XW-MPPT80-600_Install.book Page i Friday, November 17, 2017 10:20 AM Conext™ MPPT 80 600 Solar Charge Controller (865-1032) Installation Guide 975-0540-01-01 Rev F November 2017 ! http://solar.schneider-electric.
XW-MPPT80-600_Install.
XW-MPPT80-600_Install.book Page i Friday, November 17, 2017 10:20 AM Conext™ MPPT 80 600 Solar Charge Controller Installation Guide http://solar.schneider-electric.
XW-MPPT80-600_Install.book Page ii Friday, November 17, 2017 10:20 AM Copyright © 2013-2017 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
XW-MPPT80-600_Install.book Page iii Friday, November 17, 2017 10:20 AM About This Guide Purpose This Guide provides explanations and procedures for installing and troubleshooting the Schneider Electric Conext™ MPPT 80 600 Solar Charge Controller. Scope This Guide provides safety guidelines, detailed planning and setup information, procedures for installing the charge controller, and information about troubleshooting.
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XW-MPPT80-600_Install.book Page v Friday, November 17, 2017 10:20 AM Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext MPPT 80 600 Solar Charge Controller that must be followed during installation procedures. Read and keep this Installation Guide for future reference.
XW-MPPT80-600_Install.book Page vi Friday, November 17, 2017 10:20 AM Safety Safety Information 1. Before using the charge controller, 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 charge controller is designed to be permanently connected to your AC and DC electrical systems.
XW-MPPT80-600_Install.book Page vii Friday, November 17, 2017 10:20 AM Safety 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.
XW-MPPT80-600_Install.book Page viii Friday, November 17, 2017 10:20 AM Safety CAUTION BURN HAZARD Do not touch the charge controller’s heatsink during operation or before servicing immediately after ceasing operation. Failure to follow these instructions can result in injury. NOTICE LIGHTNING PROTECTION To protect the charge controller’s insulation and conductors from damage due to a sudden over-voltage surge such as a lightning strike, install a DC-rated lightning arrestor on the DC input line.
XW-MPPT80-600_Install.book Page ix Friday, November 17, 2017 10:20 AM Safety Battery Safety Information DANGER HAZARD OF ELECTRIC SHOCK, BURN, FIRE, AND EXPLOSION Batteries contain corrosive electrolyte and can give off explosive gases. Battery circuits present a shock and energy hazard. Observe proper precautions when working with batteries and battery circuits, including: • Always wear eye protection when working with batteries. • Wear rubber gloves and boots when handling batteries.
XW-MPPT80-600_Install.book Page x Friday, November 17, 2017 10:20 AM Safety FCC Information to the User This charge controller has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules and Industry Canada ICES-003. These limits are designed to provide reasonable protection against harmful interference when the charge controller is operated in a residential environment.
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XW-MPPT80-600_Install.
XW-MPPT80-600_Install.book Page 1 Friday, November 17, 2017 10:20 AM 1 Introduction Chapter 1 describes features and functions of the charge controller. It includes: • Features • Charge Controlling • Typical Installation 975-0540-01-01 F 1–1 This guide is for use by qualified personnel only.
XW-MPPT80-600_Install.book Page 2 Friday, November 17, 2017 10:20 AM Introduction Features The Conext MPPT 80 600 Solar Charge Controller (charge controller) tracks the maximum power point of a PV array to deliver the maximum available current for optimum charging of batteries. The charge controller can be used with 24 VDC and 48 VDC battery systems only. Key product features include a 600 VDC maximum input voltage, a Fast Sweep™ MPPT tracking algorithm, and built-in ground fault protection.
XW-MPPT80-600_Install.book Page 3 Friday, November 17, 2017 10:20 AM Charge Controlling Charge Controlling The charge controller regulates the PV array current to an appropriate level for 24 V or 48 V batteries. It produces up to 80 amps of charging current for both 2560 watts at 24 V, or 4800 watts at 48 V. The charge controller can be configured to use a two-stage (no float) or threestage charging algorithm.
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XW-MPPT80-600_Install.book Page 1 Friday, November 17, 2017 10:20 AM 2 Installation Chapter 2 provides installation instructions for the charge controller. Before installing the charge controller, read this entire chapter.
