Xantrex Technology STXR2500, STXR1500 User Manual

Xantrex Sun Tie XR

STXR1500 STXR2500

Installation and Operation Guide

Sun Tie XR

Installation and Operation 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

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

February 2003, Revision 1

Part Number

975-0053-01-01

Contact Information

Telephone: 360.435.8826

Fax: 360.925.5143

Email: CustomerService@xantrex.com

Web: www.xantrex.com

About This Guide

Purpose

The Sun Tie XR Installation and Operation Guide contains information for a qualified installer and authorized service person to install, operate and troubleshoot the Xantrex Sun Tie XR.

Scope

The guide provides safety guidelines, installation, operation, troubleshooting, and warranty information for the Sun Tie XR.

The guide does not provide detailed information about solar (photovoltaic or “PV”) arrays or requirements for connecting to the utility power grid. You will need to consult the PV array manufacturer’s guide and your local electrical utility for this information.

About This Guide

Organization

This guide is organized into four chapters and two appendixes:

Chapter 1, “Introduction”, outlines the main performance and safety

features of the Sun Tie XR. Reading this chapter will give you a clear understanding of the inverter’s capabilities.

Chapter 2, “Installation”, provides information about planning for and

performing a Sun Tie XR installation.

Chapter 3, “Operation”, provides procedures for starting up the inverter

and operating the unit. It explains how to read the front panel display to monitor the Sun Tie XR’s operation.

Chapter 4, “Troubleshooting”, for authorized service personnel only,

explains how to identify and solve problems that can occur with the Sun Tie XR.

Appendix A, “Specifications”, provides the electrical, mechanical and

physical specifications of the Sun Tie XR.

Appendix B, “Warranty and Product Information”, contains the product’s

warranty. The appendix also explains how to return a product for service, and to prepare for a call to Xantrex Customer Service.

Conventions Used

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

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 Sun Tie XR or to other equipment.

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Note: Notes describe additional information which may add to your

understanding of how to install or use the Sun Tie XR.

Related Information

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

About This Guide

975-0053-01-01 iii iv 975-0053-01-01

Contents

Introduction

About the Sun Tie XR- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Standard Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3 Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3

Installation

Installation Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2

Tools required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2 Hardware and materials required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–2 Locating the Sun Tie XR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3 Routing the wires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–3

Planning AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4

Recommended wire sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–4

AC circuit breaker requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5 Planning DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5 Grounding Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6 PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–7

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9 Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–9 Connecting DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15 Connecting AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16 Grounding the System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–18 Connecting Inverters in Parallel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21 Installing the Optional Remote Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22

Operation

Startup Procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Required Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–2 Checking the PV Array DC Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–2 Checking the AC Utility Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–3 Starting up the Sun Tie XR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–4 Monitoring the Front Panel Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–5 Reading the Front Panel Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–6 Status Indicator Lights - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–7 Reassembling the Sun Tie XR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–8

Contents

Factors Affecting Sun Tie XR Performance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10

PV Array Factors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–10 Other Factors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11

Troubleshooting

Troubleshooting the Sun Tie XR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Viewing the Status LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Troubleshooting Reference Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–5

Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2 Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Standard Features and Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4 Efficiency Curve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5 Temperature Derating Curve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6

Warranty and Product Information

Limited Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2 Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5 Return Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–5 Information About Your System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–6

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Important Safety Instructions

WARNING: SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of this product. Specific safety instructions for installation, operation, and troubleshooting are in their respective sections. Read and keep this manual for future reference.

DANGER: SHOCK HAZARD

Do not remove the upper cover. Removing the upper cover should be performed only by authorized service personnel. If you suspect your unit is not functioning correctly, call Xantrex.

For safe installation and operation:

• All electrical work must be done in accordance with local and national electrical codes.

