Schneider Electric SW 4048, SW 4024, SW 2524 User Manual

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Conext™ SW Inverter/Charger

Conext SW 2524 120/240 (865-2524) Conext SW 4024 120/240 (865-4024) Conext SW 4048 120/240 (865-4048)

Installation Guide

975-0639-01-01 Rev F 9-2018

solar.schneider-electric.com

This guide for use by qualified personnel only

Conext SW Inverter/Charger

Conext SW 2524 120/240 (865-2524) Conext SW 4024 120/240 (865-4024) Conext SW 4048 120/240 (865-4048)

Installation Guide

solar.schneider-electric.com

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Exclusion for Documentation

UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER (A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION

PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;

(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT,

INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION.THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK; AND

MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED.APPROVED CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT SOLAR.SCHNEIDER-ELECTRIC.COM.

Document Number: 975-0639-01-01 Revision: Rev F Date: 9-2018

Product Part Numbers: 865-2524, 865-4024, 865-4048

Contact Information solar.schneider-electric.com

Please contact your local Schneider Electric Sales Representative or visit our website at: http://solar.schneider-electric.com/tech-support/

Information About Your System

As soon as you open your product, record the following information and be sure to keep your proof of purchase.

Serial Number

Product Number

Purchased From

Purchase Date

_________________________________

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. Complete balance of system installation is not covered. For a complete balance of system installation using the Conext SW AC Switchgear, DC Switchgear, and solar charge controllers, consult the Conext SW System Guide.

It does not provide details about particular brands of batteries. You need to consult individual battery manufacturers for this information.

Audience

Organization

The Guide is intended for use by anyone who plans to install an off-grid/backup system involving the Conext SW Inverter/Charger. The information in this manual is intended for qualified personnel. Qualified personnel have training, knowledge, and experience in:

• Installing electrical equipment and PV power systems (up to 1000 volts).

• Applying all applicable installation codes.

• Analyzing and reducing the hazards involved in performing electrical work.

• Selecting and using Personal Protective Equipment (PPE).

This Guide is organized into:

Chapter 1, “Installation” covers installation instructions.

Chapter 2, “Specifications” covers product specifications.

Chapter 3, “Wiring Diagrams” covers overviews of Conext SW BOS installations and wiring diagrams.

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About This Guide

Abbreviations, Acronyms, and Symbols

AC Alternating Current LED Light Emitting Diode

AGS Automatic Generator Start SCP System Control Panel

BOS Balance of System SW Sine Wave

DC Direct Current VAC Volts, Alternating Current

PPE Personal Protective

Equipment

PV Photovoltaic IP20 Ingress protection rating

Reference to see guide (or manual) for more information

 AC  DC

Denotes a steady LED Denotes a flashing LED

Inv Enabled – see Owner’s Guide for definition.

AC IN – see Owner’s Guide for definition.

Fault – see Owner’s Guide for definition.

Clear Fault | Reset – see Owner’s Guide for definition.

VDC Volts, Direct Current

 Ground

Gen Support – see Owner’s Guide for definition.

Charging – see Owner’s Guide for definition.

Warning – see Owner’s Guide for definition.

Inv Enable – see Owner’s Guide for definition.

Related Information

You can find more information about Schneider Electric as well as its products and services at solar.schneider-electric.com.

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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.

Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of either symbol to a “Danger” or “Warning” safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in moderate or minor injury.

NOTICE

NOTICE indicates a potentially hazardous situation, which, if not avoided, can result in equipment damage.

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Safety

Safety Information

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.

ELECTRICAL SHOCK AND FIRE HAZARD

• Read all instructions, cautionary markings, and all other appropriate sections of this guide before installing the Conext SW.

• Exercise extreme caution at all times to prevent accidents.

• Do not cover or obstruct ventilation openings.

• Do not mount in a zero-clearance compartment. Overheating may result.

• Do not open nor disassemble the inverter/charger. There are no userserviceable parts inside.

• Do not expose to rain or spray.

• Disconnect and lockout all AC and DC sources before servicing. Servicing includes maintenance or cleaning or working on any circuits connected to the inverter/charger. See following note.

Failure to follow these instructions will result in death or serious injury.

DANGER

NOTE: Turning off inverter mode using the Inv Enable switch on the front panel, disabling the inverter and charger functions using the SCP, and putting the unit in Standby mode will not reduce an electrical shock hazard.

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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.

Failure to follow these instructions will result in death or serious injury.

WARNING

EXPLOSION AND FIRE HAZARD

• Charge properly rated lead-acid (GEL, AGM, Flooded, or lead-calcium) rechargeable batteries because other battery types may explode.

• When using Lithium-Ion batteries, ensure that the battery pack being used includes a certified Battery Management System (BMS) with safety controls.

• Do not work in the vicinity of lead-acid batteries. Batteries generate explosive gases during normal operation. See note #1.

• Do not install and/or operate in compartments containing flammable materials or in locations that require ignition-protected equipment. See notes #2 and #3.

Failure to follow these instructions can result in death or serious injury.

NOTES:

1. Follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products.

2. This inverter/charger contains components which tend to produce arcs or sparks.

3. Locations include any space containing gasoline-powered machinery like a generator, fuel tanks, as well as joints, fittings, or other connections between components of the fuel system.

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.

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Safety

Precautions When Working With Batteries

IMPORTANT: Battery work and maintenance must be done by qualified personnel knowledgeable about batteries to ensure compliance with battery handling and maintenance safety precautions.

DANGER

ELECTRIC SHOCK HAZARD

• Determine if the battery is inadvertently earthed (grounded). If inadvertently grounded, remove the source from ground.

• Avoid contact with any part of a grounded battery.

• Remove ground during installation and maintenance.

Failure to follow these instructions can result in moderate or minor injury.

WARNING

BURN AND FIRE HAZARD

• Always wear proper, non-absorbent gloves, complete eye protection, and clothing protection.

• Remove all personal metal items, like rings, bracelets, and watches when working with batteries. See CAUTION below.

• Never smoke or allow a spark or flame near batteries.

• Batteries can produce a short circuit current high enough to weld a ring or metal bracelet or the like to the battery terminal, causing a severe burn.

Failure to follow these instructions can result in death or serious injury.

CAUTION

CHEMICAL, BURN, AND EXPLOSION HAZARD

• Never allow battery acid to drip when reading specific gravity or filling battery.

• Make sure the area around the battery is well ventilated.

• Make sure the voltage of the batteries matches the output voltage of the inverter/charger.

Failure to follow these instructions can result in moderate or minor injury.

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Safety

WARNING

LIMITATIONS ON USE

Do not use in connection with life support systems or other medical equipment.

Failure to follow these instructions can result in death or serious injury.

NOTICE

RISK OF INVERTER/CHARGER DAMAGE

• Never place the Conext SW Inverter/Charger unit directly above batteries; gases from a battery will corrode and damage the inverter/charger.

• Never place the Conext SW Inverter/Charger unit in the same compartment as batteries due to an explosive hazard.

Failure to follow these instructions can result in damage to equipment.

NOTICE

RISK OF BATTERY DAMAGE

Study and follow all of the battery manufacturer's specific precautions, such as removing or not removing cell caps while charging, whether equalization is acceptable for your battery, and recommended rates of charge.

Failure to follow these instructions can result in damage to equipment.

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Safety

FCC Information to the User

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.

However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

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Contents

Important Safety Instructions

Safety Information ----------------------------------------------------------vi Precautions When Working With Batteries ----------------------------------------viii FCC Information to the User ---------------------------------------------------x

1 Installation

Materials List ------------------------------------------------------------1–2

Conext SW Front and Side Panels ------------------------------------------1–3

Front Panel Buttons and Status LEDs -------------------------------------1–4

Conext SW AC/DC/Ports Side Panel --------------------------------------1–5 Conext SW Supplied Accessories ------------------------------------------1–6 Conext SW Required Accessory --------------------------------------------1–7

Installation Information -----------------------------------------------------1–8

Before You Begin the Installation -------------------------------------------1–8 Installation Codes ------------------------------------------------------1–8

Xanbus Network System ----------------------------------------------------1–9

Xanbus System --------------------------------------------------------1–9 Xanbus-enabled Products and Other Accessories ------------------------------1–10

Installation Planning ------------------------------------------------------ 1–11

Planning Preparations -------------------------------------------------- 1–11 Components of the Inverter Power System ----------------------------------- 1–11

AC, DC, and Network Components -------------------------------------1–12 Unpacking and Inspecting the Conext SW Inverter/Charger -----------------------1–16 Installation Tools and Materials ------------------------------------------- 1–17

Tools ----------------------------------------------------------- 1–17

Materials -------------------------------------------------------- 1–17

Inverter/Charger Installation------------------------------------------------- 1–18

Overview -----------------------------------------------------------1–18 Step 1: Choosing a Location for the Inverter/Charger ---------------------------- 1–19 Step 2: Mounting the Inverter/Charger --------------------------------------1–20 Step 3: Connecting the AC Input and AC Output Wires -------------------------- 1–22

General AC Wiring Considerations -------------------------------------- 1–22 AC System Bonding --------------------------------------------------- 1–23 Step 4: Installing the DC Switchgear and Connecting the DC Cables ---------------- 1–25

DC Connection Precautions ------------------------------------------- 1–25

Installing the DC Switchgear next to Conext SW Inverter/Charger ---------------- 1–26

Connecting the DC Cables to the DC Switchgear --------------------------- 1–27 Step 5: Connecting the BTS and Xanbus-enabled Components -------------------- 1–29 Step 6: Performing Checks Prior to Initial Start-Up ------------------------------ 1–31 Step 7: Testing Your Installation ------------------------------------------- 1–31

