Conext Core XC-NA Series Grid Tie Photovoltaic Inverter

Transcription

1 Conext Core XC-NA Series Grid Tie Photovoltaic Inverter Planning and Installation Manual B August

2 Copyright 2016 Schneider Electric. All Rights Reserved. 3M Fire Barrier Water Tight Sealant 3000 WT is owned by 3M. PPG Industries PR-821 is owned by PPG Industries, Inc. FST Foam Sealant is owned by American Polywater Corporation. Rustoleum is a trademark of Rust-Oleum Corporation. Krylon is a trademark of Sherwin-Williams. Abesco is a trademark of LPC INDUSTRIAL SERVICES PTE LTD. All other trademarks are owned by Schneider Electric Industries SAS or its affiliated companies. Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER (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 LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, 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; AND (C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT Document Number: B Date: August 2016 Contact Information For country-specific details, please contact your local Schneider Electric Sales Representative or visit the Schneider Electric Solar Business website at: Information About Your System As soon as you open your product, record the following information and be sure to keep your proof of purchase. Serial Number Product Number Purchased From Purchase Date

3 Important Safety Information Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Please Note NOTICE NOTICE is used to address practices not related to physical injury. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction, installation, and operation of electrical equipment and has received safety training to recognize and avoid the hazards involved.

4 Audience This manual is intended for anyone who is planning or performing the installation of a Conext Core XC-NA Series Inverter. Installers must be familiar with all the safety regulations pertaining to installing high-voltage equipment as dictated by local code. Installation must be performed by qualified personnel. Qualified personnel have training, knowledge, and experience in: Installing electrical equipment and PV input systems (up to 1000 V). Applying all applicable installation codes. Analyzing and reducing the hazards involved in performing electrical work. Selecting and using Personal Protective Equipment (PPE). Configuration, servicing, and maintenance must be performed by authorized service personnel only. Authorized service personnel meet the requirements for a qualified installer, plus they have received specific training from the manufacturer on servicing the Conext Core XC-NA Series. Do not open doors or covers or attempt any servicing, maintenance, or other corrective actions unless you meet the requirements for authorized service personnel. This manual does not contain information regarding servicing or de-energization for servicing. Authorized service personnel should refer to the Conext Core XC-NA Series Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ) and the Conext Core XC-NA Series Conext Core XC-NA Series Commissioning and Configuration Manual (document number CM-XC-012).

5 About Purpose Abbreviations and Acronyms This manual provides explanations and procedures for planning the installation and installing the Schneider Electric Conext Core XC-NA SeriesGrid Tie Photovoltaic Inverters. Operating instructions are available in the Conext Core XC-NA Series Grid Tie Photovoltaic Inverter Operation Manual (document number ). Commissioning and Configuration instructions are available to authorized service personnel in the Conext Core XC-NA Series Commissioning and Configuration Manual (document number CM-XC-012). ANSI GEC GFDI HVAC IEC NFPA PE PPE PV RMS SELV VAC VDC American National Standards Institute Grounding electrode conductor Ground fault detection interrupter Heating, ventilation, and air-conditioning International Electrotechnical Commission National Fire Protection Association Protective earth (ground) Personal Protective Equipment Photovoltaic Root mean square Safety Extra Low Voltage Volts (alternating current) Volts (direct current) Related Documents You will need to have access to the following related documents: Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ) Conext Core XC-NA Series Grid Tie Photovoltaic Inverter Operation Manual (document number ) Conext Core XC-NA Series Grid Tie Photovoltaic Inverter Commissioning and Configuration Procedure and Checklist (document number CM-XC-012) Conext Core XC-NA DC Fuse Recombiner and Conext Core XC-NA DC Fused Disconnect Recombiner Installation Instructions (document number )

6 Related Information You can find more information about Schneider Electric as well as its products and services at: For specific information on Solar, visit the Schneider Electric Solar Business website at:

7 Product Safety Information Conext Core XC-NA Series Planning and Installation Manual Product Safety Information This manual contains important safety instructions for the Conext Core XC-NA Series that must be followed during installation procedures. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Read all instructions, cautionary markings, and all other appropriate sections of this manual before installing or maintaining the Conext Core XC-NA Series. To be installed only by qualified personnel and serviced only by authorized personnel equipped with appropriate personal protective equipment, and following safe electrical work practices. This inverter is energized from multiple sources: the PV array, the AC grid, and the external auxiliary AC source (if used 1 ). Before opening doors on the AC cabinet, power stage cabinet, or DC cabinet you must perform the following steps: Consult the system diagram to identify all power sources. De-energize, lock out, and tag out all power sources following the "Installation Lockout and Tag-out Procedure" on page 11. Wait at least five minutes for internal capacitors to discharge to safe voltages. Operation of the switches in or on the inverter does not remove all power from this inverter. Switch terminals remain live unless the PV, AC, and external auxiliary AC sources have been disconnected externally. The Conext Core XC-NA Series Inverter must be used with a Conext Core XC-NA DC Fuse Recombiner, Conext Core XC-NA DC Fused Disconnect Recombiner or other combiner with identical hole pattern Before servicing, test using a meter rated at least 600 VAC/CAT IV and 1000 VDC/CAT III, to ensure all circuits are de-energized. For proper circuit isolation, connect a suitably rated 2 isolating transformer between the output of the inverter and the utility power line connections. The transformer must be selected and installed in accordance with this manual. The transformer must be an isolation type having separate primary and secondary windings. See the Electrical Diagram on page 44 for details. This inverter must be mounted on a non-flammable surface. See Anchoring Requirements and Layout on page 38 for details. Failure to follow these instructions will result in death or serious injury. 1 The XC733-NA will ll always be configured to use external auxiliary AC source. 2 Minimum 540 kva rated for XC540-NA, minimum 630 kva rated for XC630-NA, minimum 680 kva rated for XC680-NA, minimum 733 kva rated for XC733-NA. See"Transformer Requirements" on page B This manual is intended for use by qualified personnel only 7

8 Product Safety Information WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE HAZARD OF EQUIPMENT DAMAGE Obey the manual s instructions, as well as all physical, electrical, and environmental specifications shipped with the Conext Core XC-NA Series. Failure to follow these instructions can result in death, serious injury, or equipment damage. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE In all installations, the installer must provide external disconnecting means for the PV input, AC output, and external auxiliary AC source input wiring. The overcurrent protection devices within the Conext Core XC-NA Series Inverter are intended to provide adequate protection for Conext Core XC-NA Series Inverter circuitry only. The installer is responsible for determining whether additional external overcurrent protection is required for the AC output and external auxiliary AC source wiring, in accordance with the applicable installation codes. Failure to follow these instructions can result in death, serious injury, or equipment damage. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Do not install or attempt to operate the Conext Core XC-NA Series Inverter if it has been dropped or has received more than cosmetic damage during transport or shipping. If the Conext Core XC-NA Series Inverter is damaged, or suspected to be damaged, contact customer service. Failure to follow these instructions can result in death, serious injury, or equipment damage. 8 This manual is intended for use by qualified personnel only B

9 Product Safety Information Conext Core XC-NA Series Planning and Installation Manual UNINTENDED USE WARNING The Conext Core XC-NA Series Inverter is not intended for use in connection with life support systems or other medical equipment or devices. The Conext Core XC-NA Series Inverter can only be used in grid-interconnected PV systems with PV modules. It is not suitable for any other application areas. Failure to follow these instructions can result in death, serious injury, or equipment damage. WARNING HAZARD OF CRUSH INJURY AND EQUIPMENT Use caution and follow the instructions in this manual for correct lifting, moving, and mounting of the Conext Core XC-NA Series Inverter. The Conext Core XC-NA Series Inverter can topple over if tipped. You must securely attach the Conext Core XC-NA Series Inverter to the mounting surface after positioning. Failure to follow these instructions can result in death, serious injury, or equipment damage. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Do not defeat or change the settings of the heater thermostat and dew point controller located inside the Conext Core XC-NA Series Inverter as these heaters are installed to help prevent condensation inside the Conext Core XC-NA Series Inverter. Do not change the settings on the AC circuit breaker. Do not defeat any of the door interlocks. They are an integral part of the Conext Core XC-NA Series Inverter protection system. Failure to follow these instructions can result in death, serious injury, or equipment damage. CAUTION HAZARD OF BURNS AND EQUIPMENT DAMAGE Components become hot during normal operation. Surfaces inside of the Conext Core XC-NA Series Inverter may continue to be hot after the five minute duration required to discharge the internal capacitors. After opening the cabinet doors, follow all posted warnings and use caution before touching conductive surfaces. Failure to follow these instructions can result in injury or equipment damage B This manual is intended for use by qualified personnel only 9

10 Product Safety Information CAUTION HAZARD OF OVERHEATING AND EQUIPMENT DAMAGE Keep the supply air and exhaust air areas unobstructed. Follow the installation, ventilation, and clearance instructions. Failure to follow these instructions can result in injury or equipment damage. NOTICE HAZARD OF EQUIPMENT DAMAGE Conext Core XC-NA Series Inverter electronics can be destroyed by electrostatic charge. Wear electrostatic protection gear, and use anti-static tools and procedures when installing the Conext Core XC-NA Series Inverter. Failure to follow these instructions can result in equipment damage. DUST OR MOISTURE INGRESS NOTICE The service area around the Conext Core XC-NA Series Inverter must be dry and free of debris during installation, commissioning, servicing or preventive maintenance. If the service area is not dry and free of debris, the installation, commissioning, servicing or preventive maintenance must be postponed until the environmental conditions have cleared. Do not open cabinet doors and covers or remove screens and filters when the environmental conditions indicate a possibility of dust, rain, or strong wind entering the cabinets. Close the doors when you are not working in the cabinets. Failure to follow these instructions can result in equipment damage and can compromise the environmental protection of the Conext Core XC-NA Series. 10 This manual is intended for use by qualified personnel only B

11 Product Safety Information Conext Core XC-NA Series Planning and Installation Manual Personal Protection Follow these instructions to help protect yourself while working with the Conext Core XC-NA Series. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Never work alone when installing the Conext Core XC-NA Series. A team of two is required until external sources are properly de-energized, locked out and tagged out, and verified de-energized with a meter, according to the Installation Lock-out and Tagout Procedure on page 11. Thoroughly inspect the Conext Core XC-NA Series prior to energizing. Verify that no tools or materials have inadvertently been left inside the cabinets and that all guards and barriers are properly reinstalled and secured. Failure to follow these instructions will result in death or serious injury. Qualified personnel must be equipped with appropriate personal protective equipment including the following: Electrical rated rubber insulating gloves with leather protectors (optional liners) Safety glasses or goggles Arc-rated long sleeve shirt and arc-rated pants OR arc-rated coverall OR arc-rated flash suit Hearing protection Electrically rated footwear Arc-rated face shield with arc-rated hard hat and hood OR arc flash suit hood Minimum five LOTO locks and tags Voltage tester or multimeter with minimum ratings of 600 VAC/CAT IV and 1000 VDC/CAT III Check local safety regulations for other requirements. Installation Lock-out and Tag-out Procedure Lock-out refers to the practice of preventing de-energized circuits from being re-energized by putting locks on the disconnecting devices, holding them open. Tag-out refers to the practice of attaching a tag to the disconnect-device locks warning others not to operate the disconnect device and containing information relating to the lock-out, such as the person responsible, the reason, and the date and time. Combined, these two practices are called the lock-out and tag-out (LOTO) procedure. The installation LOTO procedure can only be used during installation if the Conext Core XC-NA Series has never been energized. This procedure cannot be used once the Conext Core XC-NA Series has been installed and energized for the first time. If the Conext Core XC-NA Series has been previously energized, additional steps are required to correctly LOTO the Conext Core XC-NA Series for troubleshooting and B This manual is intended for use by qualified personnel only 11