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

Important Safety Instructions

• Do not expose this unit to rain, snow or liquids of any type without

• To reduce the chance of short circuits when installing or working with

• Remove all jewelry such as rings, bracelets, wristwatches and

• The Sun Tie XR contains more than one live circuit (the PV array and

• This product contains no user-serviceable parts. Return the unit to

• Wiring to the utility should only be done after receiving prior

• Completely cover the surface of all PV arrays with an opaque (dark)

the Rain Shield installed. The Rain Shield does not, however, make the Sun Tie XR waterproof.

the inverter or the PV array, use insulated tools.

necklaces prior to installing this system. This will greatly reduce the chance of accidental exposure to live circuits.

the AC line). Power may be present at more than one source even when the circuit breakers are off.

Xantrex for maintenance.

approval from the utility company and performed only by a qualified electrician.

material before wiring them. PV arrays produce electrical energy when exposed to light and could create a hazardous condition.

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Introduction

Chapter 1, “Introduction”, describes the standard features and

accessories for the Sun Tie XR.

Introduction

About the Sun Tie XR

The Xantrex Sun Tie XR grid-connect solar inverter is designed to convert a home or business into a “green” power generating station. The Sun Tie XR converts solar electric (photovoltaic, or PV) power into utility-grade electricity that can be used by the home or sold to the power company. Installing the Sun Tie XR consists of mounting it to the wall and connecting a DC source (a PV array) and the AC output to the utility. See Figure 1-1 for a simple diagram of a typical installation. In order to operate, the Sun Tie XR must have grid power available and connected. It will not provide backup power.

Solar-harvested AC power to grid

PV array

Figure 1-1

DC input voltage

Basic System Overview

Note:

Figure 1-1 is a one-line drawing intended as a system overview

only. System grounding and other electrical details are not included.

Sun Tie XR

AC output voltage

OFF

Sun Tie

OFF

AC utility meter

Main utility electrical panel

1–2 975-0053-01-01

About the Sun Tie XR

Standard Features

All-in-one design All necessary DC input and AC output connections, disconnects and

circuit breakers are housed within the Sun Tie XR’s easily installed, compact enclosure. A built-in LCD display panel provides easy-to-read system status and daily cumulative energy production information. Two status LEDs inside the unit also provide operating and troubleshooting information.

Uses most types of PV technology

The Sun Tie XR is designed to take advantage of most types of solar electric technologies. The inverter allows up to 120 VDC open circuit PV modules to be used, so it will work with both crystalline and thin film PV modules.

Sun Sweep™ Maximum Power Point Tracking (MPPT)

Sun Sweep technology that allows the Sun Tie XR to harvest the maximum amount of energy from your solar array. No matter what PV system you choose— single crystalline, polycrystalline or thin film—SunSweep

is Xantrex’s proprietary Maximum Power Point Tracking

learns your array’s specific characteristics, maximizing its output all day, all season, year after year.

High efficiency The high-frequency, solid-state design of the Sun Tie XR inverter is

extremely efficient. Above 500 watts, the inversion process is 90% efficient (or greater) with a peak efficiency of 91%.

Expandable Sun Tie XR inverters may be connected in a parallel configuration for

increasing net metering capacity. The modular expandability of the Sun Tie XR Series allows for system growth.

Meets standards and requirements

The Sun Tie XR has complete on-board islanding protection and meets U.S. and Canadian safety operating standards and code requirements.

Accessories

• STRM–Sun Tie XR Remote Monitor, for remote display of system

status, energy production, troubleshooting log, and resetting Wh.

• STRS–Sun Tie XR Rain Shield, required for outdoor installation.

975-0053-01-01 1–3 1–4 975-0053-01-01

Installation

Chapter 2, “Installation” provides information about planning for

and installing the Sun Tie XR. It contains information to help you plan wire routes, AC and DC connections, and find a suitable location for installation. It also discusses requirements for grounding the Sun Tie XR and your PV array.

This chapter then provides procedures to install the Sun Tie XR, including mounting, making DC and AC connections, and grounding the inverter and the PV array.