Testing in Invert Mode ----------------------------------------------- 1–32

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Contents

Testing in Charge Mode and AC Bypass Mode ----------------------------- 1–32 Installation Complete ----------------------------------------------- 1–33

Multiple Unit Configuration ------------------------------------------------- 1–34

DC Connections for Multiple Unit Configuration -------------------------------- 1–36 Configuring the System for Multiple Unit Operation ----------------------------- 1–37 Search Mode Operation in Multiple Unit Configuration --------------------------- 1–38 Wiring Schematic ----------------------------------------------------- 1–38

Battery Information ------------------------------------------------------- 1–39

Battery Bank Sizing --------------------------------------------------- 1–39 Estimating Battery Requirements ------------------------------------------ 1–40

Calculating Battery Size --------------------------------------------- 1–40 Battery Banks ----------------------------------------------------- 1–41

Battery Bank Sizing Worksheet ---------------------------------------- 1–41 Restrictions on Motor Size ----------------------------------------------- 1–42 Battery Cabling and Hook-up Configurations --------------------------------- 1–43

Battery Parallel Connection ------------------------------------------- 1–43

Battery Series Connection -------------------------------------------- 1–44

Battery Series-Parallel Connections ------------------------------------- 1–44

2 Specifications

Inverter Specifications ----------------------------------------------------- 2–2 Charger Specifications ----------------------------------------------------- 2–3 AC Transfer Specifications -------------------------------------------------- 2–4 Physical Specifications ----------------------------------------------------- 2–5 Environmental Specifications ------------------------------------------------ 2–5 Regulatory-------------------------------------------------------------- 2–6

3 Wiring Diagrams

Single-Inverter System (Off-Grid/Power Backup)----------------------------------- 3–3 Single-Inverter System Renewable Energy (Solar)---------------------------------- 3–5

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Figures

Figure 1-1 Materials List------------------------------------------------------1–2 Figure 1-2 Conext SW Front and Side Panels---------------------------------------1–3 Figure 1-3 Front Panel Buttons and Status LEDs ------------------------------------1–4 Figure 1-4 AC and DC Terminals, Network and Communication Ports Panel-----------------1–5 Figure 1-5 Supplied Accessories -----------------------------------------------1–6 Figure 1-6 DC Switchgear ----------------------------------------------------1–7 Figure 1-7 Xanbus System Diagram Example -------------------------------------- 1–9 Figure 1-8 AC, DC, and Network Components ------------------------------------- 1–12 Figure 1-9 AC, DC, and Network Components ------------------------------------- 1–13 Figure 1-10 Conext SW Mounting Instructions --------------------------------------1–21 Figure 1-11 Conext SW AC INPUT and OUTPUT Connections--------------------------- 1–24 Figure 1-12 Installing the DC Switchgear------------------------------------------1–26 Figure 1-13 Conext SW DC Connections ------------------------------------------1–28 Figure 1-14 Conext SW BTS and Xanbus Connections -------------------------------- 1–30 Figure 1-15 Conext SW Front Panel---------------------------------------------- 1–32 Figure 1-16 Multiple (Dual) Unit Configuration Using Two Conext SW Units ----------------- 1–35 Figure 1-17 Connecting Battery Cables-------------------------------------------1–36 Figure 1-18 Multi Menu Screen ------------------------------------------------- 1–37 Figure 1-19 Batteries Connected in Parallel ----------------------------------------1–43 Figure 1-20 Batteries Connected in Series-----------------------------------------1–44 Figure 1-21 Batteries in Series-Parallel Connections----------------------------------1–44 Figure 2-1 Output Power versus Temperature Derating Graph --------------------------2–5 Figure 3-1 Single-Inverter System (Off-Grid/Backup) Overview --------------------------3–3 Figure 3-2 Single-Inverter System (Off-Grid/Backup) Wiring ----------------------------3–4 Figure 3-3 Single-Inverter System Renewable Energy (Solar) Overview --------------------3–5 Figure 3-4 Single-Inverter System Renewable Energy (Solar) Wiring ----------------------3–6

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Tables

Table 1-1 AC Wire Size In and Out of the Inverter/Charger---------------------------- 1–14 Table 1-2 Recommended Battery Cable Sizes ------------------------------------ 1–15 Table 1-3 Recommended Fuse and Breaker Sizes --------------------------------- 1–15 Table 1-4 Battery Sizing Example --------------------------------------------- 1–41 Table 1-5 Battery Sizing Worksheet -------------------------------------------- 1–42

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xvi

1 Installation

The following topics will be covered in this chapter.

• Materials List

• Installation Information

• Xanbus Network System

• Installation Planning

• Inverter/Charger Installation

• Multiple Unit Configuration

• Battery Information

• Wiring Diagrams

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Installation

Materials List

The Conext SW ships with the following items:

• One Conext SW unit

• One set of owner’s and installation guides

• One Battery Temperature Sensor (BTS)

• Two Xanbus network terminators

• Two sets of 5/16

• Two DC terminal covers (red and black) with two sets of #6-32 screws

• One Installation bracket with one set of M6 nuts for mounting (not shown)

NOTE: If any of the items are missing, contact your dealer and/or sales representative. For code-compliant installations in Canada and USA, the DC Switchgear accessory is required. See “Conext SW DC Switchgear*” on page 1–10.

"-8

nuts and washers for the DC terminals,

Figure 1-1 Materials List

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Conext SW Front and Side Panels

TOP TOP

Materials List

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.

Item Description

1 Front Panel contains the Inv Enable and Clear Fault | Reset buttons, as

well as various LEDs (status indicator lights). See “Front Panel Buttons and Status LEDs” on page 1–4.

2 Network and communications ports. See “AC and DC Terminals,

Network and Communication Ports Panel” on page 1–5.

3 DC battery terminals. See “AC and DC Terminals, Network and

Communication Ports Panel” on page 1–5.

4 AC Ground terminals. See “AC and DC Terminals, Network and

Communication Ports Panel” on page 1–5.

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Installation

Item Description

5 AC line terminals. See “AC and DC Terminals, Network and

Communication Ports Panel” on page 1–5.

6 Two variable-speed cooling fans maintain a cool internal temperature

of critical components. The two fans control airflow through the transformer and power compartments of the unit. Ensure at least 10" (254 mm) of clearance for proper ventilation.

7 Mounting holes for permanent installation. See “Step 2: Mounting the

Inverter/Charger” on page 1–20.

Front Panel Buttons and Status LEDs

54321

Figure 1-3 Front Panel Buttons and Status LEDs

Item Description

1 The Inv Enabled LED illuminates steadily when invert mode is enabled.

If AC is present and invert mode is enabled, this LED remains illuminated even though AC power is being passed through.

Gen Support LED flashes intermittently when the inverter is in AC support mode and load shaving mode.

2 When AC is present and qualified, the AC IN LED will illuminate steadily

indicating also that AC is passing through.

Charging LED flashes intermittently when the Conext SW is in charge mode and is producing DC output to charge your batteries.

3 Fault | Warning LED illuminates steadily if a fault is detected (a fault

detection condition) and flashes intermittently when a warning condition is active.

4 Clear Fault | Reset button is used to clear any detected faults if

pressed momentarily. If held down for more than three seconds, the unit will reset (reboot) itself.

5 Inv Enable button is used to enable and disable inverter mode.

“Enabled” is different from the inverter being “on”. When enabled, the inverter can be on or off. When disabled, the inverter is always off.

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Conext SW AC/DC/Ports Side Panel

Figure 1-4 AC and DC Terminals, Network and Communication Ports Panel

Materials List

Item Description 1 Battery Positive (+) (red) DC terminal connects to the positive bus bar

of the DC Switchgear.

2 Battery Negative (–) (black) DC terminal connects to the negative bus

bar of the DC Switchgear.

3 XANBUS interface ports are used to connect Xanbus-enabled devices

including the optional SCP and AGS.

4 STACKING port. Feature not available in this model. 5 Remote (REM) port provides connection for the on/off remote switch. 6 Battery temperature sensor (BTS) port provides connection for the

battery temperature sensor (supplied).

7 AC input/output lines wiring compartment access panel without the

compartment cover.

(a) AC Input terminal block is a screw-type terminal block for attaching AC input wires. The terminals are labeled INPUT N for Neutral and INPUT L1 and L2 for split-phase lines 1 and 2 respectively.

(b) AC Output terminal block is a screw-type terminal block for attaching AC output wires. The terminals are labeled OUTPUT N for Neutral and OUTPUT L1 and L2 for split-phase lines 1 and 2 respectively.

8 All  Ground terminals are along the tab (as shown) of the AC wiring

compartment access panel opening.

9 AC knockouts (3/4" and 1") provide access for AC cables (both input

and output wiring). Detach the knockout covers and install strain-relief clamps available in hardware and electrical stores.

Not shown

AC wiring compartment cover that is taken out during wiring and put back in when wiring has been completed.

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Installation

Conext SW Supplied Accessories

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 BTS, the Battery Temperature Sensor consists of:

• Connector that plugs into the BTS port on the Conext SW.

• Sensor cable is 25 feet (7.6 meters).

• Sensor can be mounted on the side of the battery case or on the negative battery terminal.

NOTE: The BTS continuously measures the temperature of the battery and adjusts the charger output for a more accurate, temperaturecompensated charge.

2 Two sets of M6 nuts and washers are used to secure the DC

Switchgear’s bus bars to the DC battery terminals.

