ConextSWEUROInstallationGuide.book Page i Tuesday, July 21, 2015 4:22 PM Conext™ SW Inverter Charger Conext SW 2524 230 (865-2524-61) Conext SW 4024 230 (865-4024-61) Conext SW 4048 230 (865-4048-61) Installation Guide 975-0637-01-01 Rev E 7-2015 TM solar.schneider-electric.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page i Tuesday, July 21, 2015 4:22 PM Conext SW Inverter/Charger Conext SW 2524 230 (865-2524-61) Conext SW 4024 230 (865-4024-61) Conext SW 4048 230 (865-4048-61) Installation Guide solar.schneider-electric.
ConextSWEUROInstallationGuide.book Page ii Tuesday, July 21, 2015 4:22 PM Copyright and Contact Copyright © 2013-2015 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies.
ConextSWEUROInstallationGuide.book Page iii Tuesday, July 21, 2015 4:22 PM About This Guide Purpose The purpose of this Installation Guide is to provide explanations and procedures for installing the Conext SW Inverter/Charger to a main AC power source such as an AC generator for off-grid application or AC mains (main power grid) for power backup application. Scope The Guide provides safety and installation guidelines as well as information on tools and wiring.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page v Tuesday, July 21, 2015 4:22 PM Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext SW Inverter/ Charger that must be followed during operation and troubleshooting. Read and keep this Installation Guide for future reference.
ConextSWEUROInstallationGuide.book Page vi Tuesday, July 21, 2015 4:22 PM Safety Safety Information DANGER ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation and electrical codes and regulations. Instructions for installing the Conext SW are provided here for use by qualified installers only. Failure to follow these instructions will result in death or serious injury.
ConextSWEUROInstallationGuide.book Page vii Tuesday, July 21, 2015 4:22 PM Safety DANGER ELECTRIC SHOCK HAZARD • For indoor use only. This inverter/charger is designed for off-grid, solar, backup, and hybrid applications. • Do not operate the inverter/charger if it has been damaged in any way. • Do not operate the inverter/charger with damaged or substandard wiring. Wiring must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations.
ConextSWEUROInstallationGuide.book Page viii Tuesday, July 21, 2015 4:22 PM Safety CAUTION FIRE AND BURN HAZARD Do not cover or obstruct the air intake vent openings and/or install in a zeroclearance compartment. Failure to follow these instructions can result in moderate or minor injury.
ConextSWEUROInstallationGuide.book Page ix Tuesday, July 21, 2015 4:22 PM Safety WARNING CHEMICAL, BURN, AND EXPLOSION HAZARD • Do not open or use a battery which is cracked or otherwise damaged. Battery electrolyte is toxic and highly corrosive. • Never place the Conext SW Inverter/Charger unit in the same compartment as batteries due to an explosive hazard. • Make sure the area around the battery is well ventilated.
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ConextSWEUROInstallationGuide.book Page 1 Tuesday, July 21, 2015 4:22 PM 1 Installation The following topics will be covered in this chapter.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 3 Tuesday, July 21, 2015 4:22 PM Materials List Conext SW Front and Side Panels 1 2 TOP TOP 3 8 8 6 4 7 5 Figure 1-2 Conext SW Front and Side Panels Before you begin to operate the Conext SW after installation, review the front panel features shown in Figure 1-3 and described in the next table. A detailed view of the lights and buttons on the front panel is also shown.
ConextSWEUROInstallationGuide.book Page 4 Tuesday, July 21, 2015 4:22 PM Installation Item Description 5 AC line terminals. See “AC and DC Terminals, Network and Communication Ports Panel” on page 1–5. 6 Manual reset button for the built-in 30-amp AC input circuit breaker. 7 Two variable-speed cooling fans maintain a cool internal temperature of critical components. The two fans control airflow through the transformer and power compartments of the unit.
ConextSWEUROInstallationGuide.book Page 5 Tuesday, July 21, 2015 4:22 PM Materials List Conext SW AC/DC/Ports Side Panel 3 1 7 b a 4 2 5 6 8 9 Figure 1-4 AC and DC Terminals, Network and Communication Ports Panel Item 1 Description Battery Positive (+) DC terminal connects to the positive battery cable (red). Install a DC terminal cover (supplied) over the terminal. Battery Negative (–) DC terminal connects to the negative battery cable (black).
