Conext™ XW Inverter/Charger Conext XW+ 8548 E Conext XW+ 7048 E Installation Guide 975-0714-01-01 Rev E November 2017 http://solar.schneider-electric.
Conext™ XW Inverter/Charger Installation Guide http://solar.schneider-electric.
Copyright and Contact Copyright © 2007-2017 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the Schneider Electric Conext XW+ Inverter/Charger. Scope The Guide provides safety guidelines, detailed planning, and procedures for installing the Conext XW+ Inverter/Charger and related system components. It does not provide details about configuration, operation, maintenance, or troubleshooting. See the Operation Guide or Owner’s Guide of each device for this information.
About This Guide Organization This Guide is organized into five chapters and one appendix. Chapter 1, “Introduction” lists and describes the components and basic features of the Conext XW+ Inverter/Charger. Chapter 2, “Pre-Installation and Wall-Mounting” describes the pre-installation steps, and gives instructions for wall-mounting the Conext XW+ and Conext XW+ Conduit Box. Chapter 3, “Wiring the Conext XW+ Inverter/Charger” describes procedures for installing the Conext XW+ Inverter/Charger.
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext XW+ Inverter/ Charger that must be followed during installation procedures. Read and keep this Installation Guide for future reference. Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it.
Safety Information 1. Before using the inverter, read all instructions and cautionary markings on the unit, the batteries, and all appropriate sections of this manual. 2. Use of accessories not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or injury to persons. 3. The inverter is designed to be permanently connected to your AC and DC electrical systems.
DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed • Energized from multiple sources.
Precautions When Working With Batteries Note: Battery work and maintenance must be done by qualified personnel knowledgeable about batteries to ensure compliance with battery handling and maintenance safety precautions. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric.
DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric. • Servicing of batteries must only be performed by qualified personnel knowledgeable of batteries and the required precautions. Keep unqualified personnel away from batteries. • Disconnect the charging source prior to connecting or disconnecting battery terminals. • Determine if the battery is inadvertently grounded.
Explosive Gas Precautions DANGER IGNITION HAZARD • This equipment is not ignition protected. To prevent fire or explosion, do not install this product in locations that require ignition-protected equipment. This includes any confined space containing vented batteries, or flammable chemicals such as, natural gas (NG), liquid petroleum gas (LPG) or gasoline (Benzine/Petrol).
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Contents Important Safety Instructions 1 Introduction Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Inside the Box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Conext XW+ Inverter/Charger and System Components - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents 3 Wiring the Conext XW+ Inverter/Charger Removing the AC Access Panel and PDP Internal Faceplates - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 AC Access Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Communication Ports and BTS Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 AUX Port - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents AC breaker installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–50 AC Wiring with a PDP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–50 4 Xanbus Network Installation The Xanbus Network - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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1 Introduction Chapter 1, “Introduction” lists and describes the components and basic features of the Conext XW+ Inverter/Charger.
Introduction Overview The Conext XW+ 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+ 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. These configurations are capable of extending battery based off-grid/backup autonomy.
Conext XW+ Features Conext XW+ Features Front View AC1 kW Information panel AC2 A Event Inverting Charging ! Equalize Conext XW+ chassis with AC access panel removed (Internal components hidden for clarity) AC terminal block AC ground bar AC sync ports Bottom View Xanbus ports AUX port Dual nested knockouts BTS port Positive (+) battery terminal (red) Negative (–) battery terminal (black) DC ground lug Air vent Figure 1-2 Conext XW+ Inverter/Charger Features 975-0714-01-01 1–3 This manu
Introduction Optional Accessories The following optional accessories are available for the Conext XW+ Inverter/ Charger. For an up-to-date list, call an authorized dealer or visit http://solar.schneider-electric.com. Conext XW+ Conduit Box Part Number 865-1025-01 The Conext XW+ Conduit Box provides an enclosure over the bottom of the Conext XW+ and covers the cabling that runs underneath. For installation instructions, see “Installing the Conext XW+ Conduit Box” on page 2–10 of this Guide.
Optional Accessories The Conext XW+ Power Distribution Panel includes the components shown below.
Introduction Conext XW+ Connection Kit for INV2 INV3 PDP Part Number 865-1020-02 The Conext XW+ Connection Kit is the extension kit for connecting a second or third Conext XW+ Inverter/Charger in the same system. The Conext XW+ Connection Kit includes the components shown below. #4 AWG (21.
Optional Accessories Conext MPPT 60 150 Solar Charge Controller Part Number 865-1030-1 The MPPT 60 150 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 http://solar.schneider-electric.com.
Introduction Conext System Control Panel Part Number 865-1050-01 The Conext System Control Panel (SCP) gives a single point of control to set up and monitor your entire Conext XW+ Inverter/Charger installation. Featuring a graphical, backlit liquid crystal display, the SCP displays configuration and diagnostic information for devices connected to the network. For installation instructions, see “Conext System Control Panel Installation” on page 5–2 of this Guide.
Optional Accessories Conext ComBox Part Number 865-1058 The Conext ComBox Communication and Monitoring Device is a multi-function communication device that enables monitoring of system performance through a PC or the Internet. It also acts as a communications gateway between a network of Xanbus™-enabled devices and Modbus devices. For more information, see the Conext ComBox Owner’s Guide.
Introduction Figure 1-12 Battery Fuse Disconnect Box (250A) Battery Fuse Disconnect Box (160A) Part Number 865-1030-01 1 OVE EMA K EUR V DE 10 OVE EMA K EUR V D E 0 OVE K EMA EUR 500V NH kA sfest rosion e /Pb-fre 3 122 500V NH 20kAionsfest korros free Cd/Pb- B66322 2191 500V NH A 120krosionsfest kor free Cd/Pb- 3 1B66122 B219 CE CE CE Figure 1-13 Battery Fuse Disconnect Box (160A) 1–10 975-0714-01-01 This manual is for use by qualified personnel only
2 Pre-Installation and Wall-Mounting Chapter 2, “Pre-Installation and Wall-Mounting” describes the pre-installation steps, and gives instructions for wall-mounting the Conext XW+ and Conext XW+ Conduit Box.
Pre-Installation and Wall-Mounting Pre-Installation Before installing the Conext XW+ Inverter/Charger, read all instructions and cautionary markings in this 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 Location The Conext XW+ is certified for dry, indoor (heated or unheated) installations only. Locate any electronic equipment susceptible to radio frequency and electromagnetic interference as far away from the inverter as possible. Fire safety WARNING IGNITION AND FIRE HAZARD This equipment is not ignition protected. To prevent fire or explosion, do not install this product in locations that require ignition-protected equipment.
Pre-Installation and Wall-Mounting Clearance Requirements Provide at least 91 cm of clearance in front of the inverter, and a minimum of 15 cm of clearance at the top and bottom of the inverter for ventilation. Ensure the vents remain unobstructed, and that the Conext XW+ Power Distribution Panel door has adequate room to fully open. Min. clearance at top: 152 mm AC1 kW AC2 A Event Inverting Charging ! Equalize Min.
Pre-Installation Read Chapter 3, “Wiring the Conext XW+ Inverter/Charger” and choose the knockouts for your installation. Figure 2-2 Example of available knockouts on the Conduit Box Remove your choice of knockouts from the Conext XW+ chassis, Conext XW+ Power Distribution Panel, and Conext XW+ Conduit Box. Ensure that no debris remains inside the chassis. Insert appropriately-sized conduit bushings into each conduit hole.
Pre-Installation and Wall-Mounting For more information, see “AUX Port” on page 3–4 of this Guide. AUX port Air vent Air filter AUX port connector Figure 2-3 Air Filter and AUX Port Connector Installation Wall-Mounting WARNING HEAVY EQUIPMENT The Conext XW+ Inverter/Charger can cause serious injury if it falls or is dropped on a person. For structural and seismic stability, the Conext XW+ Inverter/Charger must be mounted onto a vertical supporting surface strong enough to support a minimum of 227 kg.
Wall-Mounting The type of fastener required to secure the mounting plate varies according to the vertical surface and wall structure of your installation location. For a list of recommended fasteners, see Table 2-1, below. Table 2-1 Recommended fasteners Structure Required Fastener Screws Per Plate Wood studs at 400 mm (on center - O.C.) 6 mm Ø × 89 mm long lag screw Four Wood studs not at 400 mm O.C.
Pre-Installation and Wall-Mounting 3. Using a level, secure the first mounting bracket to the wall. Ensure the mounting plate is centered on the wall studs, as shown in Figure 2-4. Use recommended anchoring hardware to secure the plate (see Table 2-1).