3 Two Xanbus network terminators are used to properly terminate each of

the two ends of the daisy-chained Xanbus network. For example, if the SCP is connected to the inverter/charger, one terminator will be plugged to the SCP, one network cable will connect both devices, and one terminator will be plugged to the inverter/charger. IMPORTANT: The SCP may perform erratically if the Xanbus network is not properly terminated.

4 Two DC terminal covers (not shown) - not needed for installation with

the DC Switchgear which is required in Canada and the USA.

5 Installation bracket (not shown)

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Conext SW Required Accessory

Figure 1-6 DC Switchgear

NOTE: The DC Switchgear is required by electrical code to be installed with the Conext SW inverter/charger in installations within Canada and the USA.

Materials List

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Installation

Installation Information

Before You Begin the Installation

Before beginning your installation:

• Read the entire Installation Guide so you can plan the installation from beginning to end.

• Assemble all the tools and materials you require for the installation.

• Review the Important Safety Instructions on page v.

• Be aware of all safety and electrical codes which must be met.

ELECTRICAL SHOCK AND FIRE HAZARD

• All wiring must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations.

• Disconnect and lockout all AC and DC power sources.

• Disable and secure all AC and DC disconnect devices and automatic generator starting devices.

Failure to follow these instructions will result in death or serious injury.

DANGER

Installation Codes

Applicable installation codes vary depending on the specific location and application of the installation. Some examples are:

• National Electrical Code (NFPA 70)

• Canadian Electrical Code (CSA C22.1)

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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.

Xanbus Network System

Xanbus Network ________

Solar

Charge

Controller

SCP

Xanbus System Control Panel

network terminator

Xanbus Automatic Generator Start

AGS

Conext

ComBox

Conext SW

network terminator

Figure 1-7 Xanbus System Diagram Example

The Xanbus-enabled designation (see below) means that this product works on a Xanbus network. Xanbus-enabled products are:

• Simple to operate and routine tasks are automated.

• Controlled by software that eliminates analog signalling errors.

• Less susceptible to interference and line loss.

• Upgradable through new software releases.

NOTICE

EQUIPMENT DAMAGE

Do not remove Xanbus cables during system operation.

Failure to follow these instructions can damage connected equipment.

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Installation

Xanbus-enabled Products and Other Accessories

Product/Accessory (Shown above) Product Number/s

1 Conext SW DC Switchgear* 865-1016* 2 Conext SW AC Switchgear 865-1017 3 MPPT 60 150 Solar Charge Controller 865-1030-1

MPPT 80 600 Solar Charge Controller (not shown) 865-1032

4 Conext SW On/Off Remote Switch (not shown) 865-1052 5 System Control Panel (SCP) 865-1050 6 Conext ComBox 865-1058 7 Automatic Generator Start (AGS) 865-1060 8 Conext Battery Monitor 865-1080-01 9 Battery Temperature Sensor (BTS) 808-0232-02 10 3-ft network cable (0.9 m) 809-0935

25-ft network cable (7.6 m) 809-0940 75-ft network cable (22.9 m) 809-0942 * required accessory for code-compliant installation in Canada and USA.

25-ft cable 75-ft cable3-ft cable

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Installation Planning

Planning Preparations

This section provides information to help plan for a basic installation of the Conext SW. There are two key factors that will have a major impact on system performance.

1. Size and Length of DC Cables

To select the appropriate size and length of DC cables, see “DC Cabling” on page 1–14.

The DC cables should be as short as possible and large enough to handle the required current, in accordance with the electrical codes or regulations applicable to your installation. If there are long battery cables which are in excess of 3 meters each and not of sufficient size, the voltage drop across the cables will have a negative impact on overall system performance.

2. Mounting Location of the Conext SW

See “Step 1: Choosing a Location for the Inverter/Charger” on page 1–19.

Installation Planning

Components of the Inverter Power System

Inverter power systems vary depending on the power requirements of the user and where the user is located. Inverter power systems typically involve one AC source, one DC source, one inverter/charger, and a control and monitoring device.

One example is an off the grid house with an AC generator, a battery, and a Conext SW inverter/charger with a System Control Panel (SCP). Another example is a house in the city, that is connected to the power grid but needs a power backup solution to cope with rolling blackouts during summer. Some power systems involve harvesting renewable energy such as solar energy in conjunction with off-grid or power backup solutions.

Before installing a Conext SW inverter/charger, know your power requirements then divide the components of the power system into AC, DC, and Xanbus network devices. Xanbus network devices control and monitor the Conext SW inverter/charger as well as AC generators and solar panels.

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Installation

AC, DC, and Network Components

The illustration below shows the different components that can go into a Conext SW inverter/charger installation.

DC Sources

AC Loads

Inverter panel

Figure 1-8 AC, DC, and Network Components

AC Generator for off-grid applications

Xanbus Network

Devices

AC Sources

Grid for power backup applications

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The illustration below shows which components you may need before you begin your installation.

DC Components Xanbus Network Components

•

24- or 48-volt battery Component -Batteries” on page 1–14.

• DC-rated fuse and/or circuit breaker, see “DC Disconnects and Overcurrent Devices” on page 1–15.

• Conext SW DC Switchgear (required component in Canada and USA)

• Battery Temperature Sensor (BTS, supplied)

• DC cables, see “DC Cabling” on page 1–14.

• solar panel for renewable energy application

or batteries, see “DC

• System Control Panel (SCP)

• Automatic Generator Start (AGS)

• Battery Monitor

• Solar charge controller

• Conext ComBox

• CAT-5 network cables

• Xanbus network terminators (supplied)

Installation Planning

120/240-volt split-phase, 60 Hz AC Loads (AC OUTPUT)

• Inverter electrical distribution panel

• AC-rated 30-amp circuit breakers to provide overcurrent protection and means of disconnect

• Conext SW AC Switchgear (recommended)

• AC cable (4-wire) and connectors, see “AC Wiring” on page 1–13.

Figure 1-9 AC, DC, and Network Components

AC Wiring Definition AC wiring includes input wiring (all the wires and connectors

between the main AC source panel and the inverter/charger AC INPUT) and output wiring (all the wires between the inverter/charger AC OUTPUT and the AC load panels, circuit breakers, and loads).

protection and means of disconnect

• Transfer switch (between two AC sources, if applicable)

• Conext SW AC Switchgear (recommended)

• AC cable (4-wire) and connectors, see “AC Wiring” on page 1–13.

120/240-volt split-phase, 60 Hz

AC Source (AC INPUT)

• Main electrical distribution panel (grid and/or generator)

• AC-rated 30-amp circuit breakers to provide overcurrent

Type The type of wiring required varies according to the electrical codes or regulations applicable to your installation. Wiring may be solid in multi-conductor cables, but stranded wire is required if single conductors are used. All wiring must be rated 90 °C or higher.

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Installation

Size of AC Input Wiring Wire size must be coordinated with the overcurrent protection provided ahead of the wire involved, in accordance with the electrical codes or regulations applicable to your installation.

Therefore, the wiring used between the main AC source panel’s circuit breaker and the inverter/charger AC INPUT must be sized to match the input breaker rating.

Table 1-1 AC Wire Size In and Out of the Inverter/Charger

Conext SW

Breaker Size Used 30 amps per line

Wire Size No. 8 AWG

Color Coding L1/L2: red or black

N: white or gray : green or bare

Size of AC Output Wiring Wire size must be coordinated with the current the wiring will carry. For example, this current may be determined by the 15-amp maximum inverter current, or by the bypass current, which is determined by the overcurrent protection provided ahead of the Conext SW 4024 120/240.

Size of Wiring Downstream of the AC Output Breaker The wiring used between the AC output breaker and your loads must be sized to match the output breaker.

DC Component Batteries

DC Cabling Definition DC cabling and connectors between the batteries, the DC

The Conext SW system requires a 24-volt or 48-volt, lead-acid deep-cycle battery or group of batteries to provide the DC current that the inverter/charger converts to AC power. The battery may be a flooded, gel, or AGM type.

See “Battery Information” on page 1–39 for information on:

• Estimating the battery size that will meet your requirements.

• Designing battery banks.

• Restrictions on the size of appliances.

For information on cabling and hooking up batteries, see “Battery Cabling and Hook-up Configurations” on page 1–43.

For detailed information about specific brands of batteries, consult individual battery manufacturers or a local battery distributor.

disconnect and overcurrent protection device, and the inverter/charger.

Type All installations require multi-strand insulated cables. The DC cables must be copper and must be sized based on 75 °C ampacity and must have an insulation rating of at least 75 °C.

Size and Length See Table 1-2 for required DC cable length, cable size and required fuse size for the Conext SW. Wire size is usually marked on the cables.

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Installation Planning

Table 1-2 Recommended Battery Cable Sizes

Model Maximum

Current (A)

Conduit

Cable Length <5ft

Cable Length 5to10ft

SW 2524 120/240 120 1 AWG

SW 4024 120/240 200 3/0 AWG

SW 4048 120/240 120 1 AWG

a.From National Electrical Code (NEC) requirements. b.Per NEC Table 310.16 for 177 °F (75 °C) rated copper conductor.

IMPORTANT: Using a smaller gauge cable or a longer cable may cause the inverter to shut down under heavy load.

WARNING

FIRE AND BURN HAZARD

Do not use battery cables that are insufficiently sized for expected current. Check local electrical codes carefully.

Failure to follow this instruction can result in death or serious injury.

DC Disconnects and Overcurrent Devices

Conext SW DC Switchgear

The DC circuit from the battery to the inverter/charger must be equipped with a disconnect and overcurrent protection device. Refer to your applicable installation code.

