Conext™ MPPT 80 600 Solar

Charge Controller (865-1032)

Installation Guide
975-0540-01-01 Rev F
November 2017

http://solar.schneider-electric.com
Conext™ MPPT 80 600
Solar Charge Controller

Installation Guide

http://solar.schneider-electric.com
Copyright © 2013-2017 Schneider Electric. All Rights Reserved. All trademarks are owned by Schneider Electric
Industries SAS or its affiliated companies.
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

(C) REMINDS YOU THAT IF THIS DOCUMENT IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN
TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT IS
CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT HTTP://SOLAR.SCHNEIDER-ELECTRIC.COM.

Document Part Number: 975-0540-01-01 Revision: F Date: November 2017

Product Part Number: 865-1032

Contact Information: http://solar.schneider-electric.com

For other country details please contact your local Schneider Electric Sales Representative or visit the Schneider
Electric Web site 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
This Guide provides explanations and procedures for installing and
troubleshooting the Schneider Electric Conext™ MPPT 80 600 Solar Charge
Controller.

Scope
This Guide provides safety guidelines, detailed planning and setup information,
procedures for installing the charge controller, and information about
troubleshooting. It does not provide details about particular brands of
photovoltaic (PV) panels or batteries.

Audience
This Guide is intended for qualified personnel planning to install the charge
controller. Qualified personnel have training, knowledge, and experience in:

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

• Applying all applicable installation codes.
• Analyzing and reducing the hazards involved in performing electrical work.
• Selecting and using personal protective equipment.

Only qualified personnel should perform the installation, commissioning, and

maintenance of the charge controller.

Organization
This Guide is organized into three chapters and one appendix:

• Chapter 1 describes features and functions of the charge controller.

• Chapter 2 provides installation instructions for the charge controller. Before
installing the charge controller, read this entire chapter.
• Chapter 3 provides information about identifying and resolving problems that
might arise while using the charge controller.
• Appendix A provides the specifications for the charge controller.

Conventions Used
This Guide uses the term charge controller to refer to the Conext MPPT 80 600
Solar Charge Controller.

975-0540-01-01 F iii

This guide is for use by qualified personnel only.

About This Guide

Abbreviations and Acronyms

BTS Battery Temperature Sensor
CB XW Conduit Box
CEC Canadian Electrical Code
CSA Canadian Standards Association
DC Direct Current
FCC Federal Communications Commission
GFP Ground Fault Protection
IMP Current at maximum power per STC
ISC Short circuit current rating of an PV panel under STC
LCD Liquid Crystal Display
LED Light Emitting Diode
MPP Maximum Power Point
MPPT Maximum Power Point Tracking
MSDS Material Safety Data Sheet
NEC United States National Electrical Code NFPA-70
NFPA National Fire Protection Association
PDP Conext Power Distribution Panel
PV Photovoltaic
SCP Conext System Control Panel
STC Standard Test Conditions specific to photovoltaic panels
(1000 W/m2, light spectrum AM 1.5 and 25°C); panel nameplate
ratings are based on STC and may be exceeded under other
conditions.
UL Underwriters Laboratories
VAC Volts AC
VDC Volts DC
VMP Voltage at maximum power per STC
VOC Open circuit voltage rating of a PV panel under STC
XW+ Conext XW+ Inverter/Charger

Related Information
You can find information about using the charge controller in the Conext MPPT 80
600 Solar Charge Controller Operation Guide (Document Part Number
975-0560-01-01). It is provided with the charge controller and is also available at
www.schneider-electric.com.

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

iv 975-0540-01-01 F

This guide is for use by qualified personnel only.

Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD
This guide contains important safety instructions for the Conext MPPT 80 600
Solar Charge Controller that must be followed during installation procedures.
Read and keep this Installation Guide for future reference.

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 a hazardous situation which, if not avoided, will result in
death or serious injury.

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

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

NOTICE
NOTICE is used to address practices not related to physical injury. The safety
alert symbol shall not be used with this signal word.

975-0540-01-01 F v

This guide is for use by qualified personnel only.