XW-MPPT80-600_Install.book Page 2 Friday, November 17, 2017 10:20 AM Installation DANGER HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION Installation of this equipment should only be planned and performed by qualified personnel in accordance with all applicable installation codes. See “Audience” on page iii for the definition of qualified personnel. Failure to follow these instructions will result in death or serious injury.
XW-MPPT80-600_Install.book Page 3 Friday, November 17, 2017 10:20 AM Required Accessories Required Accessories A Conext System Control Panel (SCP) is required for installation of the charge controller. However, in place of the SCP, a Conext ComBox (ComBox) can be used if you would like to configure and monitor the charge controller through a web-interface on a PC or laptop. For more information on accessories, see Appendix A, “Specifications”.
XW-MPPT80-600_Install.book Page 4 Friday, November 17, 2017 10:20 AM Installation Choosing a Location WARNING HAZARD OF ELECTRIC SHOCK, BURN, FIRE, AND EXPLOSION RISK OF EQUIPMENT DAMAGE The charge controller must be mounted vertically and installed indoors in a dry, protected location away from flammable materials, sources of high temperature, moisture, and vibration. The location must also be sheltered from direct sunlight, dust, and wind-blown debris.
XW-MPPT80-600_Install.book Page 5 Friday, November 17, 2017 10:20 AM Mounting Table 2-1 Minimum clearance requirements Location Minimum Clearance Above 6 inches (150 mm). Do not mount charge controllers in a vertical and below stack. One charge controller can be mounted on the side of the Conext Power Distribution Panel (PDP) (Part Number 865-1015-01). For more information, see the Conext XW+ Inverter/Charger Installation Guide. Other installations must follow the guidelines in this Guide.
XW-MPPT80-600_Install.book Page 6 Friday, November 17, 2017 10:20 AM Installation Removing the Wiring Compartment Cover DANGER HAZARD OF ELECTRIC SHOCK AND ENERGY Before removing the wiring compartment cover, make sure all electrical power sources have been disconnected for at least two minutes. Before energizing the charge controller, make sure the wiring compartment cover has been replaced and all fasteners are in place. Failure to follow these instructions will result in death or serious injury.
XW-MPPT80-600_Install.book Page 7 Friday, November 17, 2017 10:20 AM Mounting Removing Knockouts Fourteen knockouts are provided for conduit or cable entry into the charge controller (see Figure 2-4 and Figure 2-5): • Three single (one on each side and one on the back) for battery wires: 1.73 in. (44.0 mm). • Two single on the back and six dual on the sides (three on each side) for PV array wires: 1.38 in. (35.0 mm).
XW-MPPT80-600_Install.book Page 8 Friday, November 17, 2017 10:20 AM Installation Conext MPPT 80 600 Charging Event ! 764.0 (30.0) 673.4 (26.5) Equalize 44.0 (1.73) KNOCKOUT 35.0 (1.38)/ 28.2 (1.11) DUAL KNOCKOUT 3PL 108.4 (4.27) 219.7 (8.65) 61.9 (2.44) 28.2 (1.11)/ 22.2(0.87) DUAL KNOCKOUT 220.5 (8.68) Figure 2-5 Dimensions and Knockout Locations 2–8 975-0540-01-01 F This guide is for use by qualified personnel only.
XW-MPPT80-600_Install.book Page 9 Friday, November 17, 2017 10:20 AM Mounting Mounting the Charge Controller The charge controller must be vertically mounted to the wall using three ¼-inch × ½-inch (6.35 mm × 12.5 mm) pan head screws. Alternatively, the it can also be mounted on the side of the PDP (the hardware is provided with the charge controller). To mount the charge controller on the wall (see Figure 2-6): 1. Remove the wiring compartment cover (see page 2–6). 2.
XW-MPPT80-600_Install.book Page 10 Friday, November 17, 2017 10:20 AM Installation PV Grounding You can configure the charge controller to be compatible with either negativegrounded, positive-grounded, or ungrounded (floating) PV arrays. For information about routing the array ground connection, see Figure 2-9. Chassis Grounding For ground conductor requirements for your specific installation, consult your local electrical code. The recommended size of the chassis ground conductor is #8 AWG (10 mm2)1.
