Xantrex SW4024, SW4048, SW5548 Installation Manual

Installation Guide

Grid Tie Interface (GTI)

SW Series SW4024, SW4048, SW5548

P/N 975-0041-01-02 Rev A 03/02

About Xantrex

Xantrex Technology Inc., is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utilityscale 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

Trace and Xantrex are registered trademarks of Xantrex International.

Notice of Copyright

Disclaimer

While every precaution has been taken to ensure the accuracy of the contents of this guide, Xantrex International assumes no responsibility for errors or omissions. Note as well that specifications and product functionality may change without notice.

Since the use of this manual and the conditions or methods of installation, operation, use and maintenance of the unit are beyond the control of Xantrex Technology Inc., the company does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or any way connected with such installation, operation, use, or maintenance.

Due to continual improvement through product updates, photographs and/or illustrations used in this manual may not

exactly

match your unit. Xantrex Technology Inc., reserves the right to update this product without notice or releasing an updated manual when

fit, form or function

are not affected.

Date and Revision

March 2002, Revision A

Part Number

975-0041-01-02

Contact Information

Web: www.xantrex.com

Email: dpm@xantrex.com

Phone: 360/435.8826

Fax: 360/435.2229

P/N 975-0041-01-02 Rev A 03/02

iii

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety instructions that should be followed

during the installation and maintenance of this product.

To reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions.

WARNING WARNING

WARNING - A DANGEROUS VOLTAGE OR CONDITION EXISTS IN THIS AREA. USE EXTREME CAUTION WHEN PERFORMING THESE TASKS.

VERTISSEMENT VERTISSEMENT

VERTISSEMENT - UNE TENSION OU CONDITION DANGEREUSE EXISTE DANS CETTE ZONE. FAIRE PREUVE D’EXTRÊME PRUDENCE LORS DE LA RÉALISATION DE CES TÂCHES.

CAUTION CAUTION

CAUTION - This procedure is critical to the safe installation or operation of the unit. Follow these instructions closely.

TTENTION TTENTION

TTENTION - Cette procédure est essentielle à l’installation ou l’utilisation de l’unité en toute sécurité. Suivre ces instructions de près.

NOTE NOTE

NOTE - This statement is important. Follow instructions closely.

NOTE NOTE

NOTE - Cette déclaration est importante. Suivre les instructions de près.

• All electrical work must be done in accordance with local, national, and/or international electrical codes.

• Before installing or using this device, read all instructions and cautionary markings located in the manual, and on the inverter, the batteries, and the PV array.

• Do not expose this unit to rain, snow, or liquids of any type. This product is designed only for indoor mounting.

• To reduce the chance of short-circuits use instulated tools when installing or working with the inverter, the batteries, or the PV array.

• Remove all jewelry while installing this system. This will greatly reduce the chance of accidental exposure to live circuits.

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SAVE THESE INSTRUCTIONS

• The unit contains more than one live circuit (inverter and utility grid). Power may be present at more than one source.

• This product contains no user-serviceable parts. Do not attempt to repair this unit.

• To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning.

• Do not mount this device in unventilated enclosures.

• To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning.

• Additional AC disconnects may be required as part of the system installation. Consult local and national electrical code requirements.

• This unit is designed to be horizontally wall mounted.

• The AC input and output neutral conductors are not connected (bonded) to the chassis.

• The AC input and output HOT conductor are not isolated from each other.

• The chassis housing of the GTI must be connected to a permanent grounding system as required by the National Electric Code, ANSI/NFPA 70-1996. This is the responsibility of the system installer. A grounding terminal lug is provided for connection of an equipment grounding conductor.

• CSA certified for sale in the U.S. under Photovoltaic Power Systems (UL1741).

IMPORTANT SAFETY INSTRUCTIONS (Continued)

P/N 975-0041-01-02 Rev A 03/02

ontentsontents

ontents

IMPORTANT SAFETY INSTRUCTIONS ............................................................. iii

1.0 INTRODUCTION1.0 INTRODUCTION

1.0 INTRODUCTION

............................................................................................................................

..............................................................

Introduction .......................................................................................................... 1

Standard Features .................................................................................................4

Utility Interactive Mode ....................................................................................4

Bypass Mode .................................................................................................... 4

2.0 INST2.0 INST

2.0 INST

ALLAALLA

ALLA

TIONTION

TION

..................................................................................................................................

.................................................................