TypeThis device usually consists of a circuit breaker, a “fused-disconnect,” or a separate fuse (installed at each positive cable near the battery terminal) and DC disconnect. Do not confuse AC circuit breakers with DC circuit breakers. They are not interchangeable.

RatingThe rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes.

LocationThe breaker or fuse and disconnect should be located as close as possible to the battery in the positive cable. Applicable codes may limit how far the protection can be from the battery.

Table 1-3 Recommended Fuse and Breaker Sizes

Model Fuse Size (A) Minimum Breaker Size (A)

SW 2524 120/240 250 250 SW 4024 120/240 250 250 SW 4048 120/240 250 250

The DC Switchgear (part number: 865-1016) provides complete DC disconnect and overcurrent protection for the Conext SW Inverter/Charger. The Conext DC Switchgear contains a master DC breaker that stops DC power from the main DC source. The DC Switchgear must be installed with the Conext SW Inverter/ Charger in Canada and USA.

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Installation

Unpacking and Inspecting the Conext SW Inverter/Charger

CAUTION

HEAVY LOAD HAZARD

Do not lift the unit by yourself. Use two people to lift and mount the unit. Always use proper lifting techniques during installation to prevent injury.

Failure the follow these instructions can result in injury.

To unpack and inspect:

IMPORTANT: Keep the carton and packing material in case you need to return

the Conext SW for servicing.

1. Unpack the unit and check the materials list. If anything is missing from the shipping box, contact your local Schneider Electric customer service representative. See page ii for information.

2. Record the serial number of the Conext SW and other purchase information in the beginning section under Information About Your System of the Conext SW Inverter/Charger Owner’s Guide.

3. Save your purchase receipt to use as proof of purchase. This receipt is required if the inverter/charger requires warranty service.

4. Save the original shipping carton and packing materials. If the inverter/ charger needs to be returned for service, it should be shipped in the original carton. Packing the Conext SW in the original shipping carton is also a good way to protect the inverter/charger if it ever needs to be moved.

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Installation Tools and Materials

Tools

You will need the following tools to install the Conext SW and the battery temperature sensor.

❐ Wire stripper

❐ Crimping tools for fastening lugs and terminals on DC cables

❐ Phillips screwdriver: #2

❐ Slot screwdriver (1/4" [6mm] wide blade max.)

❐ Needle-nose pliers

❐ Wrench for DC terminals and Installation bracket: 5/16" and M6

❐ Power drill/driver

Materials

You will need the following materials to complete your installation:

❐ DC Switchgear

❐ Strain-relief clamp(s) for AC cables (not provided): 3/4" and/or 1"

❐ DC battery cables sized according to Table 1-2 on page 1–15

❐ Terminals and/or crimp connectors for DC cables (3/8" [9.5mm] stud size)

❐ AC and DC disconnect switches and overcurrent protective devices and

connectors as required. See page 1–14

❐ AC output and input wire. See “AC Wiring” on page 1–13

❐ If the AC ground wire is stranded, each ground wire requires a ring terminal

❐ Four M6 nuts to secure the unit to the installation bracket (supplied)

❐ Four #12 (or equivalent) screws or bolts to mount the installation bracket to a

non-flammable wall (see page 1–19 for definition)

❐ Four #10 (or equivalent) screws for securing the DC Switchgear to the

installation bracket

Installation Planning

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Installation

Inverter/Charger Installation

Overview

This section provides detailed information on installing the Conext SW. The overall procedure is divided into seven steps:

Step 1: Choosing a Location for the Inverter/Charger on page 1–19

Step 2: Mounting the Inverter/Charger on page 1–20

Step 3: Connecting the AC Input and AC Output Wires on page 1–22

Step 4: Installing the DC Switchgear and Connecting the DC Cables on page 1–25

Step 5: Connecting the BTS and Xanbus-enabled Components on page 1–29

Step 6: Performing Checks Prior to Initial Start-Up on page 1–31

Step 7: Testing Your Installation on page 1–31

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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.

Failure to follow these instructions can result in death or serious injury.

Flammable or combustible materials are defined as “any material containing wood, compressed paper, cellulose, plant fibers, plastics, liquids, or other material that will ignite and burn, whether flame-proofed or not” according to the NFPA. Flammable liquids are defined as “any liquid whose flash point does not exceed 100 °F (38 °C).” Examples of flammable liquids are gasoline, methanol, and ether.

Inverter/Charger Installation

When choosing a wall to install the Conext SW, choose a wall that is not considered a flammable material such as concrete, brick, or metal.

The inverter should only be installed in a location that meets the following requirements:

Dry Do not allow water or other fluids to drip or splash on the

inverter/charger. Do not expose to rain, snow or water.

Cool Normal ambient air temperature should be between

32 °F and 77 °F (0 °C and 25 °C).

Close to battery but not in the same compartment

Clearance Allow as much space around the inverter/charger as

The length and size of your DC cables will affect performance. Use the DC cables recommended in Table 1-2 on page 1–15. The unit should not be installed in the battery compartment due to the possible presence of explosive hydrogen gas from the batteries.

possible. It is recommended that other objects and surfaces be at least 10" (254 mm) away from the ventilation openings for best performance.

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Installation

Step 2: Mounting the Inverter/Charger

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.

• Do not install in drywall using drywall anchors.

Failure the follow these instructions can result in injury.

IMPORTANT: Mount the inverter/charger before connecting any wires or cables.

CAUTION

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Inverter/Charger Installation

NOTE: These mounting instructions are general guidelines and are provided here for information purposes only.

You must install with care and heed precautions and warnings as stated beginning in “Step 1: Choosing a Location for the Inverter/Charger” on page 1–19 and all subsequent steps.

(1) Place the

installation bracket flat on non-flammable wall (see page 1–19 for definition) and mark the positions of the

5 7/8 in.

mounting holes on the wall.

(2)

149.0 mm

(2) Pilot drill the four

mounting holes on the wall. Install the appropriate anchors.

(3) Fasten the

installation bracket to the mounting surface with four #12 (or equivalent) screws (or bolts).

(4) With two people,

hang the Conext SW to the installation bracket carefully aligning the Conext SW’s mounting holes to the threaded bolts on the installation bracket.

(5) Secure the Conext

SW to the installation bracket using the supplied M6 nuts.

Figure 1-10 Conext SW Mounting Instructions

TIP: Use these

mounting holes.

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Installation

Step 3: Connecting the AC Input and AC Output Wires

DANGER

ELECTRICAL SHOCK AND FIRE HAZARD

Make sure wiring being connected to the inverter/charger is disconnected (physically or by opening and locking out the breaker) from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes.

Failure to follow these instructions will result in death or serious injury.

General AC Wiring Considerations

AC and DC Wiring Separation Do not mix AC and DC wiring in the same

conduit or panel. Consult the applicable installation code for details.

AC Knockouts There are two dual 3/4" /1" trade-size knockouts on the side panel and another two on the bottom panel for AC wiring. Use the same trade size of strain relief as the trade size of the knockout(s) you are using.

AC Wiring Terminals The AC wiring terminals accept cables of a specific size. See “AC Wiring” on page 1–13 for required sizes.

NOTICE

EQUIPMENT DAMAGE

Do not mix input and output wires. The terminal block is split into INPUT and OUTPUT sections. Damage may occur if the unit is wired incorrectly.

Failure to follow these instructions can damage the inverter/charger.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

Turn off all electrical sources (by opening and locking out main and inverter panel breakers) before connecting wires to and from the inverter/charger. All wiring must be done in accordance with local and national electrical wiring codes.

Failure to follow these instructions can result in death or serious injury.

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AC System Bonding

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.

System bonding refers to connection (bonding) of one of the current-carrying conductors of an electrical system to ground. This creates a "grounded conductor" or "neutral" that is at ground potential, but is separate from the equipment ground conductor. System bonding must be done at only one location. Procedures for system bonding vary between on-grid and off-grid systems.

Inverter/Charger Installation

WARNING

System bonding for on-grid systems

System bonding for off-grid systems

The Conext SW does not connect the neutral to ground. The AC input neutral is already bonded to ground by the incoming utility grid system. Do not connect the neutral to ground in any additional location.

The Conext SW does not switch or disconnect the AC neutral in any mode of operation, so even in invert (back-up) mode, the inverter load sub-panel neutral is bonded to ground by the utility grid system. It must not be grounded again in the inverter load sub-panel.

In a system without a generator, or with a generator that does not provide a grounded neutral, you must make the connection from neutral to ground in the inverter load sub-panel or main distribution panel, as applicable.

In a system with a generator that provides a grounded neutral, no additional connection from neutral to ground is needed. Do not connect neutral to ground in the inverter load sub-panel or main distribution panel, as applicable.

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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

or bottom (or both). Do not leave the knockout inside the wiring compartment.

(5) Install strain-relief clamps in the AC

knockouts.

(6) Route the AC input cable through the AC

input knockouts and inside the wiring compartment.

(7) Connect Lines1&2toL1 & L2, Neutral

to N, ground to  on the AC input terminals. If solid ground wire is being used, the wire can be connected directly under the screw heads. If stranded ground wire is being used, ring terminals must be used.

(8) Tighten the terminal screws. Leave a

service loop in the wires inside the wiring box.

(9) Route the AC output cable through the

AC output knockouts and inside the wiring compartment.

(10) Connect Lines 1 & 2 to

L1 & L2, Neutral to N,

ground to  on the AC output terminals. If solid ground wire is being used, the wire can be connected directly under the screw heads. If stranded ground wire is being used, ring terminals must be used.