XW-MPPT80-600_Install.book Page 11 Friday, November 17, 2017 10:20 AM Wiring This symbol identifies the protective conductor (grounding) connection. Ground fault protection fuse holders Chassis ground terminals (4) Figure 2-7 Chassis ground connector Wiring The following sections provide information about wiring. Connector Locations Terminal connectors for DC wiring are located inside the wiring compartment. Labels above the DC wiring terminals identify all the connection points. See Figure 2-8.
XW-MPPT80-600_Install.book Page 12 Friday, November 17, 2017 10:20 AM Installation Wire Size and Over-current Protection Requirements WARNING HAZARD OF ELECTRIC SHOCK, ENERGY, AND FIRE The wiring, over-current protection devices (fuses and circuit breakers), and installation methods used must conform to all applicable code requirements. Wiring must be protected from physical damage with appropriate methods such as the use of conduit and strain relief clamps.
XW-MPPT80-600_Install.book Page 13 Friday, November 17, 2017 10:20 AM Wiring Battery Circuit The DC-rated fuse or circuit breaker between the battery and the charge controller must be rated—at minimum—100 A and must not exceed the allowable over-current protection rating for the size of wire being used, in accordance with applicable electrical codes. PV Circuit DANGER HAZARD OF ELECTRIC SHOCK The PV array will produce a hazardous voltage with even a small amount of light.
XW-MPPT80-600_Install.book Page 14 Friday, November 17, 2017 10:20 AM Installation Connecting the Charge Controller The following procedure is illustrated in Figure 2-9. DANGER HAZARD OF ELECTRIC SHOCK Whenever a PV array is exposed to light, a shock hazard exists at the output wires or exposed terminals. Open the array disconnect switch before making the connections. Failure to follow these instructions will result in death or serious injury.
XW-MPPT80-600_Install.book Page 15 Friday, November 17, 2017 10:20 AM Wiring To connect the charge controller in a positive-grounded or floating system: ◆ Follow the same steps described above for a negative-grounded charge controller installation except modify the location of the PV array disconnect switch as follows: • For positive-grounded systems, the PV array disconnect switch must be in the negative conductor.
XW-MPPT80-600_Install.book Page 16 Friday, November 17, 2017 10:20 AM Installation For negative-grounded PV array, install fuse here. The positive or negative of the battery can be grounded independent of the array grounding. For positive-grounded PV array, install fuse here.
XW-MPPT80-600_Install.book Page 17 Friday, November 17, 2017 10:20 AM Connecting Multiple PV Array Strings to One Unit Connecting Multiple PV Array Strings to One Unit The charge controller has two three-pole PV connectors, allowing up to three PV array strings to be directly connected in the charge controller. These input connectors can accept #6 to #14 AWG (13.5 to 2.5 mm2) solid or stranded wire.
XW-MPPT80-600_Install.book Page 18 Friday, November 17, 2017 10:20 AM Installation Connecting Multiple Units In a multiple-unit installation, each charge controller must be connected to one or more separate PV arrays. See Figure 2-10. For other multiple-unit installation considerations, see “Network Installation” on page 2–20.
XW-MPPT80-600_Install.book Page 19 Friday, November 17, 2017 10:20 AM Auxiliary Output Connections Auxiliary Output Connections The auxiliary output (dry relay contacts) provides a connector which can accept wire sizes from #22 to #14 AWG (0.5 to 2.5 mm2), copper solid or stranded. As shown in Figure 2-11, the auxiliary output can control 12 VDC power to a fan to vent the battery compartment. See “Configuring the Auxiliary Output” in the Conext MPPT 80 600 Solar Charge Controller Operation Guide.
XW-MPPT80-600_Install.book Page 20 Friday, November 17, 2017 10:20 AM Installation Network Installation The charge controller is a Xanbus-enabled device. Xanbus is a network communications system which allows the charge controller to communicate settings and status information to other Xanbus-enabled devices. Xanbus connections between multiple charge controllers allow information about each charge controller and its associated PV array to be communicated among all of the charge controllers in the system.
XW-MPPT80-600_Install.book Page 21 Friday, November 17, 2017 10:20 AM Network Installation Figure 2-12 Network Terminator Network Layout Xanbus-enabled devices are connected with separate lengths of cable. The devices at each end of the chain must have a terminator inserted into their open network ports, as shown in Figure 2-13. Total cable length for the Xanbus network must not exceed 131 feet (40 m). XANBUS XANBUS BTS AUX XANBUS BATTERY _ + NEG. GND PV. PV- XANBUS BTS AUX BATTERY _ POS.
