Xantrex ACCB User's Manual
Contents
1. 1 39 AC Neutral Wiring for Dual Configurations 1 39 Installing the Safety Plate 1 40 975 0046 01 01 vii Contents 2 Operating the ACCB The Bypass Switch nsi eee eee ee eee eee py Operating the Bypass Switch 2 2 Normal Operation 2 3 Bypass Operation 2 3 AC Input Output Off 2 4 Dual Inverters 240 Vac Loads 2 4 Warranty and Product Information WA 1 Warranty WA 1 Return Material Authorization Policy WA 3 Out of Warranty Service WA 4 Information About Your System WA 4 aLe E ee a ee eee eee E eee IX 1 viii 975 0046 01 01 Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22 Figure 1 23 Figure 1 24 Figure 1 25 Figure 1 26 975 02. HOT iminy nenied H Generator if Disconnect Breaker 120 AC Ganarator M A Inverter Input Breaker Neutral to HOT REU GND Graund i Band Inverter Output Breaker TTE AC Distribution Farel 120 Yag Oniy SubPanel AC Load E ee I A I Ou Figure 1 29 Hot Connections for an On Grid Application with an AC Distribution Panel and an Internal Generator Disconnect 975 0046 01 01 1 33 Installation Wiring for On Grid Applications Using Additional Circuit Breakers in the ACCB Only Neutral to Ground Bond To Primary 120 240V AC Panel L1 L2 d il The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an on grid application using an AC distribution panel for the outputs and a 120 Vac generator for input This diagram also uses an internal generator disconnect breaker in the ACCB Wiring instructions are provided for making ground connections first page 1 35 neutral connections second page 1 36 and hot connections last page 1 37 LEGEND oe Ground Neutral HOT Owner supplied HOT Factory installed 120V AC Generator HOT NEU END Additional AC Load Circuit Breaker seeeesraseeen 7 System Ground Generator Disconnect Breaker Sine Wave Plus Inverter Charger SISLSISIS S Figure 1 30 Wiring
3. QOS Figure 1 33 Hot Connections for an On Grid Application Using Additional Circuit Breakers in the ACCB Only 975 0046 01 01 1 37 Installation Additional Accessory Wiring If you have any of the following accessories connected or to be connected to your inverter then you will also need to pass their connecting cables through the ACCB to the AC side of the inverter e Generator Start Module GSM for automatic generator control e Auxiliary Load Module ALM for controlling auxiliary loads such as alarms water pumps or ventilator fans e Emergency Power Off EPO switch Inverter Control Module ICM or an Inverter Communications Adapter ICA for remote control and monitoring of the inverter Inverter Stacking Control Series ISC S Cable for connecting to another inverter in a dual inverter configuration See your inverter owner s guide and the appropriate accessory guide for further information about the installation and configuration of these accessories 975 0046 01 01 Wiring for Dual Inverter Configurations Wiring for Dual Inverter Configurations Series stacked Sine Wave Plus inverters with ACCBs installed are wired essentially the same as single inverters with the following differences Installing the ISC S Cable The ISC S cable must be run through one of the ISC S ICM cable slots provided on the sides of the ACCB see Figure 1 7 on page 1 10 The cable slots are blocked with hole plugs These hole
4. Pre installation WARNING Ensure that no DC voltage is being supplied to the inverter and that no AC voltage is present on the AC wiring Failure to do so could cause serious injury or death Location Be sure to allow sufficient space for the ACCB to be mounted directly adjacent to the inverter s AC side Also consider the additional weight and ventilation space requirements of the ACCB Ventilation Requirements Minimum clearance for ventilation around ACCB must be at least 6 inches 152 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 For maximum ventilation 12 inches 305 mm is recommended around the top Please refer to the Sine Wave Plus Inverter Charger Owner s Guide for additional location considerations 12 305mm 6 152 mm Recommended Minimum Required 6 152 mm lt _ _ gt Minimum Required Figure 1 4 Clearance Requirements for Ventilation 975 0046 01 01 l 7 Installation Knockout Preparation Knockout preparation should be done before mounting either the inverter or the ACCB l Remove the appropriate knockouts from the AC side of the inverter for cabling from the ACCB terminal block to the inverter terminal block See Figure 1 5 for the size and locations of the knockouts on the Sine Wave Plus Inverter Charger Remove the appropr
5. x3 Figure 1 11 ACCB AC Terminal Block Distribution Blocks Table 1 2 Torque Values for Wiring Wire Gauge Torque Value 14 10 AWG 20 Ib in 8 AWG 25 b in 6 4 AWG 36 lb in 4 2 0 AWG 50 Ib in WARNING Electrical Hazard Be sure to connect the ground wires first when connecting AC wiring to prevent a potential shock hazard CAUTION Equipment Damage The inverter s AC output must never be wired to the utility or generator output This will cause severe damage to the inverter which is not covered under warranty Important These instructions assume that the DC connections have already been made and that the system ground has already been established Consult the Sine Wave Plus Owner s Manual for additional wiring information Important Be sure to use wire ties as needed to keep field and factory installed wiring neat and tidy so it does not interfere with airflow through the ACCB into the Sine Wave Plus Inverter Charger 975 0046 01 01 Pre Wiring Preparation Bypass Switch Assembly AC Terminal Block Factory installed NEUTRAL Wire labeled TO INV AC1 NEU OR AC2 NEU DIN Rail Factory installed Hot OUT Wire labeled TO INV OUT Factory installed Hot IN Wire yee nee l Factory installed AC2 GEN Ground Bar Ground Wire Figure 1 12 ACCB Internal Components and Factory installed Wiring Bypass Switch Assembly includes two 60 amp circuit br
6. 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 e The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e 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 975 0046 01 01 WA 3 Warranty and Product Information Out of Warranty Service If the warranty period for your Sine Wave Plus AC Conduit Box has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been
7. in the ACCB Only 1 36 975 0046 01 01 Wiring for On Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the hot connections 1 Connect the factory installed hot black wire from the Inverter Input Breaker in the ACCB to the AC1 GRID terminal in the inverter 2 Connect the factory installed hot wire black from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter 3 Connect the hot black wire from the main AC distribution panel to the AC IN terminal in the ACCB 4 Connect the hot black wire from the generator to the top of the generator disconnect breaker in the ACCB 5 Connect another hot black wire from the bottom of that same generator disconnect breaker in the ACCB to the AC2 GEN terminal 6 Connect a hot black wire from the AC OUT terminal in the ACCB to the bottom of the additional circuit breaker installed in the ACCB 7 Connect another hot black wire from the top of that same additional circuit breaker in the ACCB and route to the outlet that will be supporting the AC load TAIZ AC Panal m Hewiral to Ground Bond 120 AC Generate a HOT NED Ga5 e Discomeci 3 i ii T i i a Tiaa Ee I jl a B i Greater 1 y N iaa mi m i re 7 7 uo pi a To Primary AC Load i se a gy s a Systam i Groumi ajz Additional AC Load Circuit Breaker 5