Safety

Safety Information
1. Before using the charge controller, read all instructions and cautionary
markings on the unit, the batteries, and all appropriate sections of this
manual.
2. Use of accessories not recommended or sold by the manufacturer may result
in a risk of fire, electric shock, or injury to persons.
3. The charge controller is designed to be permanently connected to your AC
and DC electrical systems. The manufacturer recommends that all wiring be
done by a certified technician or electrician to ensure adherence to the local
and national electrical codes applicable in your jurisdiction.
4. To avoid a risk of fire and electric shock, make sure that existing wiring is in
good condition and that wire is not undersized. Do not operate the charge
controller with damaged or substandard wiring.
5. Do not operate the charge controller if it has been damaged in any way.
6. This unit does not have any user-serviceable parts. Do not disassemble the
charge controller except where noted for connecting wiring and cabling. See
your warranty for instructions on obtaining service. Attempting to service the
unit yourself may result in a risk of electrical shock or fire. Internal capacitors
remain charged after all power is disconnected.
7. To reduce the risk of electrical shock, disconnect both AC and DC power
from the inverter before attempting any maintenance or cleaning or working
on any components connected to the charge controller. Putting the unit in
Standby mode will not reduce this risk.
8. The charge controller must be provided with an equipment-grounding
conductor.
9. Do not expose this unit to rain, snow, or liquids of any type. This product is
designed for indoor use only. Damp environments will significantly shorten
the life of this product and corrosion caused by dampness will not be
covered by the product warranty.
10. To reduce the chance of short-circuits, always use insulated tools when
installing or working with this equipment. Do not leave tools inside the unit.
11. Remove personal metal items such as rings, bracelets, necklaces, and
watches when working with electrical equipment.

vi 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Safety

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E or CSA Z462.
• This equipment must only be installed and serviced by qualified electrical
personnel.
• Never operate energized with covers removed.
• Energized from multiple sources. Before removing covers identify all
sources, de-energize, lock-out, and tag-out and wait 2 minutes for circuits
to discharge.
• Always use a properly rated voltage sensing device to confirm all circuits
are de-energized.
• Thoroughly inspect the charge controller prior to energizing. Verify that no
tools or materials have been inadvertently left behind.
Failure to follow these instructions will result in death or serious injury.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Disconnect positive and negative PV conductors before servicing. PV
conductors are to be treated as Hazardous Live and must be
disconnected.
• Normally GROUNDED conductors may be UNGROUNDED and
ENERGIZED when a GROUND FAULT is indicated on the front panel. Must
be serviced by qualified personnel.
Failure to follow these instructions will result in death or serious injury.

WARNING
LIMITATIONS ON USE
Do not use the charge controller with life support equipment or other medical
equipment or devices.
Failure to follow these instructions can result in death or serious injury.

975-0540-01-01 F vii

This guide is for use by qualified personnel only.

Safety

CAUTION
BURN HAZARD
Do not touch the charge controller’s heatsink during operation or before
servicing immediately after ceasing operation.
Failure to follow these instructions can result in injury.

NOTICE
LIGHTNING PROTECTION
To protect the charge controller’s insulation and conductors from damage due
to a sudden over-voltage surge such as a lightning strike, install a DC-rated
lightning arrestor on the DC input line.
Failure to follow these instructions can damage the equipment.

viii 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Safety

Battery Safety Information

DANGER
HAZARD OF ELECTRIC SHOCK, BURN, FIRE, AND EXPLOSION
Batteries contain corrosive electrolyte and can give off explosive gases.
Battery circuits present a shock and energy hazard. Observe proper
precautions when working with batteries and battery circuits, including:
• Always wear eye protection when working with batteries.
• Wear rubber gloves and boots when handling batteries.
• Remove all jewellery before performing electrical work.
• Install batteries in a well-ventilated area to help prevent the possible buildup of
explosive gases.
• Do not dispose of batteries in a fire.
• Do not open or damage the batteries. Exposure to electrolyte is harmful to eyes
and skin. It is toxic.
• Do not mix battery types.
• Do not smoke in the vicinity of a battery.
• Use insulated tools when working with batteries.
• When connecting batteries, always verify proper voltage and polarity.
• Do not short-circuit the battery.
• Always use proper lifting techniques when handling batteries.
• Determine if the battery is inadvertently grounded and if so, remove the source
from ground. Contact with any part of a grounded battery can result in electrical
shock. Remove these grounds during installation and maintenance.
• When using Lithium Ion batteries, ensure that the battery pack being used
includes a certified Battery Management System (BMS) with safety protocols.
Failure to follow these instructions will result in death or serious injury.

For full installation instructions and safety information, see the documentation
provided with the batteries. Consult the MSDS for the batteries for first aid
procedures, emergency procedures, and clean-up instructions.

975-0540-01-01 F ix

This guide is for use by qualified personnel only.

Safety

FCC Information to the User

This charge controller has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules and Industry Canada
ICES-003. These limits are designed to provide reasonable protection against
harmful interference when the charge controller is operated in a residential
environment. This charge controller generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
installation and operation guides, could cause harmful radio frequency
interference with radio communications. However, there is no guarantee that
interference will not occur in a particular installation. If this charge controller does
cause harmful interference with radio or television reception, which can be
determined by turning the charge controller off and on, try to correct the
interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the charge controller and the receiver.
• Connect the charge controller to a different circuit from that to which the
receiver is connected.
• Consult the dealer or an experienced radio or TV technician for help.

CAUTION
Unauthorized changes or modifications to the equipment could void the user’s
authority to operate the equipment.

x 975-0540-01-01 F

This guide is for use by qualified personnel only.

Contents
Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v

1 Introduction
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
Charge Controlling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Typical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

2 Installation
Materials List and Tool Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Required Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
PV Array Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Choosing a Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Removing the Wiring Compartment Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Removing Knockouts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Mounting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
PV Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Chassis Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Internal Ground Fault Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Connector Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Wire Size and Over-current Protection Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
PV Current Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Minimum Wire Gauge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Over-current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Connecting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Connecting Multiple PV Array Strings to One Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–17
Connecting Multiple Units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–18
Auxiliary Output Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–19
Network Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20
Network Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–20
Network Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21
Connecting Network Cables Between Multiple Units - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–21
Installing the Battery Temperature Sensor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–23
Commissioning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Conext SCP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Conext Config Tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–25
Setting the Device Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–26
Configuring Connections and Charger Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–27
Copying Settings to Another Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–28

975-0540-01-01 F xi

This guide is for use by qualified personnel only.

Contents

Starting the Charge Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–29

3 Troubleshooting
Charge Controller Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Replacing the Ground Fault Protection Fuse- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Ground Faults in a Normally Ungrounded Array - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5

A Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
MPPT Voltage Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
Operating Below the PV Array Voltage Full Power Range - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
Default Battery Charger Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
Mechanical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Conext Config Tool- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

xii 975-0540-01-01 F

This guide is for use by qualified personnel only.

1 Introduction

Chapter 1 describes features and functions of

the charge controller.
It includes:
• Features
• Charge Controlling
• Typical Installation

975-0540-01-01 F 1–1

This guide is for use by qualified personnel only.

Introduction

Features
The Conext MPPT 80 600 Solar Charge Controller (charge controller) tracks the
maximum power point of a PV array to deliver the maximum available current for
optimum charging of batteries. The charge controller can be used with 24 VDC
and 48 VDC battery systems only.

Key product features include a 600 VDC maximum input voltage, a Fast Sweep™
MPPT tracking algorithm, and built-in ground fault protection. For information on
additional product features, see the Conext MPPT 80 600 Solar Charge Controller
Operation Guide (Document Part Number 975-0560-01-01).

The high input voltage operating range allows a high-voltage and low-current PV
array to be connected to the charge controller. A high-voltage PV array
configuration can eliminate the need for a combiner box and associated DC
circuit breakers as well as incorporate the use of smaller AWG wire for array
wiring. This simplified array configuration reduces wiring costs, installation labor
costs, and allows for long home-run wiring with minimal power loss.

The Fast Sweep MPPT algorithm frequently conducts a very fast sweep of the full
operational array voltage window to dynamically determine the array’s maximum
power point. This feature optimizes the high energy harvest of the solar array,
regardless of conditions such as temperature or shading.

The charge controller is equipped with built-in ground fault protection for a
negative, positive, or ungrounded PV array and is compatible with all PV module
manufacturers. The charge controller regulates the available power from a PV
source only. It is not designed to regulate power from other types of power
sources.