Installation

Installation Planning

Overview

Before you begin to install the Sun Tie XR you need to consider the following:

• tools required

• hardware and materials required

• mounting location

• routes for AC and DC wiring

• AC and DC connection wire size requirements

• grounding requirements

• PV array requirements

Tools required

❐ Phillips screwdrivers ❐ level ❐ slot-head screwdrivers ❐ wire strippers ❐ open-end wrenches ❐ torque wrench ❐ socket wrench and fittings ❐ electrical tape ❐ 3/32" hex bit ❐ multimeter ❐ utility knife ❐ frequency counter (optional)

❐ pencil

Hardware and materials required

❐ wood screws and washers (supplied) ❐ metal conduit and appropriate fittings ❐ anchors for screws (material dependent)

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Locating the Sun Tie XR

The Sun Tie XR should be installed in locations that meet the following requirements:

Installation Planning

Vertical The UL listing for the Sun Tie XR requires it

to be mounted vertically.

Dry When the Sun Tie is mounted outdoors, attach

the optional Rain Shield (STRS) to prevent water entering the unit.

Temperature The unit meets specifications from 32 to

113 °F (0 to 45 °C) but will operate within the temperature extremes of most climates—from

-38 to 113 °F (-39 to 45 °C). At extreme cold temperatures the LCD display may not function normally and it is recommended that an indoor-mounted Remote Monitor be used. At temperatures above 45 °C, the unit begins derating power. See “Temperature Derating

Curve” on page A–6.

Ground clearance The Sun Tie requires at least 36 inches (100

cm) of clearance between the bottom of the unit and the ground.

Dust free Dust can be drawn inside and accumulate

within the unit, interfering with wiring connections and ventilation.

WARNING: SHOCK HAZARD

Do not install the Sun Tie XR unit outdoors without the Rain Shield. Water entering the unit could cause a dangerous condition and cause the unit to fail. Failure due to improper installation will void the warranty.

Routing the wires

Typical configurations

975-0053-01-01 2–3

Determine all wire routes to and from the Sun Tie XR. Typical routing configurations include:

• AC wiring from the Sun Tie XR to the main service panel

• DC input wiring from the PV array to the Sun Tie XR

• DC ground from the PV array to an external ground rod

Installation

All wiring and installation methods should conform to applicable electrical and building codes.

Conduit holes Pre-plan the wire and conduit runs. Knockouts for conduit holes are

located on the bottom of the unit. See Figure 2-9.

Acceptable wire sizes

The DC terminal blocks in the Sun Tie XR accept up to a #6 AWG wire. The AC circuit disconnects accept cable sizes up to #6 AWG.

For maximum safety, run AC and DC wires/cables in separate conduits.

WARNING: SHOCK HAZARD

Check for existing electrical or plumbing prior to drilling holes in the walls.

Planning AC Connections

AC connections include all the wires and connectors between the Sun Tie XR AC output breakers and the main utility electrical panel.

Figure 2-14 and Figure 2-15 show simplified diagrams of the entire

installation.

Recommended wire sizes

The AC output breakers accept wire sizes from #6–14 AWG. Refer to

Table 2-1 for minimum recommended wire size. The values in Table 2-1

are the minimum recommended wire sizes in conduit. Installing a large number of wires in conduit or enclosed locations may require larger wire sizes. Consult your local/national electrical code for more information.

Table 2-1 Recommended minimum AC wire sizes

Minimum wire size for specified distance

AC amps

Inverter model

STXR1500 6.3 7.9 14 AWG 10 AWG 8 AWG

STXR2500 10.4 13.0 12 AWG 8 AWG 6 AWG

output per leg

Note:

NEC amps per leg (amps x 125%)

The six-circuit combiner board is rated for 100 amps (Imp) of

0–50 ft one way

maximum real current. Although the 20 amp fuses will theoretically allow 120 amps to be applied, always design for a maximum of 100 amps maximum current. With appropriate fuse deratings, per NEC code, the maximum allowed current is 16 amps for any of the six circuits.

