Pro XW Pro 6848 NA Installation Guide 990-91228A-01 July 2020 https://solar.schneider-electric.
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READ AND SAVE THESE INSTRUCTIONS Safety Information Important 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.
Label Symbols NOTE: The term "ground" is equivalent to "earth", and the use of these terms depends on local codes and standards. This document uses the term "ground" throughout. The following symbols appear on labels on or in the inverter.
Radio Frequency Interference Notices Federal Communications Commission (FCC) This equipment has been tested and found to comply with the limits for a Class A 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.
Audience This guide is intended for any qualified personnel planning to install the Conext XW Pro inverter/charger and related system components.The qualified personnel have training, knowledge, and experience in: n Installing electrical equipment. n Applying all applicable installation codes. n Analyzing and reducing the hazards involved in performing electrical work. n Installing and configuring batteries. n Selecting and using Personal Protective Equipment (PPE).
About Purpose This guide provides explanations and procedures for installing Schneider Electric Conext XW Pro inverter/charger. n Operational instructions are available in the Conext XW Pro Owner's Guide (document number 990-91227). n Instructions for configuring inverter settings are also available in the Conext XW Pro Owner's Guide (document number 990-91227). For explanations and procedures related to other products, please contact the manufacturer of those products.
Related Information Find more information about Schneider Electric as well as its products and services at: www.schneider-electric.com. For specific information on Solar, visit the Schneider Electric Solar Business website at: https://solar.schneider-electric.com. For available accessories, see "Optional Accessories" on page 18.
Product Safety Information Conext XW Pro Installation Guide Product Safety Information IMPORTANT: Remember to read and follow all product safety information in this document. General Safety Instructions Before using the inverter/charger, read all instructions and cautionary markings on the unit, the batteries, and all appropriate sections of this manual. n Use of accessories not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or injury to persons.
Conext XW Pro Installation Guide Product Safety Information DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE This document is in addition to, and incorporates by reference, the relevant product manuals for Conext XW Pro inverter/charger. Before reviewing this document, you must read the relevant product manuals. Unless specified, information on safety, specifications, installation and operation is as shown in the primary documentation received with the product.
Product Safety Information Conext XW Pro Installation Guide Precautions when Working with Batteries NOTE: Battery work and maintenance must be done by qualified personnel knowledgeable about batteries to help ensure compliance with battery handling and maintenance safety precautions. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH n Remove watches, rings, or other metal objects. n This equipment must only be installed and serviced by qualified electrical personnel.
Conext XW Pro Installation Guide Product Safety Information Explosive Gas Precautions WARNING EXPLOSION HAZARD The Conext XW Pro is not ignition protected. To prevent fire or explosion, do not install this product in locations that require ignition-protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system.
Conext XW Pro Installation Guide Contents Safety Information Label Symbols Radio Frequency Interference Notices Audience About Purpose 6 Scope 6 Abbreviations and Acronyms 6 Related Information 7 Product Safety Information 8 General Safety Instructions 8 Precautions when Working with Batteries 10 Limitations on Use 10 Explosive Gas Precautions 11 Introduction 16 Overview 17 Inside the Box 17 Conext XW Pro and System Components 17 Battery Temperature Sensor 17 Conext XW Jumpers (
Conext XW Pro Installation Guide Knockout Selection 28 Air Filter and AUX Port Connector Installation 29 Wall-Mounting Installing the Mounting Plate 31 Wall-Mounting the Conext XW Pro and PDP 32 Installing the XW Conduit Box 34 Communications Network Preparation 36 Battery Bank Preparation 37 Battery Bank Requirements 38 Battery Cable Requirements 38 Torque Values 40 Torque Values for the Conext XW Pro 40 Torque Values for the Power Distribution Panel (PDP) 40 Wiring 42 Removing t
Conext XW Pro Installation Guide Basic Functional Test - Multiple Inverters 87 Wiring the Conext XW Pro Inverter/Charger without a PDP 89 Pre-Installation Steps 90 Feed-in Protection Requirements 90 Conext XW Pro Inverter/Charger Grounding 91 Grounding the DC System 92 Communication The Xanbus Network Network Components Installing the Network 99 99 102 Before You Begin the Installation 102 Installation Tools and Materials 102 Installing AC sync and Xanbus cables 102 Guidelines for Routi
Conext XW Pro Installation Guide Updating the Label 15 This manual is intended for use by qualified personnel 131 990-91228A-01
Introduction Conext XW Pro Installation Guide 1 Introduction What's in This Chapter? Overview 17 Inside the Box 17 Conext XW Pro and System Components 17 Battery Temperature Sensor 17 Conext XW Jumpers (For Single-Phase Conversion) 18 Conext XW Pro Features 18 Optional Accessories 18 Conduit Box 18 Power Distribution Panel (PDP) 19 PDP 120/240V 60A Breaker Kit 20 Conext MPPT 60 150 Solar Charge Controller 21 Conext MPPT 80 600 Solar Charge Controller 21 Conext Automatic Generator
Conext XW Pro Installation Guide Introduction Overview The Conext XW Pro is a modular building block sine-wave inverter/charger that can be used for residential and commercial battery based off-grid, grid backup, and grid interactive applications. The Conext XW Pro is a self-contained DC to AC inverter, battery charger, and integrated AC transfer switch. It is configurable in a hybrid system to operate with generators and renewable energy sources.
Introduction Conext XW Pro Installation Guide Conext XW Jumpers (For Single-Phase Conversion) Conext XW Jumpers are used to reconfigure a standard unit 120V/240V, three-wire, splitphase model to accept a 120 V, 2-wire, single-phase connection. Use the jumpers to reconfigure the transformer wires. For more information, see "Converting 120 V/240 V Split-phase to 120 V Single-phase" on page 123.
Conext XW Pro Installation Guide Introduction The Conduit Box provides an enclosure over the bottom of the Conext XW Pro and covers the cabling that runs underneath. For installation instructions, see Installing the XW Conduit Box on page 34. Figure 3 Conduit Box Note: Your installation may require the inclusion of the Conduit Box, depending on local electrical code. Consult your local electrical authority to ensure your installation is code-compliant.
Introduction Conext XW Pro Installation Guide Figure 4 Conext XW Pro Power Distribution Panel with Conduit Box Not shown: n One ground terminal bus bar n One neutral terminal bus bar n One battery negative terminal bus bar n Cable ties (3x) n Xanbus clip-on ferrite bead PDP 120/240V 60A Breaker Kit Part Number 865-1215-01 Included: Three 60 A, 120/240 VAC, two-pole, Square-D, type QOU, DIN-rail mountable AC breakers, jumpers, bypass interlock.
Conext XW Pro Installation Guide Introduction Conext MPPT 60 150 Solar Charge Controller Part Number 865-1030-1 The Conext MPPT solar charge controller is a photovoltaic (PV) charge controller that tracks the maximum power point of a PV array to deliver the maximum available current for charging batteries. For more information, go to https://solar.schneider-electric.com.
Introduction Conext XW Pro Installation Guide Conext Automatic Generator Start (AGS) Part Number 865-1060-01 The Conext AGS can automatically start and stop a generator, providing your Conext XW Pro Inverter/Charger with power to recharge depleted batteries while powering your loads. The AGS adds intelligence to power management and minimizes time spent monitoring batteries and inverter loads. For more information, see the Conext Automatic Generator Start Owner’s Guide.
Conext XW Pro Installation Guide Introduction Figure 9 Conext Battery Monitor Breaker Kits 60A, 160VDC Panel Mount DC Breaker Part Number 865-DCBRK-60 80A, 125VDC Panel Mount DC Breaker Part Number 865-DCBRK-80 100A, 125VDC Panel Mount DC Breaker Part Number 865-DCBRK-100 250A, 160VDC Panel Mount DC Breaker Part Number 865-DCBRK-250 23 This manual is intended for use by qualified personnel 990-91228A-01
Pre-Installation Planning 2 Conext XW Pro Installation Guide Pre-Installation Planning What's in This Chapter? Pre-Installation 25 Planning the Installation 25 Installation Tools and Materials 25 Location 26 Clearance Requirements 26 Knockout Selection 28 Air Filter and AUX Port Connector Installation 29 Wall-Mounting 30 Installing the Mounting Plate 31 Wall-Mounting the Conext XW Pro and PDP 32 Installing the XW Conduit Box 34 Communications Network Preparation 36 Battery Bank P
Conext XW Pro Installation Guide Pre-Installation Planning Pre-Installation Before installing the Conext XW Pro, read all instructions and cautionary markings in this Installation Guide. Note: Obtain all necessary permits prior to starting the installation. Installations must meet all local codes and standards. Installation of this equipment should only be performed by skilled personnel such as qualified electricians and Certified Renewable Energy (RE) System installers.
Pre-Installation Planning Conext XW Pro Installation Guide Depending on your installation, additional hardware may be required. The following items are not included with the Conext XW Pro: n Battery cables n Grounding wire: #14 AWG to #2 AWG (1.63mm to 6.
Conext XW Pro Installation Guide Pre-Installation Planning Figure 10 Example of clearance requirements for a Conext XW Pro with PDP 27 This manual is intended for use by qualified personnel 990-91228A-01
Pre-Installation Planning Conext XW Pro Installation Guide Knockout Selection Note: Do not drill, cut, or punch holes into the Conext XW Pro, Conduit Box or Power Distribution Panel (PDP). Use only the knockouts provided for conduit entry. The Conext XW Pro, Power Distribution Panel (PDP), and Conduit Box are equipped with nested dual knockouts for wiring through conduits. Read "Removing the AC Access Panel and PDP Internal Faceplates" on page 44 and choose the knockouts for your installation.
Conext XW Pro Installation Guide Pre-Installation Planning Air Filter and AUX Port Connector Installation Insert the air filter by tucking it into the grooves on the sides of the air vent cover, see Figure 12 . If you are planning to use the auxiliary (AUX) port features, insert the AUX port connector into the AUX portr, see Figure 12 . For more information, see AUX Port on page 47 of this Guide.
Pre-Installation Planning Conext XW Pro Installation Guide Wall-Mounting WARNING HEAVY EQUIPMENT The Conext XW Pro can cause serious injury if it falls or is dropped on a person. For structural and seismic stability, the Conext XW Pro must be mounted onto a vertical supporting surface strong enough to support a minimum of 500 lbs (227 kg). Failure to follow these instructions can result in death, serious injury, or equipment damage.
Conext XW Pro Installation Guide Pre-Installation Planning Figure 13 Mounting plate dimensions 16” 1 ¾” 6 7 8” 4 ½” 2 ¼” 9 3 16” 6” 2” ¾” 17” Note: If the wall does not have 16-inch on-center studs, you will need to provide adequate support for the Mounting Plates. For example, a sheet of fire-rated plywood2 can be attached to the wall, and the Mounting Plates can then be attached to plywood. Installing the Mounting Plate To install the mounting plate: 1. Locate the wall studs. 2.
Pre-Installation Planning Conext XW Pro Installation Guide Figure 14 Mounting plate centered on wall studs Installation tip If you install the bottom of the mounting plate at 60" from floor, the inverter information panel will be approximately 65" from the floor. 4. Install additional mounting plates adjacent to each other as needed. Note: The mounting plates are designed to interlock, as shown in the figure below, so that multiple plates can be installed without additional measuring or leveling.
Conext XW Pro Installation Guide Pre-Installation Planning Figure 16 Wall-mounting the Conext XW Pro WARNING HEAVY EQUIPMENT The Conext XW Pro weighs approximately 120 lbs. A two-person lift is required. To prevent personal injury, always use proper lifting techniques during installation. Failure to follow these instructions can result in death, serious injury, or equipment damage. 2. Lower the Conext XW Pro chassis flange onto the mounting plate. 3.
Pre-Installation Planning Conext XW Pro Installation Guide Installing the XW Conduit Box The Conduit Box is divided into two parts: the rear panel and the front panel. To secure the Conduit Box to the Conext XW Pro chassis: 1. Remove both #10 screws from the bottom of the Conext XW Pro chassis. 2. Find the keyhole slots located under the top of the rear panel. 3. Align the keyhole slots on the top panel of the Conduit Box with the corresponding #10 screws on the bottom of the inverter.
Conext XW Pro Installation Guide Pre-Installation Planning To secure the front panel of the Conduit Box: 1. Slide the bottom lip of the front panel over the lower edge of the rear panel. 2. Align the two holes in the front panel with the two holes in the back panel. 3. Using two #10-32 screws (included), secure the front panel to the rear panel.
Pre-Installation Planning Conext XW Pro Installation Guide Communications Network Preparation WARNING XANBUS SHOCK HAZARD Xanbus cables in contact with DC or AC power can transmit an electric shock. Do not route the Xanbus cables in the same conduit or panel as the AC and DC power cabling. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Conext XW Pro Installation Guide Pre-Installation Planning Battery Bank Preparation WARNING BATTERY TYPE AND SET UP HAZARDS Incorrect battery configurations or settings for battery types can lead to dangerously high battery temperature, fire and explosion. To avoid damaging your batteries during charging or equalization, and to minimize the risk of fire or explosion consult battery manufacture's documentation before setting battery parameters and follow the battery manufacturer's recommended settings.
Pre-Installation Planning Conext XW Pro Installation Guide Battery Bank Requirements The DC voltage of the Conext XW Pro must match the nominal voltage of the system and battery-connected devices. The inverter is a 48 V inverter; therefore, the battery bank and battery-connected devices in the system must be configured for 48 volts. Note: The minimum recommended battery bank is 440 Ah per inverter/charger. The Conext XW Pro is designed to operate with batteries and should not be operated without them.
Conext XW Pro Installation Guide Pre-Installation Planning Overcurrent protection WARNING DC OVER CURRENT The NEC/CEC requires both DC over current protection and a DC disconnect switch for residential and commercial electrical systems. Fuses and disconnects must be sized to protect the wiring in the system and are required to open before the wire reaches its maximum current carrying capability. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Pre-Installation Planning Conext XW Pro Installation Guide Torque Values Torque Values for the Conext XW Pro Table 4 Torque Values for AC Wiring (AC Terminals and Ground Bar) Wire Size Torque Value AWG mm2 In-lb N-m 14–10 1.63–2.59 35 4.0 8 3.26 40 4.5 6–4 4.11–5.19 45 5.1 Table 5 Torque Values for the Chassis Ground Lug Wire Size Torque Value mm2 AWG In-lbs N-m 6–4 4.11–5.19 45 5.1 3–2 5.83–6.54 50 5.
Conext XW Pro Installation Guide Pre-Installation Planning Table 9 Torque Values for the Power Distribution Jumpers in the PDP Wire Size Torque Value mm2 AWG In-lbs N-m 14–10 1.63–2.59 35 4.0 8 3.26 40 4.5 6–4 4.11–5.19 45 5.1 3–2/0 5.83–9.27 50 5.6 Table 10 Torque Values for the Battery Cables to each DC Bus in the PDP Torque Value Ft-lbs 15 41 N-m 20.
Wiring Conext XW Pro Installation Guide 3 Wiring What's in This Chapter? Removing the AC Access Panel and PDP Internal Faceplates 44 Removing AC Access Panel 44 Removing Power Distribution Panel Internal Faceplate 45 Communication Ports and BTS Port AUX Port Wiring the Conext XW Pro with a PDP 47 47 50 Grounding the Conext XW Pro Inverter/Charger 50 Grounding the DC System 50 Installing the Battery Temperature Sensor 51 Making DC Connections 53 Making AC Connections 57 AC System Bondin
Conext XW Pro Installation Guide 43 Wiring Conext XW Pro Inverter/Charger Grounding 91 Grounding the DC System 92 This manual is intended for use by qualified personnel 990-91228A-01
Wiring Conext XW Pro Installation Guide Removing the AC Access Panel and PDP Internal Faceplates Removing AC Access Panel DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. n This equipment must only be installed and serviced by qualified electrical personnel. n Never operate energized with covers removed n Energized from multiple sources.
Conext XW Pro Installation Guide Wiring To remove the AC access panel, remove the two screws from the AC access cover and slide the cover slightly to the left and lift away from the Conext XW Pro chassis. Installation tip When re-securing the AC access cover, verify that its recessed edge slips inside the edge of the front panel.
Wiring Conext XW Pro Installation Guide Figure 22 Power Distribution Panel (PDP) faceplate removal 990-91228A-01 This manual is intended for use by qualified personnel 46
Conext XW Pro Installation Guide Wiring Communication Ports and BTS Port Figure 23 Conext XW Pro communication ports There are five communication ports and a Battery Temperature Sensor (BTS) port located on the bottom of the Conext XW Pro chassis (as shown above in Removing the AC Access Panel and PDP Internal Faceplates): n Two Power Distribution Panel (without AC Breakers) ports for making network connections between inverters, charge controllers, and accessories.
Wiring Conext XW Pro Installation Guide The 12 VDC output can be used to trigger an HBX (Hi Battery Transfer) relay to disconnect from the Grid. The auxiliary output is also designed to provide the following functions: n Auxiliary 12 VDC power supply. See AUX+12V Voltage Supply, below. n Remote Power Off. See AUX-RPO: User Remote Power OFF (RPO), below. Figure 24 AUX Port Location AUX+12V Voltage Supply DC voltage is available between JU-1 (AUX +12 V) and JU-3 (AUX-COM, signal return).
Conext XW Pro Installation Guide Wiring AUX Port Terminal Assignments Table 11 User Connector Terminals and Functions Pin JU-1 JU-2 JU-3 Reference AUX+12V AUX-RPO AUX-COM Name +12 V User +12 VDC Voltage source: 250 mA Voltage Supply maximum Remote Power Off EXT_TS_OUT Reference switch: Output signal External Transfer JU-5 EXT_TS_IN switch: Input signal 49 Remote Power Off Logic Level: Active Low.
Wiring Conext XW Pro Installation Guide Wiring the Conext XW Pro with a PDP NOTICE OVERLOADING THE DISTRIBUTION PANEL The amount of power that can be fed into a distribution panel and the means and location for feed-in, must be in accordance with NEC Handbook 2017, article 230 or the current requirements of the local electrical code. Failure to follow these instructions can result in equipment damage.
Conext XW Pro Installation Guide Wiring WARNING LACK OF GROUND FAULT DETECTION HAZARD Ground fault detection on the MPPT 60 150 solar charge controller is circumvented when the Conext XW Pro battery negative circuit is grounded. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Wiring Conext XW Pro Installation Guide Note: For all BTS compatible Xanbus enabled devices in the system, at least one BTS must be separately installed for each device type associated with a battery. If there is a group of the same devices forming a multi-unit setup, only one BTS is required per device type connected to the same battery (same DC association). See the installation guide of each device for BTS installation instructions.
Conext XW Pro Installation Guide Wiring Making DC Connections Connecting Battery Cables DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. n This equipment must only be installed and serviced by qualified electrical personnel. n Never operate energized with covers removed n Energized from multiple sources.
Wiring Conext XW Pro Installation Guide WARNING OVERHEATING OF DC TERMINALS AND CABLES Overheating of the DC terminals or DC cables to dangerous temperatures may occur due to improper installation. n Do not put anything between the cable lug and the terminal surface. n Do not over-tighten connections; observe all recommended torque values. n Do not apply any type of anti-oxidant paste until after the cable connection is tightened.
Conext XW Pro Installation Guide Wiring To connect the Power Distribution Panel (PDP) to the Conext XW Pro: 1. Connect the positive battery cable (pre-installed in the PDP) to the positive battery terminal at the bottom of the Conext XW Pro, as shown in Figure 27 . 2. Connect the negative battery cable (pre-installed in the PDP) to the negative battery terminal at the bottom of the Conext XW Pro.
Wiring Conext XW Pro Installation Guide Figure 29 DC Connections to a Single Inverter Using a PDP 990-91228A-01 This manual is intended for use by qualified personnel 56
Conext XW Pro Installation Guide Wiring Making AC Connections This section provides instructions for making AC connections between the Conext XW Pro and the Power Distribution Panel (PDP) (using the pre-installed AC cables in the PDP) and between the PDP and your inverter load sub-panel. Note: Install an inverter load sub-panel and AC conduit before completing your Conext XW Pro installation. For more information, see "AC Wiring to the Inverter Load SubPanel" on page 65.
Wiring Conext XW Pro Installation Guide DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Remove watches, rings, or other metal objects. n This equipment must only be installed and serviced by qualified electrical personnel. n Keep sparks and flames away from the batteries. n Use tools with insulated handles. n Wear protective glasses, gloves and boots. n Do not lay tools or other metal parts on top of batteries.
Conext XW Pro Installation Guide Wiring The neutral inputs are connected to each other, requiring only one neutral connection when installed with a Power Distribution Panel (PDP). Without the PDP, additional neutral connections may be required at the input sources. Grounding AC Equipment See "Torque Values for the Conext XW Pro" on page 40 for torque values for the AC terminal and AC ground bar.
Wiring Conext XW Pro Installation Guide AC System Bonding WARNING MULTIPLE AC NEUTRAL-TO-GROUND BONDS Verify that only one neutral-to-ground bond exists in the system. Having more than one neutral-to-ground bond in a system violates local electrical codes, may create a shock or fire hazard, and may cause some sensitive equipment to malfunction. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Conext XW Pro Installation Guide Wiring AC Wiring the Power Distribution Panel (PDP) to the Conext XW Pro To connect the Power Distribution Panel (PDP) to the Conext XW Pro: 1. In the Power Distribution Panel (PDP), locate the wire labelled INV1 N-LOAD (SPLIT PHASE), pre-installed in the neutral bus bar N-LOAD terminal. Connect the INV1 NLOAD (SPLIT PHASE) wire to the AC Load terminal (N-LOAD) on the Conext XW Pro, as shown in Figure 32 on page 62. 2.
Wiring Conext XW Pro Installation Guide Figure 32 Wiring the Conext Power Distribution Panel (PDP) to the Conext XW Pro 990-91228A-01 This manual is intended for use by qualified personnel 62
Conext XW Pro Installation Guide Wiring Wiring the Power Distribution Panel (PDP) to a Generator (On-Grid) In an on-grid installation, the generator will require an additional 60 A, 120/240 VAC, twopole, type QOU AC breaker to be installed in the Power Distribution Panel (PDP).
Wiring Conext XW Pro Installation Guide Wiring the Power Distribution Panel (PDP) to a Generator (Off-Grid) In an off-grid installation, the generator can be connected to the breakers provided in the PDP. No additional breaker is required.
Conext XW Pro Installation Guide Wiring AC Wiring to the Inverter Load Sub-Panel DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. n This equipment must only be installed and serviced by qualified electrical personnel. n Never operate energized with covers removed n Energized from multiple sources.
Wiring Conext XW Pro Installation Guide Wiring for connections between the PDP and the inverter load sub-panel is not included. Power distribution jumpers in the PDP accept up to a #2/0 AWG (9.27 mm2) cable (maximum). See "Torque Values" on page 40 for torque requirements. To install the inverter load sub-panel and AC conduit: 1. Choose a location for the inverter load sub-panel and install it according to the manufacturer’s directions. 2.
Conext XW Pro Installation Guide Wiring Figure 35 Wiring the PDP to the Inverter Load Sub-Panel or Utility Grid 67 This manual is intended for use by qualified personnel 990-91228A-01
Wiring Conext XW Pro Installation Guide Basic Functional Test – Single Inverter Complete the following steps to perform a basic functional test of the Conext XW Pro. If any test fails, refer to the Troubleshooting section in the Owner's Guide for assistance. Confirming All Connections After the AC and DC wiring have been installed and connected, check that all connections are correct and secure, and re-secure the AC access panel.
Conext XW Pro Installation Guide Wiring Applying DC Power to the Inverter NOTICE DC REVERSE POLARITY Before making the final DC connection or closing the DC breaker or disconnect, check cable polarity at both the battery and the inverter/charger. Positive (+) must be connected to positive (+). Negative (–) must be connected to negative (–). Failure to follow these instructions can result in equipment damage. To apply DC power to the inverter: 1.
Wiring Conext XW Pro Installation Guide Figure 37 Disabled Mode To enable the inverter: n On the inverter information panel, simultaneously press the STARTUP/SHUTDOWN button and the Equalize button. The Conext XW Pro is now enabled, and En (enabled) is briefly displayed on the inverter information panel, as shown in Figure 38 . Figure 38 Enabled Mode To disable the inverter: 1. On the inverter information panel, simultaneously press the STARTUP/SHUTDOWN button and the Equalize button.
Conext XW Pro Installation Guide Wiring Figure 39 Transition to Disabled Mode 2. Monitor the invert (green kW) LED to confirm which mode the inverter is in: a. kW LED OFF – Invert mode is disabled. The inverter/charger is not powering the AC loads. However, if good AC is present, it is passed through to the loads. b. Sch displayed on the inverter information panel – The inverter/charger is in searchmode and is looking for an AC load greater than the Maximum Search Watts setting (default = 25 watts).
Wiring Conext XW Pro Installation Guide Checking AC Voltage Note: This test requires the use of a voltmeter. To perform an AC voltage check: 1. With the inverter on (green kW LED is on and steady), verify the AC voltage at AC Loads block terminal L1-Load to N-Load. 2. Verify that neutral is bonded to ground in the system by measuring the hot and neutral voltages relative to ground. Neutral-to-ground should equal zero (0) volts. 3.
Conext XW Pro Installation Guide Wiring Note: Unless the inverter/charger settings have been changed, the inverter will charge as if it has a large (> 440 Ah) flooded battery bank (factory default setting). In newly installed systems, adjust the battery charging set points to match the batteries as installed. This completes the functional test. If any of the internal set points need to be adjusted on the Conext XW Pro, consult the configuration chapter of the Owner's Guide.
Wiring Conext XW Pro Installation Guide Wiring Additional Conext XW Pro units with a PDP This section provides instructions for making AC and DC connections between multiple Conext XW Pro units and a Power Distribution Panel (PDP), using the cables that are included with each PDPand Connection Kit for INV2 INV3 PDP.
Conext XW Pro Installation Guide Wiring DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Remove watches, rings, or other metal objects. n This equipment must only be installed and serviced by qualified electrical personnel. n Keep sparks and flames away from the batteries. n Use tools with insulated handles. n Wear protective glasses, gloves and boots. n Do not lay tools or other metal parts on top of batteries.
Wiring Conext XW Pro Installation Guide Grounding Conext XW Pro Inverter/Charger WARNING UNGROUNDED EQUIPMENT Equipment ground terminals must be reliably connected to ground by appropriately sized grounding conductors. All installations must comply with national and local codes. Consult local and national codes for specific grounding and bonding requirements. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Conext XW Pro Installation Guide Wiring a. the first Conext XW Pro Inverter/Charger (INV1) and b. the battery bank Note: Before connecting the DC cables from the PDP to the battery, perform the procedures in "AC Wiring for a Dual-Inverter System" on page 79. 2. Connect the positive battery cable for INV2 (included with the Connection Kit for INV2 INV3 PDP) to the top terminal on the second DC disconnect/breaker, as shown in Figure 43 . 3.
Wiring Conext XW Pro Installation Guide Grounding AC Equipment WARNING UNGROUNDED EQUIPMENT Equipment ground terminals must be reliably connected to ground by appropriately sized grounding conductors. All installations must comply with national and local codes. Consult local and national codes for specific grounding and bonding requirements. Failure to follow these instructions can result in death, serious injury, or equipment damage. See "Grounding AC Equipment" on page 59.
Conext XW Pro Installation Guide Wiring Figure 44 Dual Inverter AC Breaker Arrangement with Multiple AC Input Sources Note: If a backup generator or other secondary AC source is installed in the system, reuse two of the dual-tab jumpers previously installed on INV1 Grid/Bypass breakers for generator breakers. AC Wiring for a Dual-Inverter System 1. Connect the grid wiring and inverter load sub-panel wiring to the new jumpers as shown in Figure 45 on page 80. 2.
Wiring Conext XW Pro Installation Guide Figure 45 AC Wiring for Dual-Inverter Systems 1 3 5 L2 L1 2 L1 L2 G N 4 6 A AC OUT INV OUT L1 N AC IN GRID L2 L1 N AC OUT INV OUT AC IN GEN L2 L1 N L2 L1 N L2 L1 AC IN GRID N B C D E F G H AC IN GEN L2 L1 N L2 7 Hot L1 L2 8 9 1 AC generator A INV1 IN (Grid) 2 Generator disconnect B INV2 IN (Grid) 3 Main utility panel C Grid bypass 4 Grounding electrode connector D Grid bypass 5 Inverter load sub-panel E INV
Conext XW Pro Installation Guide Wiring n Actual wiring requirements may vary. n Cable routing may vary. See "Knockout Selection" on page 28 and "Communications Network Preparation" on page 36. See "Torque Values" on page 40 for torque values. For torque connections to the n battery terminals, see the battery manufacturer's recommendations. Installing Bypass Interlock Plate To install the custom designed bypass interlock plate: 1. Replace the upper and lower faceplates on the PDP. 2.
Wiring Conext XW Pro Installation Guide This section provides instructions for adding a second and third Conext XW Pro to your installation. Complete the following installation steps only after you have already connected the PDP to the first Conext XW Pro, as shown in Wiring the Conext XW Pro with a PDP on page 50. A system of three Conext XW Pro units can power loads of up to 20.4 kVA.
Conext XW Pro Installation Guide Wiring Note: Before connecting the DC cables from the PDP to the battery, perform the procedures in "AC Wiring for a Triple-Inverter System" on page 85. 2. Connect the positive battery cable for INV2 (included with the Connection Kit for INV2 INV3 PDP) to the top terminal on the second DC disconnect/breaker. 3. Connect the negative battery cable for INV2 (included with the Connection Kit for INV2 INV3 PDP) to the DC Negative Bus. 4.
Wiring Conext XW Pro Installation Guide Figure 47 DC Connections for a Triple-Inverter System Preparing the Power Distribution Jumper (for Triple-Inverter System Only) Each Connection Kit for INV2 INV3 PDP includes four, four-tab power distribution jumpers. In a triple-inverter system, only three tabs per jumper are needed.
Conext XW Pro Installation Guide Wiring 2. Remove bypass interlock bracket. 3. Disconnect INV1 AC LOAD (INV1 L1-LOAD, INV1 L2-LOAD) wires from the top terminals on right-hand side breaker. Note: Ensure that the neutral (INV1 N-LOAD) wiring remains connected, as shown in "AC Wiring the Power Distribution Panel (PDP) to the Conext XW Pro" on page 61. 4. Mount the 60 A, 120/240 VAC, two-pole, type QOU AC breakers onto the DIN rail, as shown in Figure 48 on page 86 and Figure 49 on page 86. 5.
Wiring Conext XW Pro Installation Guide Figure 48 Triple-Inverter AC Breaker Arrangement with a Single AC Input Source Figure 49 Triple-Inverter AC Breaker Arrangement with Two AC Input Sources Installing an External Bypass Switch Note: The Conext Power Distribution Panel (PDP) does not have enough breaker locations to accommodate bypass breakers in more than three inverter systems. Therefore, an external bypass switch may be needed.
Conext XW Pro Installation Guide Wiring Figure 50 Wiring an External Bypass Switch Basic Functional Test - Multiple Inverters The following steps will complete a basic functional test of multiple Conext XW Pros. If any test fails, please refer to the Troubleshooting section in the Owner's Guide for assistance. To perform a functional test on multiple inverters: 1. Check/verify all wiring and cable connections. 2.
Wiring Conext XW Pro Installation Guide 7. Check inverter display for startup self-test during which LEDs will flash momentarily. Once self-test is complete, the inverter will display Stb. If the inverter has been preconfigured, it may go straight into normal operating mode or display F66 warning. 8. Using the Conext Gateway, set the Second (Slave) Inverter Device Number and Inverter Mode: a. Select the new inverter XW6848, instance in the device page. b.
Conext XW Pro Installation Guide Wiring 20. Confirm both inverters start charging. Depending on the battery bank’s state-of-charge, the output from one or more inverters may quickly drop to zero. This is considered normal operation. 21. Check for events. If events exist, correct, and then restart the Functional Test. If the Inverters pass the Functional Test, proceed to the Commissioning procedure as defined in the Owner's Guide.
Wiring Conext XW Pro Installation Guide DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric. n Servicing of batteries must only be performed by qualified personnel knowledgeable of batteries and the required precautions. Keep unqualified personnel away from batteries. n Disconnect the charging source prior to connecting or disconnecting battery terminals.
Conext XW Pro Installation Guide Wiring Conext XW Pro Inverter/Charger Grounding WARNING UNGROUNDED EQUIPMENT Equipment ground terminals must be reliably connected to ground by appropriately sized grounding conductors. All installations must comply with national and local codes. Consult local and national codes for specific grounding and bonding requirements. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Wiring Conext XW Pro Installation Guide Grounding the DC System To connect the Conext XW Pro to the DC grounding system, use the ground lug at the bottom of the Conext XW Pro chassis (see Figure 2 on page 18). The terminal accepts wires from #14 AWG (1.63 mm) to #2AWG (6.54 mm). System grounding for the DC system, which typically involves bonding (connecting) the battery negative circuit to ground, is dependent on the system configuration.
Conext XW Pro Installation Guide Wiring Figure 52 DC Connections to a Single Inverter (No PDP) 93 This manual is intended for use by qualified personnel 990-91228A-01
Wiring Conext XW Pro Installation Guide Figure 53 Grounding the AC System (No PDP) 990-91228A-01 This manual is intended for use by qualified personnel 94
Conext XW Pro Installation Guide Wiring Figure 54 AC Output Wiring to the Inverter Load Sub-Panel (No PDP) 95 This manual is intended for use by qualified personnel 990-91228A-01
Wiring Conext XW Pro Installation Guide Figure 55 Generator Wiring directly to the Inverter (No PDP) 990-91228A-01 This manual is intended for use by qualified personnel 96
Conext XW Pro Installation Guide Wiring Figure 56 Utility Wiring to the Inverter Input (No PDP) 97 This manual is intended for use by qualified personnel 990-91228A-01
Communication Conext XW Pro Installation Guide 4 Communication What's in This Chapter? The Xanbus Network 99 Network Components 99 Installing the Network 102 Before You Begin the Installation 102 Installation Tools and Materials 102 Installing AC sync and Xanbus cables 102 Guidelines for Routing the Xanbus Cables 104
Conext XW Pro Installation Guide Communication The Xanbus Network A Xanbus network is a collection of Xanbus enabled devices that perform individual functions, but also communicate and interact with other devices on the network. The network capability of the Conext XW Pro provides a solution that simplifies and automates the installation, configuration, control, monitoring, and integration of devices.
Communication Conext XW Pro Installation Guide n Conext AGS n Conext Battery Monitor n Conext MPPT solar charge controller MPPT 60 150 n Conext MPPT solar charge controller MPPT 80 600 Due to network traffic, the maximum number of Conext XW Pro units in a single Xanbus network should not exceed twelve. The maximum number of Conext MPPT Solar Charge Controllers in a single Xanbus network should not exceed twelve.
Conext XW Pro Installation Guide Communication Network Terminators The Xanbus network must be properly terminated at each end to help ensure the communication signal quality on the network. Note: If the network is not properly terminated, signal quality is degraded and performance on the network is reduced. Permanent configuration without terminators is not supported. The Conext XW Pro and other Xanbus-enabled devices ship with one network terminator.
Communication Conext XW Pro Installation Guide Installing the Network Note: Installing and replacing Xanbus-enabled devices in an existing system must be performed with the Conext XW Pro in standby mode. For more information about standby mode, see the Owner’s Guide. Before You Begin the Installation n Read the entire section before installing the network. It is important to plan the installation from beginning to end. n Assemble all the tools and materials required for the installation.
Conext XW Pro Installation Guide Communication Figure 61 Conduit Box Raceways 2. Insert the RJ45 jack on the cable into one of the two AC Sync ports. 3. Route the cable as shown in Figure 62 . Route any additional communication cables through the raceways. Replace the wiring raceways, ensuring not to pinch the cables. Secure the raceways to the Conduit Box with the screw that was removed earlier.
Communication Conext XW Pro Installation Guide Guidelines for Routing the Xanbus Cables WARNING XANBUS SHOCK HAZARD Xanbus cables in contact with DC or AC power can transmit an electric shock. Do not route the Xanbus cables in the same conduit or panel as the AC and DC power cabling. Failure to follow these instructions can result in death, serious injury, or equipment damage. To help ensure maximum performance of your network, follow these guidelines when routing the Xanbus cables.
Access Installation Conext XW Pro Installation Guide 5 Access Installation What's in This Chapter? Conext Gateway Installation 107 Installing the Conext Gateway via the Xanbus Network 107 Verifying the Installation 108
Conext XW Pro Installation Guide Access Installation Conext Gateway Installation The Conext XW Pro can be controlled remotely by connecting a Conext Gateway. The Conext Gateway allows access to programming features of the Conext XW Pro and allows the system to be modified to specific installation requirements. The Conext Gateway can be connected to the Conext XW Pro via the Xanbus network.
Access Installation Conext XW Pro Installation Guide Verifying the Installation If network power (from an inverter/charger) is present, the Conext Gateway LEDs will illuminate. For more information, see the Conext XW Pro Owner’s Guide.
Specifications Conext XW Pro Installation Guide 6 Specifications What's in This Chapter? Electrical Specifications 111 Mechanical Specifications 113 Regulatory Approvals 114 Grid Support Utility Interactive Functions 115
Conext XW Pro Installation Guide Specifications This chapter provides the electrical and mechanical specifications for the Conext XW Pro. DISCLAIMER REGARDING STATUS DATA Status data reported by the Conext XW Pro are approximate values intended to provide general and non-exact information about the Conext XW Pro. Under no circumstances should this status data be used for precise evaluation of the Conext XW Pro system performance, including efficiency considerations.
Specifications Conext XW Pro Installation Guide Specification Surge Current (Inverter Mode) AC Input Voltage Range (Bypass/Charger Mode) AC Input Frequency Range (Bypass/Charger Mode) 52 ARMS for 60 seconds (240 V nominal) 160-270 VAC (240 V nominal) 52-68 Hz (default) 44-70 Hz (allowable) AC Input Maximum Breaker Capacity 60 A maximum, double-pole AC Output Maximum Breaker Capacity 60 A maximum, double-pole AC1 (Grid) Input Current 3 - 60 A AC2 (Generator) Input Current 3 - 60 A AC Output Frequ
Conext XW Pro Installation Guide Specifications Mechanical Specifications NOTE: Specifications are subject to change without prior notice. Table 13 Conext XW Pro Mechanical Specifications Model Non-Volatile Memory XW Pro 6848 NA Yes Status LEDs indicate AC In status, events/warnings, equalize mode, battery level. 3-character display Inverter Information Panel indicates output power or charge current, event/warning codes.
Specifications Conext XW Pro Installation Guide Model XW Pro 6848 NA Inverter Weight 125 lb (57 kg) Shipping Weight 132 lb (60 kg) Storage Temperature Range -40–185 °F (-40–85 °C) Figure 64 Conext XW Pro Block Diagram Regulatory Approvals Electromagnetic Compatibility The Conext XW Pro inverter complies with emission limits specified in: n FCC Part 15B Class B limits n Industry Canada ICES-003 Class B limits Utility Interactive Conext XW Pro inverter qualifies as a Smart Inverter1 and complie
Conext XW Pro Installation Guide Specifications n IEEE 1547.
Wiring Diagrams Conext XW Pro Installation Guide 7 Wiring Diagrams What's in This Chapter? Wiring Diagrams 117 Single-Inverter System (Backup Only) Without a Power Distribution Panel (PDP) 118 Single-Inverter System (Backup Only) With a Power Distribution Panel (PDP) 119 Single-Inverter System Renewable Energy (Solar) 120 Dual-Inverter System Renewable Energy (Solar) 121
Conext XW Pro Installation Guide Wiring Diagrams Wiring Diagrams The diagrams in this chapter illustrate the most basic configurations and are for reference only. Specific installations may require additional equipment to meet national or local electric codes. Ensure that all safety requirements are strictly followed.