ConextSWEUROInstallationGuide.book Page 6 Tuesday, July 21, 2015 4:22 PM Installation Conext SW Supplied Accessories 1 2 3 4 Figure 1-5 Supplied Accessories NOTE: If any of the supplied accessories are missing, contact customer service for replacement. See “Contact Information solar.schneider-electric.com” on page ii. Item Description 1 Two DC terminal covers prevent accidental contact with the DC cable connectors after installation.
ConextSWEUROInstallationGuide.book Page 7 Tuesday, July 21, 2015 4:22 PM Installation Information Installation Information Before You Begin the Installation Before beginning your installation: • Read the entire Installation Guide so you can plan the installation from beginning to end. • Assemble all the tools and materials you require for the installation. • Review the Important Safety Instructions on page v. • Be aware of all safety and electrical codes which must be met.
ConextSWEUROInstallationGuide.book Page 8 Tuesday, July 21, 2015 4:22 PM Installation Xanbus Network System Xanbus System The Xanbus system includes the Conext SW and other Xanbus-enabled devices. The Conext SW is the device in a Xanbus system that typically provides network power—500 mA at 12 VDC. All of the Xanbus-enabled devices, such as the Conext SW, the SCP, and the AGS are able to communicate their settings and activity to each other.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 10 Tuesday, July 21, 2015 4:22 PM Installation Installation Planning Planning Preparations This section provides information to help plan for a basic installation of the Conext SW. There are two key factors that will have a major impact on system performance. 1. Size and Length of DC Cables To select the appropriate size and length of DC cables, see “DC Cabling” on page 1–13.
ConextSWEUROInstallationGuide.book Page 11 Tuesday, July 21, 2015 4:22 PM Installation Planning AC, DC, and Network Components The illustration below shows the different components that can go into a Conext SW inverter/charger installation.
ConextSWEUROInstallationGuide.book Page 12 Tuesday, July 21, 2015 4:22 PM Installation The illustration below shows which components you may need before you begin your installation. DC Components Xanbus Network Components • 24- or 48-volt battery or batteries, see “DC Component -Batteries” on page 1–13. • System Control Panel (SCP) • Automatic Generator Start (AGS) • DC-rated fuse and/or circuit breaker, see “DC Disconnects and Overcurrent Devices” on page 1–14.
ConextSWEUROInstallationGuide.book Page 13 Tuesday, July 21, 2015 4:22 PM Installation Planning Size of AC Input Wiring IMPORTANT: Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved, in accordance with the electrical codes or regulations applicable to your installation. Therefore, the wiring used between the main AC source panel’s circuit breaker and the inverter/charger AC INPUT must be sized to match the input breaker rating.
ConextSWEUROInstallationGuide.book Page 14 Tuesday, July 21, 2015 4:22 PM Installation Table 1-2 Recommended Battery Cablea Sizes Model Cable Length < 1.5 m Maximum Current (A) Cable Length 1.5 to 3.0 m Conduit / (Free Air) SW 2524 230 120 50 mm2 (25 mm2) SW 4024 230 200 240 mm2 (120 mm2) 300 mm2 (150 mm2) SW 4048 230 105 50 mm2 (25 mm2) 70 mm2 (35 mm2) 70 mm2 (35 mm2) a.
ConextSWEUROInstallationGuide.book Page 15 Tuesday, July 21, 2015 4:22 PM Installation Planning Unpacking and Inspecting the Conext SW Inverter/Charger CAUTION HEAVY LOAD HAZARD Do not lift the unit by yourself. Use two people to lift and mount the unit. Always use proper lifting techniques during installation to prevent injury. Failure to follow these instructions can result in injury.
ConextSWEUROInstallationGuide.book Page 16 Tuesday, July 21, 2015 4:22 PM Installation Installation Tools and Materials Tools You will need the following tools to install the Conext SW and the battery temperature sensor. ❐ Wire stripper ❐ Crimping tools for fastening lugs and terminals on DC cables ❐ Phillips screwdriver: #2 bit ❐ Slot screwdriver (6mm wide blade max.
ConextSWEUROInstallationGuide.book Page 17 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation Inverter/Charger Installation Overview This section provides detailed information on installing the Conext SW.