(3)

strip at least 1/2” (13mm)

side AC knockouts

(4)

bottom AC knockouts

strip at least 2” (50mm)



AC Cable

to Inverter AC INPUT

(2)

(11) Tighten the terminal

(9)

screws. Leave a service loop in the wires inside the wiring box.

(12) Make the wiring

connections to the inverter load panel.

(1)

AC Source

Main Panel

(13) Replace the wiring

Inverter Load Panel

compartment cover panel on the inverter/charger.

Transfer switch

Figure 1-11 Conext SW AC INPUT and OUTPUT Connections

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Inverter/Charger Installation

Step 4: Installing the DC Switchgear and 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.

Recommended Cable Sizes and Lengths and Fuse Size

Preparing the Cables

Guidelines for Routing the DC Cables

For recommended DC cables and fuse sizes, see Table 1-2 and Table 1-3 on page 1–15.

Cut the negative and positive cables to the required length. Strip off enough insulation so you can install the terminals you will be using.

Use of crimp connectors – The connector should have a 3/8" stud size to connect to the Conext SW. If a crimp connector is used, it should be crimped using the tool indicated by the connector manufacturer.

Attach the connectors to the ends of both cables. Make sure no stray wire strands protrude from the connectors.

Follow these guidelines to ensure maximum performance.

WARNING

FIRE HAZARD

Route the cables away from sharp edges that can cut into or scrape the insulation. Wires can become exposed. Avoid sharp bends in the cable.

Failure to follow these instructions can result in death or serious injury.

To reduce the chance of radio frequency interference, keep the positive and negative cables close together—ideally, held together by straps, loom, or insulated clamps at regular intervals.

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Installation

Installing the DC Switchgear next to Conext SW Inverter/Charger

WARNING

FIRE HAZARD

• Make sure the supplied nuts on the inverter/charger are tightened to a torque of 10–11 ft-lbs (13.5–14.9 Nm). Torque all other connections to the manufacturer’s specifications.

• Make sure the bus bar, washer, and nut are assembled in the order shown in Figure 1-12 on page 1–26.

Failure to follow these instructions can result in death or serious injury.

(1) Unpack the DC Switchgear from its box, if not already. (2) Prepare four #10 (M5) machine screws. Use two screws to secure the DC Switchgear to the installation brackets of the Conext SW and two screws to secure the connecting bracket. The connecting bracket attaches to the Conext SW and DC Switchgear. (3) Remove the nuts and washers from the inverter/ charger’s DC terminals, if present. (4) Position the DC Switchgear next to the inverter/charger carefully aligning the mounting holes with the precut mounting holes on the installation bracket and the copper bus bar connectors with the inverter/charger’s DC terminals. (5) Fasten the screws to the mounting holes on the DC Switchgear with the pre-cut mounting holes on the installation bracket of the inverter/charger. (6) Fasten the screws to the connecting bracket to join the DC Switchgear and the Conext SW together. (7) Fasten the nuts and washers of the inverter/ charger’s DC terminal bolts to secure the copper bus bars.

connecting bracket

mounting hole

copper bus bar

connector

copper bus bar connector (+)

copper bus bar connector (–)

flat washer

nut

(5)

(6)

pre-cut mounting hole

(7)

pre-cut mounting hole

positive (+) DC terminal (red)

negative (–) DC terminal (black)

DC terminal

Figure 1-12 Installing the DC Switchgear

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Connecting the DC Cables to the DC Switchgear

WARNING

FIRE HAZARD

• Use only appropriately sized copper cable. Loose connections, improper connections, and under-rated cables will overheat.

• Make sure the supplied nuts on the inverter/charger are tightened to a torque of 10–11 ft-lbs (13.5–14.9 Nm). Torque all other connections to the manufacturer’s specifications.

• Make sure the DC cables, washers, and nuts are assembled in the order shown in Terminal Connection in Figure 1-13 on page 1–28.

Failure to follow these instructions can result in death or serious injury.

REVERSE POLARITY DAMAGE

Check cable polarity at both the battery and the inverter/charger before making the final DC connection or closing the DC breaker or disconnect. Positive (+) must be connected to positive (+). Negative (–) must be connected to negative (–).

Failure to follow these instructions can damage the inverter/charger.

Inverter/Charger Installation

NOTICE

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Installation

(1) Route the DC cables from the battery bank to the DC Switchgear. (2) Install a DC fuse (a) on the positive cable near the battery terminal. (3) Open the DC circuit breaker on the DC Switchgear. (4) Connect one connector on the POSITIVE (+) cable to the POSITIVE terminal on the DC

Switchgear. The connector goes on first, then the flat washer (steel), then the 3/8” (9.5mm) bolt (brass).

(5) Connect the other connector to the POSITIVE (+) terminal on the battery. (6) Connect one connector on the NEGATIVE (–) cable to the BATTERY NEGATIVE

terminal on the DC Switchgear.

(7) Connect the other end of the cable to the NEGATIVE (–) terminal on the battery.

(6)

(4)

(2)(a)

Terminal Connection

(7)

(5)

Battery or Battery

Enclosure

Figure 1-13 Conext SW DC Connections

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Inverter/Charger Installation

Step 5: Connecting the BTS and Xanbus-enabled Components

WARNING

ELECTRICAL SHOCK HAZARD

Connect and disconnect DC wiring only after opening and locking out the disconnect switches or breakers at all AC and DC sources.

Failure to follow these instructions can result in death or serious injury.

Battery Temperature Sensor (BTS)

Xanbus-enabled Components

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.

The BTS has a self-adhesive backing and attaches to the side of the battery. The BTS also comes with a metal tab. A 25-ft (7.6-m) cable is supplied with the BTS.

These include the SCP, the AGS, Conext ComBox, and a solar charge controller. The order in which the components are connected to the inverter/charger does not matter. The most important aspect of the installation of these components is the attachment of network terminators at each end of the network.

NOTICE

EQUIPMENT DAMAGE

Do not remove Xanbus cables during system operation.

Failure to follow these instructions can damage connected equipment.

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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 sensor to the negative battery post which allows the internal battery temperature to be sensed providing the most accurate results.

Method side of the battery using the selfadhesive backing which also provides good results in most situations.

(2) Plug the BTS connector to the BTS

port of the inverter/charger.

(a) involves mounting the

(b) attaches the sensor to the

(3) Connect the Xanbus-enabled devices

using the provided network cable. Terminate each end of the network with a network terminator

Battery

Positive

Battery

Negative

Xanbus Stacking REM BTS

(c)

(3)

(2)

(1)(a)

BTS

battery cable

battery terminal

Figure 1-14 Conext SW BTS and Xanbus Connections

(d)

(1)(b)

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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.

Failure to follow these instructions can result in death or serious injury.

Before testing your installation, ensure these conditions are met.

❐ AC ground are properly installed.

❐ AC input connections and AC output connections are wired correctly on the

terminal block and not reversed.

❐ Positive (+) battery cable from the DC Switchgear is connected to the

positive (+) battery terminal through the DC fuse.

❐ Negative (–) battery cable from the DC Switchgear is connected to the

negative (–) battery terminal.

❐ Battery voltage is within the proper range for this unit: 20–34 volts DC for 24-

volt models and 42–66 VDC for the 48-volt model.

❐ DC disconnect switch or breaker is turned off.

❐ AC input and output breakers are turned off.

❐ All connections are tight.

Inverter/Charger Installation

Step 7: Testing Your Installation

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. Isolate energy by turning off and locking out all AC and DC circuit breakers and test with a multimeter before checking or tightening electrical connections.

Failure to follow these instructions can result in death or serious injury.

There are several tests to be performed for testing your installation. These tests will verify that:

• The Conext SW works in invert mode.

• The Conext SW works in charge mode.

• The Conext SW works in AC bypass mode.

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Installation

If the test fails at any point, go to “Step 6: Performing Checks Prior to Initial StartUp” on page 1–31 and go through the checklist again to check the installation. Then perform the test again. If the test fails again, see the troubleshooting section in the Conext SW Inverter/Charger Owner’s Guide.

Figure 1-15 Conext SW Front Panel

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

2. After initialization, observe that none of the lights on the front panel should

3. Press the Inv Enable button. Verify that the green Inv Enabled LED

4. Connect the Conext SW to the test load by closing the AC breaker that

5. Press the Inv Enable button to disable inverter mode. The Inv Enabled LED

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. If none of the LEDs come on or flash intermittently, make sure the voltage at the DC terminals on the Conext SW is correct, as described in “Step 6: Performing Checks Prior to Initial Start-Up” on page 1–31.

remain illuminated.

illuminates.

controls the circuit that the test load is connected to. If the light bulb illuminates, the Invert mode is working.

goes off.

Testing in Charge Mode and AC Bypass Mode

1. Start the AC generator, if off-grid. If grid-connected proceed to step #2.

2. Close the main breaker in the AC input panel (the AC input panel feeds power from either the generator or grid) in order to supply AC power to the unit.

Verifying charging: 3. After a few seconds, verify that the AC IN / Charging LED on the front panel is

turned on and that it starts flashing indicating that the batteries are being charged.

Verifying AC bypass:

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4. Disable the AC source by opening the main breaker in the AC input panel and turn off inverter mode by pressing the Inv Enable button.

5. Connect the test load to the AC output connection of the unit.

6. Enable the AC source by closing main breaker in the AC input panel and the test load should turn on after ten seconds.

This guide for use by qualified personnel only

Installation Complete

Your installation is now complete. The inverter/charger is ready for use.

The preceding tests use a light test load (a light bulb) as a test case. If you encounter problems when using a load over 1000 watts (for example, a hair dryer or microwave), see the troubleshooting information in the Conext SW Inverter/ Charger Owner’s Guide.

