Xantrex Technology STXR2500, STXR1500 User Manual

4.3 (4)

STXR1500

STXR2500

Installation and Operation Guide

Xantrex

Sun Tie XR

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

Sun Tie XR Installation and Operation Guide © February 2003 Xantrex International. All rights reserved.

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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About This Guide

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

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Contents

1 Introduction

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

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

Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1–3

2 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

3 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

4 Troubleshooting

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

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

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

A Specifications

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

Standard Features and Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Efficiency Curve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5

Temperature Derating Curve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6

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

To reduce the chance of short circuits when installing or working with the inverter or the PV array, use insulated tools.

Remove all jewelry such as rings, bracelets, wristwatches and necklaces prior to installing this system. This will greatly reduce the chance of accidental exposure to live circuits.

The Sun Tie XR contains more than one live circuit (the PV array and the AC line). Power may be present at more than one source even when the circuit breakers are off.

This product contains no user-serviceable parts. Return the unit to Xantrex for maintenance.

Wiring to the utility should only be done after receiving prior approval from the utility company and performed only by a qualified electrician.

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

Sun Tie XR

AC utility meter

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

Sun Tie

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

Main utility electrical panel

 

 

 

 

DC input voltage

AC output

 

voltage

Figure 1-1 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.

1–2

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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

The Sun Tie XR is designed to take advantage of most types of solar

PV technology

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™

Sun SweepTM is Xantrex’s proprietary Maximum Power Point Tracking

Maximum Power

technology that allows the Sun Tie XR to harvest the maximum amount

Point Tracking

of energy from your solar array. No matter what PV system you choose—

(MPPT)

single crystalline, polycrystalline or thin film—SunSweepTM 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

The Sun Tie XR has complete on-board islanding protection and meets

requirements

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.

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1–4

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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

 

pencil

 

multimeter

 

utility knife

 

frequency counter (optional)

 

 

Hardware and materials required

wood screws and washers (supplied)

metal conduit and appropriate fittings

anchors for screws (material dependent)

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Installation Planning

Locating the Sun Tie XR

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

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

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

configurations

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

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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

The DC terminal blocks in the Sun Tie XR accept up to a #6 AWG wire.

sizes

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

NEC amps per leg

0–50 ft

50–100 ft

100–200 ft

Inverter model

output per leg

(amps x 125%)

one way

one way

one way

 

 

 

 

 

 

STXR1500

6.3

7.9

14 AWG

10 AWG

8 AWG

 

 

 

 

 

 

STXR2500

10.4

13.0

12 AWG

8 AWG

6 AWG

 

 

 

 

 

 

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

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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)

 

 

 

 

 

NEC amps

0–25 ft

25–50 ft

50–100 ft

(from PV array)

(amps x 156%)

one way

one way

one way

 

 

 

 

 

 

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 AWG

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

 

 

 

 

 

 

Note: For an installation requiring a two-wire run (positive and 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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Xantrex Technology STXR2500, STXR1500 User Manual

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—

pos (+)

note polarity)

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.

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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.

Ground bar

(connect to solid earth ground)

Figure 2-3 Ground bar location

PV Array Requirements

MPPT operational window

Voltage 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.

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