Pre-Installation ......................................................................................................5

Required Tools and Materials .......................................................................... 5

Removing the Top Cover .................................................................................. 5

Mounting ...............................................................................................................6

Procedure ..........................................................................................................6

Wiring .................................................................................................................... 8

AC Wiring for Single-Inverter Installations ......................................................8

Ground Wiring ........................................................................................... 10

Utility Grid AC Wiring to the GTI .............................................................. 12

Inverter AC Input Wiring to the GTI ..........................................................14

Inverter AC Output Wiring to the GTI .......................................................16

GTI Wiring to the Sub-Panel ......................................................................18

Communications Cable ............................................................................. 20

AC Wiring for Dual-Inverter Installations ...................................................... 22

Ground Wiring ........................................................................................... 24

Utility Grid AC Wiring to Dual GTIs ..........................................................26

Inverter AC Input and Output Wiring to the GTIs ...................................28

GTI Wiring to the Sub-Panel ......................................................................30

Connecting the Communications Cables for Dual Inverter Installations 30

AC Rewiring for Dual-Inverter Power Panel Installations ............................. 32

AC Rewiring for Power Module Installations ................................................ 34

AC Rewiring for Power Module Installations (continued) ............................36

Wiring Check ....................................................................................................... 37

Operating Stacked Inverters ...............................................................................37

Start-up and Test .................................................................................................37

3.0 TROUBLESHOOTING3.0 TROUBLESHOOTING

3.0 TROUBLESHOOTING

..........................................................................................................

.....................................................

3939

APPENDIX A – SPECIFICAAPPENDIX A – SPECIFICA

APPENDIX A – SPECIFICA

TIONSTIONS

TIONS

..................................................................................

.........................................

A-1A-1

A-1

Electrical Specifications1 .................................................................................. A-1

Mechanical Specifications ................................................................................ A-1

APPENDIX B – PRODUCT AND SYSTEM INFORMAAPPENDIX B – PRODUCT AND SYSTEM INFORMA

APPENDIX B – PRODUCT AND SYSTEM INFORMA

TIONTION

TION

........

....

B-1B-1

B-1

Warranty ............................................................................................................ B-1

Return Material Authorization Policy ............................................................... B-2

Return Material Procedure ........................................................................... B-2

Service Information .......................................................................................... B-3

P/N 975-0041-01-02 Rev A 03/02

List of FiguresList of Figures

List of Figures

Figure 1-1 Grid Tie Interface Flow Diangram .......................................................... 2

Figure 1-2 Grid Tie Interface Flow Diagram

with External Manual Bypass Switch ................................................. 3

Figure 1-3 Grid Tie Interface Unit .............................................................................4

Figure 2-1 Removing the Top Cover ......................................................................... 5

Figure 2-2 Mounting Holes ...................................................................................... 6

Figure 2-3 Dimensional Drawing (Not to scale) ..................................................... 7

Figure 2-4 GTI Circuit Board Enlargement ...............................................................8

Figure 2-5 AC Input and Output Wiring for Single-Inverter Installations .............. 9

Figure 2-5a Ground Wiring for a Single-Inverter Installations ................................ 11

Figure 2-5b Utility Grid AC Wiring to the GTI ..........................................................13

Figure 2-5c Inverter AC Input Wiring to the GTI ..................................................... 15

Figure 2-5d Inverter AC Output Wiring to the GTI .................................................. 17

Figure 2-5e GTI Wiring to the Sub-Panel ................................................................. 19

Figure 2-6 GTI Communications Cable Location .................................................. 20

Figure 2-7 Connecting the Communications Cable to the Circuit Board ............. 21

Figure 2-8 Wiring Diagram for Dual-Inverter Installations ................................... 23

Figure 2-8a Ground Wiring for Dual-Inverter Installations ..................................... 25

Figure 2-8b Utility Grid AC Wiring to Dual GTIs ..................................................... 27

Figure 2-8c Inverter AC Input and Output Wiring to Dual GTIs ............................ 29

Figure 2-8d GTI Wiring to the Sub-Panel ................................................................. 31

Figure 2-9 Re-wiring Power Panel Installations to include dual GTIs ................... 33

Figure 2-10 Original Power Module Wiring ............................................................. 35

Figure 2-10a Power Module Rewiring for dual GTI Installations ..............................36

P/N 975-0041-01-02 Rev A 03/02

1.0 INTRODUCTION

INTRODUCTION

The Grid Tie Interface (GTI) is an integrated assembly used with the Trace™ SW Series II inverter/charger with Revision 4.2 (or higher) software. This new device provides active anti-islanding protection and reduces current Total Harmonic Distortion (THD) as required in UL-1741-2000.