12 Product Safety Information service. These steps are detailed in the Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ) and must be performed by authorized service personnel. Follow all steps of this procedure to de-energize all sources of supply external to the Conext Core XC-NA Series. This allows access to all parts of all cabinets, including behind internal barriers, during installation. See Figure 1 for the locations of the parts of the Conext Core XC-NA Series referred to in the lock-out and tag-out steps. DANGER MULTIPLE SOURCES WITH HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE The Conext Core XC-NA Series inverter is energized from multiple sources: the PV array, the AC grid, and the external auxiliary AC source (if used 3 ). Before opening doors on the AC cabinet, power stage cabinet, or DC cabinet you must perform the following steps: Consult the system diagram to identify all power sources. De-energize, lock out, and tag out all power sources following the procedures in this chapter. Wait at least five minutes for internal capacitors to discharge to safe voltages. Before servicing, test using a meter rated at least 600 VAC/CAT IV and 1000 VDC/CAT III, to ensure all circuits are de-energized. The following procedure only applies to installation of an inverter, not to servicing. If the inverter is already installed, additional steps are needed to de-energize, LOTO, and verify internal voltages, and these steps must only be performed by authorized service personnel. Operation of the switches in or on the inverter does not remove all power from this inverter. Switch terminals remain live unless the PV, AC, and external auxiliary AC sources have been disconnected externally. Additional external disconnecting means for the PV, AC, and external auxiliary AC source (if used), capable of being locked out and tagged out, must be provided as part of the installation to help facilitate safe installation and for certain servicing operations. Failure to follow these instructions will result in death or serious injury. Refer to Figure 1 and follow these lock-out and tag-out steps: 1. Open the windowed cover located on the door of the AC cabinet. 2. Turn the ENABLE STATE/DISABLE STATE switch to the DISABLE STATE position. 3. Turn the inverter ON/OFF switch to OFF. 3 The XC733-NA will always be configured to use external auxiliary AC source. 12 This manual is intended for use by qualified personnel only B

13 Product Safety Information Conext Core XC-NA Series Planning and Installation Manual 4. Open, lock out, and tag out the AC output (grid) circuit at its external disconnecting means provided as part of the installation. 5. Open, lock out, and tag out all incoming PV input circuits at the external disconnecting means provided as part of the installation. 6. Open, lock out, and tag out the external auxiliary AC source (if used 4 ) at its external disconnecting means provided as part of the installation. 7. Wearing appropriate PPE and using a voltmeter with minimum ratings of 600 VAC/CAT IV and 1000 VDC/CAT III that has been tested on a known AC voltage source and a known DC voltage source before use, verify that all external circuits are de-energized by checking for zero voltage at all of the following locations: a. AC output (grid): Measure the voltage from each phase to ground and each phase to the other phases at the inverter side of the external disconnecting means provided as part of the installation. b. PV input: Measure the voltage from DC+ and DC- to ground and from DC+ to DC- at the inverter side of the external disconnecting means provided as part of the installation. c. External auxiliary AC source (if used): Measure the voltage from each phase to ground and from phase to phase at the inverter side of the external disconnecting means provided as part of the installation. 4 The XC733-NA will always be configured to use external auxiliary AC source B This manual is intended for use by qualified personnel only 13

14 Product Safety Information Figure 1 Conext Core XC-NA Series main external components 1 AC cabinet 2 Power stage (PS) cabinet 3 DC cabinet 4 ENABLE STATE/DISABLE STATE switch 5 Front panel user interface 6 Inverter ON/OFF switch 7 Main AC circuit breaker 8 PV Disconnect switch When steps 1-7 have been completed the external sources are verified de-energized, locked out, and tagged out. This completes the LOTO procedure for the external sources and the Conext Core XC-NA Series for first-time installation. 14 This manual is intended for use by qualified personnel only B

15 Contents Important Safety Information 3 Audience 4 About 5 Purpose 5 Abbreviations and Acronyms 5 Related Documents 5 Related Information 6 Product Safety Information 7 Personal Protection 11 Installation Lock-out and Tag-out Procedure 11 Introduction 23 Operator Interface Controls 24 ENABLE STATE/DISABLE STATE Switch 25 Inverter ON/OFF Switch 26 Front Panel User Interface 27 Local Ground Fault Status Indicator 28 Available Options 29 Local vs. Remote Monitoring 30 Setting the Communication Method 30 AC Circuit Breaker and PV Disconnect Switch 31 Planning 33 Conext Core XC-NA Series Requirements 34 Site Requirements 34 Conduit Entry 36 Anchoring Requirements and Layout 38 Grounding the Conext Core XC-NA Series Inverter 38 Installation at High Elevation 39 Indoor Configuration Ventilation Requirements 39 Heat Load 39 PV Shelter Requirements 39 Exhaust Duct Requirements 40 Venting Recommendations 41 PV Array Requirements 42 Number of PV Panels 42 Grounding the Array 43 Utility Side Requirements 43 Transformer Requirements B This manual is intended for use by qualified personnel only 15

16 Electrical Diagram 44 Installation 45 Unloading 46 Removing the Inverter from a Truck 47 Removing the Inverter from the Pallet 48 Mounting and Anchoring the Inverter 50 Connecting to a DC recombiner 51 Opening Access Doors 52 General Wiring Requirements 52 AC Circuit Breaker Trip Settings 53 Phase Rotation 53 Conductor Termination 54 Grounding 59 AC Wiring 59 Removing AC Barriers 59 Preparing the AC Cabinet Floor 62 Connecting the AC Output to the AC Cabinet 63 PV Array Wiring 65 Auxiliary AC Source Wiring 65 External AC Auxiliary Power Source 67 Internal AC Auxiliary Power Source 72 Remote Communication and Control Wiring 77 Modbus/RS-485 Wiring 78 Gateway TCP/IP Wiring 78 Connecting the Remote Communication and Control Devices 79 Masterpact Wiring for Grounded PV Configurations 83 Completing the Installation 84 Inspection 85 Visual Inspection 86 Reinstalling Internal Barriers 87 Arranging for Commissioning and Configuration 88 Specifications 89 System Specifications 90 Electrical Specifications 90 Physical and Environmental Specifications 91 Regulatory Specifications 93 Over Voltage, Under Voltage, Frequency, and Tolerances 93 Bolt Sizes and Torque Requirements This manual is intended for use by qualified personnel only B

17 Dimensions 96 Pre-Commissioning Checklist B This manual is intended for use by qualified personnel only 17

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19 Figures Figure 1 Conext Core XC-NA Series main external components 14 Figure 2 Conext Core XC-NA Series main external components 24 Figure 3 enable state/disable state switch and inverter on/off switch 27 Figure 4 Front panel user interface 28 Figure 5 Setting parameter control 31 Figure 6 AC circuit breaker and PV disconnect switch 32 Figure 7 Cabinet conduit entries, viewed from the bottom 36 Figure 8 DC Cabinet conduit entries, viewed from the side 37 Figure 9 Inverter anchor bolt pattern 38 Figure 10 Mounting locations: exhaust routing 41 Figure 11 PV shelter airflow with shroud 42 Figure 12 Conext Core XC-NA Series electrical diagram (sample only) 44 Figure 13 Using a fork lift 48 Figure 14 Removing bolts without lifting the inverter 49 Figure 15 Removing bolts by lifting the inverter with a forklift 49 Figure 16 Attaching lifting bar and using a crane sling 50 Figure 17 Micrologic 3.0 A (left) and Micrologic 5.0 A (right) 53 Figure 18 Graphical representation of three-phase voltages 54 Figure 19 Front view: Minimum required clearance between lugs 55 Figure 20 Front view: Minimum required clearance from the lugs to the flange 55 Figure 21 Front view: minimum required clearance from AC lugs to enclosure wall 56 Figure 22 Side view: minimum required clearance from lugs on L1 to the ground bar 56 Figure 23 AC terminal lug L-bus connections 57 Figure 24 DC terminal lug connections 58 Figure 25 Single point ground (PE) and GEC; ground bar 59 Figure 26 QS2 switch: shaft and bracket removal 60 Figure 27 Metal mesh barrier around Masterpact (AC cabinet) 60 Figure 28 Horizontal metal mesh barrier above Masterpact (AC cabinet) 61 Figure 29 External auxiliary AC source barrier (AC cabinet) 62 Figure 30 Main metal mesh barrier (AC cabinet) 62 Figure 31 Removing the AC floor plate 63 Figure 32 AC terminal connections from the external transformer 64 Figure 33 Bottom plastic barrier screws (DC cabinet) 65 Figure 34 Connecting XT4:1, XT4:2, and XT4:3 68 Figure 35 XT2 location in AC cabinet 69 Figure 36 Moving the voltage tap wire 70 Figure 37 XT19 location in DC cabinet B This manual is intended for use by qualified personnel only 19

20 Figure 38 Moving the voltage tap wire (120 V service receptacle) 71 Figure 39 XT2 location in AC cabinet 72 Figure 40 XT2 terminal block settings for internal auxiliary AC source 73 Figure 41 Moving the voltage tap wire 74 Figure 42 Moving the 120 V service receptacle to internal auxiliary AC 75 Figure 43 XT19 location in DC cabinet 76 Figure 44 Moving the voltage tap wire (120 V service receptacle) 77 Figure 45 DC cabinet conduit hole for communication and control cables 79 Figure 46 Routing the communication cable in the DC cabinet 80 Figure 47 XT14 terminal block 81 Figure 48 Connecting the communication cables 82 Figure 49 RJ-45 connector pin-out 82 Figure 50 XT14 terminal identification 83 Figure 51 Masterpact wiring for grounded PV configurations 84 Figure 52 Conext Core XC-NA Series dimensions This manual is intended for use by qualified personnel only B

21 Tables Table 1 Communication features 30 Table 2 AC Circuit Breaker Trip Settings 53 Table 3 Voltage ranges and transformer taps for auxiliary AC source 66 Table 4 TC1:TAP cable location for transformer tap 73 Table 5 XT19:3 cable location for transformer tap for 120 V service receptacle 76 Table 6 Electrical specifications 90 Table 7 Physical and environmental specifications 91 Table 8 Over/under voltage and over/under frequency 93 Table 9 Voltage and frequency tolerances 94 Table 10 AC terminal bolt size and torque values 94 Table 11 PV terminal bolt sizes and torque values B This manual is intended for use by qualified personnel only 21

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23 Introduction Conext Core XC-NA Series Planning and Installation Manual 1 Introduction What's in This Chapter? Operator Interface Controls 24 ENABLE STATE/DISABLE STATE Switch 25 Inverter ON/OFF Switch 26 Front Panel User Interface 27 Local Ground Fault Status Indicator 28 Available Options 29 Local vs. Remote Monitoring 30 Setting the Communication Method 30 AC Circuit Breaker and PV Disconnect Switch 31

24 Introduction Operator Interface Controls Figure 2 Conext Core XC-NA Series main external components 1 Exhausts 2 Front panel user interface behind cover 3 ENABLE STATE/DISABLE STATE switch behind cover 4 Inverter ON/OFF switch 5 AC circuit breaker behind cover 6 AC cabinet 7 Power stage cabinet 8 DC cabinet 9 PV Disconnect Switch behind cover 10 Ground fault status indicator *Air intakes at the rear of the Conext Core XC-NA Series. 24 This manual is intended for use by qualified personnel only B

25 Introduction Conext Core XC-NA Series Planning and Installation Manual ** Conext Core XC-NA Series Inverter shown with covers open; covers are closed during normal operation. All Conext Core XC-NA Series Inverters' covers must be closed and cabinet doors must be closed and locked during normal operation. For specific maintenance operations, Conext Core XC-NA Series Inverters have a feature that will allow the DC cabinet door to be opened without interrupting the Conext Core XC-NA Series Inverter's operation (opening any other doors will interrupt Conext Core XC-NA Series Inverter's operation). This feature is only intended to allow visual inspection of components or monitoring devices located inside the DC compartment while the inverter is running. The door must be closed again immediately after inspection. NOTICE DUST OR MOISTURE INGRESS Do not open cabinet doors and covers or remove screens and filters when the environmental conditions indicate a possibility of dust, rain, or strong wind entering the cabinets. Close the doors when you are not working in the cabinets. Failure to follow these instructions can result in equipment damage and can compromise the environmental protection of the Conext Core XC-NA Series. ENABLE STATE/DISABLE STATE Switch The Conext Core XC-NA Series Inverter has an ENABLE STATE/DISABLE STATE switch behind a cover located on the door of the AC cabinet, see Figure 3 on page 27. The cover has provisions for a lock to prevent unauthorized access, although this is not a lock-out and tag-out location. Use a 4 mm hex key to unlock the latch and open the cover in order to access the ENABLE STATE/DISABLE STATE switch. Under normal conditions, the ENABLE STATE/DISABLE STATE switch is in the ENABLE STATE position. The main AC circuit breaker and PV disconnect switch will not close unless the switch is in the ENABLE STATE position. The Conext Core XC-NA Series will not operate unless the switch is in the ENABLE STATE position. To change any grid parameter, the switch must be turned to the DISABLE STATE position. Turning the switch to the DISABLE STATE position initiates an immediate controlled shutdown of the Conext Core XC-NA Series and opens both the main AC circuit breaker and PV disconnect switch within the inverter. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Turning the switch to the DISABLE STATE position does not de-energize the Conext Core XC-NA Series; it only stops power production. Externally disconnect the PV, AC, and external auxiliary AC sources to de-energize the Conext Core XC-NA Series. Failure to follow these instructions will result in death or serious injury B This manual is intended for use by qualified personnel only 25

26 Introduction DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Turning the inverter ON/OFF switch to the ON position energizes auxiliary and control circuits. The upper section of the AC cabinet must be accessed only if wearing PPE appropriate for the hazards presented by the AC auxiliary circuit. The DC cabinet must be accessed only if wearing PPE appropriate for the hazards presented by both the DC input circuit and AC auxiliary circuit. Failure to follow these instructions will result in death or serious injury. Inverter ON/OFF Switch The Conext Core XC-NA Series has an inverter ON/OFF switch located on the AC cabinet door, see Figure 3. The inverter ON/OFF switch is also the auxiliary power switch. Under normal conditions, the inverter ON/OFF switch is in the ON position, providing the auxiliary power necessary for power production and for maintenance functions such as viewing and extracting data from the front panel user interface or performing software updates. The main AC circuit breaker and PV disconnect switch cannot be closed unless the switch is in the ON position. The Conext Core XC-NA Series will not restart unless the switch is in the ON position. To initiate a power cycle, the switch must be turned to the OFF position and then back to the ON position. Turning the switch to the OFF position initiates an immediate controlled shutdown of the Conext Core XC-NA Series and opens both the main AC circuit breaker and PV disconnect switch within the Conext Core XC-NA Series. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Turning the switch to the OFF position does not de-energize the Conext Core XC-NA Series; it only stops power production. Externally disconnect the PV, AC, and external auxiliary AC sources to de-energize the Conext Core XC-NA Series. Failure to follow these instructions will result in death or serious injury. 26 This manual is intended for use by qualified personnel only B

27 Introduction Conext Core XC-NA Series Planning and Installation Manual Figure 3 ENABLE STATE/DISABLE state switch and inverter ON/OFF switch Front Panel User Interface The front panel user interface on the Conext Core XC-NA Series has a display and keypad with scroll wheel for local monitoring and configuration (see Figure 4 on page 28). The front panel user interface is behind a cover located on the door of the AC cabinet. The cover has a window to allow you to easily see the display and read status information. In order for the front panel user interface to function correctly, and to help protect the Conext Core XC-NA Series from the external environment, the cover must remain closed during normal operation. Extensive status information and Offline state or Service state events are reported to the front panel user interface. Use a 4 mm hex key to unlock the latch and open the cover in order to make changes via the front panel user interface. The cover has provisions for a lock to prevent unauthorized access. Use the scroll wheel to navigate through menu or value options, and press the center of the scroll wheel to select the menu or value. The keypad has four F function keys, RUN (remote enable) and STOP/RESET (remote disable) keys, and an ESC escape key B This manual is intended for use by qualified personnel only 27

28 Introduction Figure 4 Front panel user interface 1 Periodic servicing reminder 2 Inverter operating mode 3 Access level 4 Event ID 5 Inverter activity or state description 6 Display parameter use scroll wheel to change 7 F1 return to default parameter display 8 Disable via software command 9 Enable via software command 10 Inverter status line 11 Inverter state 12 Parameter value 13 F2, F3, and F4 function keys (context-specific) 14 Exit current menu 15 Unused 16 Scroll wheel Local Ground Fault Status Indicator The ground fault status indicator light will only be functional if the optional insulation monitoring device is installed in the inverter. The indicator light, located in the middle of the DC cabinet door, illuminates red if the insulation monitoring device detects a ground fault. The indicator light may also illuminate in the event of a loss of power in the insulation monitoring device. 28 This manual is intended for use by qualified personnel only B

29 Introduction Conext Core XC-NA Series Planning and Installation Manual DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Measure voltage before proceeding. In the case of a ground fault, normally grounded conductors may be ungrounded and energized, or normally ungrounded conductors may be grounded. Normally grounded DC conductors will become intermittently ungrounded with indication by the ground fault status indicator when the Conext Core XC-NA Series measures the PV isolation. Do not defeat or modify the GFDI circuit in any way. Do not operate the Conext Core XC-NA Series without a functioning GFDI circuit. Failure to follow these instructions will result in death or serious injury. Available Options When an option is ordered, it will be factory-installed before shipping. Power level: 540 kva, 630 kva, 680 kva, or 733 kva Language: English, French, or Spanish Cold temperature operation: Operation to -35 C (-31 F) with cold weather option (the standard Conext Core XC-NA Series Inverter operates to -20 C (-4 F)) Communication: Gateway Modbus to TCP/IP Array grounding: Positive, negative, or ungrounded (floating) B This manual is intended for use by qualified personnel only 29

30 Introduction Local vs. Remote Monitoring The Conext Core XC-NA Series provides information to users about the system s current state and recent events, as described in Table 1. Table 1 Communication features Information Type System status Offline state event Service state event Description The system states are: Disable Online Offline Service The time and details are stored in non-volatile memory. The time and details are stored in non-volatile memory. Communication Method Front panel user interface Optional remote monitoring system Front panel user interface: event ID and a brief text description Optional remote monitoring system: event ID and an extensive text description Front panel user interface: event ID and a brief text description Optional remote monitoring system: event ID and an extensive text description Data logging Optional remote monitoring system Setting the Communication Method The Parameter Control menu on the front panel user interface sets whether the Conext Core XC-NA Series is controlled locally on the front panel user interface or remotely. To change the communication method: 1. Check that you are at the home screen. If not, press Esc multiple times or F4 to return to the home screen. 2. Press the center of the scroll wheel. 3. Scroll to Language, Time, Interface, and then press the center of the scroll wheel. 4. Scroll to Parameter Control Station, and then press the center of the scroll wheel. 5. Scroll to highlight either Panel Control or Modbus, and then press the center of the scroll wheel to apply the change. a. Select Panel Control to use the front panel user interface for communication. b. Select Modbus to communicate through an optional remote monitoring interface. 30 This manual is intended for use by qualified personnel only B

31 Introduction Conext Core XC-NA Series Planning and Installation Manual Figure 5 Setting parameter control 6. Press F4 to return to the home screen. When the parameter control is set to Modbus, you can still access the Parameter Control Station menu on the front panel interface to change back to panel control. AC Circuit Breaker and PV Disconnect Switch DANGER MULTIPLE SOURCES WITH HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Operation of the switches in or on the Conext Core XC-NA Series does not remove all power from the Conext Core XC-NA Series. Switch terminals remain live unless the PV, AC, and external auxiliary AC source have been disconnected externally. All service and maintenance must be performed by authorized service personnel only by following the instructions in Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ). Failure to follow these instructions will result in death or serious injury. The main AC circuit breaker is located behind a cover on the AC cabinet door and the PV disconnect switch is located behind a cover on the DC cabinet door as shown in Figure 6 on page 32. These covers help to protect the circuit breaker and PV disconnect from the external environment. Twist the knob to open the covers. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Do not change the settings on the AC breaker. Although the covers are hinged at the top and they fall closed, you must manually twist the knob to latch the covers closed after use. Failure to follow these instructions can result in death, serious injury, or equipment damage. Additional external AC and PV disconnecting means, capable of being locked out and tagged out, must be provided as part of the installation to help facilitate safe installation of the Conext Core XC-NA Series and for certain service operations. The main AC circuit breaker and PV disconnect switch are each load-break rated disconnects. During an Offline state or Service state event or if the Conext Core B This manual is intended for use by qualified personnel only 31

32 Introduction XC-NA Series is shut off for any reason the AC circuit breaker and PV disconnect switch automatically open. Each is capable of breaking its full load current. Figure 6 AC circuit breaker and PV disconnect switch 1 AC cabinet 2 DC cabinet 3 AC circuit breaker 4 PV disconnect switch 32 This manual is intended for use by qualified personnel only B