8. 01 Wiring for Off Grid Applications Using an AC Distribution Panel and an External Generator Disconnect To make the ground connections 1 Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel See the Sine Wave Plus Inverter Charger Owner s Manual for information regarding preparing the primary system ground 2 Route cable s hot neutral and ground from the AC distribution panel through one of the knockouts prepared in the ACCB and connect the ground wire green to the ground bar in the ACCB 3 Connect the factory installed ground wire green in the ACCB to the AC ground bar in the inverter 4 Prepare the cabling from the generator a Route the hot wire black from the generator through a discon nect switch b Route cable s hot neutral and ground from the generator and generator disconnect switch into one of the knockouts prepared in the ACCB Connect the ground wire green from the generator to the ground bar in the ACCB LEGEND IZIV AC Garami Biana dirmi Mii ES HOT Chae foto HOT MEU GND neste HOT imio mrri i Exenal Genai se Dreporervesct Sach oe a AC Distibeticn Parel 120 Vac Oniy oe EL Stelelslsis ststs zi fo Pomery Sym Genre Figure 1 15 Ground Connections for an Off Grid Application with an AC Distribution Panel and an External Generator Disconnect 975 0046 01 01 1 19 In
9. ACCB to the AC2 GEN terminal in the inverter 2 Connect the factory installed hot wire black from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter 3 Connect a HOT Black wire AC OUT in the ACCB to the HOT IN in the AC Distribution Panel 4 Connect a hot black wire from the generator disconnect to the AC IN terminal in the ACCB i LEGEND 120V AC Generator a HOT DAT bpi m HOT jlankory ri External Generator Disconnect Switch SS Se el tne SS a r AC Distribution Panel 120 Vac Only NEUTRAL i Trn T a RTGS a Te M M a a a aa a a n ani A Neutral to Ground Bond i E i To Primary System Ground Figure 1 17 Hot Connections for an Off grid Application with an AC Distribution Panel and an External Generator Disconnect 975 0046 01 01 1 21 Installation Wiring for Off Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off grid application using an AC distribution panel for the outputs and a 120 Vac generator for input This diagram also includes the use of a generator disconnect breaker in the ACCB Wiring instructions are provided for making ground connections first page 1 23 neutral connections second page 1 24
10. a E A a E run m HOT r Hil Wij 120 AG Ganeratar j HOT ary aa FF VL Q Aeuiral in Graund Bori RaT NEU GNG P ae 7 papapa Coe pg 4 T T E aed q uana memmen i Li AG Disirbuilon Pami EO O Re Vac Only To Primary fam f Ground i i i E d i E i E i SubPanel E E E E E 4 Figure 1 28 Neutral Connections for an On grid Application with an AC Distribution Panel and internal Generator Disconnect Breaker in the ACCB 1 32 975 0046 01 01 Wiring for On Grid Applications Using an AC Distribution Panel To make the hot connections 1 Connect the factory installed hot black wire from the Inverter Input Breaker in the ACCB to the AC1 GRID terminal in the inverter 2 Connect the factory installed hot wire black from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter 3 Connect the hot black wire from the main AC distribution panel to the AC IN terminal in the ACCB 4 Connect the hot black wire from the generator to the top of the generator disconnect breaker in the ACCB 5 Connect another hot black wire from the bottom of that same generator disconnect breaker in the ACCB to the AC2 GEN terminal 6 Connect a hot black wire from the AC OUT terminal in the ACCB to the sub panel l q20 240V AC Panel sss LEGEND Main AC eee Bac o eee ante Distribution Heuiral o HOT Cer upaj Panel
11. an External Generator Disconnect 1 21 Wiring an Off grid Application Using an AC Distribution Panel and an Internal Generator Disconnect Breaker 1 22 Ground Connections for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect Breaker 1 23 Neutral Connections for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect 1 24 Hot Connections for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect 1 25 Wiring an Off Grid Application Using Additional Circuit Breakers in the ACCB Only 1 26 Ground Connections for an Off Grid Application with Additional Circuit Breakers in the ACCB 1 27 Neutral Connections for an Off grid Application with Additional Circuit Breakers in the ACCB 1 28 Hot Connections for an Off grid Application with Additional Circuit Breakers in the ACCB1 29 Wiring an On grid Application USING an AC Distribution Panel 1 30 Figures Figure 1 27 Figure 1 28 Figure 1 29 Figure 1 30 Figure 1 31 Figure 1 32 Figure 1 33 Figure 1 34 Figure 1 35 Figure 1 36 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Ground Connections for an On Grid Application with an A
12. and hot connections last page 1 25 LEGEND EE eee eee Ground 120V AC Generator Neutral HOT Owner supplied HOT Factory installed eee ese ee88 Breaker l 2 Generator Disconnect AC Distribution Panel 120 Vac Only Sine Wave Plus Inverter Charger NEUTRAL HOT Neutral to Ground Bond AC Load GROUND lan sea 222 CTO T rm To Primary System Ground mlll Figure 1 18 Wiring an Off grid Application Using an AC Distribution Panel and an Internal Generator Disconnect Breaker WARNING Shock Hazard Ensure that all AC and DC power is not live before proceeding 1 22 975 0046 01 01 Wiring for Off Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect To make the ground connections 1 Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel See the Sine Wave Plus Inverter Charger Owner s Manual for information regarding preparing the primary system ground 2 Route cable s hot neutral and ground from the AC distribution panel through one of the knockouts prepared in the ACCB and connect the ground wire green to the ground bar in the ACCB 3 Connect the factory installed ground wire green in the ACCB to the AC ground bar in the inverter 4 Prepare the cabling from the generator Route cable s hot neutral and ground from the genera
13. hazard can exist if 120 Vac only sources such as inverters and generators are wired incorrectly into 120 240 Vac distribution panels containing multiwire branch circuits Accessing the Terminal Blocks Consult the Sine Wave Plus Inverter Charger Owner s Manual for additional information on wire and disconnect requirements To prepare the ACCB and Inverter for wiring installation 1 Expose the terminal block in the ACCB by removing the ACCB cover as described on page I 11 2 Expose the terminal block in the inverter by removing the AC access cover as described in your inverter s owner s guide Wire Sizes and Disconnect Requirements Determine the wire sizes and disconnect sizes required for the installation See Table 1 1 for disconnects and wire sizes and Table 1 2 for torque values Important Only use copper conductors rated for 75 C 167 F Table 1 1 AC Disconnect and Wire Sizing Full Maximum Cable Size Pass Through Fuse Breaker Required in Capability Required Conduit 60 Amps 60 Amps 6 AWG THHN 975 0046 01 01 1 15 Installation The distribution blocks in the ACCB AC terminal block accept the following gauge wires e The 1 1 distribution blocks accept 2 0 14 AWG e The 1 4 distribution blocks accept 2 0 14 AWG on the single terminal and 4 14 AWG on the quad terminals The ground bar in the ACCB accepts 4 to 14 AWG wires 1 1 distribution block 1 4 distribution block
14. is secured by the Sems screws that attach the top cover WARNING Shock Hazard Be sure to disconnect all DC and AC power before removing the inverter and installing the safety plate To install the safety plate 3 Remove the two 8 Sems screws on the top and bottom of the ACCB Put these screws is a safe place 4 Slide the safety plate over the open end of the conduit box inserting the cover tabs into the slots on the safety plate Be sure to align the holes for the screws for resecuring the top cover 5 Replace the two 8 Sems screws on the top and bottom of the chassis to secure the Safety Plate into place Remove these 2 8 Sems Screws only Cover Tabs Inverter side of ACCB Figure 1 35 Removing the Sems Screws From the ACCB Top Cover 1 40 975 0046 01 01 Installing the Safety Plate Top Cover Ensure the top cover tabs protrude through the cover tab slots Replace the 8 lt Sems screw from the top of the chassis Replace the 8 Sems screw from the bottom of the chassis Figure 1 36 Installing the Safety Plate SP 1 on the ACCB 1 41 975 0046 01 01 Operating the ACCB Chapter 2 Operating the ACCB describes the different modes and operation of the Bypass Switch on the ACCB The following topics are covered in this chapter For this topic See The Bypass Switch page 2 2 Operating the Bypass Switch page 2 2 Dual Inverters 240 Vac Loads p
15. plugs must be removed before inserting the ISC S cable Remove the hole plug for the slot to be used by the cable only Do not remove any other hole plugs Ensure that the all the other hole plugs are still in place as shown in Figure 1 34 Grommet Hole Plug Figure 1 34 SC S Cable in an ISC S ICM Cable Slot of the ACCB AC Neutral Wiring for Dual Configurations All of the AC wiring for dual Sine Wave Plus inverters remains the same except for two changes in the neutral wiring 1 All NEUTRAL IN wiring goes only to the neutral terminals in the L1 ACCB attached to the L1 Sine Wave Plus inverter 2 A neutral bond between the inverters is created by connecting an owner supplied 6 AWG THHN neutral wire white from the ACCB neutral terminal attached to the L1 Sine Wave Plus inverter to the ACCB neutral terminal attached to the L2 Sine Wave Plus inverter This wire should be long enough to pass from the L2 inverter AC terminal block through adjacent knockouts on both ACCBs to the L1 inverter ACCB terminal block 975 0046 01 01 1 39 Installation Installing the Safety Plate The purpose of the Safety Plate SP 1 is to prevent accidental contact with any live circuits or wires within the AC Conduit Box The Safety Plate only needs to be installed in the event that the Sine Wave Plus is removed The Safety Plate SP 1 covers the open end of AC Conduit Box on the inverter side It attaches to the base of the conduit box and
16. 046 01 01 AC Conduit Box Front View 1 2 ACCB Dimensions not to scale 1 3 Safety Plate SP 1 1 4 Clearance Requirements for Ventilation 1 7 SW Plus Inverter AC Side Showing Knockout Location 1 8 Knockouts on ACCB Top Cover for Additional Circuit Breakers 1 9 ACCB Knockout Locations 1 10 ACCB Cover Removal 1 12 Installing Additional Breakers on the DIN rail 1 13 Installing the ACCB on the Sine Wave Plus Inverter Charger 1 14 ACCB AC Terminal Block Distribution Blocks 1 16 ACCB Internal Components and Factory installed Wiring 1 17 ACCB AC Terminal Block For Customer installed Wiring 1 17 Wiring an Off Grid Application Using an AC Distribution Panel and an External Generator Disconnect Switch 1 18 Ground Connections for an Off Grid Application with an AC Distribution Panel and an External Generator Disconnect 1 19 Neutral Connections for an Off Grid Application with an AC Distribution Panel and an External Generator Disconnect 1 20 Hot Connections for an Off grid Application with an AC Distribution Panel and
17. 09 Bs tanna Figure 1 26 Wiring an On grid Application USING an AC Distribution Panel WARNING Shock Hazard Ensure that all AC and DC power is not live before proceeding Important The inverter bypass circuit breaker can only be wired directly to and work with a single AC source In a system that has multiple AC sources you must decide which AC source will be wired through the inverter bypass circuit breaker and which will not The following illustrations assume that the primary AC input source will be the utility grid 1 30 975 0046 01 01 Wiring for On Grid Applications Using an AC Distribution Panel To make the ground connections l Main AC Distribution Panel pees a i i i i AC Distritithen Parm 120 Vac Ordy Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel See the Sine Wave Plus Inverter Charger Owner s Manual for information regarding preparing the primary system ground Connect a ground wire green from the main AC distribution panel to the ground bar in the sub panel Route cable s hot neutral and ground from the main AC distribution panel through one of the knockouts prepared in the ACCB and connect the ground wire green to the ground bar in the ACCB Connect the factory installed ground wire green in the ACCB to the AC ground bar in the inverter Connect the ground wire green from the generato
18. 1 8 ACCB Cover Removal 1 12 975 0046 01 01 Pre installation Installing Additional Breakers If additional AC circuit breakers are to be installed for specific AC loads or a generator disconnect then install them per the manufacturer s instructions in the space to the left of the inverter bypass and AC disconnect breakers Note The ACCB DIN Rail accepts Square D Type QOU circuit breakers To install additional Square D Type QOU circuit breakers 1 Remove the top cover as described on page 1 11 2 Loosen the screw in the DIN Rail End Clamp and slide the clamp to the left to make room for the additional circuit breaker s 3 Install the circuit breaker s on the DIN rail to the left of the bypass switch Be sure to align them to fit into the spaces made by the knockouts that were removed on the top cover 4 Slide the clamp tight against the last circuit breaker on the right and tighten the screw to secure the clamp on the DIN Rail These factory installed wires will be routed and connected to the inverter DIN Rail DIN Rail End Clamp Figure 1 9 Installing Additional Breakers on the DIN rail 975 0046 01 01 1 13 Installation Mounting the ACCB to the Inverter Important Ensure that the factory installed cables in the ACCB are not pinched crushed removed or damaged during the installation to the inverter To install the ACCB on the inverter 1 Mount the inverter into place either wa
19. C Distribution Panel sub panel and a Generator Disconnect Breaker in the ACCB 1 31 Neutral Connections for an On grid Application with an AC Distribution Panel and internal Generator Disconnect Breaker in the ACCB 1 32 Hot Connections for an On Grid Application with an AC Distribution Panel and an Internal Generator Disconnect 1 33 Wiring an On Grid Application Using Additional Circuit Breakers in the ACCB Only 1 34 Ground Connections for an On grid Application Using Additional Circuit Breakers in the ACCB Only 1 35 Neutral Connections for an On Grid Application Using Additional Circuit Breakers in the ACCB Only 1 36 Hot Connections for an On Grid Application Using Additional Circuit Breakers in the ACCB Only 1 37 ISC S Cable in an ISC S ICM Cable Slot of the ACCB 1 39 Removing the Sems Screws From the ACCB Top Cover 1 40 Installing the Safety Plate SP 1 on the ACCB 1 41 Bypass Switch Mode Summary 2 2 Normal Operation 2 3 Bypass Operation 2 3 AC Output OFF 2 4 975 0046 01 01 Installation Chapter 1 Installation provides in
20. CALLY PLEASE NOTE THAT THE SINE WAVE PLUS AC CONDUIT BOX SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES WITHOUT LIMITING THE GENERALITY OF THE FOREGOING XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX SINE WAVE PLUS AC CONDUIT BOX IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES Please note that the Sine Wave Plus AC 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 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 e The serial number of your product e Information about the installation and use of the unit e Information about the failure and or reason for the return e A copy of your dated proof of purchase Record these details in on page WA 4 Return Procedure
21. EU GND ee HOT DAT bpe i a HIT jiy meso k Coenerator Disconnect AC Distribution Panel 120 Vac Only Ee TS wor Newiral io Ground Bond 2S Se a a a a pom Figure 1 20 Neutral Connections for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect l 24 975 0046 01 01 Wiring for Off Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect To make the hot connections 1 Connect the factory installed hot black wire from the Inverter Input Breaker in the ACCB to the AC2 GEN terminal in the inverter 2 Connect the factory installed hot wire black from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter 3 Connect a hot black wire from the AC OUT in the ACCB to the HOT IN on the AC distribution panel 4 Connect another hot black wire from the generator disconnect breaker to the AC IN terminal in the ACCB 5 Connect the hot black wire from the generator to the top of the generator disconnect breaker 120V AC Generator HOT DTe ipei HOT jle mri kaa Inverter Input Breaker i Inverter Output a Breaker Generator Disconnect Fi Breaker AC Distribution Panel i 120 Vac Only L j pa F i E E E E d i i I i Neutral to Ground i Bond i i i i i 1 4 To Primary System Ground Figure 1 21 Hot Connec
22. OFF Left Breaker OFF Right Breaker OFF Right Breaker ON Right Breaker OFF Inverter AC power Utility or Generator AC Utility Generator Inverter AC available to Inverter power available to Inverter power disconnected to AC Distribution Panel AC Distribution Panel Inverter AC Distribution Panel Figure 2 1 Bypass Switch Mode Summary 2 2 975 0046 01 01 Operating the Bypass Switch Normal Operation Inverter AC power passes through the inverter to the load Figure 2 2 In this configuration power passes through the inverter to the connected load When external AC power is not available power from the external DC source is used by the inverter to power the AC loads p 60 aN OFF INVERTER INVERTER BYPASS DISCONNECT BOTH OFF TO DISCONNECT AC OUTPUT Inverter in Circuit Figure 2 2 Normal Operation Bypass Operation External AC power routed directly to the AC loads Figure 2 3 In this configuration power passes directly to the connected load bypassing the inverter This allows the inverter to be removed from service without affecting the connected load If the extenal source of AC becomes unavailable while the Bypass Operation is selected the load will be dropped Inverter out of Circuit t INVERTER INVERTER BYPASS DISCONNECT BOTH OFF TO DISCONNECT AC OUTPUT Figure 2 3 Bypass Operation 975 0046 01 01 2 3 Operating the ACCB AC Input Output Off No power to the load or ch
23. OR 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 August 2003 Revision A Part Number 975 0046 01 01 Contact Information Telephone 1 800 670 0707 toll free in North America 1 360 435 8826 direct Fax 1 360 435 3547 Email CustomerService xantrex com Web www xantrex com About This Guide Purpose Scope Audience Organization 975 0046 01 01 The purpose of this Installation Guide is to provide explanations and procedures for installing and operating the Sine Wave Plus AC Conduit Box ACCB The Sine Wave Plus AC Conduit Box ACCB Installation Guide provides safety guidelines and procedures for installing and operating the ACCB This Guide is intended for those who need to install and operate the Sine Wave Plus AC Conduit Box Only skilled personnel such as certified electricians and solar technicians should attempt installation of this equipment Skills required include the ability to read and understand how to follow single line wiring diagrams This Guide is organized into two chapters Chapter 1 Installation provides installation and wiring instructions for the Sine Wave Plus AC Conduit Box ACCB Chapter 2 Operating the ACCB describes the different modes and operation of the Bypass Switch on the ACCB Warranty and product i
24. Smart choice for power Xa nt rex ONT Y acm Guide Sine Wave Plus AC Conduit Box ACCB Owner s Guide www xantrex com Smart choice for power Xa ntrex Sine Wave Plus AC Conduit Box ACCB Installation Guide About Xantrex Xantrex Technology Inc is a world leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility scale systems for wind solar batteries fuel cells microturbines and backup power applications in both grid connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks Sine Wave Plus AC 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 Sine Wave Plus AC Conduit Box ACCB Installation Guide August 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 F
25. TICULAR 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 WA 2 975 0046 01 01 Return M aterial Authorization Policy Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFI
26. age 2 4 Operating the ACCB The Bypass Switch During normal operation Figure 2 2 on page 2 3 AC power passes from the external AC source generator or grid through the inverter to the AC loads The inverter monitors the incoming power and can keep the batteries charged When external sources of AC power are not available the inverter switches to external DC power e g batteries generator solar wind hydro fuel cell and continues to power the load When performing inverter maintenance the breakers can be switched to the Bypass Operation Figure 2 3 on page 2 3 which allows the AC loads to be powered directly from the the external AC source without affecting connected AC loads To de energize both circuits switch the breaker pair to the OFF position Figure 2 4 on page 2 4 Operating the Bypass Switch Once the AC voltage has been applied the bypass switch is ready for operation Under normal operation the Inverter Output breaker is ON There are three possible modes of operation for the bypass switch e Normal Operation e Bypass Operation e AC Input Output Off INVERTER INVERTER INVERTER INVERTER INVERTER INVERTER BYPASS DISCONNECT BYPASS DISCONNECT BYPASS DISCONNECT BOTH OFF TO DISCONNECT AC OUTPUT BOTH OFF TO DISCONNECT AC OUTPUT BOTH OFF TO DISCONNECT AC OUTPUT NORMAL OPERATION BYPASS OPERATION AC OFF OPERATION Left Breaker ON Left Breaker
27. al circuit breaker to the outlet that will support the AC load 120W AC Generator Inverter Input Breaker Inverter Output Breaker Generator Disconnect Breaker ese SS SS ee ne M o e Heutral to 1 o 4 Ground Bond To Primary System Ground Figure 1 25 Hot Connections for an Off grid Application with Additional Circuit Breakers in the ACCB 975 0046 01 01 1 29 Installation Wiring for On Grid Applications Using an AC Distribution Panel and an Internal Generator Disconnect Breaker The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an on grid application using an AC distribution panel for the outputs and a 120 Vac generator for input This diagram also uses an internal generator disconnect breaker in the ACCB Wiring instructions are provided for making ground connections first page 1 31 neutral connections second page 1 32 and hot connections last page 1 33 120 240V AC Panel u eG LEGEND e Ground Neutral HOT Owner supplied HOT Factory installed FELCH Neutral to gt gt Ground Bond 1 i i a e AC Distribution Panel 120 Vac Only To Primary NEUTRAL System G3 HOT Ground Oa GROUND 99009000
28. all appropriate sections of this guide 2 Do not expose the ACCB to rain snow or spray To reduce risk of fire hazard do not cover or obstruct the ventilation openings Do not install the ACCB in a zero clearance compartment Overheating may result Minimum clearance for ventilation around the unit must be six inches at the end and three inches top and bottom 3 Use only attachments recommended or sold by the manufacturer Doing otherwise may result in a risk of fire electric shock or injury to persons 4 The ACCB is designed to be permanently connected to your inverter It can be mounted on a vertical surface or wall or on a shelf Xantrex recommends that all wiring be done by a certified technician or electrician to ensure adherence to the local and national electrical codes applicable in your application 5 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 ACCB or inverter with damaged or substandard wiring 6 Do not install the ACCB if it has received a sharp blow been dropped or otherwise damaged in any way If the unit is damaged see the Warranty section at the end of this guide 7 To reduce the risk of electrical shock disconnect all power to the ACCB and the Sine Wave Plus Inverter Charger before attempting any maintenance or cleaning or working on the ACCB 8 The ACCB is provided with an equipment grounding conducto
29. ally damaged or altered either internally 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 hereaf ter 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 PAR
30. an On Grid Application Using Additional Circuit Breakers in the ACCB Only 1 34 WARNING Shock Hazard Ensure that all AC and DC power is not live before proceeding Important The inverter bypass circuit breaker can only be wired directly to and work with a single AC source In a system that has multiple AC sources you must decide which AC source will be wired through the inverter bypass circuit breaker and which will not The following illustrations assume that the primary AC input source will be the utility grid 975 0046 01 01 Wiring for On Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the ground connections 1 Prepare the primary system ground and connect it to the ground bar in the main AC distribution panel See the Sine Wave Plus Inverter Charger Owner s Manual for information regarding preparing the primary system ground 2 Route cable s hot neutral and ground from the main AC distribution panel through one of the knockouts prepared in the ACCB and connect the ground wire green to the ground bar in the ACCB 3 Connect the factory installed ground wire green in the ACCB to the AC ground bar in the inverter 4 Connect the ground wire green from the generator to the ground bar in the main AC distribution panel 5 Route and connect a ground wire to the outlet that will be supporting the AC load T2240 AC Panel Ho eB REUTHAL ii Gene
31. arger Figure 2 4 In this configuration power from both the external sources of AC and the inverter 1s removed from the loads This allows the inverter the connected loads or any other installed equipment beyond the ACCB to be serviced Both external AC source and Inverter OFF AC Input from Grid or Gen INVERTER INVERTER BYPASS DISCONNECT BOTH OFF TO DISCONNECT AC OUTPUT Figure 2 4 AC Output OFF AC Output to Loads Dual Inverters 240 Vac Loads WARNING Fire Hazard In a series stacked inverter installation 120 240 Vac with a bypass switch for each inverter both bypass switches must be in the same position If the bypass switches are not in the same position the resulting AC output of the two bypass switches may not be 180 out of phase from each other This can result in excess current on the neutral wire creating a potential fire hazard This can also result in less than 240 Vac output Loads requiring 240 Vac will not run 2 4 975 0046 01 01 Warranty and Product Information Warranty What does this warranty cover This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your Sine Wave Plus AC Conduit Box This watranty lasts for a Warranty Period of two 2 years from the date of purchase at point of sale to you the original end user customer This Limited Warranty is transferable to subsequent owners but only for t
32. duit Box Front View The ACCB comes pre wired for connection to a Sine Wave Plus inverter You must provide wires for connection from the AC distribution panel and from a generator and or utility to the ACCB This guide provides instructions for installing additional circuit breakers into the ACCB and for connecting the ACCB to the inverter and other system components 1 e utility panel AC distribution panel grounding and generator Important Before installing the ACCB read all instructions and cautionary markings located in this guide and in your inverter manual 975 0046 01 01 Specifications YVAN ANS ALARA AAR AAA ORAARRRAAARRAAA ee Dimensions Weight Shipping Weight Operating Voltage Breakers Bypass Inverter Input Output Operating Temperature Storage Temperature Enclosure Finish Color Regulatory 5 3 8 137 mm Specifications 15 1 8 H x 10 3 4 W x 8 7 8 D 384 mm x 273 mm x 225 mm 12 pounds 5 kg 15 pounds 7 kg 120 Vac 60 Amp SPST 60 Amp DPST 10 to 60 C 14 to 140 F 55 to 100 C 67 to 212 F Indoor rated Powdercoat White Certified by CSA to UL 1741 and CSA 107 1 01 10 3 4 273 mm 5 m ao 15 1 8 384 mm 13 5 8 346 mm E 20 mm 1 5 8 41 mm Figure 1 2 ACCB Dimensions not t
33. eakers and a lockout rocker NEU Neutral In Out mu Ih AC OUT TO LOADS AC IN FROM GRID OR GEN Figure 1 13 ACCB AC Terminal Block For Customer installed Wiring 975 0046 01 01 1 17 Installation Wiring for Off Grid Applications Using an AC Distribution Panel and an External Generator Disconnect The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off grid application using an AC distribution panel for the outputs and a 120 Vac generator for input Wiring instructions are provided for making ground connections first page 1 19 neutral connections second page 1 20 and hot connections last page 1 21 LEGEND 120V AC Generator Ground Neutral HOT Owner supplied H HOT Factory installed KJ External i Generator om fa c O 0 0 O gt 0 Disconnect B 1 yM Switch be i panes AC Distribution Panel 120 Vac Only NEUTRAL Al HOT i a i i B I a L E E B E E a i I B i AC TERMINAL 2 B a a B Na Neutral to Ground Bond GROUND nnnm na SSS SSS SS SSS i LS To Primary System Ground Figure 1 14 Wiring an Off Grid Application Using an AC Distribution Panel and an External Generator Disconnect Switch WARNING Shock Hazard Ensure that all AC and DC power is not live before proceeding 1 18 975 0046 01
34. es vary depending on the location and type of installation Electrical installations must meet local and national wiring codes Installations of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy RE System Installers For a list of Xantrex Certified RE dealers please visit our website at www XantrexREdealers com Important Be sure to obtain the appropriate permits if necessary prior to starting this installation Installation Tools and Materials Tools Required Hardware Materials Required 975 0046 01 01 The following tools may be required for installing this equipment n Ean Een een oO oO oO oOo Oo E Wire strippers Assorted open end wrenches or socket wrench and fittings Torque wrench Electrical tape Multi meter AC DC volts frequency Assorted Phillips screw drivers 3 16 Allen Hex head driver Slotted screw driver Level Pencil Utility knife The following materials may be required for completing this installation YOO Oo oO Conduits bushings and appropriate fittings for wire runs Wire nuts Electrical wire of appropriate size and length Breaker Panels Ground busses bars and or rods Six 10 wood screws or 1 4 inch 6 mm lag bolts and washers l 5 Installation Wiring Scenarios Wiring scenarios will depend upon the configuration of the overall system 1 e Off Grid or On Grid Pre installation and mounti
35. he unexpired portion of the Warranty Period 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
36. iate knockouts from the ACCB for wire runs from utility and or inverter panels a generator and or additional inverters See Figure 1 7 for the locations of the knockouts on the ACCB If additional circuit breakers are to be added to the ACCB remove one knockout on the top cover for each additional circuit breaker to be installed See Figure 1 6 for the locations of the knockouts on the ACCB top cover Ensure that there are no metal shavings in the ACCB or inverter before proceeding with the rest of the installation Install bushings in knockouts provided to protect the wires from damage Slots for ACCB Cover Tabs HaT 1 io rn a i iH ii E B HH 3 4 and 1 19 mm and 25 mm Dual Knockouts DDIIN i MTT MT TTT NTE TTT TTT i 7 E i Figure 1 5 SW Plus Inverter AC Side Showing Knockout Location Important If larger knockouts are required an electricians knockout punch may be used for larger size knockout holes if necessary 1 8 975 0046 01 01 Pre installation Knockout Locations for four additional circuit breakers Figure 1 6 Knockouts on ACCB Top Cover for Additional Circuit Breakers Accessory Cable Slots 975 0046 01 01 Two slots on the top and bottom of the ACCB base are provided to route the cables for the Inverter Stacking Cable Series ISC S and the remote Inverter Control Module ICM if used These slots are covered by small hole pl