The Grid Tie Interface is an accessory, which is connected between the grid, the AC loads, and the SW Series II inverter to optimize the “SELL” feature. While there is a small inductor in the GTI, this device is not a “filter”; rather it contains an additional control microprocessor, which connects to the SW Series II with a communications cable.

When the GTI is connected and the Inverter “SELL” mode is selected, the microprocessor of the GTI takes control of the SW Series II and operates the inverter “SELL” feature. The GTI affords a dedicated microprocessor and new, sophisticated control algorithms that are able to optimize the sell function.

The SW Series II with the GTI meets all power quality requirements of UL1741, including harmonic distortion, power factor, and anti-islanding requirements. In addition, it has increased the SW Series II’s efficiency in SELL mode to within 1% of the impressive off-grid efficiency of the SW.

The GTI also contains an automatic transfer/shorting relay, which the SW Series II uses to disconnect the GTI from the circuit when it is not needed, for example when the SW Series II is charging batteries from the grid. This is also used to disconnect the GTI so that it does

NOTNOT

NOT

represent a phantom load or parasitic

loss to the system.

All new SW Series II units (manufactured since December of 2001) are equipped to allow the GTI to be installed in the field. The SW Series II inverter is Certified to UL1741 for off grid and backup power applications. The SW can be connected to the grid as a battery charger; however, it is

NOTNOT

NOT

approved to use the SELL feature (net meter) without the GTI accessory. The GTI carries all necessary approvals and markings to allow a safety inspector to approve the installation for net metering.

1.0 INTRODUCTION

P/N 975-0041-01-02 Rev A 03/02

Figure 1-1

Grid Tie Interface Flow Diagram

1.0 INTRODUCTION

P/N 975-0041-01-02 Rev A 03/02

Figure 1-2

Grid Tie Interface Flow Diagram with External Manual Bypass Switch

1.0 INTRODUCTION

P/N 975-0041-01-02 Rev A 03/02

STANDARD FEATURES

The Grid Tie Interface (GTI) is an external unit that is required for use with the Xantrex SW Series Inverters, models SW4024, SW4048, and SW5548 with Rev. 4.2 firmware or higher, being used in Utility Interactive “Sell” mode. This device ensures compliance with regulatory standards for utility interface applications.

The GTI utilizes a highly-efficient inductor constructed of high temperature materials and M-6 grade steel laminations, meeting UL Class-H standards.

The unit is housed in a powder-coated, steel enclosure, suitable for indoor installations and contains dual knockouts for ¾" - 1" and ½" - ¾" conduit connections. The unit includes a control board with one 10-pin, polarized, connector that connects to the SW inverter.

The GTI has two functions: 1) Utility Interactive Mode, and 2) Bypass Mode.

Utility Interactive Mode

Utility Interactive Mode is only engaged when the SW inverter begins selling power in the “Sell” mode. When in this mode, the GTI engages an inductor through an internal relay that filters out current harmonics and ensures that the power transferred to the grid has Total Harmonic Distortion (THD) levels that are within acceptable ranges and ensures the power factor is high. The GTI also provides anti-islanding protection in the event of a utility grid failure.

Bypass Mode

The GTI includes a bypass relay that is controlled by the current direction and levels in the GTI and allows the critical loads to be connected to the grid or to the output of the SW inverter. When a low level “sell” current begins, the GTI will engage the bypass relay to allow the loads to be connected to the grid. In this operation (grid-connected), the inverter’s AC1 relay and the bypass relay work together to ensure fast transfer of the critical loads in a backup situation.

The critical loads are effectively connected directly to the grid – through the GTI – rather than passing through the inverter, resulting in the “LOAD AMPS AC” menu item displayed on the SW inverter to read zero. This zero reading will continue until the inverter batteries require a “buy” current of 10-15 amps AC or if a loss of grid power is detected. If either one of these conditions is detected, the bypass relay will engage to allow the critical loads to be directly powered by the inverter (inverterconnected). The inverter will continue to power the critical loads until another “sell” current begins, which again switches to the grid-connected operation.

Figure 1-3

Grid Tie Interface Unit

P/N 975-0041-01-02 Rev A 03/02

2.0 INSTALLATION

PRE-INSTALLATION

The GTI is only designed to work with the SW4024, SW4048 and SW5548 models that have revision 4.2 (or higher) software. Prior to installing the GTI, ensure that you have the appropriate model, the proper level of software and the inverter has the communication cable located within.

See Figure 2-6 for the location of this cable.