33 Planning Conext Core XC-NA Series Planning and Installation Manual 2 Planning What's in This Chapter? Conext Core XC-NA Series Requirements 34 Site Requirements 34 Conduit Entry 36 Anchoring Requirements and Layout 38 Grounding the Conext Core XC-NA Series Inverter 38 Installation at High Elevation 39 Indoor Configuration Ventilation Requirements 39 Heat Load 39 PV Shelter Requirements 39 Exhaust Duct Requirements 40 Venting Recommendations 41 PV Array Requirements 42 Number of PV Panels 42 Grounding the Array 43 Utility Side Requirements 43 Transformer Requirements 43 Electrical Diagram 44

34 Planning DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Installation of the Conext Core XC-NA Series must only be planned and performed by qualified personnel in accordance with all applicable installation codes. See "Audience" on page 4 for the definition of qualified personnel. The Conext Core XC-NA Series must be mounted over a non-flammable surface in accordance with the instructions in Conext Core XC-NA Series Requirements on page 34. Failure to follow these instructions will result in death or serious injury. Conext Core XC-NA Series Requirements Site Requirements Accessibility Enclosure type Establish and maintain the following site conditions to help facilitate safe and efficient installation, operation, and servicing of the Conext Core XC-NA Series. NOTICE DUST OR MOISTURE INGRESS The service area around the Conext Core XC-NA Series must be dry and free of debris during installation, commissioning, servicing or preventive maintenance. If the service area is not dry and free of debris, the installation, commissioning, servicing or preventive maintenance must be postponed until the environmental conditions have cleared. Failure to follow these instructions can result in damage to equipment and can compromise the environmental protection of the Conext Core XC-NA Series. Make sure the site is fork-lift accessible. A customer-supplied fork-lift and licensed forklift operator are required to perform many maintenance tasks. Make sure that the installation position does not prevent access to the disconnection means. Outdoor enclosure rating: Type 3R Indoor enclosure rating: Type 1 Inverters installed indoors will not have the roof and damper assemblies installed and must have appropriate venting and ducting as described in Indoor Configuration Ventilation Requirements on page 39. The installation location must meet the physical and environmental specifications listed in Table 7 on page This manual is intended for use by qualified personnel only B

35 Planning Conext Core XC-NA Series Planning and Installation Manual Clearance Clearance Outdoor Indoor In front, minimum Behind, minimum Above, minimum 977 mm (38½ in.) 914 mm (36 in.) 300 mm (11¾ in.) above roof assembly "Indoor Configuration Ventilation Requirements" on page 39 Maintain a minimum clearance and service padin front of and behind the Conext Core XC-NA Series, as stated in the table above or more if required by local codes for service clearance for air intake, maintenance, and serviceability. For outdoor installations, maintain a minimum of 300 mm (11¾ in.) clearance above the Conext Core XC-NA Series roof assembly for maintenance and serviceability. Flammability To help reduce the risk of fire, the Conext Core XC-NA Series must be mounted over non-flammable surfaces below the Conext Core XC-NA Series. That area under the Conext Core XC-NA Series must also be kept clear of flammable materials during operation of the Conext Core XC-NA Series. The Conext Core XC-NA Series must be mounted flush to the mounting surface, without openings around the bottom perimeter of the Conext Core XC-NA Series. Openings for wire entry must be filled or closed to maintain a non-flammable, air tight barrier under the Conext Core XC-NA Series. Cabling External cabling for power circuits enters the inverter from the bottom into the wiring compartment of the AC cabinet and either from the bottom or from the side (with bus bars) of the DC cabinet. When using side DC entry, conduit and fittings must be used to maintain outdoor enclosure 3R rating. External communication wiring exits the inverter from the bottom of the wiring compartment in the DC cabinet. Low voltage communication cables must be appropriately isolated from high voltage DC input cables, using the provided cable channels in the DC cabinet. Appropriate conduits and fittings must be used based on local electrical codes. Ventilation The inverter part of the Conext Core XC-NA Series has exhaust openings at the top of the cabinets, and air intake openings in the rear of all cabinets. Ventilation requirements must be followed when installing the inverter indoors, see Indoor Configuration Ventilation Requirements on page 39. Heat Load See "Heat Load" on page 39 for information on heat load and derating. Air intake quality The intake for the inverter is located on the rear (see Figure 11 on page 42). The intake air quality must meet the requirements of the environmental specifications listed in Table B This manual is intended for use by qualified personnel only 35

36 Planning on page 91. If these conditions cannot be met, filtration must be implemented external to the intake to ensure contaminants do not enter the inverter. Conduit Entry Power circuit conduit and cable entry is from outside the Conext Core XC-NA Series through the bottom of the AC cabinet and either from the bottom or from the side (with bus bars) of the DC cabinet. Communication wiring exits the inverter from the bottom of the DC cabinet. When using side DC entry, conduits and fittings must be used to maintain outdoor enclosure 3R rating. Before installing the Mating Kit, you will need to remove the protective film over the conduit entry holes. Note: Do not remove the protective film until just before installing the Mating Kit. Figure 7 shows a bottom view of the maximum allowable area and location in which electrical conduits can penetrate the cabinets of the Conext Core XC-NA Series. Conductor size must be pre-determined when the conduit is installed and must be based on local code requirements. DANGER HAZARD OF ELECTRIC SHOCK The circuits provided for use with external communications and control equipment are designed to provide safety isolation from neighboring hazardous circuits within the inverter. Separate conduit entries must be provided for the communications and control circuits and the PV circuits and all AC circuits. See Remote Communication and Control Wiring on page 77 for proper maintenance of safety isolation for wiring related to these circuits. Failure to follow these instructions will result in death or serious injury. Figure 7 Cabinet conduit entries, viewed from the bottom Dimensions in mm (inches) 1 AC cabinet 2 DC cabinet 36 This manual is intended for use by qualified personnel only B

37 Planning Conext Core XC-NA Series Planning and Installation Manual Figure 8 DC Cabinet conduit entries, viewed from the side Dimensions in mm (inches) There are conduit holes in the right wall of the DC cabinet and in the left wall of the DC recombiner. You will need to remove the protective film covering over the conduit holes and line up the holes in the DC recombiner with the holes in the inverter s DC cabinet. NOTICE RISK OF EQUIPMENT DAMAGE Do not remove the film until immediately before connection with the recombiner mating kit. Use the recommended fittings and seal the conduit as explained in the DC Recombiner planning and install manual. Failure to follow these instructions can result in equipment damage. NOTICE COMPROMISED ENVIRONMENTAL PROTECTION As you move the DC recombiner next to the inverter, take care not to scratch the paint on either cabinet. The paint helps to maintain the environmental protection of the system. Failure to follow these instructions can result in equipment damage. Use fire-rated caulk and expanding foam to seal the conduits after assembly. For more information, see "Mounting and Anchoring the Inverter" on page B This manual is intended for use by qualified personnel only 37

38 Planning Anchoring Requirements and Layout HAZARD OF FIRE WARNING The Conext Core XC-NA Series must be mounted on, and anchored to, a level, nonflammable surface. Failure to follow these instructions can result in death, serious injury, or equipment damage. The mounting surface upon which the Conext Core XC-NA Series is anchored must be structurally designed to meet any applicable local codes for weight bearing and seismic requirements. The mounting surface must meet ASTM E1155 requirements, FF Floor Flatness = 38, FL Floor Levelness = 25. Eight 28 mm holes are provided on the bottom of the inverter cabinets for anchoring to the mounting surface. Secure as per local code. Figure 9 depicts the layout pattern of the anchoring holes for the Conext Core XC-NA Series. The mounting surface must either be pre-drilled to accept masonry anchors or have pre-installed anchoring bolts. See Figure 52 on page 96 for dimensions of the Conext Core XC-NA Series inverter. Figure 9 Inverter anchor bolt pattern Dimensions in mm (inches) 1 8 x Ø28 mm clearance holes for inverter anchoring. Secure as per local code. Grounding the Conext Core XC-NA Series Inverter Both the grounding electrode terminal and equipment grounding conductor location for grounding the Conext Core XC-NA Series inverter is located on the AC ground bus bar in the AC cabinet; the grounding electrode terminal is marked with GEC and the equipment grounding conductor is marked with. That point must be connected to ground (earth) in the installation in accordance with applicable installation codes. The DC recombiner must also be grounded by using the provided ground cable from the DC Recombiner Mating Kit. For instructions, see Conext Core XC-NA DC Fuse 38 This manual is intended for use by qualified personnel only B

39 Planning Conext Core XC-NA Series Planning and Installation Manual Installation at High Elevation Recombiner and Conext Core XC-NA DC Fused Disconnect Recombiner Installation Instructions (document number ). Conext Core XC-NA Series that are installed at elevations greater than 1000 m may produce slightly less power than inverters that are installed at lower elevations. Depending on ambient temperature at altitude, the output power may automatically derate above 1000 m (up to maximum 2000 m). For more information about inverter performance at altitude, see the Conext Core XC-NA Series Grid Tie Photovoltaic Inverter: Altitude Derating Application Note (document number AP-XC-016-EN). Indoor Configuration Ventilation Requirements Heat Load PV Shelter Requirements Ventilation must be provided on the exterior of the PV shelter, and ducting must be provided between the inverter and the interior of the PV shelter. The heat load of the inverter is approximately 17 kw (58,000 BTU/hour) at full load. External ventilation or air conditioning must be designed to keep the ambient air outside of the inverter cabinets to a maximum of 50 C (122 F) to allow for full-rated inverter output power. Above 50 C (122 F), the inverter may derate its power output up to 55 C (131 F). Note: For XC733-NA inverters, the inverter will derate its power output up to 55 C (131 F) when operating without salt fog filters (for example, with standard particle filters), and up to 52 C (125.6 F) when operating with salt fog filters. Consult with Schneider Electric on derating charts for power output depending on ambient temperature and PV input voltage. The total cooling air flow required for the inverter at 50 C ambient temperature is 5300 m³/h. Overall pressure drop between the intake and the exhaust must not exceed 165 Pa at maximum airflow at 50 C ambient temperature. The exhaust cooling flows between the AC, DC, and power stage cabinets must be kept separate until they exit the PV box. Any exhaust duct assembly installed with indoor inverters must meet the air flow numbers specified. Conext Core XC-NA Series inverters can be installed in a PV shelter designed typically to house inverters, distribution boxes, transformers, and monitoring equipment. Schneider Electric sells PV shelters, under the product name 'PV Boxes'. Any holes that are made in the PV shelter (for example ones made to accommodate venting requirements) must be fully sealed around the perimeter with appropriate weatherproofing materials to prevent debris, moisture, contaminants, and vermin from entering the PV shelter. The ventilation required when using a PV shelter must meet the following criteria: Wind, including lateral wind, must not be allowed to stop outgoing air flow while the inverter is operating B This manual is intended for use by qualified personnel only 39