37. ire from the generator or generator disconnect and connect it to one of the neutral terminals in the ACCB 4 Route and connect a neutral wire from one of the neutral connections in the ACCB to the outlet that will support the AC load 1207 AC Generator HOT NEU GND Generator Disconnect Breaker AC Loads ae ee ee a J F my fF a Neutral to 2 f Ground Bond C i ie To Primary System Ground Figure 1 24 Neutral Connections for an Off grid Application with Additional Circuit Breakers in the ACCB 1 28 975 0046 01 01 Wiring for Off Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the hot connections 1 Connect the factory installed hot black wire from the Inverter Input Breaker in the ACCB to the AC2 GEN terminal in the inverter 2 Connect the factory installed hot wire black from the Inverter Output Breaker in the ACCB to the INV OUT terminal in the inverter 3 Connect another hot black wire from the generator disconnect breaker to the AC IN terminal in the ACCB Connect the other end of that same hot black wire to the bottom of the generator disconnect breaker 4 Connect another hot black wire from the AC OUT terminal in the ACCB to the bottom of the new circuit breaker 5 Connect the hot black wire from the generator to the top of the generator disconnect breaker 6 Connect another hot black wire from the top of the addition
38. ll mounted or shelf mounted and secure with appropriate lag bolts See the Sine Wave Plus Inverter Charger Owner s Manual for specific mounting instructions for the inverter 2 Line up the ACCB at the AC end of the inverter so that the mounting rails are aligned together and the ACCB base is as close to the inverter as possible The gap between the ACCB and the inverter should be no more than 1 16 inch 3 Secure the ACCB in place with six 10 wood screws of an appropriate length or lag bolts in the six mounting and keyhole slots on the mounting rails of the ACCB 4 Leave the top cover off the ACCB to proceed with wire connections Mounting holes Mounting Rails and keyhole slots for ACCB ACCB Base with top cover i 4 it xantrex Sine Wave Plus Inverter Charger removed Mounting holes and keyhole slots for ACCB Sine Wave Plus Inverter Charger Figure 1 10 Installing the ACCB on the Sine Wave Plus Inverter Charger 1 14 975 0046 01 01 Pre Wiring Preparation Pre Wiring Preparation The ACCB is pre wired at the factory and ready for connection to the Sine Wave Plus Inverter Charger The factory installed wires are labeled to assist with the installation procedure A WARNING Electrical Hazard Do not remove or alter in any way the pre installed factory wiring Any changes can result in personal injury and or equipment damage and will void your warranty A WARNING Fire Hazard A possible fire
39. 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 AC 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 Information About Your System As soon as you open your Sine Wave Plus AC Conduit Box package record the following information and be sure to keep your proof of purchase 1 Purchased From 1 Purchase Date WA 4 975 0046 01 01 Index A abbreviations and acronyms 1v AC conduit box ACCB introduction 1 2 specifications 1 3 AC load breakers 1 13 AC wiring for dual inverters 1 39 additional accessory wiring 1 38 additional breakers in the ACCB 1 13 Auxiliary Load Module ALM wiring for 1 38 B breakers 1 3 DIN rail 1 13 owner installed 1 13 bypass switch 1 4 AC output OFF 2 4 bypass operation 2 3 normal operation 2 3 C Customer Service email WA 1 fax number WA 1 phone number WA 1 D DIN rail 1 13 dual inver
40. n material authorization policy WA 3 return under warranty WA 3 terms and conditions WA 1 wiring additional accessories 1 38 grounding the ACCB 1 19 1 20 1 21 1 23 1 24 1 25 1 27 1 28 1 29 1 31 1 32 1 33 1 35 1 36 1 37 X Xantrex Authorized Service Center ASC WA 1 WA 3 Customer Service WA 1 WA 4 web site 1V IX 2 975 0046 01 01 Xantrex Technology Inc 360 435 8826 Tel 360 435 3547 Fax 800 670 0707 Toll Free North America customerservice xantrex com wWww xantrex com 975 0046 01 01 Printed in usa
41. nformation is provided at the end of the guide About This Guide Conventions Used The following conventions are used in this guide A WARNING Warnings identify conditions that could result in personal injury or loss of life AN CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warning Abbreviations and Acronyms AC ACCB ALM ASC AWG DC EPO GSM ICA ICM ISC S RMA SP 1 SEMS Screw Related Information Alternating Current AC Conduit Box Auxiliary Load Module Authorized Service Center American Wire Gauge Direct Current Emergency Power Off Generator Start Module Inverter Communications Adapter Inverter Control Module Inverter Stacking Control Series Return Material Authorization Safety Plate Screw with a captive lockwasher You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com 975 0046 01 01 Important Safety Instructions 975 0046 01 01 WARNING This chapter contains important safety and operating instructions for Sine Wave Plus AC Conduit Boxes ACCB Read and keep this Sine Wave Plus AC Conduit Box ACCB Installation Guide for future reference 1 Before installing the ACCB read all instructions and cautionary markings on the ACCB and
42. ng instructions apply to all configurations Follow the instructions from page 1 7 to page 1 17 for all installations After the pre installation procedures have been completed select the wiring scenario that applies to your configuration Once you have completed the wiring instructions for your specific application proceed to the Operation section Off Grid Applications The following Off Grid scenarios are covered in this guide Off Grid Applications using an AC distribution panel sub panel and an external generator disconnect switch See page 1 18 for wiring instructions for this application Off Grid Applications using an additional circuit breaker in the ACCB for a generator disconnect See page 1 22 for wiring instructions for this application Off Grid Applications using additional circuit breakers in the ACCB for AC loads and a generator disconnect See page 1 26 for wiring instructions for this application On Grid Applications 1 6 The following On Grid scenarios are covered in this guide On Grid Applications with generator backup using an AC Distribution Panel and an additional circuit breaker in the ACCB for a generator disconnect See page 1 30 for wiring instructions for this application On Grid Applications using additional circuit breakers in the ACCB for AC distribution 1 e no sub panel See page 1 34 for wiring instructions for this application 975 0046 01 01 Pre installation
43. nts 1 7 Knockout Preparation 1 8 Accessory Cable Slots 1 9 Removing and Replacing the ACCB Cover 1 11 Installing Additional Breakers 1 13 Mounting the ACCB to the Inverter 1 14 Pre Wiring Preparation 1 15 Accessing the Terminal Blocks 1 15 Wire Sizes and Disconnect Requirements 1 15 Wiring for Off Grid Applications Using an AC Distribution Panel and an External Generator Disconnect 1 18 Wiring for Off Grid Applications using an AC Distribution Panel and an Internal Generator Disconnect 1 22 Wiring for Off Grid Applications Using Additional Circuit Breakers in the ACCB Only 1 26 Wiring for On Grid Applications Using an AC Distribution Panel and an Internal Generator Disconnect Breaker 1 30 Wiring for On Grid Applications Using Additional Circuit Breakers in the ACCB Only 1 34 Additional Accessory Wiring 1 38 Wiring for Dual Inverter Configurations 1 39 Installing the ISC S Cable
