Controls XCAN-AC User manual

Product Manual
ACPowerMonitoringModule
Part Number: XCAN-AC
Revision: 2.3
______________________________________________________________________________________________________________________________________
Copyright ©Controls, Inc.
P.O. Box 368 • Sharon Center, OH 44274
Phone [phone] • Fax [phone] • www.controlsinc.com

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Introduction
1.1 The XCAN-AC is a sealed microprocessor-based AC Power measurement module
1.2 It is designed to be used in conjunction the Controls, Inc. control panels or other J1939 based displays.
1.3 The product is packaged with a sealed polycarbonate enclosure for maximum durability.
1.4 The controller is plug & play with two sealed bulkhead connectors incorporated into the case. One for the
module DC power and CAN connections and one for the AC source connections.
1.5 Operating temp to –45C to +85C and the storage temp to –55C to +95C.
1.6 The unit monitors AC power source with connections to each phase for voltage, current and frequency.
1.7 AC Power information is transmitted on the CAN Bus in SAE J1939 format.
Enclosure
1. Sealed DT series connectors
2. Polycarbonate case with mounting holes
3. Vented Gortex membrane for breathability

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Generator Control Installation Kits
Installation kits are available which include the following
1) Control panel, P/N G3-2500
2) Generator monitor, P/N XCAN-AC
3) Current transformers, size and quantity depend on installation
4) Generator wiring harnesses, P/N 70-0670-5 (5 Foot)
5) Intermediate Harness, P/N 70-0671-5 (5 Foot)
PART NUMBER BREAKDOWN
G3 2500 803 K
Model
Enclosure
Package
CT Size (800:5)
And QTY (3)
“Kit” Includes Harnesses and
XCAN-AC Module
Five Foot Standard

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Connections
The XCAN-AC module has two twelve-pin sockets that are keyed and color-coded to make identification
easy and prevent miswiring. The right socket (black) is the DC side connection and the left socket (gray) is
the AC side connection. Note the Pin 1 locations are not in the same orientation on both connectors.
Pin Assignments
DC Socket: [BLACK]
Pin #
Assignment
1
V Battery + (12-24)
2
Alternate CAN Addrs
3
Not Used
4
Not Used
5
CAN L
6
Ground (V-)
7
Ground (V-)
8
CAN H
9
Not Used
10
Not Used
11
Not Used
12
V Battery +
AC Power Socket: [GREY]
Pin #
Assignment
1
CT Phase A Return
2
CT Phase B Return
3
CT Phase C Return
4
Generator Neutral
5
Not Used
6
Not Used
7
Generator Phase B
8
Generator Phase C
9
Generator Phase A
10
CT Phase C
11
CT Phase B
12
CT Phase A

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Neutral Isolation
The AC neutral is isolated from battery ground. Up to 3kV of potential difference may be tolerated.
Connecting the neutral to battery ground is optional and will not affect the generator readings either way.
Phase A Required
Phase A Voltage and CT inputs must be connected in order for the XCAN-AC to determine frequency and
phase angle. In the event of Phase A loss in a three-phase wye connection, the voltages and currents on the
other two phases will still be reported, but the frequency will be reported as zero, and the KVar and KW
readings will be based on a power factor of 1.0.
All CT Returns Required
The XCAN-AC generator socket has six pins assigned to the Current Transformers. Each CT return wire must
be routed back to the correct pin on the connector. Mixing return connections, or combining returns into a
single wire will result in bad readings.
Unused Inputs
Unused voltage inputs should be tied to neutral (except when using Delta connection, see below). Unused
CT inputs should be tied to their respective return.
Delta Connection Instructions
To use the XCAN-AC with Delta-wired generators, follow these steps connect the voltage inputs as described
below. The CTs connect the same as for wye wiring.
AC Power Source Lead
XCAN-AC Input
Phase A
Phase A
Phase B
Neutral
Phase C
Phase C

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Wiring Diagram –Wye

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Wiring Diagram –Delta
Must be specified at time of order or configured through CI Station

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MODULE SETUP
The XCAN-AC can be configured by two methods, by configuring a bank of dip switches on the PCB or by
using the CI Station, pc-based programming software.
DIP SWITCH CONFIGURATION
1. Remove the PCB from the case by pressing the tabs on the side and pulling the connectors from
the case.
2. The DIP Switches are located on the upper left corner of the PCB. To configure the XCAN-AC by
the DIP Switches, the switches are turned on/off per the table below to meet the amperage
requirement.
3. For DIP Switch Configuration, set switch CTCONFIG to ON
AMPERAGE
CT0
CT1
CT2
CT3
50
ON
ON
ON
ON
75
OFF
ON
ON
ON
100
ON
OFF
ON
ON
200
OFF
OFF
ON
ON
250
ON
ON
OFF
ON
300
OFF
ON
OFF
ON
400
ON
OFF
OFF
ON
500
OFF
OFF
OFF
ON
600
ON
ON
ON
OFF
800
OFF
ON
ON
OFF
1000
ON
OFF
ON
OFF
1200
OFF
OFF
ON
OFF
1500
ON
ON
OFF
OFF
2000
OFF
ON
OFF
OFF
2500
ON
OFF
OFF
OFF
3000
OFF
OFF
OFF
OFF

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CI STATION CONFIGURATION
The XCAN-AC Can be configured using the CI Station, pc-based programming software. Current transformer
size, AC configuration, primary and secondary CAN Source Addresses can be selected and saved for future
use.
For CI Station Configuration, the DIP Switch marked CICONFIG must be in the OFF Position.
Programming
1. Disconnect the XCAN-AC from field wiring.
2. Connect the unit to the CI Station using supplied cabling. Minimum connections required are
Battery +, Battery -, CAN High and CAN Low.
3. Launch CI Station and connect to the unit.
4. Click on the AC Setup tab and use the drop-down box to select the CT Ratio desired.

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5. To change the AC winding configuration, use the drop-down box labeled Phasing. Select the correct
configuration for your application. If it is a reconnectable source, select Auto Detect. If it is a Delta
configuration, you must select Delta as Auto Detect will not be able to identify.
6. CAN Source addresses can be set in the module and will be used when broadcasting the AC
information. The defaults are Primary 44, Secondary 51. Any value from 0 to 255 can be used.
7. Once the selections are made, Press the program button on the CI Station for the changes to be
downloaded to the unit. You can use the Save button to retain a copy for your records on your PC.

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CAN Termination
1. The XCAN-AC is a J1939 CAN Based device. The communication between this device and other
nodes are the bus require proper bus termination. Each end of the CAN Bus should contain a 120-
ohm terminating resistor. The pcb in the XCAN-AC has a 120-ohm resistor that can be included into
the CAN High and CAN Low lines by using a pcb jumper. The jumper is labeled JP1 on is identified in
the picture below. By default, this jumper is installed from the factory, terminating one end of the
communication bus.
120 ohm
Termination
Resistor
CPU Active
Blue LED
CT Selection
Dipswitches
POWER
Red LED

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J1939 Broadcast Data
Below is a table of the broadcast information. Information is available without requesting.

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CAN Trace

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10) Warranty
CONTROLS, INC. is herein called “Seller”. The person, firm or corporation to whom or which
the sale is made is herein called “Buyer”. Seller warrants to the Buyer that all products
furnished under this order will conform to Seller’s specification, drawings as described in its
current catalog or quotation and will be free from defects in materials and workmanship.
Seller must approve other special requirements asked for by the Buyer in its purchase order in
writing. Parts replaced or repaired in the warranty period shall carry the unexpired portion of
the original warranty. The foregoing is subject to the provisions that in no case will the total
warranty period extend beyond twelve (12) months from date seller ships equipment from
point of sale.
The Liability of Seller hereunder is limited to replacing or repairing at Seller’s factory any part or
parts which have been returned to the Seller and which are proved by buyer as defective or not
conforming to Seller’s specifications, drawings or other written descriptions, accepted by Seller,
provided that such part or parts are returned by the buyer within thirty (30) days after such
defect is discovered. All items returned to Seller for repair or replacement must be sent freight
prepaid to its factory. Buyer must obtain Seller’s Return Merchandise Authorization # prior to
returning items. The above conditions must be met if warranty is valid. Seller will not be liable
for any damage done by unauthorized repair work, or unauthorized misapplication in non-
suitable environment.
In no event shall the Seller be liable for loss, damage, or expense directly or indirectly arising
from the use of the units, or from any other cause, except as expressly stated in the warranty.
Seller makes no warranties, express or implied, including any warranty as to merchantability of
fitness for a particular purpose or use. Seller is not liable for and buyer waives any right or
action it has or may have against seller for any consequential or special damages arising out of
any breach of warranty, and for any damages buyer may claim for damage to any property or
injury or death to any person arising out of its purchase or the use, operation or maintenance
of the product. Seller will not be liable for any labor subcontracted or performed by buyer for
preparation of warranted item for return to Seller’s factory or for preparation work for field
repair or replacement. The Seller will not consider invoicing of Seller for labor either
performed or subcontracted by buyer as a liability. This warranty shall be exclusive of any and
all other warranties express or implied and may be modified only by a writing signed by an
officer of the Seller. With respect to accessories supplied by Seller, but manufactured by
others, there is no warranty of any kind, express or implied, and specifically there is no
warranty of merchantability or fitness, except as may be set forth in any warranty the
manufactures have made to Seller and which can be passed to the Buyer.