40 Planning Exhaust Duct Requirements Predict any way that wind, including lateral wind, may compromise the venting method used, such as partially closing vents, or closing all of the vents on one side of the PV shelter. The result of this compromise must not exceed the allowable overall pressure drop and must maintain the minimum airflow requirements of the inverter (see Heat Load on page 35). Wind, including lateral wind, must not be allowed to create a back-flow of air (carrying humidity, snow, rain, or dust) into the inverter at any time. You may use a single component, such as an actuated damper, or a combination of components, such as a duct, shroud, and louvers, to meet the criteria. A standard HVAC sheet metal duct can be integrated and sealed to the interior wall of the PV shelter to prevent exhaust airflow from recirculating within the PV shelter. The duct may exit out the top of the shelter but care must be taken to ensure that: The exhaust air is not recirculated into the inlet. The exhaust opening of the duct is located so as to prevent falling debris from entering the inverter and to meet safety certification requirements. One 90 bend with a smooth transition is permitted. Ducting should maintain a minimum vertical run of 300 mm (12") above the inverter top surface, with access openings to allow servicing of the inverter fans. Louvers must be no more than 300 mm (12") long and can cover an area not more than 130 mm 2 (5" 2 ). If expanded metal mesh or screens are used in the place of louvers, they must be a minimum of 0.5 mm (0.020") thick for uncoated materials, or 0.6 mm (0.024") thick for zinc coated materials. The diameter of the wires of a mesh screen must not be less than 1.30 mm (0.051 in.) for screen openings of 330 mm 2 (13" 2 ) or less; or not less than 2.0 mm (0.081") for larger openings. Duct material must be non-flammable (for example, metallic) in construction. Allowable overall pressure drop must not be exceeded and minimum airflow requirements of the inverter must be maintained, see Heat Load on page 39. Figure 10 shows the mounting locations on top of the inverter to accommodate an exhaust duct. DANGER HAZARD OF ELECTRIC SHOCK AND AMPUTATION Do not modify the roof panels of the inverter as doing so could expose energized electrical components and moving parts and compromise the environmental protection of the inverter. Failure to follow these instructions will result in death or serious injury. 40 This manual is intended for use by qualified personnel only B

41 Planning Conext Core XC-NA Series Planning and Installation Manual Figure 10 Mounting locations: exhaust routing Venting Recommendations Dimensions in mm (not to scale) 1 AC cabinet fan 2 Power stage exhaust fan 3 DC cabinet fan You can use any configuration that meets the requirements in Indoor Configuration Ventilation Requirements on page 39. One recommended venting configuration is side venting with fixed and gravity louvers and a shroudtop venting with gravity louvers B This manual is intended for use by qualified personnel only 41

42 Planning Figure 11 PV shelter airflow with shroud 1 Gravity louvers 2 Duct 3 Intake airflow PV Array Requirements Number of PV Panels In all installations, the installer must provide disconnecting means for the PV inputs. The installer is also responsible for determining any external overcurrent protection required for these circuits, in accordance with the applicable installation codes, the currents involved (see Appendix A, Specifications ), the wiring size used, and any other system parameters required by the local installation codes. To determine the number of photovoltaic panels required for the PV power plant, use the Conext Designer Sizing Tool on the Schneider Electric website (solar.schneiderelectric.com). 42 This manual is intended for use by qualified personnel only B

43 Planning Conext Core XC-NA Series Planning and Installation Manual Grounding the Array The PV input can be ungrounded (floating), positive grounded, or negative grounded, depending on the options ordered. For all grounding options, a factory-installed PV isolation monitoring relay will monitor the array insulation resistance to ground. If the array insulation resistance falls below the setpoint, the isolation monitor will shut down the Conext Core XC-NA Series, open the AC breaker and PV disconnect, and report an event with the appropriate event ID to the front panel user interface and to any optional remote monitoring system. For positive grounded or negative grounded arrays, a factory-installed PV grounding option provides positive or negative grounding of the array, depending on the version ordered, and it includes a 5 A ground fault detector/interrupter (GFDI). This circuit breaker will open the array grounding path to interrupt ground fault currents exceeding the trip levels of the breaker. At the same time, it will shut down the Conext Core XC-NA Series, open the AC breaker and PV disconnect, and report an event with the appropriate event ID to the front panel user interface and to any optional remote monitoring system. Utility Side Requirements Transformer Requirements In all installations, the inverter must be installed on a dedicated branch circuit and the installer must provide disconnecting means for the AC output and external auxiliary AC source input wiring. The installer is also responsible for determining any external overcurrent protection required for these circuits, in accordance with the applicable installation codes, the currents involved (see Electrical Specifications on page 90), the wiring size used, and any other system parameters required by the installation codes. A custom, high-efficiency, line-frequency isolation transformer must be placed between the inverter AC output and the grid. This transformer is not provided and must be supplied as a separate component. Refer to the Application Note: Medium Voltage Transformer Selection (document number AP-XC-048-EN) for more information on selecting the correct transformer. NOTICE EQUIPMENT DAMAGE Selecting the correct isolation transformer is crucial to prevent damage to the inverter and/or transformer. Refer to the Application Note: Medium Voltage Transformer Selection (document number AP-XC-048-EN). Failure to follow these instructions can result in equipment damage B This manual is intended for use by qualified personnel only 43

44 Planning Electrical Diagram Since installations vary widely, a sample electrical diagram of the Conext Core XC-NA Series is provided here. Use this diagram for system planning purposes only. Figure 12 Conext Core XC-NA Series electrical diagram (sample only) Example only. Details such as external disconnects, overcurrent protection, and grounding are not shown. 44 This manual is intended for use by qualified personnel only B

45 Installation Conext Core XC-NA Series Planning and Installation Manual 3 Installation What's in This Chapter? Unloading 46 Removing the Inverter from a Truck 47 Removing the Inverter from the Pallet 48 Mounting and Anchoring the Inverter 50 Connecting to a DC recombiner 51 Opening Access Doors 52 General Wiring Requirements 52 AC Circuit Breaker Trip Settings 53 Phase Rotation 53 Conductor Termination 54 Grounding 59 AC Wiring 59 Removing AC Barriers 59 Preparing the AC Cabinet Floor 62 Connecting the AC Output to the AC Cabinet 63 PV Array Wiring 65 Auxiliary AC Source Wiring 65 External AC Auxiliary Power Source 67 Internal AC Auxiliary Power Source 72 Remote Communication and Control Wiring 77 Modbus/RS-485 Wiring 78 Gateway TCP/IP Wiring 78 Connecting the Remote Communication and Control Devices 79 Masterpact Wiring for Grounded PV Configurations 83 Completing the Installation 84

46 Installation DANGER MULTIPLE SOURCES WITH HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE The Conext Core XC-NA Series inverter is energized from the PV array, the AC grid, and the external auxiliary AC source (if used 1 ). Before installing the inverter: Consult system diagram to identify all power sources. De-energize, lock out, and tag out all power sources following the Conext Core XC- NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ). Wait at least five minutes for internal capacitors to discharge to safe voltages. Test using a meter rated at least 600 VAC/CAT IV and 1000 VDC/CAT III to ensure all circuits are de-energized. The lock-out and tag-out procedure beginning on page 1 in this manual only applies to installation of an inverter, not to servicing. If the inverter is already installed, additional steps are needed to de-energize, lock out, tag out, and verify internal voltages, and must only be performed by authorized service personnel. See the Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ). Operation of the switches in or on the inverter does not remove all power from this inverter. Switch terminals remain live unless the PV, AC, and external auxiliary AC sources have been disconnected externally. Additional external disconnecting means for the PV, AC, and external auxiliary AC source (if used), capable of being locked out and tagged out, must be provided as part of the installation to help facilitate safe installation and for certain servicing operations. Failure to follow these instructions will result in death or serious injury. Unloading NOTICE STATEMENT OF HAZARD The service area around the Conext Core XC-NA Series must be dry and free of debris during installation, commissioning, servicing or preventive maintenance. If the service area is not dry and free of debris, the installation, commissioning, servicing or preventive maintenance must be postponed until the environmental conditions have cleared. Failure to follow these instructions can result in equipment damage and can compromise the environmental protection of the Conext Core XC-NA Series 1 The XC733-NA will always be configured to use external auxiliary AC source. 46 This manual is intended for use by qualified personnel only B

47 Installation Conext Core XC-NA Series Planning and Installation Manual DANGER HAZARD OF CRUSH INJURY AND EQUIPMENT DAMAGE The inverter weighs approximately 2190 kg (4828 lb), including the packing crate and pallet. Attempting to lift or move the inverter by other than the recommended lifting points and methods could cause the inverter to drop unexpectedly or fall over. Keep all the doors closed and latched when moving the inverter. Use appropriately rated lifting equipment. Failure to follow these instructions will result in death or serious injury or damage to equipment. NOTICE EQUIPMENT DAMAGE Before proceeding with the installation, determine the location and layout of the components, conduit penetration locations, conductor and conduit sizing, and method for anchoring the Conext Core XC-NA Series. Make sure adequate space is provided for clearance for ventilation and serviceability. If necessary, review the chapter on Planning before proceeding. Failure to follow these instructions can result in equipment damage. NOTICE EQUIPMENT DAMAGE Verify the Conext Core XC-NA Series has not been tilted excessively in shipping by checking the tilt indicator on the front and side of the packing crate. The top and bottom balls should be in the 30, 40, or 50 location and the middle ball should be in the 180 location. Verify the Conext Core XC-NA Series has not been dropped more than six inches by checking the shockwatch label on the front of the packing crate. The circle on the shockwatch label should be yellow. If any of the indicators are not as described, you must address this with the shipper. During commissioning, follow the instructions in the Tilt and Shockwatch Indicators section. Failure to follow these instructions can result in equipment damage. Removing the Inverter from a Truck To load or unload the inverter from a truck, a fork-lift must be used to lift the inverter, inside the packing crate, from either the left or right end. You will either need to use a fork-lift with extra long prongs, or you will need to add extensions to your existing fork-lift. The total length of the prongs needed to lift the B This manual is intended for use by qualified personnel only 47

48 Installation inverter from the end is 2580 mm (101.6 in.). If you use extensions, the fork-lift prongs must be a minimum of 66% of the total length of the prongs plus the extension. Both the prongs and the extensions must be rated for the full weight of the inverter. Figure 13 Using a fork lift 1 Total length 100% (minimum 2580 mm/101.6 in.) 2 Maximum extension length 33% 3 Minimum prong length 66% Removing the Inverter from the Pallet To remove the inverter from the pallet: 1. Do a visual check for any damage to the wooden shipping crate. 2. Disassemble the shipping crate and remove the shrink-wrap from the inverter. Leave the plastic covers over the intake and exhaust grills at the front and rear of the inverter. 3. Remove the four bolts on the bottom of the pallet attaching it to the inverter in one of the two following ways: Reach under the pallet and locate the four bolts. These bolts attach from the bottom so use a torque, open-ended, or box wrench with a very short head to remove them. 48 This manual is intended for use by qualified personnel only B

49 Installation Conext Core XC-NA Series Planning and Installation Manual Figure 14 Removing bolts without lifting the inverter OR Using an appropriately rated forklift, lift the inverter a maximum of 2 ft (610 mm) and remove the four bolts with a standard torque wrench. Return the inverter and pallet to the floor after removing the bolts. DANGER HAZARD OF CRUSH INJURY AND EQUIPMENT DAMAGE Do not lift the inverter more than 2 ft (610 mm) with the forklift. Do not put any part of your body underneath the raised pallet, including your hands. Failure to follow these instructions will result in death or serious injury or damage to equipment. Figure 15 Removing bolts by lifting the inverter with a forklift B This manual is intended for use by qualified personnel only 49

50 Installation Mounting and Anchoring the Inverter For information about mounting and anchoring requirements, see Anchoring Requirements and Layout on page 38. Before anchoring the inverter, you may need to remove the AC cabinet and DC cabinet floor panels. To mount and anchor the inverter: 1. Drill the floor, metal skid, or pad to accept masonry anchors or stainless steel A2- grade bolts unless it has pre-installed anchoring bolts that will fit the 19 mm mounting holes. See Figure 9 on page After removing the bolts connecting the inverter to the wooden pallet, locate the lifting tubes that run along the bottom of the inverter and remove the covers on the ends. 3. You can lift the inverter in one of two ways: Place the prongs of a forklift into the lifting tubes. Install a lifting bar with crane hooks into the lifting tubes, connect a sling to the crane hooks, and lift the inverter with a crane. NOTICE EQUIPMENT DAMAGE When lifting the inverter, use dunnage between the inverter and the forklift or lifting bar to avoid damaging the exterior of the inverter. Failure to follow these instructions can result in equipment damage. Figure 16 Attaching lifting bar and using a crane sling 50 This manual is intended for use by qualified personnel only B

51 Installation Conext Core XC-NA Series Planning and Installation Manual Connecting to a DC recombiner 4. Lift the inverter into place. 5. Secure the cabinet to the floor with the appropriate anchoring hardware. 6. Use a level to check that the inverter is both horizontally and vertically aligned and plumb. 7. Reinstall the covers over the ends of the forklift lifting tubes. To connect to a DC recombiner: 1. Follow the instructions in the Conext Core XC-NA DC Fuse Recombiner and Conext Core XC-NA DC Fused Disconnect Recombiner Installation Instructions (document number ). 2. Remove the protective film from the conduit entries in the sides of the inverter and DC recombiner. NOTICE COMPROMISED ENVIRONMENTAL PROTECTION As you move the DC recombiner next to the inverter, take care not to scratch the paint on either cabinet. The paint helps to maintain the environmental protection of the system. Failure to follow these instructions can result in equipment damage. 3. Ensure that the conduit holes are correctly aligned. 4. Ensure the mounting plate lines up with the mounting studs on the rear of the inverter and DC recombiner. 5. Attach the provided Mating Kit conduit fittings between the Conext Core XC-NA Series inverter's DC cabinet and the DC recombiner. Tighten each conduit fitting as much as allowable without deforming the cabinet panels while tightening. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Use only the supplied busbar kit to connect to the DC terminals. Use only the provided conduit connections. The Type 3R rating is only maintained when these specific conduit connections are installed as described. Failure to follow these instructions can result in death, serious injury, or equipment damage B This manual is intended for use by qualified personnel only 51

52 Opening Access Doors General Wiring Requirements To open all doors: 1. Unlock the door. 2. You must pull each handle towards you and up as far as it will go, and then rotate the handle 135 degrees toward the center of the door. 3. Pull open the door. To close all doors: 1. Ensure the handle is rotated 135 degrees toward the center of the door. 2. Close the door. 3. Twist the handle as far as it will go away from the center of the door. 4. Push the handle down. NOTICE EQUIPMENT DAMAGE Do not force the handle; it should pull, push, or twist smoothly. Failure to follow these instructions can result in equipment damage. All wiring methods and materials must be in accordance with applicable electrical installation codes. Examples include the US National Electrical Code ANSI/NFPA 70, IEC 60364, CENELEC HD 384, and DIN VDE NOTICE EQUIPMENT DAMAGE When connecting external AC wires to the Conext Core XC-NA Series, positive, clockwise phase rotation must be maintained throughout the installation process. Crimp lugs that are used to fasten aluminum conductors to the AC or PV terminals must be rated and marked for use with both copper and aluminum. For example, a dual-rated crimp lug could be marked Al9Cu or Cu7Al. Failure to follow these instructions can result in equipment damage B This manual is intended for use by qualified personnel only 52

53 AC Circuit Breaker Trip Settings When choosing cables for your site, base cable sizings on the trip settings of the Micrologic, which is a part of the AC Masterpact. Table 2 contains trip settings for the Micrologic 3.0 A and the Micrologic 5.0 A (see Figure 17). Figure 17 Micrologic 3.0 A (left) and Micrologic 5.0 A (right) Table 2 AC Circuit Breaker Trip Settings Masterpact Configuration H2 Micrologic 3.0 A (UL) H1 and H2 Micrologic 5.0 A (IEC and UL) Long-Time Pickup (Ir) 0.8 (=1600 A) 0.6 (=1200 A) Long-Time Delay (tr) 0.5s 0.5s Instantaneous Pickup (li) 1.5 (=2400 A) OFF Short-Time Pickup (Isd) N/A 2 (=2400 A) Short-Time delay (tsd) N/A 0 (OFF) Phase Rotation Three-phase power is characterized by three different phases, each with a phase shift 120 degrees from the other two phases. The three phases are typically referred to as A, B, and C. Figure 18 shows a graphic representation of three-phase voltages B This manual is intended for use by qualified personnel only 53

54 Figure 18 Graphical representation of three-phase voltages Conductor Termination The peaks of the voltage waveforms are 120 (5.5 ms at 60 Hz) apart. Note that the peak of phase A occurs before the peak of phase B, which in turn occurs before the peak of phase C. This is referred to as an ABC (or clockwise) phase rotation. If any two phase labels are swapped, the result will be CBA (counter-clockwise) phase rotation. The Conext Core XC-NA Series requires clockwise phase rotation at all times 2. Incorrect phase rotation on Conext Core XC-NA Series with firmware version lower than v3.02 may result in incorrect production of reactive power, resulting in Voltage Stable Timeout, and Pre-charge Timeout events. The Conext Core XC-NA Series has terminals and bus bars for making all wiring connections required for installation. All terminals used for making AC connections require the use of copper, aluminum, or copper-clad aluminum conductors with an insulation rating of 75 C (or higher). If conductors rated higher than 75 C are used, base the wire size on the requirements for 75 C wire to help prevent excessive heating of the bus bars, terminals, and connected devices. All terminals used for making DC connections require the use of copper, aluminum, or copper-clad aluminum conductors with an insulation rating of minimum 90 C. Ensure that you understand the local requirements regarding the material type for the conductors. AC Wiring The AC output phase wiring connects to the AC terminals identified as XT1 (~ L1, ~ L2, and ~ L3) in the AC cabinet. These terminals require the use of a crimp-on type ring terminal or compression-type lug. Keep the cables close together as much as possible and make sure that all cables pass through the same conduit fittings and the same access point in the floor of the Conext Core XC-NA Series. This allows any inductive currents to cancel. Each terminal has a pole with five threaded holes for bolts, and each bolt accommodates a maximum of one cable. Two of the threaded holes on the terminal are connected to L-bus terminals to increase the available connection points. These terminals each have six holes 2 Version 3.02 of the firmware auto-detects and corrects phase rotation. Older firmware versions require the inverter to be physically connected in the correct phase rotation B This manual is intended for use by qualified personnel only 54

55 for bolts, and each bolt accommodates a maximum of two cables, one on either side of the L-bus. For the location of these terminals and wiring instructions see Connecting the AC Output to the AC Cabinet on page 63. For bolt sizes and torque values, see Table 10 on page 94. For the dimensions of the terminal lug connections, see Figure 23. The bolts must maintain the minimum spacing and clearances specified in the following figures. Figure 19 Front view: Minimum required clearance between lugs 1 Minimum required clearance from L1 to L2 and from L2 to L3 = 9.5 mm (⅜ ") Figure 20 Front view: Minimum required clearance from the lugs to the flange 1 Minimum required clearance from lugs on L1, L2, or L3 to the flange on the horizontal busbar support = 9.5 mm (⅜ ") B This manual is intended for use by qualified personnel only 55

56 Conext Core XC-NA Series Planning and Installation Manual Figure 21 Front view: minimum required clearance from AC lugs to enclosure wall mm (0.5") Figure 22 Side view: minimum required clearance from lugs on L1 to the ground bar B mm (0.5") mm (⅜ ") 3 Ground bar This manual is intended for use by qualified personnel only 56

57 Note: Left enclosure wall removed in this view. Clearance is from any lug on L1 to any lug on the ground bar on the left enclosure wall or to the auxiliary AC hardware. Figure 23 AC terminal lug L-bus connections Dimensions in mm(inches) 1 6 x Ø12.50 mm holes Auxiliary AC wiring The auxiliary AC input wiring connects to the terminals identified as XT4 (1, 2, and 3) in the AC cabinet. These terminals require a crimp-on ferrule properly sized for the wire and accommodate one wire per terminal. For the location of these terminals, see Figure 2 on page 1. For bolt sizes and torque values, see Table 10 on page 94. DC Wiring The PV input wiring enters the Conext Core XC-NA Series through the floor of the DC recombiner and connects to the string input fuse busbars. The DC Recombiner Mating Kit B This manual is intended for use by qualified personnel only 57

58 then connects to the PV terminals identified as + and - in the DC cabinet. For the location of these terminals, see Figure 4 on page 1 to Figure 8 on page 1. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Use only the provided bus bar connections in the DC Recombiner Mating Kit. The system certifications are only maintained when these specific busbars are installed as described in this manual. Failure to follow these instructions can result in death, serious injury, or equipment damage. For bolt sizes and torque values, see Table 11 on page 94. For the dimensions of the terminal lug connections, see Figure 24. Figure 24 DC terminal lug connections Dimensions in mm(inches) 1 7 x M12 threaded nut Communication Wiring The Communication wiring enters the Conext Core XC-NA Series through the floor of the DC cabinet and connects to the communication (CMX) board (Modbus/RS-485) or to the Schneider Electric gateway EGX100SD (Gateway TCP/IP option). For the location of these terminals, see Figure 46 on page B This manual is intended for use by qualified personnel only 58

59 Grounding Both the grounding electrode terminal and equipment grounding conductor location for grounding the Conext Core XC-NA Series is an M10 bolt on a copper grounding bar located at the bottom left side of the AC cabinet; the grounding electrode terminal is marked with GEC and the equipment grounding conductor is marked with. The ground conductor size depends on the rating or setting of the overcurrent protection provided for the circuit. Refer to local applicable electrical installation codes for grounding requirements for your system. The ground wire for the external auxiliary AC source is terminated at the ground terminal block beside XT4. Equivalent grounding terminals for PV array frames are provided in the cabinet. Figure 25 Single point ground (PE) and GEC; ground bar AC Wiring Removing AC Barriers 1 Ground bar This section provides information for connecting the AC conductors. Table 10 on page 94 shows the specifications for the provided wiring terminals. To help protect personnel, barriers are installed over the AC and DC electrical wiring compartments inside the Conext Core XC-NA Series. To perform the initial installation you must remove these barriers. To remove the AC cabinet internal barriers: 1. Open the AC cabinet door to its fully open position. 2. Remove the inverter ON/OFF switch shaft and bracket (see Figure 26): a. Remove and save the two M6x16 Phillips pan head screws and washers that secure the bracket. Store the bracket for later reinstallation B This manual is intended for use by qualified personnel only 59

60 b. Using a POZIDRIV 2, loosen the screw that secures the connecting shaft to the switch assembly. Slide the shaft out from the assembly and store it for later reinstallation. Figure 26 QS2 switch: shaft and bracket removal 1 Two M6x16 Phillips pan head screws 2 One POZIDRIV screw 3. Remove and save the seven M6x16 Phillips pan head screws from the vertical metal mesh barrier around the Masterpact, and then carefully lift out the barrier. Store the barrier for later reinstallation. NOTICE HAZARD OF EQUIPMENT DAMAGE The metal mesh barriers are not rigid. Be careful not to bend a barrier out of shape when lifting it out. Failure to follow these instructions can result in equipment damage. Figure 27 Metal mesh barrier around Masterpact (AC cabinet) B This manual is intended for use by qualified personnel only 60

61 4. Remove and save the two M6x16 Phillips pan head screws from the horizontal metal mesh barrier above the Masterpact, and then carefully lift out the barrier. Store the barrier for later reinstallation. Figure 28 Horizontal metal mesh barrier above Masterpact (AC cabinet) 5. Remove and save the five M6x16 Phillips pan head screws from the small external auxiliary AC source barrier in the bottom of the AC cabinet, and then carefully lift out the barrier. Store the barrier for later reinstallation. NOTICE HAZARD OF EQUIPMENT DAMAGE The metal mesh barriers are not rigid. Be careful not to bend a barrier out of shape when lifting it out. Failure to follow these instructions can result in equipment damage B This manual is intended for use by qualified personnel only 61

62 Figure 29 External auxiliary AC source barrier (AC cabinet) 6. Remove and save the two remaining M6x16 Phillips pan head screws from the large metal mesh barrier in the bottom of the AC cabinet, and then carefully lift out the barrier. Store the barrier for later reinstallation. Figure 30 Main metal mesh barrier (AC cabinet) Preparing the AC Cabinet Floor To prepare the floor of the inverter for cable routing: 1. Remove the plate from the floor of the AC cabinet and keep the screws. You will need to cut this plate to allow cable entry into the AC cabinet B This manual is intended for use by qualified personnel only 62

63 NOTICE EQUIPMENT DAMAGE The AC floor plate must be cut only enough to allow cable entry. Reinstall the AC floor plate after cutting holes. Use correctly sized conduit fittings to seal the cables in place. Failure to follow these instructions can result in equipment damage and can compromise the Type 3R rating of the enclosure. Figure 31 Removing the AC floor plate 2. Pre-mark all the holes to be cut out in the plate. 3. Punch or cut holes. Ensure any holes are free from burrs and sharp edges. 4. Mask and treat any exposed, cut edges with a rust primer. 5. After the rust primer dries, paint these edges with white appliance epoxy paint, such as Rustoleum / Krylon or equivalent. 6. Reinstall the AC plate using the screws removed in Step 1. Connecting the AC Output to the AC Cabinet To connect the AC output (grid) to the AC cabinet: 1. Route the AC power conductors ~ L1, ~ L2, and ~ L3 and ground conductor(s) through the conduit fittings in the AC plate over the access point in the floor of the inverter. 2. Connect the AC power conductors at the ~ L1 (A phase), ~ L2 (B phase), and ~ L3 (C phase) terminals using M12 hardware. Cables to these terminals must use a crimp-on type ring terminal or compression-type lug. See Figure 32 for the location of these terminals. Maintain clearances according to the guidelines in AC Wiring on page B This manual is intended for use by qualified personnel only 63

64 NOTICE EQUIPMENT DAMAGE When connecting external AC wires to the Conext Core XC-NA Series, positive, clockwise phase rotation must be maintained throughout the installation process 3. See Phase Rotation on page 53 for more information. Crimp lugs that are used to fasten aluminum conductors to the AC or PV terminals must be rated and marked for use with both copper and aluminum. For example, a dual-rated crimp lug could be marked Al9Cu or Cu7Al. Failure to follow these instructions can result in equipment damage. 3. Connect the AC output ground conductor to the equipment grounding bus bar/grounding electrode terminal. Use M10 hardware to make terminations for the ground conductors at the bottom left of the AC cabinet at the grounding bus bar. Cables to these terminals must use a crimp-on type ring terminal or compression-type lug. See Figure 32 for the location of these terminals. Maintain clearances according to the guidelines in AC Wiring on page 59 NOTE: The single-point ground (PE) connection point must not be used for grounding any other ground conductors, as explained on page 59. Figure 32 AC terminal connections from the external transformer 1 ~ L1 Phase terminal 2 ~ L2 Phase terminal 3 ~ L3 Phase terminal 4 Grounding bus bar (including grounding electrode terminal) 4. If you plan to install an external auxiliary AC source, follow the procedure starting on page 1 now, and then return to step 5 in this procedure. 5. Once all of the incoming cables are connected, seal the conduit holes to prevent dust and debris from entering the bottom of the cabinet. The recommended way to do this is 3 Version 3.02 of the firmware auto-detects and corrects phase rotation. Older firmware versions require the inverter to be physically connected in the correct phase rotation B This manual is intended for use by qualified personnel only 64

65 PV Array Wiring using a sealing foam, such as: American Polywater Corporation FST Foam Sealant, 3M Fire Barrier Water Tight Sealant 3000 WT, or PPG Industries PR-821 CFC-free conduit sealing compound. 6. Do not reinstall the AC barriers (Reinstalling Internal Barriers on page 87) until all other installation steps and Visual Inspection on page 86 have been completed. You cannot connect the PV array directly to the DC cabinet, you need to use a recombiner cabinet. Contact your sales representative for available options. To connect a Schneider Electric DC Recombiner to a Conext Core XC-NA Series inverter: 1. Open the DC cabinet door of the Conext Core XC-NA Series inverter to its fully open position. 2. Remove the bottom barrier in the DC cabinet of the Conext Core XC-NA Series inverter. Figure 33 Bottom plastic barrier screws (DC cabinet) 3. Follow the instructions in Conext Core XC-NA DC Fuse Recombiner and Conext Core XC-NA DC Fused Disconnect Recombiner Installation Instructions (document number ) to connect a Schneider Electric DC recombiner to a Conext Core XC-NA Series inverter. Auxiliary AC Source Wiring Power for the ventilation fans and heaters is provided by an internal auxiliary AC supply transformer (TC1). The source of supply to that transformer can be configured to be one of B This manual is intended for use by qualified personnel only 65

66 the following sources: An external auxiliary AC source (a separate source of supply provided at the installation site). 4 The inverter AC output circuit. The transformer has multiple taps that can be selected to allow for different AC supply voltage ranges. NOTICE COMPONENT DAMAGE Auxiliary power can only be supplied from the inverter AC output if the AC output voltage will always be in one of the following ranges: VAC phase-to-phase VAC phase-to-phase VAC phase-to-phase Auxiliary AC supply transformer (TC1) taps must be set correctly according to the information in Table 3. Failure to follow these instructions can result in equipment damage. As shipped, the Conext Core XC-NA Series is configured for auxiliary supply from the external AC auxiliary source and for a three phase input voltage of 208 VAC. If a three phase 208 VAC auxiliary supply will be connected to the external AC auxiliary source input terminals (XT4), no further changes to the auxiliary AC source wiring or to the auxiliary AC supply transformer are needed. Proceed to To connect an external auxiliary AC source to terminal XT4 in the AC cabinet: on page 67. Changes to the configuration of the auxiliary supply wiring and transformer tap selection will be required if either of the following is true: The external AC auxiliary source is being used, but the voltage is not 208 VAC. The auxiliary AC will be supplied from the inverter output. Table 3 Voltage ranges and transformer taps for auxiliary AC source Auxiliary AC source voltage (VAC rms phase to phase) Auxiliary AC supply transformer (TC1) primary tap 208 (± 10%) 208 (as shipped) 240 (± 10%) 240 (external supply) 300 (± 10%) 300 (internal supply) 350 (± 10%) 350 (internal supply) 380 (± 10%) 380 (internal supply) 4 The XC733-NA will always be configured to use external auxiliary AC source B This manual is intended for use by qualified personnel only 66

67 External AC Auxiliary Power Source The external auxiliary AC source must be a three phase nominal voltage of 208 or 240 VAC rms phase-to-phase and must be sourced from one of the following types: Utility side Inverter side Delta (D) Delta (D) Wye with neutral (Yn) Wye with neutral (Yn) delta (d) wye (y) wye (y) delta (d) The inverter-side windings of the external AC auxiliary transformer can only be configured as a Delta or floating Wye. If the source provided is 208 VAC, no change is needed. If the source provided is 240 VAC then the XT2 wires labelled TC1:TAP, which is the tap selection for the auxiliary supply transformer (TC1), must be changed from XT2:58/59/60 to XT2:61/62/63. WARNING HAZARD OF FIRE External over-current protection must be installed for the AC auxiliary input circuit of the inverter. Failure to follow these instructions can result in death, serious injury, or equipment damage. The selection of external over-current protection for the AC auxiliary input circuit of the Conext Core XC-NA Series must be coordinated with both the internal inverter circuitry and your local electrical installation code(s). You must use an external over-current protection device with a maximum thermal trip current of 20 A plus a suitable magnetic trip curve. There are many different trip curves available which vary between manufacturers. You may need to test a variety of over-current protection devices with your specific circuit to prevent nuisance tripping. Connecting the External AC Auxiliary Power Source To connect an external auxiliary AC source to terminal XT4 in the AC cabinet: 1. Route the external auxiliary AC source conductors and their ground wire through the access point in the floor of the inverter to the AC cabinet. 2. Route the external auxiliary AC source ground conductor to ground terminal beside XT4. 3. Connect one external auxiliary AC source conductor each to XT4:1, XT4:2, and XT4:3. Strain relief points are available for this application B This manual is intended for use by qualified personnel only 67