44. o scale 975 0046 01 01 lt p gt 7 9 16 192 mm 9 3 16 234 mm 1 3 Installation Bypass Switch Assembly The bypass switch assembly in the ACCB is designed for 120 Vac applications and comes with two 60 amp circuit breakers one SPST and one DPST The breaker pair is equipped with a lockout rocker that allows only one breaker to be ON at any given time The bypass switch allows the generator or grid to provide power to the inverter loads in the event that the inverter is disabled or removed for Service For more information see Chapter 2 Operating the ACCB in this guide A WARNING Electrical Hazard If the inverter is removed from service while the bypass is used live circuits inside the ACCB will not be guarded from accidental touch Be sure to install the Safety Plate SP 1 to prevent accidental electrocution if the inverter is removed from the system Safety Plate SP 1 1 4 A Safety Plate SP 1 is provided to enclose the ACCB to prevent accidental contact with any AC power within the ACCB 1f the inverter is ever removed from the system configuration The safety plate is not used in the initial installation and should be stored in a convenient location See page 1 40 for installation instructions for the Safety Plate Figure 1 3 Safety Plate SP 1 975 0046 01 01 Code Compliance Code Compliance Governing installation cod
45. r which must be connected to the inverter system equipment ground Important Safety Instructions Explosive gas precautions 1 Working in the vicinity of lead acid batteries is dangerous Batteries generate explosive gases during normal operation Therefore you must read this guide and follow the instructions exactly before installing the ACCB 2 To reduce the risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed vi 975 0046 01 01 Contents Important Safety Instructions 1 Installation Introduction 1 2 Specifications 1 3 Bypass Switch Assembly 1 4 Safety Plate SP 1 1 4 Code Compliance 1 5 Installation Tools and Materials 1 5 Wiring Scenarios 1 6 Off Grid Applications 1 6 On Grid Applications 1 6 Pre installation 1 7 Location 1 7 Ventilation Requireme
46. r ati Diegom J Breaker HETH A Hga Lae aj i bb se PEI Figure 1 31 Ground Connections for an On grid Application Using Additional Circuit Breakers in the ACCB Only 975 0046 01 01 1 35 Installation To make the neutral connections 1 Ensure there is only one neutral to ground bond in the system In this case it would be in the main AC distribution panel Important Ensure there is only one neutral to ground bond in the entire system See the Sine Wave Plus Inverter Charger Owner s Manual for additional information regarding the neutral to ground bond requirements 2 Connect the neutral white wire from the neutral bar in the main AC distribution panel to one of the neutral terminals in the ACCB 3 Connect the factory installed neutral wire white in the ACCB to the NEU 1 terminal in the inverter 4 Connect the neutral white wire from the generator and connect it to one of the neutral terminals in the ACCB 5 Route and connect a neutral white wire from one of the neutral terminals in the ACCB to the outlet that will be supporting the AC load TIMON AC Pare u0 elC m E Neutralta 2 Ground Bernd 120V AG Generator D A ETE GROUND Pocepooeeor l l iaamarator NE et ree te ee ea il I Disconnect eae bd Figure 1 32 Neutral Connections for an On Grid Application Using Additional Circuit Breakers
47. r to the ground bar in the main AC distribution panel 122404 AC Panal ife eae LEGEND Grund Peete HOT ihar mupp HOT acka ataia 120V AC G n ralo ii e pE r E E i E E E J a HOT NEW CNO E GOROUD Figure 1 27 Ground Connections for an On Grid Application with an AC Distribution Panel sub panel and a Generator Disconnect Breaker in the ACCB 975 0046 01 01 Installation To make the neutral connections 1 Ensure there is only one neutral to ground bond in the system In this case it would be in the main AC distribution panel Important Ensure there is only one neutral to ground bond in the entire system See the Sine Wave Plus Inverter Charger Owner s Manual for additional information regarding the neutral to ground bond requirements 2 Connect the neutral white wire from the neutral bar in the main AC distribution panel to one of the neutral terminals in the ACCB 3 Connect a neutral white wire from the sub panel to one of the neutral terminals in the ACCB 4 Connect the factory installed neutral wire white in the ACCB to the NEU 1 terminal in the inverter 5 Connect the neutral white wire from the generator or generator disconnect and connect it to one of the neutral terminals in the ACCB They AC Panal Li caji Main AC Distribution ses SS Panel F a j A i IAN T Perini k LEGEND Ns N a
48. stallation Neutral to Ground Bown To make the neutral connections 1 Create only one neutral to ground bond in the system In this case it would be in the main AC distribution panel Important Ensure there is only one neutral to ground bond in the entire system See the Sine Wave Plus Inverter Charger Owner s Manual for additional information regarding the neutral to ground bond requirements 2 Connect the neutral white wire from neutral bar in the AC distribution panel to one of the neutral terminals in the ACCB 3 Connect the factory installed neutral wire white in the ACCB to the NEU2 terminal in the inverter 4 Connect the neutral white wire from the generator and connect it to one of the neutral terminals in the ACCB LEGEND ee i Minia HIT A ute HOT jien rire S 120 AC Generator HOT GND External Gennaio Disconnect Switch ee es ee 22 AC Distribution Panel 120 Vac Only ha UT Fa Tana a a a mmm SSS ss 2S SSE a oes To Primary syelemn Ground Figure 1 16 Neutral Connections for an Off Grid Application with an AC Distribution Panel and an External Generator Disconnect 1 20 975 0046 01 01 Wiring for Off Grid Applications Using an AC Distribution Panel and an External Generator Disconnect To make the hot connections 1 Connect the factory installed hot black wire from the Inverter Input Breaker in the
49. stallation and wiring instructions for the Sine Wave Plus AC Conduit Box ACCB The following topics are covered in this chapter For this topic See Introduction page 1 2 Specifications page 1 3 Bypass Switch Assembly page 1 4 Code Compliance page 1 5 Installation Tools and Materials page 1 5 Wiring Scenarios page 1 6 Pre installation page 1 7 Mounting the ACCB to the Inverter page 1 14 Pre Wiring Preparation page 1 15 Off Grid Wiring page 1 18 through page 1 29 On Grid Wiring page 1 30 through page 1 37 Wiring for Dual Inverter Configurations page 1 39 Installation Introduction 1 2 The ACCB connects to the AC side of a Sine Wave Plus inverter and accepts AC conduit runs It protects the cable connections to the inverter and provides an inverter bypass for a single AC source and AC disconnect breakers Additional circuit breakers may be added to the ACCB Use Square D Type QOU DIN rail mounted breakers which can be readily purchased from most electrical suppliers Square D filler plates QOFP may be used to refill a knockout panel if the knockout is no longer used or removed in error Outer Side inn Inverter Side f Bypass Switch Assembly i Covei tabs Knockout panels for Inverter Bypass AC Disconnect additional circuit Circuit Breaker Circuit Breaker breakers x4 Figure 1 1 AC Con
50. t it to the ground bar in the ACCB See the Sine Wave Plus Inverter Charger Owner s Manual for information regarding preparing the primary system ground 2 Connect the factory installed ground wire green in the ACCB to the AC ground bar in the inverter 3 Prepare the cabling from the generator Route cable s hot neutral and ground from the generator into one of the knockouts prepared in the ACCB Connect the ground wire green from the generator to the ground bar in the ACCB 4 Route and connect a ground wire from the ground bar in the ACCB to the outlet that will support the AC load 120Y AC Generator me mm Generator Disconnect Breaker AC Loads ti I i ii I i I I i Tt rie a a Neutral ta Ground Bond To Primary system Ground Figure 1 23 Ground Connections for an Off Grid Application with Additional Circuit Breakers in the ACCB 975 0046 01 01 1 27 Installation To make the neutral connections 1 Create only one neutral to ground bond in the system In this case it would be in the ACCB Important Ensure there is only one neutral to ground bond in the entire system See the Sine Wave Plus Inverter Charger Owner s Manual for additional information regarding the neutral to ground bond requirements 2 Connect the factory installed neutral wire white in the ACCB to the NEU2 terminal in the inverter 3 Connect the neutral white w