WARNING: THE CRITICAL LOADS ARE NOW POWERED THROUGH THE GTI; THESE LOADS WILL NOT BE POWERED IF THE SW INVERTER OR THE GTI ARE OFF OR DISCONNECTED. IT IS RECOMMENDED THAT AN EXTERNAL BYPASS SWITCH/BREAKER BE INSTALLED BETWEEN THE GRID AND THE CRITICAL LOAD-PANEL. THIS SWITCH, WHEN ENGAGED, WILL ALLOW THE GRID TO DIRECTLY POWER THE LOADS WHILE THE GTI OR SW INVERTER IS OFF OR DISCONNECTED. SEE FIGURE 2-9 FOR AN EXAMPLE OF THIS RELAY IN A XANTREX POWER PANEL.

Required Tools and Materials

• Wire strippers

• Phillips screw driver

• Slotted screw driver

• Torque wrench

• 3/16" Hex-Head wrench

• #6 AWG Wire

Removing the Top Cover

1. Remove the four Phillips screws and starwashers and set aside. Be sure to put these screws and washers somewhere where they can’t get lost.

Figure 2-1

Removing the Top Cover

Remove

these

phillips

screws to

remove

top cover

Remove

these

phillips

screws to

remove

top cover

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Figure 2-2

Mounting Holes

Mounting

Hole

Mounting

Hole

Mounting

Hole

Mounting

Hole

MOUNTING

Place the GTI in a convenient location, close to the inverter. The GTI must be mounted horizontally on a flat surface (such as a wall) in a clean, dry environment. Do not mount the GTI where it will be exposed to the weather or in a damp location.

NOTE: The GTI weighs approximately 25 pounds. Use appropriate wall anchors or backing material (plywood, 2 x 4’s, etc.) that will support its weight.

CAUTION: Do not mount vertically as water may enter the enclosure and damage the internal circuitry. Damage caused by mounting the unit vertically is NOT covered under the limited warranty.

Procedure

1. Use a level and mark the location for mounting the unit on the wall.

2. Measure out the four mounting screw holes according to Figure 2-3.

3. Use a #10 x 3/8 (or 1/2) inch long screw and washer (and appropriate anchors if necessary) and mount the GTI securely to the wall or backing material (plywood, 2 x 4’s, etc.).

4. Remove the appropriate knockouts for the conduit. Install the conduit between the GTI and the inverter. Use separate conduit for the AC wiring and the communications cable.

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Figure 2-3

Dimensional Drawing (Not to scale)

Front Internal view of unit

Side of unit

Ends of unit (both ends)

2 3/8"

4 3/8"

1 1/8"

19 7/8"

4 3/4"

3/4"

6 1/8"

1 3/4"

3 1/8"

1 3/8"

21"

1 7/8" 1 7/8" 1 7/8"

3 1/5"

1 3/8"

6 1/4"

6 3/4"

18 3/4"

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Figure 2-4

GTI Circuit Board Enlargement

WIRING

AC Wiring for Single-Inverter Installations

NOTE: All wiring should be performed by a qualified person or a licensed electrician.

NOTE: Ensure that wire size and conduit sizes are appropriate for this installation. AC wiring should be routed in separate conduits from the communications cable.

CAUTION: AC pass-through ability through the GTI is 60 amps. It is recommended to use minimum #6 AWG (THHN) wiring.

See Figure 2-7 for an enlargement of this circuit board showing the location of the communications cable port.

NEUTRAL

Bar

AC IN

from the

inverter output

AC OUT

to the

subpanel

AC OUT

to the

inverter’s

AC HOT IN1

Communications

Cable Port

(behind this cable)

AC IN

from the grid

GROUND

LUG

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Figure 2-5

AC Input and Output Wiring for Single-Inverter Installations

AC Wiring for Single-Inverter Installations (continued)

See pages 10 through 21 for detailed instructions for AC Input and AC output wiring for single-inverter/GTI installations.

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Wiring (continued)

AC Wiring for Single-Inverter Installations (continued)

Ground Wiring

Note: Ground wiring must be established at each unit. Ground wiring can also be accomplished in a variety of ways. The following instructions describe only one method. Please consult your local electrician for specific wiring details pertaining to your installation.

1. Connect a wire from the ground bus in the main service panel to the ground lug in the GTI.

2. Connect a wire from the ground bus in the main service panel to the ground terminal in the inverter.

3. Connect a wire from the ground bus in the main service panel to the ground terminal in the sub-panel.

See Figure 2-5a for an illustration of ground wiring for a single-inverter installation with the GTI.

2.0 INSTALLATION

P/N 975-0041-01-02 Rev A 03/02

Figure 2-5a

Ground Wiring for a Single-Inverter Installations

AC Wiring for Single-Inverter Installations (continued)

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Xantrex SW4024, SW4048, SW5548 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual