diy solar

diy solar

Adding Schneider XW Pro

Off grid with two stacked XW6848+. All diy. 6 years with no issues with inverters or system function. I did have a MPPT 60/150 cc fail which schneider replaced under warranty. Also had a firmware update failure (my fault) and brick a unit. Was able to recover from that using the configuration tool. Thanks to a software update that can now be done through the Insight gateway.

If you can register with schneider as an installer or technician you'll find it easier to get through to technical support.

If I was to do it again I'd probably still use schneider or outback gear. Maybe more $ upfront but living off grid and having to support some large loads (welders, machine tools and AC) I consider the extra cost as an investment in reliability and life expectancy. Something that I am willing to pay for.

Maybe some of less expensive AIOs will prove to have good reliability and support over time. I think that still remains to be seen.

YMMV, Just my $.02, etc.
 
Off grid with two stacked XW6848+. All diy. 6 years with no issues with inverters or system function. I did have a MPPT 60/150 cc fail which schneider replaced under warranty. Also had a firmware update failure (my fault) and brick a unit. Was able to recover from that using the configuration tool. Thanks to a software update that can now be done through the Insight gateway.

If you can register with schneider as an installer or technician you'll find it easier to get through to technical support.

If I was to do it again I'd probably still use schneider or outback gear. Maybe more $ upfront but living off grid and having to support some large loads (welders, machine tools and AC) I consider the extra cost as an investment in reliability and life expectancy. Something that I am willing to pay for.

Maybe some of less expensive AIOs will prove to have good reliability and support over time. I think that still remains to be seen.

YMMV, Just my $.02, etc.
This is part of my longer term choice for a new totally off grid home I am building, the WX6848 type unit over an LV6548 type unit at half the cost. I am well capable of handling setup and running of either, but the WAF has to be 100%....if she hits a switch the light had better come on.
 
Off grid with two stacked XW6848+. All diy. 6 years with no issues with inverters or system function. I did have a MPPT 60/150 cc fail which schneider replaced under warranty. Also had a firmware update failure (my fault) and brick a unit. Was able to recover from that using the configuration tool. Thanks to a software update that can now be done through the Insight gateway.

If you can register with schneider as an installer or technician you'll find it easier to get through to technical support.

If I was to do it again I'd probably still use schneider or outback gear. Maybe more $ upfront but living off grid and having to support some large loads (welders, machine tools and AC) I consider the extra cost as an investment in reliability and life expectancy. Something that I am willing to pay for.

Maybe some of less expensive AIOs will prove to have good reliability and support over time. I think that still remains to be seen.

YMMV, Just my $.02, etc.
Can you elaborate more on your setup; can you take some pics maybe? Are you using their pdp panels? I want to go this route with either two maybe even three 6848's or perhaps outback radians ..but one thing that really discourages me is that they really gouge you for the add-ons to make it all work. If I spend 4k for a inverter it should come with the simple metal box with some breakers and a buss bar in it if that's what's needed. If the inverter doesn't have a way to program it built in and I have to use a add on like the gateway etc that should be consider part of the deal. Lets face it, a cheap router with the software to make the system work isn't that expensive for them nor is a metal box "pdp" with some breakers in it. That's just my opinion not trying to flame. The mini pdp was 1k and the pdp for two was almost 2k..for a metal box. What do you use if you want three inverters etc? I'm curious if people are using other ways to hook these all up cheaper but still be safe, UL and NEC compliant to pass inspections if necessary. Maybe one of those QO panels?
 
In some circumstances QO can be used for DC.

I use QO for AC, busbars or Polaris connectors for high current splices (AC or DC), DIN rail in a box for PV fuses or breakers and AC relays.
I have one battery string feeding four inverters. Copper busbar for negative, cables fan to two class-T fuse holders each fan to two inverters for positive.

My equipment is SMA not Schneider so a different set of comms, Ethernet router is one. In my system that is all optional for monitoring, except for initial configuration. Set it and forget it, look at the LEDs and display.
 
In some circumstances QO can be used for DC.

I use QO for AC, busbars or Polaris connectors for high current splices (AC or DC), DIN rail in a box for PV fuses or breakers and AC relays.
I have one battery string feeding four inverters. Copper busbar for negative, cables fan to two class-T fuse holders each fan to two inverters for positive.

My equipment is SMA not Schneider so a different set of comms, Ethernet router is one. In my system that is all optional for monitoring, except for initial configuration. Set it and forget it, look at the LEDs and display.
Do you have any diagrams, pics of your layout when you put it all together? Not trying to be intrusive on these sorts of request..just trying to learn how people, regardless of system, are putting things together safely.
 
I still haven't done a system diagram. Really should, before I forget. But it keeps changing, as-built and improvements are still in my head.

This post shows how I split output of meter & main breaker between inverter and utility panel (previously inverter got power from panel.)


I have multiple interlocked panels, so just flipping breakers will restore direct grid power if inverters fail.

Diagram on data sheet shows the basic layout. Beyond that I have several breaker panels, some with interlocks. Also load-shed relays, as described in manual, necessary to avoid over-discharge of battery with only AC coupled PV.

 
Can you elaborate more on your setup; can you take some pics maybe? Are you using their pdp panels? I want to go this route with either two maybe even three 6848's or perhaps outback radians ..but one thing that really discourages me is that they really gouge you for the add-ons to make it all work. If I spend 4k for a inverter it should come with the simple metal box with some breakers and a buss bar in it if that's what's needed. If the inverter doesn't have a way to program it built in and I have to use a add on like the gateway etc that should be consider part of the deal. Lets face it, a cheap router with the software to make the system work isn't that expensive for them nor is a metal box "pdp" with some breakers in it. That's just my opinion not trying to flame. The mini pdp was 1k and the pdp for two was almost 2k..for a metal box. What do you use if you want three inverters etc? I'm curious if people are using other ways to hook these all up cheaper but still be safe, UL and NEC compliant to pass inspections if necessary. Maybe one of those QO panels?
No PDP panels. I use standard electrical panels. The two inverter outputs are combined in a small panel with two 50-amp 2P breakers with the buss feeding the (existing) Main Panel. The generator output is also split into two breakers, one for each inverter. This was done to allow an inverter to be isolated if needed and to keep the current limits below the 60-amp rating of the XW internal transfer relay. Battery power is fed thru an old Xantrex breaker panel that also contains the CC output breakers. I used a piece of wireway below the CC for the PV breakers. Lately I've been using the small Midnight Solar small breaker boxes or even some of the cheap DIN boxes for my neighbor's systems.

Things to be aware of: for 120/240 breakers it is important to verify they are rated for reverse feed. Most smaller current ones are but worth checking on. With DIN breakers there are lots of low cost sellers. You have to be careful the breakers are rated for the use, DC and/or voltage. The Midnight breakers are good but also pays to verify DC and voltage rating.
 

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No PDP panels. I use standard electrical panels. The two inverter outputs are combined in a small panel with two 50-amp 2P breakers with the buss feeding the (existing) Main Panel. The generator output is also split into two breakers, one for each inverter. This was done to allow an inverter to be isolated if needed and to keep the current limits below the 60-amp rating of the XW internal transfer relay. Battery power is fed thru an old Xantrex breaker panel that also contains the CC output breakers. I used a piece of wireway below the CC for the PV breakers. Lately I've been using the small Midnight Solar small breaker boxes or even some of the cheap DIN boxes for my neighbor's systems.

Things to be aware of: for 120/240 breakers it is important to verify they are rated for reverse feed. Most smaller current ones are but worth checking on. With DIN breakers there are lots of low cost sellers. You have to be careful the breakers are rated for the use, DC and/or voltage. The Midnight breakers are good but also pays to verify DC and voltage rating.
Very clean!
 
Very clean!
Thanks. I'd lay it out differently if I was starting from scratch. But the house was built when we bought it and being Mexico there's lots of funky construction compared to construction in the states.
 
The two inverter outputs are combined in a small panel with two 50-amp 2P breakers with the buss feeding the (existing) Main Panel. The generator output is also split into two breakers, one for each inverter. This was done to allow an inverter to be isolated if needed and to keep the current limits below the 60-amp rating of the XW internal transfer relay.

Two branches in parallel, carrying current from grid to load? How well balanced are they?
I did that landing on two QO270 breakers and had 3:1 imbalance. Despite perfectly matched 60' lengths of 6 awg.
Replaced with two Schneider 2 pole 63A DIN rail in another box and landed on main lugs, which balances it within 10%.
 
Since I am still in Los Angeles County, I know the inspection is pretty picky. I used the small XW conduit box. It just ads a box on the bottom of the XW to enclose the DC connections. I only have a single inverter, but this box is set up to allow installing them side by side. The only thing inside this box is a small metal raceway to separate the Xanbus lines from the high power stuff.

IMG_0674.jpg

It's the flat panel under the XW-Pro inverter. Under the inverter I have a small Square D breaker panel for the output side of the inverter. I currently don't have a simple way to bypass the XW. I was going to install a cam switch for that, but when I got it from Amazon, I just didn't trust it for the power. The grey outlet box on the right side of the XW conduit box is the plug to attach my generator to the AC2 input. While you might be able to come up with another box for the bottom, this thing was well worth the $100 or so as it has the correct screw holes to bolt up, fits the form factor nicely, has the Xanbus raceway, and it is properly vented for cooling air to get into the bottom of the XW inverter. My Class T battery fuse is in my battery cabinet, but there is enough room in the conduit box, so I do plan to add a pair of DC fuses in there. So the battery cables will be protected at both ends.

The larger box to the right of the inverter is my power meter setup. That is a DIN rail box I got off Amazon. If (when) I add a DC charge controller, I will get another box like that for the charge controller DC breakers.

I did look into the PDP or mini PDP and even the Midnight Solar connection boxes, but I just could not justify the cost for a box with a breaker in it. My seup is not as clean as it could be, but it is not bad.

IMG_8938.JPG
This shot shows the vents and the knock out. I used the offset nipples for the AC side wiring. There is also a conduit going out the back of the conduit box. It goes through the wall to get the wires from the Enphase solar and the feed from the main breaker panel. I do sort of want to replace the small breaker panel with something a little bigger. I only have 4 backed up breakers feeding into the house. The left side 240 breaker is the solar, and the right side 240 breaker is the XW inverter. The backed up 120 volt loads are fed out of the middle breakers. It's 2 tandem breakers to get 4 circuits. The black cabinet is my original 360 amp hour battery cabinet with a 300 amp Anderson connecter for the DC cables out the top. I now have a second battery cabinet that I made much smaller in a Craftsman cabinet. Both battery banks are on wheels so I can yank the plug and roll it out. The batteries are not UL listed, so they are not supposed to be in my garage. Oops.
 
If this is the box you'd like to have bypass the inverter ...

1657773990622.png

Here's the QO generator input box I used:

house interlock.jpg

8 positions, of which 4 are used for two feeds. Came as 100A & 30A, I changed to 70A & 70A.
The main lugs then go to my house. I've since replaced the unused generator input plug with an outlet and installed a 2-pole GFCI feeding it.
 
Two branches in parallel, carrying current from grid to load? How well balanced are they?
I did that landing on two QO270 breakers and had 3:1 imbalance. Despite perfectly matched 60' lengths of 6 awg.
Replaced with two Schneider 2 pole 63A DIN rail in another box and landed on main lugs, which balances it within 10%.

No grid here.

Inverter output is rarely close to equal as the master inverter will supply most of the current and slave inverter output is added to the supply for larger loads. The inverters do not try to split the load equally although it can get close under large loads.

Current doesn't need to be balanced anyway as long as the conductors are sized correctly for full system potential. Voltage is the critical factor. Voltage of each inverter is measured at the combination point and individually adjusted as part of the commissioning process. There is adjustment for this in the Conext configuration tool but not in the regular menu of the Insight Gateway. Although the Gateway gives you the ability to choose master/slave inverter settings you really need the configuration tool to do it properly.

The conductors and the XW internal transfer relay of one inverter will handle the full potential current of the 12kW genset so no issue there. If the system had a total supply potential greater then 60 amps an external transfer switch would be required due to the current limitation of the XW's internal xfer relay.

You are correct about keeping conductor lengths equal when using parallel conductors to split the current between multiple conductors. But that has to do with the fact the an individual conductor is not capable of carrying the full current without overheating. The NEC allows this for conductors over 1/0 size. I certainly don't miss having to wrestle 8 pieces of 500 mcm at a time.
 
OK, generator input being the only pass-through, and that below limit of a single relay, eliminates issue.

My SMA can have 2 in parallel for split-phase, 4 in parallel for single phase. Each watches its own current and could invert from battery, otherwise open relay if still too high. The 3 second 2x surge should accommodate timing differences, maybe for up to 3 in parallel but not maximum current of four.

You have to measure and tune XW to load share?
Sunny Island communicates, and probably both/all supply up to their maximum output in order to achieve target voltage on their terminals. I'm not sure if multiple would coordinate to share load equally, or one with lower wire resistance would max out first and limit, letting the other take up the rest. Also have option for one to work while the others sleep until called upon to carry some. But apparently in a split-phase setup the firmware lets the other phase sleep too; will need balancing transformer if I try that.
 
. "The 3 second 2x surge should accommodate timing differences..."
The relay doesn't have any surge capacity only its make or break rating of the contacts.

"You have to measure and tune XW to load share?"
The inverter sees its voltage at its internal terminal. And there can be minor variations in the voltage readings between different inverters. Ideally you want the voltages of each inverter to be exactly the same at the combination point. The configuration tool allows for small changes to the output voltage of each inverter to make this possible. Also accounts for any variation in wiring that might induce a bit of voltage drop. The communication allows the inverters to sync AC and control load sharing but cannot account for voltage differences at the combination point. While the voltages don't have to exactly match, the closer the better for system performance. You don't really want one inverter to fight the other trying to match voltage.
 
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No grid here.

Inverter output is rarely close to equal as the master inverter will supply most of the current and slave inverter output is added to the supply for larger loads. The inverters do not try to split the load equally although it can get close under large loads.

Current doesn't need to be balanced anyway as long as the conductors are sized correctly for full system potential. Voltage is the critical factor. Voltage of each inverter is measured at the combination point and individually adjusted as part of the commissioning process. There is adjustment for this in the Conext configuration tool but not in the regular menu of the Insight Gateway. Although the Gateway gives you the ability to choose master/slave inverter settings you really need the configuration tool to do it properly.

The conductors and the XW internal transfer relay of one inverter will handle the full potential current of the 12kW genset so no issue there. If the system had a total supply potential greater then 60 amps an external transfer switch would be required due to the current limitation of the XW's internal xfer relay.

You are correct about keeping conductor lengths equal when using parallel conductors to split the current between multiple conductors. But that has to do with the fact the an individual conductor is not capable of carrying the full current without overheating. The NEC allows this for conductors over 1/0 size. I certainly don't miss having to wrestle 8 pieces of 500 mcm at a time.
I'm new to this solar stuff..just been here a few days. I've stated this before..I'm shocked that companies sell you a product then nickle and dim you for stuff to make it work. Schneider seems to be one of the worst. I see your post about this configuration tool I've heard others talking about and decided to look it up. $600 dollars for a flipping usb stick? And, worst it's something a customer would really need to configure the product you just bought from them. I can't believe they get away with this crap. Can't they make that expensive gateway they sell to ..once again manage and configure the product do the same thing as this tool? They should either add this software to the gateway or give you this usb tool that's super cheap for them to make. I'm shocked this sort of stuff doesn't generate a class action against these companies.
 
I, as a Schneider customer, certainly don't agree with all the things they do to put up road blocks to the DIY crowd, but I do understand why they do some of it.

Companies like Schneider support their installers. An installer only needs to buy one configuration tool. The $600 is not for the USB stick, it is for the license to use the software to do the configuration. If a DIY person buys the stick for their one install, they are not the target customer for it. They want installers to do this type of setup as it would be just too easy to put in bad values. An error in configuration at that level could do more than just stop it from working, it could actually damage the equipment. While many of us DIY people do take the time to study what we are doing, to make sure we do it right, that might not be the case of every person who buys an inverter. They basically locked out controls that could be dangerous. If it just needed a password, then someone would just post the password, and anyone could poke around and ruin their equipment if they didn't understand what they were doing. So yes, $600 for the USB device and some software seems crazy, but it really is not that bad. For an installer who puts in several systems a year, it won't even register as an expense.

The other complaint about Schneider is the "nickel and dime" of having to buy each separate part. Again, this is a bigger picture choice on their part. If you are building a really small system, like mine with just one XW-Pro and nothing else... Having to buy the Gateway was a fairly big cost add. But if this was a large system to power a factory, with 6 XW-Pro's making 3 phase to run machines, and it also had five 600 volt charge controllers and a shipping container full of batteries.... This setup still only needs ONE Gateway to monitor and configure it. IF that capability was built into every device, you would now have the equivalent of 11 Gateways on your network. As the system gets bigger, it makes more sense.

Having the battery monitor as a separate device also does make sense. I may still get one, but for now, I am happy with voltage control. If (when) I change to LFP cells, I will probably go with either a BMS the XW can talk to, or a Xanbus battery monitor.

When I looked at other systems, there were certainly pros and cons. The OutBack SkyBox looked like a great idea. It rolled all the things a normal DIY user needs into a single box. Had it been available 6 months sooner, and had some better early reviews, I probably would have gone that way. It has a charge controller, that I would still not be using, but other than that, it is less powerful, and cost a lot more than I got the Schneider for, even with the extra cost of the gateway and the conduit box. For a single inverter, it is easy to set up with the Gateway, and no config tool is needed. Needing the gateway is no different than an Enphase system needing an Envoy.

My only HUGE complaint about Schneider is they just don't want to add functions in their built in software. They feel it does what it needs to do. I called them out on their sideways lies on their website about supporting energy time shifting AND AC coupling. Their fix was a change to the wording on the website. It is still a little misleading, but now has a little fine print to tell you some features only work in some configurations.

The all in one hybrid inverters are getting better. I don't think they are up to the quality of the Schneider gear, and none of them can take overloads like an XW can. Has anyone been able to make one of them use only excess solar for battery charging, and then zero the grid all day? I would love to see production and utility usage graphs on someone doing time of use energy shifting on an all in one. I don't think a Sol-Ark can do what I am making my Schneider do now. The time shifting ability in the new OutBack Mojave looks very limited and kind of crude. To make mine work the way I wanted it to, I had to add a PLC and write my own code, but the Schneider let's me do it. Can a Growatt do it?
 
I, as a Schneider customer, certainly don't agree with all the things they do to put up road blocks to the DIY crowd, but I do understand why they do some of it.

Companies like Schneider support their installers. An installer only needs to buy one configuration tool. The $600 is not for the USB stick, it is for the license to use the software to do the configuration. If a DIY person buys the stick for their one install, they are not the target customer for it. They want installers to do this type of setup as it would be just too easy to put in bad values. An error in configuration at that level could do more than just stop it from working, it could actually damage the equipment. While many of us DIY people do take the time to study what we are doing, to make sure we do it right, that might not be the case of every person who buys an inverter. They basically locked out controls that could be dangerous. If it just needed a password, then someone would just post the password, and anyone could poke around and ruin their equipment if they didn't understand what they were doing. So yes, $600 for the USB device and some software seems crazy, but it really is not that bad. For an installer who puts in several systems a year, it won't even register as an expense.

The other complaint about Schneider is the "nickel and dime" of having to buy each separate part. Again, this is a bigger picture choice on their part. If you are building a really small system, like mine with just one XW-Pro and nothing else... Having to buy the Gateway was a fairly big cost add. But if this was a large system to power a factory, with 6 XW-Pro's making 3 phase to run machines, and it also had five 600 volt charge controllers and a shipping container full of batteries.... This setup still only needs ONE Gateway to monitor and configure it. IF that capability was built into every device, you would now have the equivalent of 11 Gateways on your network. As the system gets bigger, it makes more sense.

Having the battery monitor as a separate device also does make sense. I may still get one, but for now, I am happy with voltage control. If (when) I change to LFP cells, I will probably go with either a BMS the XW can talk to, or a Xanbus battery monitor.

When I looked at other systems, there were certainly pros and cons. The OutBack SkyBox looked like a great idea. It rolled all the things a normal DIY user needs into a single box. Had it been available 6 months sooner, and had some better early reviews, I probably would have gone that way. It has a charge controller, that I would still not be using, but other than that, it is less powerful, and cost a lot more than I got the Schneider for, even with the extra cost of the gateway and the conduit box. For a single inverter, it is easy to set up with the Gateway, and no config tool is needed. Needing the gateway is no different than an Enphase system needing an Envoy.

My only HUGE complaint about Schneider is they just don't want to add functions in their built in software. They feel it does what it needs to do. I called them out on their sideways lies on their website about supporting energy time shifting AND AC coupling. Their fix was a change to the wording on the website. It is still a little misleading, but now has a little fine print to tell you some features only work in some configurations.