ConextSWEUROInstallationGuide.book Page 18 Tuesday, July 21, 2015 4:22 PM Installation Step 1: Choosing a Location for the Inverter/Charger WARNING FIRE HAZARD For indoor use only. • Do not install and/or operate in compartments containing flammable materials or in locations that require ignition-protected equipment. • Do not cover or obstruct the ventilation openings. • Do not install this unit in a compartment with limited airflow. • Do not install where access to disconnecting means is obstructed.
ConextSWEUROInstallationGuide.book Page 19 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation TIP: Align the mounting holes in the center of wall studs. If necessary, fasten a plywood board first to a wall with non-standard-spaced wall studs. Then mount the inverter/charger on the plywood board. 406mm standardspaced wall studs. (1) Place the installation bracket flat on the wall (or plywood) and mark the positions of the mounting holes on the wall. (2) 5 7/8 in. 149.
ConextSWEUROInstallationGuide.book Page 20 Tuesday, July 21, 2015 4:22 PM Installation Step 3: Connecting the AC Input and AC Output Wires DANGER ELECTRICAL SHOCK AND FIRE HAZARD • Make sure all AC and DC wiring being connected to the inverter/charger is disconnected (physically or by opening and locking out all relevant disconnecting means) from all electrical sources before handling. • All wiring must be done in accordance with local and national electrical wiring codes.
ConextSWEUROInstallationGuide.book Page 21 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation (1) Make the wiring connections to the AC source main panel. (2) Route the AC cable to the inverter/ charger. (3) Remove the wiring compartment cover panel on the inverter/charger. (4) Remove the AC knockouts from the side (3) side AC knockouts or bottom (or both). Do not leave the knockout inside the wiring compartment. (5) Install strain-relief clamps in the AC knockouts.
ConextSWEUROInstallationGuide.book Page 22 Tuesday, July 21, 2015 4:22 PM Installation Step 4: Connecting the DC Cables DC Connection Precautions WARNING BURN AND FIRE HAZARD Connect and disconnect DC wiring only after opening and locking out the disconnect switches or breakers at all AC and DC sources. Failure to follow these instructions can result in death or serious injury.
ConextSWEUROInstallationGuide.book Page 23 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation Connecting the DC Cables to the Inverter/Charger WARNING FIRE HAZARD • Use only appropriately sized copper cable. Loose connections, improper connections, and under-rated cables will overheat. • Make sure the supplied nuts on the inverter/charger are tightened to a torque of 13.5–14.9 Nm. Torque all other connections to the manufacturer’s specifications.
ConextSWEUROInstallationGuide.book Page 24 Tuesday, July 21, 2015 4:22 PM Installation (1) Route the DC cables from the battery bank to the inverter/charger. (2) Install a DC disconnect switch (a) and DC fuse (b) or a DC circuit breaker (c) between the inverter/charger and the battery on the positive terminal. (3) Open and lockout the DC disconnect switch or DC circuit breaker. (4) Connect one connector on the POSITIVE (+) cable to the BATTERY POSITIVE terminal on the inverter/charger.
ConextSWEUROInstallationGuide.book Page 25 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation Step 5: Connecting the BTS and Xanbus-enabled Components Battery Temperature Sensor (BTS) Installing a BTS extends the life of a battery by preventing overcharging in warm temperatures and undercharging in cold temperatures. With a BTS monitoring the battery temperature, the voltage delivered to the battery is adjusted according to the battery’s actual temperature.
ConextSWEUROInstallationGuide.book Page 26 Tuesday, July 21, 2015 4:22 PM Installation WARNING FIRE HAZARD Follow the stacking of wires as shown in 1(a) of the illustration below. Failure to follow these instructions can result in death or serious injury. (1) Install the BTS sensor on the battery. Method (a) involves mounting the sensor to the (3) Connect the Xanbus-enabled devices negative battery post which allows the internal battery temperature to be sensed providing the most accurate results.
ConextSWEUROInstallationGuide.book Page 27 Tuesday, July 21, 2015 4:22 PM Inverter/Charger Installation Step 6: Performing Checks Prior to Initial Start-Up WARNING ELECTRICAL SHOCK HAZARD The Inv Enable button on the Conext SW front panel and the SCP do not disconnect DC or AC input power to the Conext SW. Open and lockout the disconnect switches or breakers at all AC and DC sources. Test with a multimeter before tightening electrical connections.