XW-MPPT80-600_Install.book Page 22 Friday, November 17, 2017 10:20 AM Installation NOTE • Connect only Xanbus-enabled devices. Although the cabling and connectors used in this network system are the same as ethernet connectors, this network is not an ethernet system. • Do not connect one end of the network to the other to make a ring or loop. To connect network cables between multiple charge controllers: 1.
XW-MPPT80-600_Install.book Page 23 Friday, November 17, 2017 10:20 AM Installing the Battery Temperature Sensor Installing the Battery Temperature Sensor 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.
XW-MPPT80-600_Install.book Page 24 Friday, November 17, 2017 10:20 AM Installation 3. Connect the ring terminal on the BTS directly to the negative battery terminal or positive battery terminal, or use the adhesive backing on the sensor back to attach the sensor to any side of the battery to be monitored. See Figure 2-14. If connecting to the battery terminal, make sure the BTS does not prevent the power wiring from making the best possible contact with the battery terminal.
XW-MPPT80-600_Install.book Page 25 Friday, November 17, 2017 10:20 AM Commissioning Insert the BTS plug into the charge controller’s BTS port. + + – + – + – Attach the BTS to a battery terminal or to the side of a battery. – Figure 2-15 Installing the BTS Commissioning Conext SCP You must use the SCP to commission the charge controller. For information about SCP navigation and menus, see the Conext MPPT 80 600 Solar Charge Controller Operation Guide.
XW-MPPT80-600_Install.book Page 26 Friday, November 17, 2017 10:20 AM Installation To commission one or more charge controllers: 1. “Setting the Device Number” on page 2–26 2. “Configuring Connections and Charger Settings” on page 2–27 3. If commissioning multiple charge controllers: “Copying Settings to Another Charge Controller” on page 2–28 4.
XW-MPPT80-600_Install.book Page 27 Friday, November 17, 2017 10:20 AM Commissioning The charge controller appears as XW MPPT80 xx on the menu, where xx is the device number you selected. 10. Repeat steps 3 through 9 if you are commissioning multiple charge controllers. Configuring Connections and Charger Settings WARNING HAZARD OF FIRE AND EXPLOSION Battery charging settings must be configured by qualified personnel in accordance with the battery manufacturer's recommended charging instructions.
XW-MPPT80-600_Install.book Page 28 Friday, November 17, 2017 10:20 AM Installation Copying Settings to Another Charge Controller WARNING HAZARD OF FIRE AND EXPLOSION • Do not copy settings from one charge controller to another unless the battery banks are identical: same size, type, and so on. • See the Conext MPPT 80 600 Solar Charge Controller Operation Guide for additional configuration information and details including setting descriptions and value ranges.
XW-MPPT80-600_Install.book Page 29 Friday, November 17, 2017 10:20 AM Commissioning NOTE The Copy from command will not give you any indication that it has completed its task. To check that the charger settings have been copied properly, view some of the settings you originally configured. 4. Repeat steps 1 to 3 for the remaining charge controllers. 5. After you have finished configuring, press the Enter, up arrow, and down arrow buttons simultaneously to hide the Advanced Settings menu item.
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XW-MPPT80-600_Install.book Page 1 Friday, November 17, 2017 10:20 AM 3 Troubleshooting Chapter 3 provides information about identifying and resolving problems that might arise while using the charge controller. It includes: • Charge Controller Troubleshooting • Replacing the Ground Fault Protection Fuse • Ground Faults in a Normally Ungrounded Array 975-0540-01-01 F 3–1 This guide is for use by qualified personnel only.
XW-MPPT80-600_Install.book Page 2 Friday, November 17, 2017 10:20 AM Troubleshooting Charge Controller Troubleshooting DANGER HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION This chapter includes hazardous tasks that must be performed only by qualified personnel equipped with appropriate personal protective equipment and following safe electrical work practices. Review the “Important Safety Instructions” beginning on page v before proceeding.
