) 2–11 proof of purchase WA–4 purchase date WA–4 PV GFP 2–11

Flag Terminals 2–11

GJ-Series Breakers 2–11 Grounding 2–16

Safety Instructions vii serial number WA–4 Size of the bonding jumper 2–18

TM500A 2–31 TM500A-NS) 2–31 tools required for installation 2–2

Ventilation Requirements 2–4

warranty

out of warranty service terms and conditions WA–1

wiring

additional accessory

WA–3

2–33

Xantrex

web site

IX-2

Xantrex Technology Inc.

1 800 670 0707 Tel. toll free NA 1 360 925 5097 Tel. direct

1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct

customerservice@xantrex.com www.xantrex.com

973-0032-01-01

PC Printed in USA

Xantrex DCCB-L, DCCB-L-175, DCCB-L-250 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual