ConextSW-NA-InstallationGuide.book Page i Thursday, December 20, 2012 2:05 PM Conext™ SW Inverter Charger Conext SW 2524 120/240 (865-2524) Conext SW 4024 120/240 (865-4024) Installation Guide TM www.schneider-electric.
ConextSW-NA-InstallationGuide.book Page ii Thursday, December 20, 2012 2:05 PM YOUR ^ ,E / Z > dZ/ DISTRIBUTOR SOLIGENT 800-967-6917 www.soligent.
ConextSW-NA-InstallationGuide.book Page i Thursday, December 20, 2012 2:05 PM Conext SW Inverter Charger Conext SW 2524 120/240 (865-2524) Conext SW 4024 120/240 (865-4024) Installation Guide www.schneider-electric.
ConextSW-NA-InstallationGuide.book Page ii Thursday, December 20, 2012 2:05 PM Copyright and Contact Copyright © 2012 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
ConextSW-NA-InstallationGuide.book Page iii Thursday, December 20, 2012 2:05 PM About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the Conext SW Inverter/Charger to a main AC power source such as an AC generator for off-grid application or AC mains (main power grid) for power backup application. Scope The Guide provides safety and installation guidelines as well as information on tools and wiring.
ConextSW-NA-InstallationGuide.book Page iv Thursday, December 20, 2012 2:05 PM About This Guide Conventions Used The following conventions are used in this guide. DANGER DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death or serious injury.
ConextSW-NA-InstallationGuide.book Page v Thursday, December 20, 2012 2:05 PM Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD DANGER ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation and electrical codes and regulations. Instructions for installing the Conext SW are provided here for use by qualified installers only.
ConextSW-NA-InstallationGuide.book Page vi Thursday, December 20, 2012 2:05 PM Safety DANGER ELECTRIC SHOCK HAZARD • For indoor use only. This inverter/charger is designed for off-grid, solar, backup, and hybrid applications. • Do not operate the inverter/charger if it has been damaged in any way. • Do not operate the inverter/charger with damaged or substandard wiring. Wiring must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations.
ConextSW-NA-InstallationGuide.book Page vii Thursday, December 20, 2012 2:05 PM Safety Precautions When Working With Batteries Important: Battery work and maintenance must be done or supervised by qualified personnel knowledgeable about batteries to ensure compliance with battery handling and maintenance safety precautions. WARNING ENERGY AND FIRE HAZARD • Always wear proper, non-absorbent gloves, complete eye protection, and clothing protection.
ConextSW-NA-InstallationGuide.book Page viii Thursday, December 20, 2012 2:05 PM Safety CAUTION CHEMICAL HAZARD • Never allow battery acid to drip when reading specific gravity or filling battery. • Make sure the area around the battery is well ventilated. • Make sure the voltage of the batteries matches the rated nominal output DC voltage of the inverter/charger.
ConextSW-NA-InstallationGuide.book Page ix Thursday, December 20, 2012 2:05 PM Safety FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
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ConextSW-NA-InstallationGuide.book Page 1 Thursday, December 20, 2012 2:05 PM 1 Installation The following topics will be covered in this chapter.
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ConextSW-NA-InstallationGuide.book Page 3 Thursday, December 20, 2012 2:05 PM Materials List Conext SW Front and Side Panels 1 2 TOP TOP 3 7 7 4 6 5 Figure 1-2 Conext SW Front and Side Panels Before you begin to operate the Conext SW after installation, review the front panel features shown in Figure 1-3 and described in the next table. A detailed view of the lights and buttons on the front panel is also shown.
ConextSW-NA-InstallationGuide.book Page 4 Thursday, December 20, 2012 2:05 PM Installation Item Description 5 AC line terminals. See “AC and DC Terminals, Network and Communication Ports Panel” on page 1–5. 6 Two variable-speed cooling fans maintain a cool internal temperature of critical components. The two fans control airflow through the transformer and power compartments of the unit. Ensure at least 10" (254 mm) of clearance for proper ventilation. 7 Mounting holes for permanent installation.
ConextSW-NA-InstallationGuide.book Page 5 Thursday, December 20, 2012 2:05 PM Materials List Conext SW AC/DC/Ports Side Panel 3 1 7 b a 4 2 5 6 8 9 Figure 1-4 AC and DC Terminals, Network and Communication Ports Panel Item 1 2 3 4 5 6 7 Description Battery Positive (+) (red) DC terminal connects to the positive bus bar of the DC Switchgear. Battery Negative (–) (black) DC terminal connects to the negative bus bar of the DC Switchgear.
ConextSW-NA-InstallationGuide.book Page 6 Thursday, December 20, 2012 2:05 PM Installation Conext SW Supplied Accessories 1 2 3 Figure 1-5 Supplied Accessories NOTE: If any of the supplied accessories are missing, contact customer service for replacement. See “Contact Information www.schneider-electric.com” on page ii. Item Description 1 BTS, the Battery Temperature Sensor consists of: • Connector that plugs into the BTS port on the Conext SW. • Sensor cable is 25 feet (7.6 meters).
ConextSW-NA-InstallationGuide.book Page 7 Thursday, December 20, 2012 2:05 PM Materials List Conext SW Required Accessory Figure 1-6 DC Switchgear NOTE: The DC Switchgear is required by electrical code to be installed with the Conext SW inverter/charger in installations within Canada and the USA.
ConextSW-NA-InstallationGuide.book Page 8 Thursday, December 20, 2012 2:05 PM Installation Installation Information Before You Begin the Installation Before beginning your installation: • Read the entire Installation Guide so you can plan the installation from beginning to end. • Assemble all the tools and materials you require for the installation. • Review the Important Safety Instructions on page v. • Be aware of all safety and electrical codes which must be met.
ConextSW-NA-InstallationGuide.book Page 9 Thursday, December 20, 2012 2:05 PM Xanbus Network System Xanbus Network System Xanbus System The Xanbus system includes the Conext SW and other Xanbus-enabled devices. The Conext SW is the device in a Xanbus system that typically provides network power—500 mA at 12 VDC. All of the Xanbus-enabled devices, such as the Conext SW, the SCP, and the AGS are able to communicate their settings and activity to each other.
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ConextSW-NA-InstallationGuide.book Page 11 Thursday, December 20, 2012 2:05 PM Installation Planning Installation Planning Planning Preparations This section provides information to help plan for a basic installation of the Conext SW. There are two key factors that will have a major impact on system performance. 1. Size and Length of DC Cables To select the appropriate size and length of DC cables, see “DC Cabling” on page 1–14.
ConextSW-NA-InstallationGuide.book Page 12 Thursday, December 20, 2012 2:05 PM Installation AC, DC, and Network Components The illustration below shows the different components that can go into a Conext SW inverter/charger installation.
ConextSW-NA-InstallationGuide.book Page 13 Thursday, December 20, 2012 2:05 PM Installation Planning The illustration below shows which components you may need before you begin your installation. DC Components Xanbus Network Components • 24-volt battery or batteries, see “DC Component -Batteries” on page 1–14. • System Control Panel (SCP) • Automatic Generator Start (AGS) • DC-rated fuse and/or circuit breaker, see “DC Disconnects and Overcurrent Devices” on page 1–15.
ConextSW-NA-InstallationGuide.book Page 14 Thursday, December 20, 2012 2:05 PM Installation Size of AC Input Wiring Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved, in accordance with the electrical codes or regulations applicable to your installation. Therefore, the wiring used between the main AC source panel’s circuit breaker and the inverter/charger AC INPUT must be sized to match the input breaker rating.
ConextSW-NA-InstallationGuide.book Page 15 Thursday, December 20, 2012 2:05 PM Installation Planning Table 1-2 Recommended Battery Cable Sizesa Conduitb Maximum Current (A) Model Cable Length < 5 ft (1.5 m) Cable Length 5 to 10 ft (1.5 to 3 m) SW 2524 120/240 120 1 AWG SW 4024 120/240 200 3/0 AWG a.From National Electrical Code (NEC) requirements. b.Per NEC Table 310.16 for 177 °F (75 °C) rated copper conductor.
ConextSW-NA-InstallationGuide.book Page 16 Thursday, December 20, 2012 2:05 PM Installation Unpacking and Inspecting the Conext SW Inverter/Charger CAUTION HEAVY LOAD HAZARD Do not lift the unit by yourself. Use two people to lift and mount the unit. Always use proper lifting techniques during installation to prevent injury. Failure the follow these instructions can result in injury.
ConextSW-NA-InstallationGuide.book Page 17 Thursday, December 20, 2012 2:05 PM Installation Planning Installation Tools and Materials Tools You will need the following tools to install the Conext SW and the battery temperature sensor. ❐ Wire stripper ❐ Crimping tools for fastening lugs and terminals on DC cables ❐ Phillips screwdriver: #2 ❐ Slot screwdriver (1/4" [6mm] wide blade max.
ConextSW-NA-InstallationGuide.book Page 18 Thursday, December 20, 2012 2:05 PM Installation Inverter/Charger Installation Overview This section provides detailed information on installing the Conext SW.
ConextSW-NA-InstallationGuide.book Page 19 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation Step 1: Choosing a Location for the Inverter/Charger WARNING FIRE HAZARD For indoor use only. Do not install and/or operate in compartments containing flammable materials or in locations that require ignition-protected equipment. Do not cover or obstruct the ventilation openings. Do not install this unit in a compartment with limited airflow.
ConextSW-NA-InstallationGuide.book Page 20 Thursday, December 20, 2012 2:05 PM Installation TIP: Align the mounting holes in the center of wall studs. If necessary, fasten a plywood board first to a wall with non-standard-spaced wall studs. Then mount the inverter/charger on the plywood board. 16-inch standardspaced wall studs. (1) Place the installation bracket flat on the wall (or plywood) and mark the positions of the mounting holes on the wall. (2) 5 7/8 in. 149.
ConextSW-NA-InstallationGuide.book Page 21 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation Step 3: Connecting the AC Input and AC Output Wires DANGER ELECTRICAL SHOCK AND FIRE HAZARD Make sure wiring being connected to the inverter/charger is disconnected (physically or by opening and locking out the breaker) from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes.
ConextSW-NA-InstallationGuide.book Page 22 Thursday, December 20, 2012 2:05 PM Installation NOTE: Make the connections to the AC INPUT side first (steps (3) to (8)) then the AC OUTPUT side (steps (4) to (9)). Finish with step (10). (1) Make the wiring connections to the AC source main panel. (2) Route the AC cable to the inverter/ (3) side AC knockouts charger. (3) Remove the wiring compartment cover panel on the inverter/charger. (4) Remove the AC knockouts from the side (4) or bottom (or both).
ConextSW-NA-InstallationGuide.book Page 23 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation Step 4: Installing the DC Switchgear and Connecting the DC Cables DC Connection Precautions WARNING ELECTRICAL SHOCK HAZARD Connect and disconnect DC wiring only after opening and locking out the disconnect switches or breakers at all AC and DC sources. Failure to follow these instructions can result in death or serious injury.
ConextSW-NA-InstallationGuide.book Page 24 Thursday, December 20, 2012 2:05 PM Installation Installing the DC Switchgear next to Conext SW Inverter/Charger WARNING FIRE HAZARD • Make sure the supplied nuts on the inverter/charger are tightened to a torque of 10–11 ft-lbs (13.5–14.9 Nm). Torque all other connections to the manufacturer’s specifications. • Make sure the bus bar, washer, and nut are assembled in the order shown in Figure 1-12 on page 1–25..
ConextSW-NA-InstallationGuide.book Page 25 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation T (1) Unpack the DC Switchgear from its box, if not already. (2) Prepare four #10 (M5) machine screws. Use two screws to secure the DC Switchgear to the installation brackets of the Conext SW and two screws to secure the connecting bracket. The connecting bracket attaches to the Conext SW and DC Switchgear.
ConextSW-NA-InstallationGuide.book Page 26 Thursday, December 20, 2012 2:05 PM Installation Connecting the DC Cables to the DC Switchgear WARNING FIRE HAZARD • Use only appropriately sized copper cable. Loose connections, improper connections, and under-rated cables will overheat. • Make sure the supplied nuts on the inverter/charger are tightened to a torque of 10–11 ft-lbs (13.5–14.9 Nm). Torque all other connections to the manufacturer’s specifications.
ConextSW-NA-InstallationGuide.book Page 27 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation (1) Route the DC cables from the battery bank to the DC Switchgear. (2) Install a DC fuse (a) on the positive cable near the battery terminal. (3) Open the DC circuit breaker on the DC Switchgear. (4) Connect one connector on the POSITIVE (+) cable to the POSITIVE terminal on the DC Switchgear. The connector goes on first, then the flat washer (steel), then the 3/8” (9.5mm) bolt (brass).
ConextSW-NA-InstallationGuide.book Page 28 Thursday, December 20, 2012 2:05 PM Installation Step 5: Connecting the BTS and Xanbus-enabled Components WARNING ELECTRICAL SHOCK HAZARD Connect and disconnect DC wiring only after opening and locking out the disconnect switches or breakers at all AC and DC sources. Failure to follow these instructions can result in death or serious injury.