Inverter/Charger Installation

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Installation

Multiple Unit Configuration

The Conext SW inverter/chargers support multiple unit configuration to increase power output. This gives the system engineer and/or installer more options to work with when tailoring a system to meet load demands.

In a multiple unit configuration, only two Conext SW inverter/chargers of the same model can be used. For example, two Conext SW 4024 120/240 units can be configured because both units each have a 24-volt rating and a continuous power rating of up to 3500 watts.

In this configuration, the inverter and charger capacity of a system is doubled. In the case of two Conext SW 4024 120/240 units, the inverter power rating doubles to 7000 watts and the charging output current doubles to 180 amps. However, the AC transfer relay rating of 30-amps remains the same. Inverter/chargers can operate from different battery banks, meaning each unit is connected to its own battery bank. However, it is highly recommended to use only a single battery bank. See “DC Connections for Multiple Unit Configuration” on page 1–36.

IMPORTANT: In a multiple unit configuration where two Conext SW units are set up together, the AC transfer relay rating remains the same at 30 amps. This AC transfer relay rating does not double to become 60 amps.

WARNING

FIRE HAZARD

Do not power multiple loads in excess of 30 amps even in a multiple unit configuration.

Failure to follow this instruction can result in death or serious injury.

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Multiple Unit Configuration

The Input and Output Neutrals are electrically tied at the inverter terminals. Only a Neutral wire (from the AC Out cable) is necessary from each inverter.

AC Out

Cable

AC Out

Cable

AC In Cable

AC Output Breakers AC Input Breakers

AC Bypass breakers are not shown. For detailed wiring illustration, see “DualInverter System Renewable Energy (Solar) Wiring” on page 3–8.

Figure 1-16 Multiple (Dual) Unit Configuration Using Two Conext SW Units

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Installation

DC Connections for Multiple Unit Configuration

Individual overcurrent devices are to be used between the battery positive and each positive cable leading to the DC Switchgear. Keep cable lengths to the two DC switchgears the same in order to balance cable losses.

Connect the units as follows:

1. Connect the positive cables. Follow the steps in “Connecting the DC Cables to the DC Switchgear” on page 1–

27. Also, do not tie the positives in series together between inverters.

2. Connect the negative cables. Follow the steps in “Connecting the DC Cables to the DC Switchgear” on page 1–

27.

3. Connect the battery temperature sensors (BTS), if needed. Follow the steps in “Step 5: Connecting the BTS and Xanbus-enabled Components” on page 1–29.

Xanbus Stacking REM BTS Xanbus Stacking REM BTS

A DC fuse for

each (+) cable

24 V

Figure 1-17 Connecting Battery Cables

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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.

For both units to operate in multiple unit configuration, a Master and Slave have to be assigned. The default out-of-box configuration for all Conext SW inverter/chargers is Master which causes a conflict the first time the system is powered up. The installer will need to change configuration on one of the inverter/chargers to Slave mode.

To configure the system for multiple unit configuration:

1. Apply DC power to both inverter/chargers. Power up order has no impact. Because there are now two Master units in the system, the SCP will detect an F71 fault, a “system configuration fault”.

2. From the SCP System Status screen, press Enter. The Select Device screen appears.

3. Select the inverter to configure as a Slave unit from the list, then press Enter.

4. Bring up the Advanced Settings screen by pressing Enter, Up, and Down arrow buttons all together.

5. Select Advanced Settings and press Enter. The Advanced Settings screen appears.

6. Scroll down to select Multi Unit Config. At this point all devices in the system will be automatically placed in standby mode. All three LEDs on the inverter to be configured will start flashing

Multiple Unit Configuration

CSW4024 00: Adv

Inverter Settings Charger Settings AC Settings Gen Support

Multi Unit Config

Restore Defaults Adv Features

CSW4024 00: Multi

Dev Name Dev Number Invtr Mode Battery

[00] [01]

[Master]

[HouseBatt1]

[*Master] [Slave]

[*HouseBatt1]...[HouseBatt5]

Figure 1-18 Multi Menu Screen

7. Select Invtr Mode and press Enter.

8. Select Slave and press Enter.

9. Press the Exit button repeatedly until the System Status screen appears.

NOTE: The only situation in which the Slave may shut down the Master inverter is during fault detection conditions such as high or low battery voltage, overcurrent, or over-temperature conditions. Both inverters will auto reset after a fault detection condition has been cleared. The exception is that an overcurrent condition will generate a shutdown for both inverters that will require a manual restart of the system.

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Installation

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.

For more information on when to set up the Search mode, refer to the Conext SW Inverter/Charger Owner’s Guide (document part number: 975-0638-01-01) under Chapter 4 -> Configuring Advanced Settings -> Using Search Mode.

Wiring Schematic

NOTE: Please refer to “Multiple Unit Configuration” on page 1–34 that shows the wiring schematic employed between two Conext SW inverter/chargers.

IMPORTANT: Follow the same guidelines in “Inverter/Charger Installation” on page 1–18 when choosing cables and/or wires for AC and DC connections.

WARNING

FIRE, ELECTRICAL SHOCK, AND EXPLOSION HAZARD

Make sure all wiring being used to make multiple unit configurations between inverter/chargers is disconnected (physically or by opening and locking out the breaker) from all electrical sources before handling. All wiring must be done in accordance with local and national electrical wiring codes.

Failure to follow these instructions will result in death or serious injury.

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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.

It is recommended to have a minimum battery size of 100 amp-hours (Ah) for moderate loads (<1000W) and greater than 200 Ah for heavy loads.

See “Estimating Battery Requirements” for information on a more detailed calculation.

About Amp-hours A number of different standards are used to rate battery energy storage capacity. Automotive starting batteries are normally rated in cranking amps. This is not a relevant rating for continuous loads like an inverter. Deep-cycle batteries use a more suitable rating system such as amp-hours (Ah).

Amp-hour capacity is the number of amps a battery can continuously deliver during a specified number of hours. It is represented by the product of the two —amps multiplied by hours.

Battery Information

A battery rated for 100 Ah can deliver 5 amps for 20 hours (5 amps × 20 hours = 100 Ah). Depending on the battery chemistry, this battery can deliver a higher or lower current for less or more time.

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Installation

Estimating Battery Requirements

Calculating Battery Size

Step 1: Compute Amp-hours

Step 2: Calculate Battery Size

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. Obtain the Watt-hours by multiplying that amount by the hours the appliance will be used: WATT-HOURS = WATTS × HOURS.

3. Obtain the amp-hours that the appliance requires by dividing that amount by 20 (the factor for the Conext SW, which is a 24-volt system):

BATTERY AMP-HOURS USED = AC WATT-HOURS/20

For example, a 100 W light bulb that is used for 4 hours will use 400 watt-hours (Wh) and the inverter will consume approximately 20 Ah from a 24-volt battery.

4. Enter this information on the blank calculation worksheet (page 1–42).

5. Complete the rest of the worksheet; see Table 1-4, “Battery Sizing Example” on page 1–41 for an example.

Size the batteries for approximately twice the estimated total amp-hour usage. Doubling the expected amp-hour usage ensures that the batteries will not be overly discharged and extends battery life.

Do not skip this doubling step. More capacity is better since you will have more reserve capacity, be better able to handle large loads and surge loads, and your battery won’t be discharged as deeply. Battery life is largely dependent on how deeply the battery is discharged. The deeper the discharge, the shorter the battery life.

Troubleshooting If you find that the system shuts down when appliances with large motors are started, the problem may be that this motor is too much for the battery. Even though you calculated the amp-hour requirements appropriately, the startup of a large motor makes high demands on the battery. You may find that adding more amp-hours (in the form of extra batteries or replacement with a bigger battery) solves the problem.

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Table 1-4 Battery Sizing Example

Daily watt-hours needed for this appliance

(A) Power

Appliance

TV & VCR 200 W 2 hours 400 Wh

Small microwave oven 800 W 15 min = 1/4 hour 200 Wh

3 lamps, 60 W each 180 W 4 hours 720 Wh

Coffee maker 600 W 15 min = 1/4 hour 150 Wh

Hair dryer 1500 W 6 min = 1/10 hour 150 Wh

Total daily watt-hours of AC load 1620 Wh

× Number of days between charges 3

= Total watt-hours of AC load between charges 4860 Wh

Battery Ah used between charges (divide by 20 for 24 volt system) 243 Ah

Recommended Battery Bank Size in Ah (multiply by 2) 486 Ah

Consumption (Watts)

(B) Operating Time per Day (Hours)

(=A×B)

Battery Information

This example illustrates how quickly your battery needs can escalate. To reduce the required battery bank size, you can either conserve energy by eliminating or reducing the use of some loads, or recharge more frequently.

Battery Banks

As your power requirements increase, you may need to use more than one battery to obtain sufficient capacity. Batteries can be connected in parallel, in series, or in seriesparallel to create higher capacity systems.

See “Battery Cabling and Hook-up Configurations” on page 1–43 for more information about battery inter-connection schemes.

Mixing Batteries Batteries connected in parallel should be of the same type and amphour rating and from the same manufacturer.

It is not recommended to connect batteries of different types, amp-hour ratings or manufacturers. Improper charging and decreased battery life will result.

Battery Bank Sizing Worksheet

The following worksheet is a guide to help you determine your battery needs. Be generous in estimating the time for which you will run each of the loads to ensure sufficient battery capacity.