XW-MPPT80-600_Install.book Page 3 Friday, November 17, 2017 10:20 AM Charge Controller Troubleshooting Table 3-1 Charge controller problems Problem Possible Cause Solution The charge controller’s Error/ Warning (red) LED is on or flashing. An active fault, error, or warning is present on the charge controller. See “Viewing Active Faults, Errors, and Warnings” in the Conext MPPT 80 600 Solar Charge Controller Operation Guide to determine which alarm is active on the charge controller.
XW-MPPT80-600_Install.book Page 4 Friday, November 17, 2017 10:20 AM Troubleshooting Table 3-1 Charge controller problems Problem Possible Cause Solution All of the charge controller’s LEDs are off and the charge controller does not show up on the SCP. A. No battery connection to the charge controller. A. Change the battery disconnect from the off position to the on position. B. The charge controller is wired incorrectly. B.
XW-MPPT80-600_Install.book Page 5 Friday, November 17, 2017 10:20 AM Ground Faults in a Normally Ungrounded Array 3. Remove the blown fuse and replace it with a new AC/DC midget cartridge, DC-rated 600 VDC, 1 A (Littelfuse KLKD 1 or equivalent). Be careful not to damage the fuse clips, circuit board, and surrounding components. 4. Replace the wiring compartment cover. 5. Clear the fault and reset the system by removing and then reapplying both PV and battery power.
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XW-MPPT80-600_Install.book Page 1 Friday, November 17, 2017 10:20 AM A Specifications Appendix A provides the specifications for the charge controller. It includes: • Electrical Specifications • Default Battery Charger Settings • Mechanical Specifications • Accessories • Regulatory Approvals All specifications are subject to change without notice. 975-0540-01-01 F A–1 This guide is for use by qualified personnel only.
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XW-MPPT80-600_Install.book Page 3 Friday, November 17, 2017 10:20 AM Electrical Specifications NOTE • PV array voltages often exceed STC voltage specifications, especially when the array is cold. A voltage temperature correction factor based on the local code (i.e., NEC 690 or CEC Section 50), ambient temperature conditions, and module manufacturer specifications must be applied to the array STC VOC to keep array voltage within specifications listed above.
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XW-MPPT80-600_Install.book Page 5 Friday, November 17, 2017 10:20 AM Default Battery Charger Settings Default Battery Charger Settings All settings in the following table are based on a 48 V nominal battery bank. For a 24 V nominal battery bank, divide the voltage values in this table by two. Battery Type Floodeda Setting Gel AGM Equalize Voltage 64.0 V n/a n/a ReCharge Voltage 50.0 V 50.0 V 50.0 V Bulk Voltage 57.6 V 56.8 V 57.2 V Absorption Voltage 57.6 V 56.8 V 57.
XW-MPPT80-600_Install.book Page 6 Friday, November 17, 2017 10:20 AM Specifications Altitude Limit (operating) Sea level to 6,500 feet (approximately 2000 m) Unit Dimensions (H × W × D) 30 × 8 5/8 × 8 5/8" (760 × 220 × 220 mm) Mounting Vertical wall mount Weight (charge controller only) 29.8 lb (13.5 kg) Weight (shipping) 45 lb (20.4 kg) Accessories The SCP (Part Number 865-1050-01) is required for installation of the charge controller and is strongly recommended for ongoing operation.
XW-MPPT80-600_Install.book Page 7 Friday, November 17, 2017 10:20 AM Regulatory Approvals Regulatory Approvals Certified to UL 1741 and to CSA 107.1 and carries the c(CSA)us mark. EMC - North America: • FCC Part-15 sub part B, Class B • Industry Canada ICES-003, Class B CE Marked and complies with the following: Low Voltage Directive 2006/95/EC, per: • EN50178 Electronic Equipment for Use in Power Installations.
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XW-MPPT80-600_Install.book Page 3 Friday, November 17, 2017 10:20 AM Index removing cover 2–6 X Xanbus overview 2–20 power supply 2–20 975-0540-01-01 F IX–3 This guide is for use by qualified personnel only.
XW-MPPT80-600_Install.book Page 4 Friday, November 17, 2017 10:20 AM Index IX–4 975-0540-01-01 F This guide is for use by qualified personnel only.
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XW-MPPT80-600_Install.book Page 6 Friday, November 17, 2017 10:20 AM 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.