51. ters wiring for 1 39 email contacting Customer Service by WA 1 Emergency Power Off EPO wiring for 1 38 F fax number for Customer Service WA 1 G Generator Start Module GSM wiring for 1 38 I Information about Your System form W A 4 installation additional breakers in ACCB 1 13 codes 1 5 knockout preparation 1 8 materials 1 5 removing cover 1 12 tools 1 5 inverter purchase date WA 4 Inverter Communications Adapter ICA wiring for 1 38 Inverter Control Module ICM wiring for 1 38 Inverter Stacking Control Series ISC S cable ACCB slots for 1 10 additional accessory wiring 1 38 grommets for ACCB slots 1 12 install for dual inverters 1 39 ISC S ICM cable slots 1 12 1 39 K knockouts location on the ACCB 1 10 location on the inverter 1 8 preparation 1 8 M materials required for installation 1 5 neutral bond for dual inverters 1 39 O operation of bypass switch 2 2 P preparation for installation 1 2 proof of purchase WA 4 purchase date W A 4 Index R return material authorization RMA policy WA 3 return procedure under warranty W A 3 RMA number WA 4 S safety instructions V V1 Safety Plate SP 1 1 40 series stacked inverters see dual inverters specifications for the ACCB 1 3 T telephone number for Customer Service WA 1 tools required for installation 1 5 W warranty out of warranty service WA 4 retur
52. the top and bottom of the cover Place the loose screws and washers somewhere safe where they will not be lost 2 Lift the cover off the ACCB If the ACCB is already installed on the inverter then slide the cover away from the inverter before lifting to remove the ACCB cover tabs from the inverter slots To replace the ACCB cover 1 Place the cover on top of the ACCB with the screw holes lined up If the ACCB is already installed on the inverter then first insert the three cover tabs into the appropriate slots on the AC side of the inverter 2 Replace the 12 Phillips screws and lock washers that were removed from the front and tighten into place Torque the 12 Phillips screws to 26 28 in lbs 4 Replace the 8 Phillips head Sems screws from the top and bottom of the chassis 5 Torque the 8 Phillips head Sems screws to 19 211in lbs 975 0046 01 01 1 11 Installation Remove these 8 Phillips head Sems Remove these 12 Phillips screws and lock washers from the front of the chassis When screws and washers from the top and replaced torque to 26 28 in lbs bottom of the chassis When replaced torque to 19 271 in lbs Top Cover Knockout panels for additional circuit breakers Hole Plugs for the ACCB B i aa ISC S and ICM cable slots ISC S and ICM cable slots Hole Plugs for the ISC S and ICM cable slots ISC S and ICM AC Terminal Block cable slots Figure
53. tions for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect 975 0046 01 01 1 25 Installation Wiring for Off Grid Applications Using Additional Circuit Breakers in the ACCB Only The following diagram shows the complete wiring diagram for wiring the ACCB and Sine Wave Plus Inverter inputs and outputs in an off grid application using additional circuit breakers in the ACCB for the outputs and a 120 Vac generator for input This diagram also includes the use of a generator disconnect breaker in the ACCB Wiring instructions are provided for making ground connections first page 1 27 neutral connections second page 1 28 and hot connections last page 1 29 LEGEND 120V AC Generator Neutral HOT Owner supplied Additional AC Load oe HOT Factory installed Circuit Breaker Generator Disconnect Breaker Sine Wave Plus Inverter Charger ACIaSiie Neutral to Ground Bond p e emee To Primary System Ground Figure 1 22 Wiring an Off Grid Application Using Additional Circuit Breakers in the ACCB Only WARNING Shock Hazard Ensure that all AC and DC power is not live before proceeding 1 26 975 0046 01 01 Wiring for Off Grid Applications Using Additional Circuit Breakers in the ACCB Only To make the ground connections 1 Prepare the primary system ground and routing it through one of the knockouts prepared in the ACCB connec
54. to provide service contact Xantrex directly at Phone 1 800 670 0707 toll free 1 360 435 8826 direct Fax 1 360 435 3547 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 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 975 0046 01 01 WA 1 Warranty and Product Information Proof of purchase may be in any one of the following forms e The dated purchase receipt from the original purchase of the product at point of sale to the end user or e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or e The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs 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 physic
55. tor into one of the knockouts prepared in the ACCB Connect the ground wire green from the generator to the ground bar in the ACCB LEGEND 120V AC Generator ccc rim Miia SRT HOT CMT p HOT NEU GND HOT jli i ee ee te CSieraeretor Disconnect Breaker AC Distribution Panel 4 120 Vac Only NEUTRAL e HOT E L iz m Neutral bt isround Bond E E E a o cima To Primary Syeiam Ground Figure 1 19 Ground Connections for an Off Grid Application with an AC Distribution Panel and an Internal Generator Disconnect Breaker 975 0046 01 01 1 23 Installation To make the neutral connections 1 Create only one neutral to ground bond in the system In this case it would be in the main AC distribution panel Important Ensure there is only one neutral to ground bond in the entire system See the Sine Wave Plus Inverter Charger Owner s Manual for additional information regarding the neutral to ground bond requirements 2 Connect the neutral white wire from the neutral bar in the AC distirbution palen to one of the neutral terminals in the ACCB 3 Connect the factory installed neutral wire white in the ACCB to the NEU2 terminal in the inverter 4 Connect the neutral white wire from the generator and connect it to one of the neutral terminals in the ACCB LEGEND 120V AC Generator occa ri Minia N
56. ugs if these accessories are not used If your configuration will include the use of the ISC S or remote ICM accessories then determine which slot s will be needed and remove the hole plug s for that slot only Do not remove any hole plugs from slots that will not be used 1 9 Installation 1 2 and 3 4 13mm and 19 mm Dual Knockout See below for location of knockouts on vented end 3 4 and 1 19 mm and 25 mm Dual Knockouts x2 1 2 and 3 4 13 mm and 19 mm Dual Knockout Slots for optional ISC S and ICM cables 3 4 and 1 19 mm and 25 mm Dual Knockouts x2 Slots for optional ISC S and ICM cables Vented End Knockouts 1 2 and 3 4 as 13 mm and 19 mm 2 1 2 and 3 4 Dual Knockout 13 mm and 19 mm Dual Knockout 3 4 and 1 SS 19 mm and 25 mm SS S35 22220 _ 3 4 and 1 Dual Knockout S gt 19 mm and 25 mm Dual Knockout Figure 1 7 ACCB Knockout Locations 1 10 975 0046 01 01 Pre installation Removing and Replacing the ACCB Cover Remove the top cover to install additional breakers and to connect the AC wiring of the inverter to the ACCB See Figure 1 8 for the locations of screws and cover tabs To remove the ACCB cover 1 Remove the three 12 Phillips screws and lock washers from the front of the cover and the two 8 Phillips head Sems screws from
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