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Installation

Restrictions on Motor Size

An appliance may require three to six times its normal running current in order to start. The Conext SW can handle surges up to twice its rated amount (surge current) for five seconds. For example, the model Conext SW 4024 120/240 is rated as having a maximum continuous output current of 15 amps and a surge capability of 32 amps. In motors, the locked rotor amp (also called its starting current) may be specified on the motor nameplate as “LRA” or “LRI”. The LRA must not exceed the surge current rating of 32 amps.

When considering appliances with large motors, follow these guidelines:

• Make sure that the motor’s LRA rating is no more than surge current amps. The Conext SW may not be able to start a motor with a higher LRA, and the Conext SW will shut down if the attempt is made.

• Make sure the battery bank, DC cables and DC fuses are capable of handling up to 600 amps DC for five seconds. A weaker circuit may not be able to provide sufficient power to the Conext SW to allow the Conext SW to start up the appliance. Again, if the circuit cannot deliver the required current, the system may shut down or the fuse may open.

• In a multiple unit configuration, two Conext SW units do not double up the surge current rating. If a motor’s starting current exceeds the surge capacity of one Conext SW unit, it will also exceed the surge capacity of two Conext SW units.

Table 1-5 Battery Sizing Worksheet

(A) Power

Appliance

Total daily watt-hours of AC load Wh

× Number of days between charges

= Total watt-hours of AC load between charges Wh

Battery Ah used between charges (divide by 20 for 24 volt system) Ah

Consumption (Watts)

W hours Wh

Recommended Battery Bank Size in Ah (multiply by 2) Ah

(B) Operating Time per Day (Hours)

Daily watt-hours needed for this appliance (=A×B)

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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. Generally, the cable should not be smaller than the inverter cables—if the main cables are 4/0 AWG, the battery interconnects should be 4/0 AWG.

The best configuration is to connect the batteries in series and parallel. This requires additional cables, but reduces imbalances in the battery bank and can improve the overall performance. Consult your battery supplier for more information regarding the hook-up configuration required for your system.

Battery Parallel Connection

Batteries are connected in parallel when all the positive terminals of a group of batteries are connected and then, separately, all the negative terminals are connected. In a parallel configuration, the battery bank has the same voltage as a single battery, but an Ah rating equal to the sum of the individual batteries. See below.

Battery Information

Figure 1-19 Batteries Connected in Parallel

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Installation

Battery Series Connection

When batteries are connected with the positive terminal of one battery to the negative terminal of the next battery, they are connected in series. In a series configuration, the battery bank has the same Ah rating of a single battery, but an overall voltage equal to the sum of the individual batteries. See below.

Figure 1-20 Batteries Connected in Series

Battery Series-Parallel Connections

As the name series-parallel implies, both the series and parallel configurations are used in combination. The result is an increase in both the voltage and the capacity of the total battery bank. The smaller, lower voltage batteries are first connected in series to obtain the necessary voltage, and then these “batteries connected-in-series” sets are connected in parallel to increase the battery bank capacity. See below.

Figure 1-21 Batteries in Series-Parallel Connections

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2 Specifications

NOTE: Specifications are subject to change without prior notice.

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Specifications

Inverter Specifications

NOTE: All inverter specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), 24 VDC, unless otherwise specified.

AC Output

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

Output waveform true sine wave true sine wave true sine wave

Continuous output power (AC)

- Maximum

- 30 minutes

Maximum load power on a

3000 W 3300 W

3400 W 4000 W

4400 W

3800 W

1800 W 2550 W 2700 W

single phase (L1/N or L2/N)

Maximum continuous output

12.5 A 15 A 15.2 A

current

Surge power rating (5

5000 W

7000 W

seconds)

Inverter peak output current 24.3 A 41 A 41 A

AC OUTPUT connection Split-phase

(L1/L2)

Split-phase (L1/L2)

Peak efficiency 91.5% 92% 94%

Output power factor

0.5 - 1.0 0.6 - 1.0 0.6 - 1.0

(capacitive or inductive)

Operating voltage range single-phase/split-phase

104/208 VAC to 127/ 254 VAC

Nominal voltage

120/240 VAC 120/240 VAC 120/240 VAC

single-phase/split-phase

Operating frequency range selectable

50 or 60 Hz

selectable 50 or 60 Hz

Default output frequency 60 Hz 60 Hz 60 Hz

a.Only when NoLoadVD is enabled. b.Duty cycle 3300 W for 30 minutes, 0 W for 45 minutes, NoLoadVD is enabled. c.Duty cycle 4000 W for 30 minutes, 0 W for 45 minutes. d.Duty cycle 5000 W for 5 seconds, 3000 W for 300 seconds. e.Duty cycle 7000 W for 5 seconds, 3400 W for 300 seconds.

DC Input

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

Voltage range 20–34 VDC 20–34 VDC 40–64 VDC

Maximum continuous power

22–27 VDC 22–28 VDC 46–48 VDC

voltage range

Maximum battery current 150 A 230 A 105 A

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Charger Specifications

DC Input

No-load power draw (Inverter On)

Low battery voltage shutdown cut-off (other values selectable)

High battery voltage shutdown cut-off (other values selectable)

Charger Specifications

NOTE: All charging specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), split-phase 120/240 VAC, 60 Hz unless otherwise specified.

DC Output

Maximum output current 65 A 90 A

Nominal output voltage 24 VDC 24 VDC 48 VDC

Charging output voltage operation range

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

21 W 26 W 27 W

21.0 V (default)

33.0 V (default)

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

12.0–

32.0 VDC

21.0 V (default)

33.0 V (default)

12.0–

32.0 VDC

42.0 V (default)

62.0 V (default)

45 A

24.0–

64.0 VDC

Equalization cycle Automatic,

Manual by SCP

Optimal charging efficiency 90% 90% 92%

Dead battery charge voltage > 12.0 VDC > 12.0 VDC > 24.0 VDC

Charging methods (two settings)

Without a battery temperature sensor (three settings)

Three-stage charge (Bulk, Absorption, Float) [default]

Two-stage charge (Bulk, Absorption)

Cool 50 °F (10 °C) Warm 77 °F (25 °C) [default] Hot 104 °F (40 °C)

Automatic, Manual by SCP

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Specifications

DC Output

With a battery temperature sensor (provided)

a.Charging current derates up to 5% between 35 to 60 °C. b.Recharging does not occur when battery voltage is below 12 V.

AC Input

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

The temperature compensation coefficients on a

24-volt battery are as follows:

Flooded: 54 mV × (25 °C – BTS °C)

Gel: 54 mV × (25 °C – BTS °C)

AGM: 42 mV × (25 °C – BTS °C)

The temperature compensation coefficients on a

48-volt battery are as follows:

Flooded: 108 mV × (25 °C – BTS °C)

Gel: 54 mV × (25 °C – BTS °C)

AGM: 42 mV × (25 °C – BTS °C)

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

Power factor at full charge rate > 0.98 > 0.98 > 0.98

Current 9 A 13 A 12 A

Voltage 120/240 VAC 120/240 VAC 120/240 VAC

Voltage range single-phase/split-phase

Frequency range 44–70Hz 44–70 Hz 44–70 Hz

AC INPUT Connection Split-phase

AC Transfer Specifications

NOTE: All transfer specifications are at nominal conditions: ambient temperature of 77 °F (25 °C), split-phase 120/240 VAC, 60 Hz input, unless otherwise specified.

Transfer time—utility to invert < 20 ms

Relay current rating 30 A Minimum line-to-neutral AC input

voltage for transfer Maximum

voltage for transfer Minimum AC input frequency for transfer Maximum AC input frequency for transfer Cooling Fan-cooled, temperature controlled

line-to-neutral

a.Limited by SCP to 24 A due to CEC/NEC regulatory requirements.

AC input

95/190 VAC to 135/270 VAC

(L1/L2)

95/190 VAC to 135/270 VAC

Split-phase (L1/L2)

All Models

95 VAC RMS

135 VAC RMS

44 Hz 70 Hz

95/190 VAC to 135/270 VAC

Split-phase (L1/L2)

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Physical Specifications

SW 2524 120/240 SW 4024 120/240 SW 4048 120/240

L×W×H

15.2×13.5×7.6 in (387×343×197 mm)

Unit Net

50.7 lbs. (23 kg) 67.2 lbs. (30.5 kg) 67.2 lbs. (30.5 kg)

Weight

Environmental Specifications

Nominal ambient temperature 77 °F (25 °C)

Operating temperature range

Storage temperature range –40 to 185 °F (–40 to 85 °C)

Humidity: Operation/Storage 95% RH, non-condensing

Ingress protection rating Indoor only, IP 20

Pollution degree 3

Over voltage category (AC mains) CAT III

Altitude: Operating 6,562 ft. (2,000 m)

Mounting wall mount using installation bracket

15.2×13.5×7.6 in (387×343×197 mm)

All Models

–4 to 140 °F (–20 to 60 °C)

starts derating above 77 °F (25 °C) (see following graph)

Full power at ambient

3750 3500 3250 3000 2750 2500

SW 4048 120/240

SW 4024 120/240

SW 2524 120/240

3400W

3000W

3800W

3600W

2750W

3400W

3200W

3000W

2800W

2500W

2250 2000 1750 1500

-4 14 32 41 50 59 68 77 86 95 104 113 122 131 140 °F

-20 -10 0 5 10 15 20 25 30 35 40 45 50 55 60 °C

Figure 2-1 Output Power versus Temperature Derating Graph

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Specifications

Regulatory

All Models

Safety UL 1741 Ed. 2,

UL 1778 Ed. 4

CSA C22.2 NO. 107.1-01, CSA C22.2 NO. 107 3-05

EMC FCC Part 15, Class B

Industry Canada ICES-0003, Class B

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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....