ConextSWEUROInstallationGuide.book Page 28 Tuesday, July 21, 2015 4:22 PM Installation Testing in Invert Mode To test the Conext SW in invert mode, using a 100 watt light bulb as the test load: 1. Close the DC disconnect switch or the DC circuit breaker to supply DC power to the Conext SW. Wait for the LEDs on the front panel to flash on and off, indicating that the unit is successfully initializing (10 to 30 seconds). The LEDs will turn off after initialization.
ConextSWEUROInstallationGuide.book Page 29 Tuesday, July 21, 2015 4:22 PM Multiple Unit Configuration Multiple Unit Configuration The Conext SW inverter/charger supports multiple unit configuration to increase power output. This gives the system engineer and/or installer more options to work with when tailoring a system to meet load demands. Multiple inverter/ chargers of different power levels can be installed in a system as stand alone or in parallel.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 31 Tuesday, July 21, 2015 4:22 PM Multiple Unit Configuration DC Connections for Multiple Unit Configuration Individual overcurrent devices are to be used between the battery positive and each inverter. Keep cable lengths to the two inverter/chargers the same in order to balance cable losses. The battery cable between the two inverter/chargers should not exceed 30 cm in length. Connect the units as follows: 1. Connect the positive cables.
ConextSWEUROInstallationGuide.book Page 32 Tuesday, July 21, 2015 4:22 PM Installation Configuring the System for Multiple Unit Operation Verify all DC and AC connections. Check Xanbus network connections and ensure that terminators are installed at devices at each end of the network. The simplest system includes a Xanbus SCP, the two multi-unit-configured Conext SW inverter/chargers, and two Xanbus terminators.
ConextSWEUROInstallationGuide.book Page 33 Tuesday, July 21, 2015 4:22 PM Multiple Unit Configuration Search Mode Operation in Multiple Unit Configuration Search mode is automatically enabled in multiple unit installations with two paralleled Conext SW units. Only the master Conext SW operates, and the slave unit comes online only when the load exceeds approximately 60% of the rated output of the master unit. When the load drops below 20% of the master’s rated output, the slave unit turns off.
ConextSWEUROInstallationGuide.book Page 34 Tuesday, July 21, 2015 4:22 PM Installation Battery Information Battery Bank Sizing Battery capacity Battery size or capacity is just as important as the battery type selected for use with the Conext SW. The batteries are the most important part of your system, so it is recommended that you purchase as much battery capacity as possible. A large battery will extend running time and ensure that your inverter/charger delivers full rated surge.
ConextSWEUROInstallationGuide.book Page 35 Tuesday, July 21, 2015 4:22 PM Battery Information Estimating Battery Requirements Calculating Battery Size Step 1: Compute Amp-hours For each appliance, compute the number of amp-hours that will be used between charging cycles, as follows: 1. Obtain the wattage. If the wattage is marked on the nameplate rating, use that. Otherwise, multiply the marked voltage and amperage: WATTS = VOLTS × AMPS. 2.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 37 Tuesday, July 21, 2015 4:22 PM Battery Information Restrictions on Motor Size An appliance may require three to six times its normal running current in order to start. The Conext SW can handle surges up to twice its rated amount (surge current) for five seconds. For example, the model Conext SW 4024 230 is rated as having a maximum continuous output current of 16 amps. Its surge current is twice this value, which is 32 amps.
ConextSWEUROInstallationGuide.book Page 38 Tuesday, July 21, 2015 4:22 PM Installation Battery Cabling and Hook-up Configurations Several smaller batteries can be connected to create a battery bank of substantial size. You can connect batteries in three ways: in parallel, series, or series-parallel. To make a larger battery bank, connect individual batteries with heavy cables. The actual size of the cable depends on whether the batteries are connected in parallel or series.
ConextSWEUROInstallationGuide.book Page 39 Tuesday, July 21, 2015 4:22 PM Battery Information Battery Series Connection When batteries are connected with the positive terminal of one battery to the negative terminal of the next battery, they are connected in series. In a series configuration, the battery bank has the same Ah rating of a single battery, but an overall voltage equal to the sum of the individual batteries. See below.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 1 Tuesday, July 21, 2015 4:22 PM 2 Specifications NOTE: Specifications are subject to change without prior notice.