ConextSW-NA-InstallationGuide.book Page 29 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation (1) Install the BTS sensor on the battery. Method (a) involves mounting the sensor to the (3) Connect the Xanbus-enabled devices negative battery post which allows the internal battery temperature to be sensed providing the most accurate results. using the provided network cable. Terminate each end of the network with a network terminator (c) and (d).
ConextSW-NA-InstallationGuide.book Page 30 Thursday, December 20, 2012 2:05 PM Installation Step 6: Performing Checks Prior to Initial Start-Up Before testing your installation, ensure these conditions are met. ❐ AC ground are properly installed. ❐ AC input connections and AC output connections are wired correctly on the terminal block and not reversed. ❐ Positive (+) battery cable from the DC Switchgear is connected to the positive (+) battery terminal through the DC fuse.
ConextSW-NA-InstallationGuide.book Page 31 Thursday, December 20, 2012 2:05 PM Inverter/Charger Installation Testing in Invert Mode To test the Conext SW in invert mode, using a 100 watt light bulb as the test load: 1. Close the DC disconnect switch or the DC circuit breaker to supply DC power to the Conext SW. Wait for the LEDs on the front panel to flash on and off, indicating that the unit is successfully initializing (10 to 30 seconds). The LEDs will turn off after initialization.
ConextSW-NA-InstallationGuide.book Page 32 Thursday, December 20, 2012 2:05 PM Installation Multiple Unit Configuration The Conext SW inverter/chargers support multiple unit configuration to increase power output. This gives the system engineer and/or installer more options to work with when tailoring a system to meet load demands. In a multiple unit configuration, only two Conext SW inverter/chargers of the same model can be used.
ConextSW-NA-InstallationGuide.book Page 33 Thursday, December 20, 2012 2:05 PM Multiple Unit Configuration DC Connections for Multiple Unit Configuration Individual overcurrent devices are to be used between the battery positive and each positive cable leading to the DC Switchgear. Keep cable lengths to the two DC switchgears the same in order to balance cable losses. Connect the units as follows: 1. Connect the positive cables.
ConextSW-NA-InstallationGuide.book Page 34 Thursday, December 20, 2012 2:05 PM Installation Neutral Wiring for Inverters in Multiple Unit Configuration In a multiple unit configuration, connect the two AC input neutrals together at the main distribution panel and the two AC output neutrals at an isolated neutral location in the inverter AC distribution panel.
ConextSW-NA-InstallationGuide.book Page 35 Thursday, December 20, 2012 2:05 PM Multiple Unit Configuration Configuring the System for Multiple Unit Operation Verify all DC and AC connections. Check Xanbus network connections and ensure that terminators are installed at devices at each end of the network. The simplest system includes a Xanbus SCP, the two multi-unit-configured Conext SW inverter/chargers, and two Xanbus terminators.
ConextSW-NA-InstallationGuide.book Page 36 Thursday, December 20, 2012 2:05 PM Installation Search Mode Operation in Multiple Unit Configuration When two inverter/chargers are configured, search mode behavior on the Slave unit is modified and is dependent on how much total load is on the system. Disabling Search Mode on the Master Unit Search mode on the Master unit will not function properly.
ConextSW-NA-InstallationGuide.book Page 37 Thursday, December 20, 2012 2:05 PM Battery Information Battery Information Battery Bank Sizing Battery capacity Battery size or capacity is just as important as the battery type selected for use with the Conext SW. The batteries are the most important part of your system, so it is recommended that you purchase as much battery capacity as possible. A large battery will extend running time and ensure that your inverter/charger delivers full rated surge.
ConextSW-NA-InstallationGuide.book Page 38 Thursday, December 20, 2012 2:05 PM Installation Estimating Battery Requirements Calculating Battery Size Step 1: Compute Amp-hours For each appliance, compute the number of amp-hours that will be used between charging cycles, as follows: 1. Obtain the wattage. If the wattage is marked on the nameplate rating, use that. Otherwise, multiply the marked voltage and amperage: WATTS = VOLTS × AMPS. 2.
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ConextSW-NA-InstallationGuide.book Page 40 Thursday, December 20, 2012 2:05 PM Installation Restrictions on Motor Size An appliance may require three to six times its normal running current in order to start. The Conext SW can handle surges up to twice its rated amount (surge current) for five seconds. For example, the model Conext SW 4024 120/240 is rated as having a maximum continuous output current of 15 amps and a surge capability of 32 amps.
ConextSW-NA-InstallationGuide.book Page 41 Thursday, December 20, 2012 2:05 PM Battery Information Battery Cabling and Hook-up Configurations Several smaller batteries can be connected to create a battery bank of substantial size. You can connect batteries in three ways: in parallel, series, or series-parallel. To make a larger battery bank, connect individual batteries with heavy cables. The actual size of the cable depends on whether the batteries are connected in parallel or series.
ConextSW-NA-InstallationGuide.book Page 42 Thursday, December 20, 2012 2:05 PM Installation Battery Series Connection When batteries are connected with the positive terminal of one battery to the negative terminal of the next battery, they are connected in series. In a series configuration, the battery bank has the same Ah rating of a single battery, but an overall voltage equal to the sum of the individual batteries. See below.
ConextSW-NA-InstallationGuide.book Page 1 Thursday, December 20, 2012 2:05 PM 2 Specifications NOTE: Specifications are subject to change without prior notice.
ConextSW-NA-InstallationGuide.book Page 2 Thursday, December 20, 2012 2:05 PM Specifications Inverter Specifications NOTE: All inverter specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), 24 VDC, unless otherwise specified.
ConextSW-NA-InstallationGuide.book Page 3 Thursday, December 20, 2012 2:05 PM Charger Specifications Charger Specifications NOTE: All charging specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), split-phase 120/240 VAC, 60 Hz unless otherwise specified. DC Output SW 2524 120/240 SW 4024 120/240 Maximum output current 65 A 90 A Nominal output voltage 24 VDC 24 VDC Charging output voltage operation range 12.0–32.0 VDC 12.0–32.
ConextSW-NA-InstallationGuide.book Page 4 Thursday, December 20, 2012 2:05 PM Specifications AC Transfer Specifications NOTE: All transfer specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), split-phase 120/240 VAC, 60 Hz input, unless otherwise specified.
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ConextSW-NA-InstallationGuide.book Page 1 Thursday, December 20, 2012 2:05 PM 3 Wiring Diagrams “Wiring Diagrams” illustrate the most basic BOS configurations and are for reference only. Specific installations may require additional equipment to meet national or local electric codes. Ensure all safety requirements are strictly followed. For...... See....
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ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 3 Wednesday, December 19, 2012 2:21 PM Single-Inverter System (Off-Grid/Power Backup) Single-Inverter System (Off-Grid/Power Backup) DANGER ELECTRICAL SHOCK AND FIRE HAZARD Accessories Communication System Control Panel Automatic Generator Start (optional) (optional) Conext SW DC Switchgear Conext SW DC Switchgear Fault/ Warning System Status AC Battery 20. 4 A 53.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 4 Wednesday, December 19, 2012 2:21 PM ACCESSORIES Communication Cable (Category 5) BTS Conext SW Inverter/Charger Conext SW DC Switchgear Xanbus DC Disconnect Automatic Generator Start (optional) System Control Panel (optional) Xanbus Network Terminator Conext ComBox (optional) Power Fault/Warning Battery Positive System Status Battery 20.4 A 53.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 5 Wednesday, December 19, 2012 2:21 PM Single-Inverter System Renewable Energy (Solar) Single-Inverter System Renewable Energy (Solar) DANGER ELECTRICAL SHOCK AND FIRE HAZARD Accessories Communication Failure to follow these instructions will result in death or serious injury.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 6 Wednesday, December 19, 2012 2:21 PM ACCESSORIES Communication Cable (Category 5) BTS Conext SW Inverter/Charger Conext SW DC Switchgear Solar Charge Controller Xanbus Renewable Energy Photovoltaic DC Disconnect Ente r Standby BTS PV + DC Combiner Box Fault Exit Automatic Generator Start Xanbus Network Terminator NOTE: Be sure to check the generator for a neutral-toground bond and remove it.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 7 Wednesday, December 19, 2012 2:21 PM Dual-Inverter System Renewable Energy (Solar) Dual-Inverter System Renewable Energy (Solar) DANGER Communication Conext SW DC Switchgear Conext SW DC Switchgear Accessories System Control Panel Automatic Generator Start (optional) (optional) Fault/ Warning System Status AC Battery 20. 4 A 53.
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ConextSW-NA-InstallationGuide.book Page 4 Thursday, December 20, 2012 2:05 PM Schneider Electric www.schneider-electric.com For other country details please contact your local Schneider Electric Sales Representative or visit the Schneider Electric website at: http://www.schneider-electric.com/sites/corporate/en/support/operations/local-operations/local-operations.