Wall-Mounting Wall-Mounting the Conext XW+ To wall-mount the Conext XW+ Inverter/Charger: 1. Align the flange on the back of the Conext XW+ chassis with the bottom edge of the mounting plate, as shown in Figure 2-6. Conext XW+ chassis bracket Mounting plate Conext XW+ chassis flange Figure 2-6 Wall-mounting the Conext XW+ WARNING HEAVY EQUIPMENT The Conext XW+ Inverter/Charger weighs approximately 54 kg. A two-person lift is required.
Pre-Installation and Wall-Mounting Installing the Conext XW+ Conduit Box The Conext XW+ Conduit Box is divided into two parts: the rear panel and the front panel. To secure the Conduit Box to the Conext XW+ chassis: 1. Remove both #10 screws from the bottom of the Conext XW+ 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.
Wall-Mounting 5. Using two screws (not included), secure the bracket at the bottom edge of the rear panel to the wall. See Figure 2-8. Figure 2-8 Wall-mounting the Conduit Box Installation tip Do not secure the front panel of the Conduit Box until you have completed all wiring. 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.
Pre-Installation and Wall-Mounting 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 or serious injury.
Battery Bank Preparation 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 and Wall-Mounting Battery Bank Requirements The DC voltage of the Conext XW+ Inverter/Charger 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+ Inverter/Charger is designed to operate with batteries and should not be operated without them.
Battery Bank Preparation Overcurrent protection WARNING FIRE HAZARD FROM DC OVER CURRENT Your local electrical code may require 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 or serious injury.
Pre-Installation and Wall-Mounting Torque Values Torque values for the Conext XW+ Inverter/Charger Table 2-4 Torque Values for AC Wiring (AC Terminals and Ground Bar) Wire Size Torque Value AWG mm2 In-lb N-m 14–10 2.5–6 35 4.0 8 10 40 4.5 6–4 16–25 45 5.1 Table 2-5 Torque Values for the Chassis Ground Lug Wire Size Torque Value AWG mm2 In-lbs N-m 6–4 16–25 45 5.1 3–2 25–35 50 5.6 Table 2-6 Torque Values for the Inverter Battery Terminals Torque Value Ft-lbs N-m 15 20.
Torque Values Table 2-9 Torque Values for the power distribution jumpers in the Conext XW+ Power Distribution Panel Wire Size Torque Value AWG mm2 In-lbs N-m 14–10 2.5–6 35 4.0 8 10 40 4.5 6–4 16–25 45 5.1 3–2/0 25–35 50 5.6 Table 2-10 Torque Values for the Battery Cables to the DC Negative Bus, and DC Positive Bus in the Conext XW+ Power Distribution Panel Torque Value Ft-lbs N-m 15 20.
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3 Wiring the Conext XW+ Inverter/ Charger Chapter 3, “Wiring the Conext XW+ Inverter/ Charger” describes procedures for installing the Conext XW+ Inverter/Charger.
Wiring the Conext XW+ Inverter/Charger Removing the AC Access Panel and PDP Internal Faceplates AC Access Panel Removal DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed • Energized from multiple sources.
Removing the AC Access Panel and PDP Internal Faceplates DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric. • Servicing of batteries must only be performed by qualified personnel knowledgeable of batteries and the required precautions. Keep unqualified personnel away from batteries. • Disconnect the charging source prior to connecting or disconnecting battery terminals.
Wiring the Conext XW+ Inverter/Charger Communication Ports and BTS Port AC sync port Xanbus ports AUX port BTS port Figure 3-2 Conext XW+ Inverter/Charger communication ports There are five communication ports and a Battery Temperature Sensor (BTS) port located on the bottom of the Conext XW+ chassis (as shown above in Figure 3-2): Two Xanbus ports for making network connections between inverters, charge controllers, and accessories. For more information, see Chapter 4, “Xanbus Network Installation”.
Communication Ports and BTS Port The 12 VDC output can be used to trigger a relay to disconnect batteries from the inverter/charger when battery voltage or temperature are out of range. The auxiliary output is also designed to provide the following functions: • Auxiliary 12 VDC power supply. See AUX+12V Voltage Supply, below. • Remote Power Off. See AUX-RPO: User Remote Power OFF (RPO), below.
Wiring the Conext XW+ Inverter/Charger User Line Wiring Use twisted pairs of 0.2mm2 to 3.31mm2 (#24 AWG to #12 AWG) for connections. Carefully route the wires away from high power load cables to minimize noise effects on signal integrity. AUX Port Terminal Assignments Table 3-1 User Connector Terminals and Functions Pin Reference Name Function JU-1 AUX+12V +12 V User Voltage Supply +12 VDC Voltage source: 250 mA maximum JU-2 AUX-RPO Remote Power Off Remote Power Off Logic Level: Active Low.