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ConextSWEUROInstallationGuide.book Page 3 Tuesday, July 21, 2015 4:22 PM Charger Specifications Charger Specifications NOTE: All charging specifications are at nominal conditions: ambient temperature of 25 °C, 230 VAC, 50 Hz input, unless otherwise specified. DC Output SW 2524 230 SW 4024 230 SW 4048 230 Maximum output current 65 A 90 Aa 45 A Nominal output voltage 24 VDC 24 VDC 48 VDC Charging output voltage operation rangeb 12.0– 32.0 VDC 12.0– 32.0 VDC 24.0– 64.
ConextSWEUROInstallationGuide.book Page 4 Tuesday, July 21, 2015 4:22 PM Specifications AC Input SW 2524 230 SW 4024 230 SW 4048 230 230 VAC 230 VAC 230 VAC 170–270 VAC 170–270 VAC 170–270 VAC Frequency range 40 – 70Hz 40 – 70 Hz 40 – 70 Hz Maximum short-circuit current 10,000 A 10,000 A 10,000 A AC INPUT Connection Single-Phase (L, N, ) Single-Phase (L, N, ) Single-Phase (L, N, ) Supplemental protector (resettable) 30 A 30 A 30 A Voltage Voltage range b a.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 6 Tuesday, July 21, 2015 4:22 PM Specifications Regulatory NOTE: Regulatory certifications may change without notice. To see the latest information, visit solar.schneider-electric.com. Safety Europe Australia/New Zealand CE marked for the Low Voltage Directive 2006-95-EC per: RCM marked per: • • • EMC IEC/EN 62109-1, Safety of power converters for use in photovoltaic power systems – Part 1: General requirements.
ConextSWEUROInstallationGuide.book Page 1 Tuesday, July 21, 2015 4:22 PM 3 Wiring Diagrams “Wiring Diagrams” illustrate the most basic BOS configurations and are for reference only. Specific installations may require additional equipment to meet national or local electric codes. Ensure all safety requirements are strictly followed. For...... See....
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ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 3 Friday, January 30, 2015 2:18 PM Single-Inverter System (Off-Grid/Power Backup) Single-Inverter System (Off-Grid/Power Backup) DANGER ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations. Instructions for installing the Conext SW are provided in a separate installation guide for use by qualified installers only.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 4 Friday, January 30, 2015 2:18 PM ACCESSORIES Communication Cable (Category 5) BTS Communication Cable (6-conductor telephone cable) The actual positions of the Negative shunt and Ground bus may be different than what is shown here. This drawing is for illustration purpose only.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 5 Friday, January 30, 2015 2:18 PM Single-Inverter System Renewable Energy (Solar) Single-Inverter System Renewable Energy (Solar) DANGER ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations. Instructions for installing the Conext SW are provided in a separate installation guide for use by qualified installers only.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 6 Friday, January 30, 2015 2:18 PM ACCESSORIES Communication Cable (Category 5) BTS Communication Cable (6-conductor telephone cable) The actual positions of the Negative shunt and Ground bus may be different than what is shown here. This drawing is for illustration purpose only.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 7 Friday, January 30, 2015 2:18 PM Dual-Inverter System Renewable Energy (Solar) Dual-Inverter System Renewable Energy (Solar) DANGER ELECTRICAL SHOCK AND FIRE HAZARD Communication Installation must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations. Instructions for installing the Conext SW are provided in a separate installation guide for use by qualified installers only.
ConextSW_IG_3_Wiring Diagrams_11x16p6.fm Page 8 Friday, January 30, 2015 2:18 PM The actual positions of the Negative shunt and Ground bus may be different than what is shown here. This drawing is for illustration purpose only. Solar Charge Controller Solar Charge Controller Conext SW DC Switchgear CC CC + + Fault/Warning Battery Positive Battery Positive System Status Battery 20.4 A 53.
ConextSWEUROInstallationGuide.
ConextSWEUROInstallationGuide.book Page 10 Tuesday, July 21, 2015 4:22 PM Schneider Electric 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.