68 Figure 34 Connecting XT4:1, XT4:2, and XT4:3 1 XT4:1, XT4:2, and XT4:3 connections 2 Cable tie location for auxiliary AC source voltage conductors 4. If the source auxiliary AC voltage is 240 VAC, move the XT2 wires labelled TC1:TAP, which is the tap selection for the auxiliary supply transformer (TC1), from XT2:58/59/60 to XT2:61/62/63, see Figure B This manual is intended for use by qualified personnel only 68

69 Figure 35 XT2 location in AC cabinet 1 XT B This manual is intended for use by qualified personnel only 69

70 Figure 36 Moving the voltage tap wire 5. Do not reinstall the AC barriers (Reinstalling Internal Barriers on page 87) until all other installation steps and the Visual Inspection on page 86 have been completed. Setting the Voltage Tap for the 120 V Service Receptacle in the DC Cabinet DANGER HAZARD OF FIRE Do not use receptacle while inverter is producing power. Failure to follow these instructions will result in death or serious injury. To set the correct voltage tap for the 120 V service receptacle: The voltage taps for the 120 V service receptacle are set at the XT19 terminal block in the DC cabinet B This manual is intended for use by qualified personnel only 70

71 Figure 37 XT19 location in DC cabinet 1 XT19 1. If changing from the factory default tap of 208 VAC to 240 VAC, move the auxiliary power cable from XT19:3 to XT19:4. Figure 38 Moving the voltage tap wire (120 V service receptacle) 2. Do not reinstall the DC barriers (see Reinstalling Internal Barriers on page 87) until all other installation steps and the Visual Inspection on page 86 have been completed B This manual is intended for use by qualified personnel only 71

72 Internal AC Auxiliary Power Source The auxiliary power supply can be taken from the AC output if the AC output will remain within one of the following ranges under all conditions: VAC phase-to-phase VAC phase-to-phase VAC phase-to-phase If one of these conditions cannot be met, then the auxiliary power must be supplied from an external auxiliary AC source as described in External AC Auxiliary Power Source on page 67. Changing the Configuration to Internal AC Auxiliary Power To configure the Conext Core XC-NA Series for internal auxiliary power supplied from the AC output: 1. Change the factory configuration by moving the conductors connected to terminals XT2:47/48/49 (external supply - labelled TC1:EX/IN) over to terminals XT2:52/53/54 (internal supply). Figure 39 XT2 location in AC cabinet 1 XT B This manual is intended for use by qualified personnel only 72

73 Figure 40 XT2 terminal block settings for internal auxiliary AC source 2. Move the XT2 cables labelled TC1:TAP, which is the tap selection for the auxiliary supply transformer (TC1). Table 4 TC1:TAP cable location for transformer tap Cable XT2 location XT2:70/71/72 XT2:67/68/69 XT2:64/65/66 XT2:58/59/60 Transformer (TC1) tap 380 V (internal supply) 350 V (internal supply) 300 V (internal supply) 208 V (as shipped) B This manual is intended for use by qualified personnel only 73

74 Figure 41 Moving the voltage tap wire 3. Do not reinstall the AC barriers (Reinstalling Internal Barriers on page 87) until all other installation steps andvisual Inspection on page 86 have been completed. Reconfiguring the 120 V Service Receptacle in the DC Cabinet DANGER HAZARD OF FIRE Do not use receptacle while inverter is producing power. Failure to follow these instructions will result in death or serious injury. When you change the AC auxiliary power from external supply to internal supply, you also have to change the XT2 settings and the voltage tap for the 120 V service receptacle. To change the XT2 settings: 1. If changing from the factory default of external auxiliary AC supply to internal auxiliary AC supply, move the cable labelled TC11:EX/IN from XT2:45/46 to XT2:50/ B This manual is intended for use by qualified personnel only 74

75 Figure 42 Moving the 120 V service receptacle to internal auxiliary AC 2. Do not reinstall the AC barriers (Reinstalling Internal Barriers on page 87) until all other installation steps andvisual Inspection on page 86 have been completed. To set the correct voltage tap for the 120 V service receptacle: The voltage taps for the 120 V service receptacle are set at the XT19 terminal block in the DC cabinet B This manual is intended for use by qualified personnel only 75

76 Figure 43 XT19 location in DC cabinet 1 XT19 1. If changing from the factory default tap of 208 VAC, move the auxiliary power cable from its factory location terminal to the new terminal. Table 5 XT19:3 cable location for transformer tap for 120 V service receptacle Cable XT19 location Transformer (TC1) tap XT19:7 XT19:6 XT19:5 XT19:3 380 V 350 V 300 V 208 V (as shipped) B This manual is intended for use by qualified personnel only 76

77 Figure 44 Moving the voltage tap wire (120 V service receptacle) 2. Do not reinstall the DC barriers (see Reinstalling Internal Barriers on page 87) until all other installation steps and the Visual Inspection on page 86 have been completed. Remote Communication and Control Wiring In the Conext Core XC-NA Series, the Modbus/RS485 communication circuits are to be connected only to external Modbus/RS485 circuits that are Safety Extra-Low Voltage (SELV), also called Class 2 or Limited Voltage Limited Energy. SELV is a common designation that refers to a circuit in which the voltages within the circuit and from the circuit to ground have values that are not a shock hazard, under both normal and single fault conditions. This is achieved by the design of the circuits, and by maintaining protective separation (fault-tolerant insulation and isolation) between the SELV circuits and all hazardous voltage circuits, within the inverter and in the installation. DANGER HAZARD OF ELECTRIC SHOCK Connect only to Safety Extra Low Voltage (SELV) Class 2, limited voltage limited energy circuits. The circuits provided for use with external communications and control equipment are designed to provide isolation from neighboring hazardous circuits within the inverter. The communications and control circuits within the Conext Core XC-NA Series are floating from ground and are classified as SELV. They must be connected only to other SELV circuits in a manner which maintains all the circuits within SELV limits and prevents ground loops. Separate conduit entries must be provided for the communications and control circuits and the PV circuits and all AC circuits. Physical and electrical separation of the communications and control circuits from non- SELV electrical circuits must be maintained both within the inverter and external to the inverters. Failure to follow these instructions will result in death or serious injury B This manual is intended for use by qualified personnel only 77

78 Modbus/RS-485 Wiring Gateway TCP/IP Wiring In the Conext Core XC-NA Series, the communication circuits and their intended connections are: The Modbus/RS485 circuits on connectors S43, S44, S201, and S201-1, which must be connected only to external Modbus/RS485 circuits that are SELV. The external ENABLE/DISABLE switch circuit on terminals 16 and 17 of terminal block XT14, which must be connected only to a switch that has dry contacts (with no external voltage applied to them) and has protective separation to hazardous voltage circuits. The circuits for external control of active and reactive power on terminals 12, 13, 14, and 15 of terminal block XT14, which must be connected only to 4-20 ma loop circuits that are SELV. Make sure the communication and control cables enter the cabinet away from the PV and AC wiring and are routed and mechanically secured away from the PV and AC wiring throughout the length of the communications and control wiring. Maintain no less than 50 mm (2 in.) separation at all points and use the provided cable channels. Isolation and Surge Protection The recommended best practice is the use of fiber optic isolation, installed as close to the inverter as possible. This provides full isolation, removing the risk of damaging electrical surges coupling to the inverter. Daisy-chaining The RS-485 bus is a multi-drop bus implemented as a daisy chain. The Conext Core XC-NA Series provides two RJ-45 connectors to the same Modbus ports to facilitate daisy chaining. Either port can be connected to the upstream or downstream device and a standard ethernet (straight-through) patch cable may be used to connect the devices. Note: Ethernet cross-over cables must not be used. Shielding and Grounding The RJ-45 cable must use a shielded cable with the Modbus master end (not the inverter end) connected to protective ground. On the inverter end, the male connector must be shielded. This Modbus-to-TCP/IP gateway is an option that is factory-installed if purchased. A shielded CAT5e ethernet cable is required for the connection to the RJ-45 port on the ethernet gateway. The Schneider Electric gateway EGX100SD resides near the communication (CMX) board, so the cable can be routed along the same cable channel as other communication (CMX) board connections B This manual is intended for use by qualified personnel only 78

79 Connecting the Remote Communication and Control Devices To route and connect the remote communication and control devices: DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE Do not attempt to use this procedure to install communications wiring on a Conext Core XC-NA Series that has already been energized or in operation. If the Conext Core XC-NA Series has been previously energized, different lock-out and tag-out procedure steps are needed and the installation must be performed by authorized service personnel. See the Conext Core XC-NA Series Service Bulletin for Lock-Out and Tag-Out Procedures (document number ). Failure to follow these instructions will result in death or serious injury. 1. Route the communication and control cables (including the Modbus-to-TCP/IP cabling, if that option was purchased) along the following path (see Figure 46): a. Through the small conduit holes in the right wall of the Conext Core XC-NA Series inverter's DC cabinet (see Figure 45). Figure 45 DC cabinet conduit hole for communication and control cables 1 Small conduit hole for communication and control cables b. Through the cable channels on the left wall of the DC cabinet. c. Up the cable channels on the left side of the back wall of the DC cabinet. 2. Use cable ties to hold the cables in place to prevent contact from other field wiring and factory bus bars B This manual is intended for use by qualified personnel only 79

80 Figure 46 Routing the communication cable in the DC cabinet 3. If the option has been purchased, connect the Modbus-to-TCP/IP cable to the RJ-45 port of the Schneider Electric gateway EGX100MG (near the left wall of the DC cabinet) B This manual is intended for use by qualified personnel only 80

81 4. Connect the remote control cables to the following locations, see Figure 47. Cable Type Connection Point Active power control XT14, terminals 12 and 13 Reactive power control XT14, terminals 14 and 15 External enable/disable XT14, terminals 16 and 17 Figure 47 XT14 terminal block 1 Leave this jumper if you are not going to install an external ENABLE/DISABLE switch 5. Connect the remote communication cable to either RJ-45 port (S43 or S44) or either strip terminal port (S201 or S201-1) on the communications (CMX) board (see Figure 48 and Figure 49). 6. If you are connecting other Conext Core XC-NA Series in a Modbus chain: a. Make sure SW2 is in the OFF (right) position, so that the Modbus communication is not terminated in this Conext Core XC-NA Series. b. Connect a second RS-485/Modbus communication cable to the unused RJ-45 port (either S43 or S44) or the unused strip terminal port (either S201 or S201-1). c. Connect the other end of the RJ-45 communication cable to the next Conext Core XC-NA Series in the chain. 7. If you are not connecting other Conext Core XC-NA Series in a chain, or if this is the last Conext Core XC-NA Series in the chain, make sure switch JMP2 is in the ON (left) position, so that the Modbus communication is terminated in this Conext Core XC-NA Series. 8. If using the 4 20 ma loop circuits for external control of active and/or reactive power, connect the cables to terminal block XT14, terminals 12 and 13 (active power), and/or 14 and 15 (reactive power), with the direction of current as indicated in Figure B This manual is intended for use by qualified personnel only 81