Wiring the Conext XW+ Inverter/Charger without a PDP Conext XW+ 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 or serious injury.
Wiring the Conext XW+ Inverter/Charger AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 3 1 2 ON OFF 4 5 LEGEND 1. Ground lug Actual wiring requirements may vary. 2. Negative ground/bus Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12. 3. Battery 4. Primary system ground For torque values, see page 2-16 and 2-17. 5.
Wiring the Conext XW+ Inverter/Charger without a PDP Battery Temperature Sensor Installation WARNING BATTERY TEMPERATURE The Battery Temperature Sensor provides necessary information for performance and safety. Always install and connect the Battery Temperature Sensor (BTS). See the note directly below. Failure to follow these instructions can result in death or serious injury.
Wiring the Conext XW+ Inverter/Charger Installation tip Place the sensor between batteries and place the batteries in an insulated box to reduce the influence of the ambient temperature outside the battery enclosure. OR Figure 3-5 Battery Temperature Sensor Installation Making DC Connections without a PDP Battery Cables and Battery Terminals DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices.
Wiring the Conext XW+ Inverter/Charger without a PDP DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Remove watches, rings, or other metal objects. • This equipment must only be installed and serviced by qualified electrical personnel. • Keep sparks and flames away from the batteries. • Use tools with insulated handles. • Wear protective glasses, gloves and boots. • Do not lay tools or other metal parts on top of batteries.
Wiring the Conext XW+ Inverter/Charger 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 damage to equipment. Battery cables are not included in the Conext XW+ Inverter/Charger package.
Wiring the Conext XW+ Inverter/Charger without a PDP To connect DC cables to the Conext XW+ Inverter/Charger (without a PDP): 1. Route the DC cables through your chosen knockouts on the Conext XW+ Inverter/Charger. 2. Install a Conext Battery Fuse Disconnect Box (see “Optional Accessories” on page 1–4) between the Conext XW+ Inverter/Charger and the battery, as close to the battery as possible. (For detailed installation instructions, consult the documentation included with the Battery Fuse Disconnect Box.
Wiring the Conext XW+ Inverter/Charger AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 2 LEGEND 1. Battery Fuse Disconnect Box 2. Battery Actual wiring requirements may vary. Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12. Positive (+) Battery cable Negative (–) Battery cable BTS cable For torque values, see page 2-16 and 2-17.
Wiring the Conext XW+ Inverter/Charger without a PDP AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 2 LEGEND 1. Battery Fuse Disconnect Boxes 2. Battery Actual wiring requirements may vary. Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12.
Wiring the Conext XW+ Inverter/Charger AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 2 3 LEGEND 1. Battery Fuse Disconnect Box #1 2. Battery Fuse Disconnect Box #2 3. Battery Actual wiring requirements may vary. Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12.
Wiring the Conext XW+ Inverter/Charger without a PDP Making AC Connections This section provides instructions for making AC connections between the Conext XW+ Inverter/Charger, the main utility panel, and your inverter load sub-panel without a PDP. Note: AC breakers are not included with the Conext XW+ Inverter/Charger. You will need to provide your own appropriately sized and rated AC breakers. For more information, contact your local Schneider Electric Sales Representative.
Wiring the Conext XW+ Inverter/Charger AC Terminal Block DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed • Energized from multiple sources.
Wiring the Conext XW+ Inverter/Charger without a PDP The AC terminal block includes two terminals each (L and Neutral) for AC Grid input (AC1), AC Generator input (AC2), and AC Out (AC LOAD) connections.
Wiring the Conext XW+ Inverter/Charger AC Equipment Grounding See Table 2-4 on page 2–16 for torque values for the AC terminal and AC ground bar. See Table 2-4 on page 2–16 for torque requirements for the ground bar in the Conext XW+ Power Distribution Panel. N 3 G AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) LIVE IN N LIVE OUT 2 4 1 G L G N 5 LEGEND 1. Generator disconnect Grounding requirements may vary. 2. Primary system ground Cable routing may vary.
Wiring the Conext XW+ Inverter/Charger without a PDP 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 or serious injury.
Wiring the Conext XW+ Inverter/Charger AC wiring the Conext XW+ Inverter/Charger to the Inverter Load Sub-Panel DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed. • Energized from multiple sources.
Wiring the Conext XW+ Inverter/Charger without a PDP Wiring Wiring for connections between the PDP and the inverter load sub-panel is not included. See “Torque Values” on page 2–16 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. Install an AC conduit between the PDP and the inverter load sub-panel. 3.
Wiring the Conext XW+ Inverter/Charger To connect the Conext XW+ Inverter/Charger to the main utility panel: 1. See Figure 3-13 on page 3–24. Connect the neutral wire from the main utility panel to the inverter GRID (AC1) neutral terminal. 2. Connect the AC LINE wire from the main utility panel to the inverter GRID (AC1) L terminal. 2 N LIVE IN LIVE OUT G AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 3 N G 1 LEGEND 1. Primary ground system 2. Inverter load sub-panel 3.
Wiring the Conext XW+ Inverter/Charger without a PDP 3. Connect the L (LINE) wire from the generator breaker or disconnect to the inverter’s AC IN GEN (AC2) L terminal. AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 2 L G N LEGEND 1. Primary ground system 2. Generator breaker (or AC disconnect) Grounding wire Neutral Line (L) Actual wiring requirements may vary. Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12.
Wiring the Conext XW+ Inverter/Charger AC wiring additional Conext XW+ Inverter/Chargers without a PDP DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed. • Energized from multiple sources.
Wiring the Conext XW+ Inverter/Charger without a PDP NOTICE BACK FED AC POWER Back fed AC Power can damage equipment. Do not wire the inverter’s AC output port directly to the utility line or generator output. Failure to follow these instructions can result in damage to 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.
Wiring the Conext XW+ Inverter/Charger Basic Functional Test – Single Inverter Complete the following steps to perform a basic functional test of the Conext XW+ Inverter/Charger. If any test fails, refer to the Troubleshooting section in the Conext XW+ Inverter/Charger 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.
Basic Functional Test – Single Inverter DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric. • Servicing of batteries must only be performed by qualified personnel knowledgeable of batteries and the required precautions. Keep unqualified personnel away from batteries. • Disconnect the charging source prior to connecting or disconnecting battery terminals.
Wiring the Conext XW+ Inverter/Charger Figure 3-15 Power-up display Enabling the Inverter Invert mode is enabled by default, and the Conext XW+ should begin inverting upon transitioning from standby mode. If invert mode is disabled, the inverter information panel will display "" once out of standby mode, as shown in Figure 3-16. If the Conext XW+ powers up in standby mode, press the STARTUP/ SHUTDOWN button momentarily to change the mode from standby to operating.
Basic Functional Test – Single Inverter To enable the inverter: ◆ On the inverter information panel, simultaneously press the STARTUP/ SHUTDOWN button and the Equalize button. The Conext XW+ is now enabled, and (enabled) is briefly displayed on the inverter information panel, as shown in Figure 3-17. Equalize button STARTUP/SHUTDOWN button Figure 3-17 Enabled mode To disable the inverter: ◆ On the inverter information panel, simultaneously press the STARTUP/ SHUTDOWN button and the Equalize button.
Wiring the Conext XW+ Inverter/Charger 3. Monitor the invert (green kW) LED to confirm which mode the inverter is in: • • • 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. displayed on the inverter information panel – The inverter/charger is in search mode and is looking for an AC load greater than the Search Watts setting (default = 25 watts).
Basic Functional Test – Single Inverter Confirming Battery Charger Operation To confirm battery charger operation: 1. Apply AC from grid or generator. LEDs will blink while the power source is qualified. 2. Check LEDs (AC1 or AC2) on the front panel. One of them must be ON for the unit to charge. 3. Check the amp (A) LED. If the A LED is ON, the unit is charging and the battery current is displayed on the inverter information panel.
Wiring the Conext XW+ Inverter/Charger Check/verify all wiring and cable connections Check Battery Bank. Within tolerance? 44 to 64 volts for a 48~volt system Measure DC Voltage and confirm the correct polarity at all of the cable connections No Is polarity on cables correct? Recharge by external charger if necessary. Correct Polarity on Cable Connections. Apply DC Power Check display for startup self-test Press the Startup/ Shutdown button momentarily.
Basic Functional Test - Multiple Inverters Basic Functional Test - Multiple Inverters The following steps will complete a basic functional test of multiple Conext XW+ Inverter/Chargers. If any test fails, please refer to the Troubleshooting section in the Conext XW+ Inverter/Charger Owner’s Guide for assistance. To perform a functional test on multiple inverters: 1. Check/verify all wiring and cable connections. 2.
Wiring the Conext XW+ Inverter/Charger b) Change System Mode to Operating. c) Press Exit until you see the System Status screen. 12. Confirm the Master inverter displays . and the Slaves displays “” on their front panels. 13. Check for faults. If fault condition(s) exist, correct, and then restart Functional Test. 14. Check voltage at AC LOAD terminals of the Master inverter. 15. Switch the AC Load breakers ON. 16. Confirm operation of connected AC loads. 17. Disconnect AC LOAD breakers. 18.
Wiring the Conext XW+ Inverter/Charger with a PDP Wiring the Conext XW+ Inverter/Charger with a PDP This section provides instructions for making AC and DC connections between the Conext XW+ Inverter/Charger and a Conext XW+ Power Distribution Panel, using the cables that are included with the PDP and Conext XW+ Connection Kit. Note: AC breakers are not included with the Conext XW+ Inverter/Charger or Conext XW+ Power Distribution Panel.
Wiring the Conext XW+ Inverter/Charger Pre-Installation Steps DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel. • Never operate energized with covers removed • Energized from multiple sources.
Wiring the Conext XW+ Inverter/Charger with a PDP Depending on your installation, you may need to perform the following pre-installation steps: 1. Wall-mount Conext XW+ Inverter/Charger(s), as needed. See “Wall-Mounting the Conext XW+” on page 2–9. 2. Install Conext XW+ Conduit Box as needed. See “Installing the Conext XW+ Conduit Box” on page 2–10. 3. Prepare the communications network. See “Communications Network Preparation” on page 2–12. 4.
Wiring the Conext XW+ Inverter/Charger Conext XW+ Power Distribution Panel Internal Faceplate Removal If you are wiring the Conext XW+ Inverter/Charger to a Conext XW+ Power Distribution Panel (PDP), you will need to remove the two front faceplates from the PDP. For easier access to the faceplates, begin by removing the panel door from its hinges. To remove the PDP door: 5. Remove the screw at the top hinge of the PDP door and remove the top section of the hinge. 6.
Wiring the Conext XW+ Inverter/Charger with a PDP Conext XW+ 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 or serious injury.
Wiring the Conext XW+ Inverter/Charger DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Remove watches, rings, or other metal objects. • This equipment must only be installed and serviced by qualified electrical personnel. • Keep sparks and flames away from the batteries. • Use tools with insulated handles. • Wear protective glasses, gloves and boots. • Do not lay tools or other metal parts on top of batteries.
Wiring the Conext XW+ Inverter/Charger with a PDP 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 damage to equipment. See “Battery Cables and Battery Terminals” on page 3–10.
Wiring the Conext XW+ Inverter/Charger To connect the Conext XW+ Power Distribution Panel (PDP) to the Battery Bank: 1. Connect your battery cables (not included) to the PDP. Connect the negative battery cable to the DC Negative Bus, and the positive battery cable to the input end of the GJ250A 160 VDC, 3/8" stud DC breaker (pre-installed in the PDP), as shown in Figure 3-23 on page 3–45.
Wiring the Conext XW+ Inverter/Charger with a PDP AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 LEGEND 1. Battery bank BTS cable Grounding conductor Positive (+) Battery cable Negative (–) Battery cable Actual wiring requirements may vary. Cable routing may vary. See Knockout Selection on page 2-4 and Communications Network Preparation on page 2-12. For torque values, see page 2-16 and 2-17.
Wiring the Conext XW+ Inverter/Charger Dual Inverter/Charger DC Connections DC 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 or serious injury. See “Grounding the DC System” on page 3–7.
Wiring the Conext XW+ Inverter/Charger with a PDP 4. Connect the positive battery cable to the positive terminal on the second Conext XW+ (INV2) and the negative battery cable to the negative terminal on INV2. INV2 AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) INV1 AC OUT L N GEN (AC2) L AC LOAD AC IN AC IN N N L GRID (AC1) L GEN (AC2) 1 LEGEND 1.
Wiring the Conext XW+ Inverter/Charger Triple Inverter/Charger DC Connections DC 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 or serious injury. See “Grounding the DC System” on page 3–7.
Wiring the Conext XW+ Inverter/Charger with a PDP 5. Connect the positive battery cable for INV3 (included with the Conext XW+ Connection Kit) to the top terminal on the third DC disconnect/breaker. 6. Connect the negative battery cable for INV3 (included with the Conext XW+ Connection Kit) to the DC Negative Bus. 7. Connect the positive battery cable to the positive terminal on INV3 and the negative battery cable to the negative terminal on INV3.
Wiring the Conext XW+ Inverter/Charger AC Wiring with a Conext XW+ Power Distribution Panel AC equipment grounding See “AC Equipment Grounding” on page 3–20. AC breaker installation The Conext XW+ Power Distribution Panel does not include AC breakers. Mount appropriately sized and rated AC breakers onto the DIN rail inside the Conext XW+ Power Distribution Panel; ensure that your installation is done in accordance with all applicable local installation codes.
Wiring the Conext XW+ Inverter/Charger with a PDP 5. Repeat steps 1 through 4 for INV2 and INV3, as necessary. AC1 kW AC2 A Event Inverting Charging ! Equalize AC OUT N L AC LOAD AC IN AC IN N N L GRID (AC1) L Connect INV2 and INV3 the same way GEN (AC2) GEN Breaker GRID Breaker LOADS Breaker Figure 3-26 Inverter/Charger Three-Phase AC Wiring Note: Neutral inputs are connected to each other, requiring only one neutral connection when installed with a Conext XW+ Power Distribution Panel.
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4 Xanbus Network Installation Chapter 4, “Xanbus Network Installation” provides detailed information for planning and installing the components necessary for network communication on a Xanbus system.
Xanbus Network Installation 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+ provides a solution that simplifies and automates the installation, configuration, control, monitoring, and integration of devices. Network Components NOTICE SHORT CIRCUIT OF NETWORK COMPONENTS • This network is not an ethernet system.
The Xanbus Network Xanbus-enabled devices A Xanbus-enabled device is any product that works on a Xanbus network. Below are some examples of Xanbus-enabled devices: • Conext System Control Panel • Conext XW+ Inverter/Charger • Conext Automatic Generator Start • Conext Battery Monitor • MPPT 60 150 Solar Charge Controller • MPPT 80 600 Solar Charge Controller Due to network traffic, the maximum number of Conext XW+ units in a single Xanbus network should not exceed twelve.
Xanbus Network Installation Figure 4-2 Xanbus Cable Network terminators The Xanbus network must be properly terminated at each end to 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+ Inverter/Charger and other Xanbus-enabled devices ship with one network terminator.
Installing the Network Installation Tools and Materials Tools A Phillips head screwdriver, appropriately sized is required to install the Xanbus cables. Materials The following materials may be required to complete the installation. ❐ CAT 5 or CAT 5e cables (available from computer supply stores) ❐ Terminators Note: Mount cables and network connectors in a dry location.
Xanbus Network Installation To install the AC sync and Xanbus cables: 1. Remove the two raceways for the communication cabling by removing the screw holding each raceway in place, as shown in Figure 4-5. Raceway Raceway ► Raceway screw Raceway screw Figure 4-5 XW+ 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 4-6. Route any additional communication cables through the raceways.
Installing the Network Note: In a dual-inverter system, install an AC Sync Cable from INV1 to INV2. In a triple-inverter system, daisy-chain an AC Sync Cable from INV1 to INV2 and from INV2 to INV3. 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.
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5 Conext XW+ Inverter/Charger Accessories Installation Chapter 5, “Conext XW+ Inverter/Charger Accessories Installation” provides detailed instructions for installing certain accessories for your Conext XW+ Inverter/Charger.
Conext XW+ Inverter/Charger Accessories Installation Conext Combox Installation The Conext XW+ Inverter/Charger can be controlled remotely by connecting a Conext ComBox. The Conext ComBox allows access to programming features of the Conext XW+ and allows the system to be modified to specific installation requirements. For installation instructions, see the Conext Combox Owner’s Guide (975-0679-01-01).
Conext System Control Panel Installation Installing the SCP via the Xanbus Network WARNING IGNITION AND FIRE HAZARD This equipment is not ignition protected. To prevent fire or explosion, do not install this product in locations that require ignition-protected equipment. This includes any confined space containing vented batteries, or flammable chemicals such as, natural gas (NG), liquid petroleum gas (LPG) or gasoline (Benzine/Petrol).
Conext XW+ Inverter/Charger Accessories Installation Replacing the Inverter Information Panel with the SCP To remove the inverter information panel from the Conext XW+ chassis: DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See EN 50110. • This equipment must only be installed and serviced by qualified electrical personnel.
Conext System Control Panel Installation DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Battery Circuit Breakers must be installed according to the specifications and requirements defined by Schneider Electric. • Servicing of batteries must only be performed by qualified personnel knowledgeable of batteries and the required precautions. Keep unqualified personnel away from batteries. • Disconnect the charging source prior to connecting or disconnecting battery terminals.
Conext XW+ Inverter/Charger Accessories Installation 3. For easier access, remove the right-side panel of the Conext XW+, as shown in Figure 5-3. (Internal components hidden for clarity.) Figure 5-3 Right-side panel removal 4. Carefully remove the inverter information panel from the Conext XW+ chassis, and detach it from the inverter communication cable. 5. Remove the metal support plate from the housing of the Conext XW+ chassis. 6.
Conext System Control Panel Installation 3. Secure the SCP with the four screws removed from the inverter information panel. Figure 5-4 Mounting plate centered on wall studs 4. When all wiring is complete, re-secure the AC access panel to the Conext XW+ chassis For more information, see “Removing the AC Access Panel and PDP Internal Faceplates” on page 3–2. 5. Re-secure the right-side panel (if applicable).
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A Specifications Appendix A, “Specifications” provides the electrical and mechanical specifications for the Conext XW+ Inverter/Charger.
Specifications Electrical Specifications Table A-1 Conext XW+ Electrical Specifications Conext XW+ 8548 Conext XW+ 7048 Continuous Output Power 6,800 W 5,500 W Surge Rating (Overload for 1 minute) 12,000 W 9,500 W Surge Rating (Overload for 5 minutes) 11,000 W 9,000 W Surge Rating (Overload for 30 minutes) 8,500 W 7,000 W Surge Current 53 Arms (60 s) 40 Arms (60 s) Waveform True Sine Wave Idle Consumption—invert mode, no load 28 W 26 W Idle Consumption—search mode <7W AC Output Volt
Electrical Specifications Conext XW+ Overload Capability Loads connected to the inverter are seldom constant, and large loads are often operated for short periods. To accommodate larger loads, the Conext XW+ can temporarily exceed its continuous output power rating. The graphs below illustrate approximate operation time versus load. Inverter operation time during overload is limited by both inverter internal temperature protection and by the product of AC output current and elapsed time.
Specifications Output Power Versus Ambient Temperature When the internal temperature of the Conext XW+ exceeds a preset limit, it begins to limit output power automatically to stop maximum internal temperatures from being exceeded.
Electrical Specifications Charging Efficiency (Typical) 100% Efficiency (%) 95% 90% ;: 85% ;: 80% 75% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Charge Current (Amps) Figure A-4 Charging Efficiency (Typical) Charging Efficiency Power Factor ;: 100% ;: Power Factor (%) 95% 90% 85% 80% 75% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Charge Current (Amps) Figure A-5 Charging Efficiency Power Factor 975-07
Specifications Mechanical Specifications Table A-2 Conext XW+ Inverter/Charger Mechanical Specifications Conext XW+ 8548 Supported Battery Types Conext XW+ 7048 Flooded (default), Gel, AGM, Lithium Ion, Custom Battery bank size 440–10000 Ah Non Volatile Memory Yes Inverter Information Panel Status LEDs indicate AC In status, faults/ warnings, equalize mode, battery level. Three-character display indicates output power or charge current, fault/warning codes. Startup/shutdown and equalize button.
Mechanical Specifications Internal Transfer Relay Control & Monitoring L-Gen N L-Grid N EMI Filter AC Filter EMI Filter DC+ Power Transformer DC- L-Load N +12V RPO RTN OUT IN BTS XBus XBus Power Bridge Sync Sync PE Figure A-6 Conext XW+ Block Diagram 975-0714-01-01 A–7 This manual is for use by qualified personnel only
Specifications Accessories Table A-3 Conext XW+ Accessories Accessory Part Number Conext XW+ Power Distribution Panel 865-1015-01 Conext XW+ Power Distribution Panel (Without AC Breakers) 865-1014-01 Conext XW+ Conduit Box 865-1025-01 Conext XW+ Connection Kit for INV2 INV3 PDP 865-1020-02 Conext System Control Panel 865-1050-01 Conext Automatic Generator Start 865-1060-01 Conext MPPT 60 150 Solar Charge Controller 865-1030-1 Conext MPPT 80 600 Solar Charge Controller 865-1032 Conext ComB
Schneider Electric http://solar.schneider-electric.com As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication. © 2015 Schneider Electric. All rights reserved. 975-0714-01-01 Rev E Printed in China.