“Single-Inverter System (Off-Grid/Backup) Overview” page 3–3

“Single-Inverter System Renewable Energy (Solar) Overview”

975-0639-01-01 Rev F 3–1

page 3–5

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Wiring Diagrams

3–2 975-0639-01-01 Rev F

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Single-Inverter System (Off-Grid/Power Backup)

Communication

Loads

Vented Battery

Enclosure

Battery Bank

Inverter AC

Distribution

Panel

Utility Grid

AC Source(s)

AC Generator

DC Charging

and DC In

AC Out

AC In

Conext SW AC Switchgear

Conext SW DC Switchgear

Automatic Generator

Start (optional)

System Control Panel

(optional)

Accessories

System Control Panel

Enter Exit

Fault/Warning

System Status

Battery 20.4 A 53.9V

BatLev E --F

Load 1235W

AC 1 115 W 3202V

Standby

12: 00 AM Jan 01

Power

Generator On

Network

Fault

Automatic Generator Start

Conext ComBox

(optional)

Remote Switch

(optional)

Battery Temperature

Sensor

(optional)

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 this installation guide for use by qualified installers only.

Failure to follow these instructions will result in death or serious injury.

Single-Inverter System (Off-Grid/Power Backup)

Figure 3-1 Single-Inverter System (Off-Grid/Backup) Overview

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Inverter

AC Distribution Panel

NEUTRAL

GROUND

Neutral

HOT L1

HOT L2

Ground

AC LEGEND

AC Cable

Generator Disconnect

System Control Panel (optional)

Vented Battery

Enclosure

Battery Temperature Sensor

(BTS)

24-volt Battery Bank Enclosure

Bypass INV 1 OUT

INV IN

AC Breakers

Bypass

Utility

Grid

Grounding

Electrode

Conductor

Main

AC Distribution

Panel

Conext SW DC Switchgear

DC Disconnect

Battery

Negative

Battery Positive

Xanbus Stacking REM BTS

120/240 Vac or

240 Vac only

AC Generator

Conext SW Inverter/Charger

Conext SW AC Switchgear

Negative (–)

Positive (+)

BATTERY

LEGEND

Ground

'&Bus Bar

Neutral-to-Ground

Bond inside.

NOTE: Be sure to check the generator for a neutral-toground bond and remove it. There can only be one neutr alto-ground bond in the system.

System Control Panel

Ente

Exit

Fault/Warning System S tatus

Battery 20.4 A 53.9V

BatLev E --F

Load 1235W

AC 1 115 W 3202V

Standby

12:00 AM Jan 01

INV OUT

Xanbus Network Terminator

This AC Switch is a

customer-supplied

component.

Battery System

Ground

Ensure DC Switchgear chassis is properly bonded to Inverter chassis using supplied bonding busbar.

The actual positions of the Neutral bus and the Ground bus may be different than what is shown he re. This drawing is for illustration purpose only.

NOTE: If no Grid

is available, the

generator can be

connected to the

AC breakers in the

Conext SW AC

Switchgear,

instead of to a

separate AC

Generator

Disconnect.

The actual positions of the Negative shu nt and Ground bus may be different tha n what is shown here. This drawing is for illustration pur pose only.

Automatic Generator

Start (optional)

Xanbus Network Terminator

Power

Generator On

Network

Fault

Automatic Generator Start

Conext ComBox

(optional)

TRANSFER

SWITCH

Remote Switch

(optional)

Battery

Negative

Battery Positive

Communication Cable

(Category 5)

BTS

ACCESSORIES

Communication Cable

(6-conductor telephone cable)

20-contact wiring harness

24-volt or 48-volt

Battery Bank Enclosure

Figure 3-2 Single-Inverter System (Off-Grid/Backup) Wiring

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Single-Inverter System Renewable Energy (Solar)

Renewable Energy

Conext SW

Inverter/Charger

BA T +

PV+BAT–PV

–

Solar Charge Controller

DC Charging

and DC In

Conext SW AC Switchgear

Conext SW DC Switchgear

Inverter AC

Distribution

Panel

Utility Grid

AC Source(s)

AC Generator

DC In

AC Out

AC In

Communication

Vented Battery

Enclosure

Battery Bank

Combiner

Box

Photovoltaic

Conext SW DC Switchgear

Automatic Generator

Start (optional)

System Control Panel

(optional)

Accessories

System Control Panel

Enter Exit

Fault/Warning

System Status

Battery 20.4 A 53.9V

BatLev E --F

Load 1235W

AC 1 115 W 3202V

Standby

12: 00 AM Jan 01

Power

Generator On

Network

Fault

Automatic Generator Start

Conext ComBox

(optional)

Remote Switch

(optional)

Battery Temperature

Sensor

(optional)

DANGER

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow these instructions will result in death or serious injury.

Single-Inverter System Renewable Energy (Solar)

Figure 3-3 Single-Inverter System Renewable Energy (Solar) Overview

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Inverter

AC Distribution Panel

NEUTRAL

GROUND

Neutral

HOT L1

HOT L2

Ground

AC LEGEND

AC Cable

Solar Charge Controller

BATT+BATT–PV–PV

System Control

Panel (optional)

Renewable

Energy

Vented Battery

Enclosure

Battery Temperature Sensor

(BTS)

24-volt Battery Bank Enclosure

Bypass INV 1 OUT

INV IN

AC Breakers

Bypass

Utility

Grid

Grounding

Electrode

Conductor

Main

AC Distribution

Panel

Conext SW DC Switchgear

DC Disconnect

Battery

Negative

Battery

Positive

Xanbus Stacking REM BTS

Photovoltaic

Combiner Box

Negative (–)

Positive (+)

Ground

DC LEGEND

DC Cable

120/240 Vac or

240 Vac only

AC Generator

Conext SW Inverter/Charger

Negative (–)

Positive (+)

BATTERY

LEGEND

Ground

'&Bus Bar

Neutral-to-Ground

Bond inside.

NOTE: Be sure to check the generator for a neutral-toground bond and remove it. There can only be one neutra lto-ground bond in the system.

System Control Panel

Ente

Exit

Fault/Warning

System Status

Battery 20.4 A 53. 9V

BatLev E --F

Load 1235W

AC 1 115 W 3202V

Standby

12:00 AM Jan 01

INV OUT

Xanbus Network Terminator

Generator Disconnect

This AC Switch is a

customer-supplied

component.

Battery System

Ground

The actual positions of the Neutral bus and the Ground bus may be different than what is shown here. This drawing is for illustration purpose only.

NOTE: If no Grid is available, the generator can be connected to the AC breakers in the Conext SW AC Switchgear, instead of to a separate AC Generator Disconnect.

Install a DC breaker

on the positive line.

Automatic Generator

Start (optional)

Xanbus Network Terminator

Power

Generator On

Network

Fault

Automatic Generator Start

Conext ComBox

(optional)

TRANSFER

SWITCH

The actual positions of the Negative sh unt and Ground bus may be different than what is shown here. This drawing is for illustration purpose only.

Ensure DC Switchgear chassis is properly bonded to Inverter chassis using supplied bonding busbar.

Remote Switch

(optional)

Conext SW AC Switchgear

Charge Controller

Disconnect

Battery

Negative

Battery

Positive

Communication Cable

(Category 5)

BTS

ACCESSORIES

Communication Cable

(6-conductor telephone cable)

20-contact wiring harness

24-volt or 48-volt

Battery Bank Enclosure

Figure 3-4 Single-Inverter System Renewable Energy (Solar) Wiring

3–6 975-0639-01-01

This guide for use by qualified personnel only

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.

975-0639-01-01 Rev F

Printed in China

Schneider Electric SW 4048, SW 4024, SW 2524 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Conext™ SW Inverter/Charger

Copyright and Contact

Exclusion for Documentation

Document Number: 975-0639-01-01 Revision: Rev F Date: 9-2018

Contact Information solar.schneider-electric.com

Information About Your System

About This Guide

Important Safety Instructions

Safety Information

Precautions When Working With Batteries

FCC Information to the User

1 Installation

Materials List

Conext SW Front and Side Panels

Conext SW Supplied Accessories

Conext SW Required Accessory

Installation Information

Before You Begin the Installation

Installation Codes

Xanbus Network System

Xanbus System

Xanbus-enabled Products and Other Accessories

Installation Planning

Planning Preparations

Components of the Inverter Power System

Unpacking and Inspecting the Conext SW Inverter/Charger

Installation Tools and Materials

Inverter/Charger Installation

Overview

Step 1: Choosing a Location for the Inverter/Charger

Step 2: Mounting the Inverter/Charger

Step 3: Connecting the AC Input and AC Output Wires

AC System Bonding

Step 4: Installing the DC Switchgear and Connecting the DC Cables

Step 5: Connecting the BTS and Xanbus-enabled Components

Step 6: Performing Checks Prior to Initial Start-Up

Step 7: Testing Your Installation

Multiple Unit Configuration

DC Connections for Multiple Unit Configuration

Configuring the System for Multiple Unit Operation

Search Mode Operation in Multiple Unit Configuration

Wiring Schematic

Battery Information

Battery Bank Sizing

Estimating Battery Requirements

Restrictions on Motor Size

Battery Cabling and Hook-up Configurations

2 Specifications

Inverter Specifications

Charger Specifications

AC Transfer Specifications

Physical Specifications

Environmental Specifications

Regulatory

3 Wiring Diagrams

Single-Inverter System (Off-Grid/Power Backup)

Single-Inverter System Renewable Energy (Solar)