Wiring Diagrams Conext XW Pro Installation Guide Single-Inverter System (Backup Only) Without a Power Distribution Panel (PDP) Figure 65 Single-Inverter System (Backup Only) Without a Power Distribution Panel (PDP) Actual wiring requirements may vary. Cable routing may vary. See sections on “Knockout Selection” and “Communications Network Preparation”. See “Torque Requirements” for torque values. For torque connections to the battery terminals, consult the battery manufacturer’s recommendations.
Wiring Diagrams Conext XW Pro Installation Guide Single-Inverter System (Backup Only) With a Power Distribution Panel (PDP) Figure 66 Single-Inverter System (Backup Only) With a Power Distribution Panel (PDP) 1 3 4 L1 L2 2 L1 L2 G N Actual wiring requirements may vary. Cable routing may vary. See sections on “Knockout Selection” and “Communications Network Preparation”. See “Torque Requirements” for torque values.
Wiring Diagrams Conext XW Pro Installation Guide Single-Inverter System Renewable Energy (Solar) Figure 67 Single-Inverter System Renewable Energy (Solar) 1 Actual wiring requirements may vary. Cable routing may vary. See sections on “Knockout Selection” and “Communications Network Preparation”. See “Torque Requirements” for torque values. For torque connections to the battery terminals, consult the battery manufacturer’s recommendations.
Wiring Diagrams Conext XW Pro Installation Guide Dual-Inverter System Renewable Energy (Solar) Figure 68 Dual-Inverter System Renewable Energy (Solar) 1 Actual wiring requirements may vary. Cable routing may vary. See sections on “Knockout Selection” and “Communications Network Preparation”. See “Torque Requirements” for torque values. For torque connections to the battery terminals, consult the battery manufacturer’s recommendations.
Converting Split-phase to Single-phase 8 Conext XW Pro Installation Guide Converting Split-phase to Single-phase What's in This Chapter? Converting 120 V/240 V Split-phase to 120 V Single-phase 123 Installation Tools and Materials 124 Disconnecting Power Sources 124 AC Access Panel Removal 125 Reconfiguring the Secondary Transformer Wires on X1 and X2 Connectors 127 Reconfiguring the AC Ports on the Load, AC1, and AC2 Connectors 129 Upgrading the Firmware 130 Updating the Label 131
Conext XW Pro Installation Guide Converting Split-phase to Single-phase Converting 120 V/240 V Split-phase to 120 V Single-phase This chapter explains how to convert a standard 120 V/240 V, three-wire, split-phase Conext XW Pro model to accept a 120 V, 2-wire, single-phase connection. Converting from 120 V/240 V split-phase to 120 V single-phase is required in systems with single-phase (2-wire 120 V) or three-phase (208/120 V) sources.
Converting Split-phase to Single-phase Conext XW Pro Installation Guide Note: To complete the conversion, you must refer to firmware upgrade instructions in the Conext Gateway Owner's Guide (975-0806-01-01) available from http://solar.schneider-electric.com. Note: To set up a three-phase system using three 120 V-configured Conext XW Pro units, perform the conversion procedure for all three Conext XW Pros.
Conext XW Pro Installation Guide Converting Split-phase to Single-phase AC Access Panel Removal DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, ARC FLASH, AND FIRE n Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. n This equipment must only be installed and serviced by qualified electrical personnel. n Never operate energized with covers removed n Energized from multiple sources.
Converting Split-phase to Single-phase Conext XW Pro Installation Guide Installation tip For easier access, first remove the right-side panel of the Conext XW Pro, as shown in Figure 70 . When re-securing the AC access cover, ensure its recessed edge slips inside the edge of the front panel.
Conext XW Pro Installation Guide Converting Split-phase to Single-phase Reconfiguring the Secondary Transformer Wires on X1 and X2 Connectors To reconfigure the secondary transformer wires on the X1 and X2 connectors: 1. Locate the X1 and X2 connectors (shown below). Figure 71 Connector Locations 2. Remove the secondary transformer wire X2 (black) from slot X2-A, and then insert it into slot X2-B, see Figure 72 and Figure 73 . 3.
Converting Split-phase to Single-phase Conext XW Pro Installation Guide Figure 72 Slot Locations on X1 and X2 Connectors Figure 73 X1 and X2 Connectors Before and After Reconfiguration 990-91228A-01 This manual is intended for use by qualified personnel 128
Conext XW Pro Installation Guide Converting Split-phase to Single-phase Reconfiguring the AC Ports on the Load, AC1, and AC2 Connectors To reconfigure the AC ports on the Load, AC1 (Grid), and AC2 (Gen) connectors: 1. Locate the Load, AC1 (Grid), and AC2 (Gen) connectors, see Figure 74 . 2. Insert one large jumper in each connector to short out N and L2. Figure 74 Jumper Locations and AC Cable Configuration on AC Ports 3. Connect the AC cables as shown in Figure 74 . Insert jumper on top of the wire. 4.
Converting Split-phase to Single-phase Conext XW Pro Installation Guide Upgrading the Firmware To upgrade the firmware, refer to instructions in the Conext Gateway Owner's Guide (975-0806-01-01). If you do not have this guide, download it from http://solar.schneiderelectric.com. To upgrade the firmware: 1. Download the latest firmware for your Conext XW Pro Inverter/Charger from http://solar.schneider-electric.com and save it onto your computer. 2.
Conext XW Pro Installation Guide Converting Split-phase to Single-phase Updating the Label On the inverter/charger, mark the box on the bottom of the label beside “ OPTIONAL CONFIGURATION, 120 V, 2 WIRE” to indicate the inverter has been converted.
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