50–100 ft one way

100–200 ft one way

2–4 975-0053-01-01

Installation Planning

AC circuit breaker requirements

The main service panel must dedicate a 15 amp minimum, double pole breaker (120/240 volts AC) to operate the Sun Tie XR.

Planning DC Connections

DC connections include all the wires and connectors between your PV array and the Sun Tie XR’s combiner board. Figure 2-1 and Figure 2-2 show the combiner board and connection points. Figure 2-14 and Figure

2-15 show simplified diagrams of the entire installation.

Wire Sizes The DC connections are made on the combiner board inside the

Sun Tie XR. The combiner board accepts wire sizes from #6–14 AWG. Refer to Table 2-2 for minimum recommended wire sizes.

Exceptions The values in Table 2-2 are the minimum recommended wire sizes.

Installing a large number of wires in conduit or enclosed locations may require larger wire sizes. Consult your local or national electrical code for more information.

NEC Restrictions The National Electrical Code (NEC) places restrictions on minimum DC

wire bending radius. A #6 AWG wire is the largest that may be used on the Sun Tie XR when connecting to the individual fused circuits of the combiner board.

Table 2-2 Recommended minimum DC wire sizes

Minimum wire size for specified distance

DC amps (Imp) (from PV array)

1.0 1.6 14 AWG 14 AWG 14 AWG

3.0 4.7 14 AWG 12 AWG 10 AWG

5.0 7.8 12 AWG 10 AW G 6 AWG

7.0 10.9 12 AWG 8 AWG 6 AWG

9.0 14.0 10 AWG 8 AWG Not Recommended

11.0 17.2 10 AWG 6 AWG Not Recommended

NEC amps (amps x 156%)

Note:

For an installation requiring a two-wire run (positive and

0–25 ft one way

25–50 ft one way

50–100 ft one way

negative), the PV array wires can bypass the individual fused combiner board terminals and connect directly to the input terminals (through an externally mounted DC fused combiner box) by using the positive and negative bypass terminals on the combiner board. Refer to Figure 2-2 and Table 2-2 for connection and wire sizes.

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Installation

PV Array Fuses (F1 to F6)

Positive PV Array Fused Terminal Connections (1 to 6)

Negative PV Array Fused Terminal Connections

DC conduit wiring (from PV arrays)

Figure 2-1 Combiner board with PV array wiring to individual terminal connections

PV array wiring (two-line run to bypass terminals— note polarity)

pos (+)

neg (–)

Figure 2-2 Combiner board with PV array wiring to bypass terminals

Grounding Requirements

AC grounding The Sun Tie XR must be connected to a grounded, permanent wiring

system.

2–6 975-0053-01-01

Installation Planning

DC grounding The negative PV conductor must be bonded to the grounding system at

only one point in the system. See Figure 2-3 for the location of the Sun Tie XR ground bar. The size for the conductor is usually based on the size of the largest conductor in the DC system. Negative/ground bonding is accomplished by factory-wired PVGFP breakers.

Figure 2-3 Ground bar location

PV Array Requirements

MPPT operational window

Vo l t a g e requirements

The Sun Tie XR is optimized to work with 4-each, 12 volt nominal crystalline PV modules in series (48 VDC nominal), or various combinations of amorphous, thin film PV modules. Ensure the PV array used in the system operates within the maximum peak power tracking (MPPT) operational window.

The solar array connected to the Sun Tie XR should have a minimum of 50 volts DC open-circuit in full sunlight conditions. Crystalline solar arrays configured for 48 volts DC nominal will have an open-circuit voltage of around 84 volts DC in full sunlight. The MPPT software controls the output of the solar modules, under loaded conditions, in the 42–85 volts DC range (full inverter output power occurs between 52–85 VDC for the STXR1500 and between 52–75 VDC for the STXR2500). Other array voltages will either not operate the inverter, may cause damage, or will not allow maximum harvest of the sun’s energy.

Ground bar (connect to solid earth ground)

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