The all in one hybrid inverters are getting better. I don't think they are up to the quality of the Schneider gear, and none of them can take overloads like an XW can. Has anyone been able to make one of them use only excess solar for battery charging, and then zero the grid all day? I would love to see production and utility usage graphs on someone doing time of use energy shifting on an all in one. I don't think a Sol-Ark can do what I am making my Schneider do now. The time shifting ability in the new OutBack Mojave looks very limited and kind of crude. To make mine work the way I wanted it to, I had to add a PLC and write my own code, but the Schneider let's me do it. Can a Growatt do it?

Thanks for the in depth feedback! I see your view points and while I agree I also have opposing views. First, if you buy the product and install it yourself you are the installer and should have the support and tools you need on day one as part of the system not add-ons. Your point about people not knowing what values to enter and causing issues of which some might be catastrophic is a 100% valid argument. I've worked three decades in IT..mostly linux support / network etc. I know what you're saying unfortunately. But, at the same time I also know that a good dev team working with the engineering team can create a configuration wizard on the gateway that would help to drastically reduce this concern. There could be a basic config option which ask you sets of questions and maybe uses it's sensors etc and simply click next, next submit. There could also be a advanced section to the wizard that you click a box to enable and agree to the terms etc where they can put a disclaimer. But, even in this section they can let the wizard ask sets of questions and help you config it safely and should a manual entry be need the software can check to see if your manual entry is going to be damaging and grey it out if that's the case. This should be the case for all of these setups just not Schneider. Make your products more diy compatible. Some of this is blatant and on purpose so you have to use one of their certified installers for yet another revenue stream. I've been looking at the 6848 and the outback radian 8k inverter which is just slightly more expensive than a 6848. Not sure how their features stack up against what you stated above.

This is the one I was looking at, wonder how well it would stack up against the conext system? I'm trying to find more on it and how they stack them and what their features are. One thing I did notice while the power is higher the surge time is shorter than the 6848.

 
Thanks for the in depth feedback! I see your view points and while I agree I also have opposing views. First, if you buy the product and install it yourself you are the installer and should have the support and tools you need on day one as part of the system not add-ons. Your point about people not knowing what values to enter and causing issues of which some might be catastrophic is a 100% valid argument. I've worked three decades in IT..mostly linux support / network etc. I know what you're saying unfortunately. But, at the same time I also know that a good dev team working with the engineering team can create a configuration wizard on the gateway that would help to drastically reduce this concern. There could be a basic config option which ask you sets of questions and maybe uses it's sensors etc and simply click next, next submit. There could also be a advanced section to the wizard that you click a box to enable and agree to the terms etc where they can put a disclaimer. But, even in this section they can let the wizard ask sets of questions and help you config it safely and should a manual entry be need the software can check to see if your manual entry is going to be damaging and grey it out if that's the case. This should be the case for all of these setups just not Schneider. Make your products more diy compatible. Some of this is blatant and on purpose so you have to use one of their certified installers for yet another revenue stream. I've been looking at the 6848 and the outback radian 8k inverter which is just slightly more expensive than a 6848. Not sure how their features stack up against what you stated above.

This is the one I was looking at, wonder how well it would stack up against the conext system? I'm trying to find more on it and how they stack them and what their features are. One thing I did notice while the power is higher the surge time is shorter than the 6848.

For my cabin, I’ve been bouncing around the idea of XW Pro or Radian 8048 for months. I need the LF inverter for my well pump 37a surge @240v and I want this inverter to always be working to cover critical loads such as lights and refrigeration. I have settled on the Radian for two reasons: 1) A Few less pieces to buy with Outback and 2) Support including their dedicated forum with a lot of history. These inverters can surge up to 16kva for 10 seconds. Both XW and Raidian need additional components to have a full system like the PDP by Schneider.
 
I did look into a Radian as well. It is a quality unit. It does also require you to buy a few other items. You need a MATE3 and a HUB to connect and monitor the system. Not too different from the Gateway or Insight Home on Schneider. And they have their own set of interconnection panels. The only big difference is it seems the Outback support people are a bit more DIY friendly. The cost for a similar capability is pretty close. The deal at the time and the shipping can flip it either way.
 
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