The charge controller can be installed with a Conext XW+ inverter/charger or as

a stand alone battery charger. To configure the charge controller, a Conext
System Control Panel (SCP) or Conext ComBox (ComBox) is also required (see
“Accessories” on page A–6 for product part numbers). While both the SCP and
ComBox provide status information and configuration capabilities, the ComBox
provides additional access to configuration settings through a web interface.

1–2 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Charge Controlling

Charge Controlling
The charge controller regulates the PV array current to an appropriate level for
24 V or 48 V batteries. It produces up to 80 amps of charging current for both
2560 watts at 24 V, or 4800 watts at 48 V.

The charge controller can be configured to use a two-stage (no float) or three-
stage charging algorithm. The charging algorithm assures that the battery is
optimally charged with the available amount of solar energy. See the Conext
MPPT 80 600 Solar Charge Controller Operation Guide for more information on
two-stage and three-stage charging as well as the different stages.

Typical Installation
A typical Conext XW+ installation (see Figure 1-1) with charge controller includes
the following Conext devices:

• Conext XW+ inverter/charger

• Conext Power Distribution Panel (PDP)
• Conext MPPT 80 600 Solar Charge Controller
• Conduit Box (CB)
• Conext SCP

Conext
SCP

Conext Conext PDP Conext

XW+ MPPT
80 600

100 ADC

Conduit Box
PV Array
Typical PV array:
• 200–240 W modules
+ - + - + - + -
• 10–12 modules per string
• 4800 W maximum for 48 V
Battery Bank systems (2 strings)
• 2560 W maximum for 24 V
systems (1 string)

Figure 1-1 Typical Installation

975-0540-01-01 F 1–3

This guide is for use by qualified personnel only.

1–4
2 Installation

Chapter 2 provides installation instructions for

the charge controller. Before installing the
charge controller, read this entire chapter.
It includes:
• Materials List and Tool Requirements
• System Control Panel Requirements
• PV Array Requirements
• Mounting
• PV Grounding
• Wiring
• Connecting Multiple PV Array Strings to One
Unit
• Connecting Multiple Units
• Auxiliary Output Connections
• Network Installation
• Installing the Battery Temperature Sensor
• Commissioning

975-0540-01-01 F 2–1

This guide is for use by qualified personnel only.

Installation

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION
Installation of this equipment should only be planned and performed by
qualified personnel in accordance with all applicable installation codes. See
“Audience” on page iii for the definition of qualified personnel.
Failure to follow these instructions will result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION
RISK OF EQUIPMENT DAMAGE
Unsafe conditions and damage to the charge controller could result if the
instructions and electrical, physical, and environmental installation
specifications in this Guide are not obeyed.
Failure to follow these instructions can result in death or serious injury.

Materials List and Tool Requirements

The following materials are shipped with the charge controller:

• One Conext MPPT 80 600 Solar Charge Controller

• One Conext MPPT 80 600 Solar Charge Controller Installation Guide
• One Conext MPPT 80 600 Solar Charge Controller Operation Guide
• One Factory Test Certificate
• One Battery Temperature Sensor (BTS)
• One fuse: 1 A 600 VAC/DC
• One network terminator

The following tools are required for installation:

• Phillips head screwdriver

• Wire cutters and wire strippers

2–2 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Required Accessories

Required Accessories
A Conext System Control Panel (SCP) is required for installation of the charge
controller.

However, in place of the SCP, a Conext ComBox (ComBox) can be used if you
would like to configure and monitor the charge controller through a web-interface
on a PC or laptop.

For more information on accessories, see Appendix A, “Specifications”.

PV Array Requirements
NOTE
The following information only provides general guidelines. PV array
installation is subject to installation codes and, in some areas, inspection and
approval by the authority having jurisdiction. For example, installations in the
United States must be compliant with NEC and, in particular, Article 690.

Each charge controller must be connected to its own PV array. Up to three PV

array strings can be connected in parallel to a single charge controller. See
“Connecting Multiple PV Array Strings to One Unit” on page 2–17.

WARNING
HAZARD OF ELECTRIC SHOCK AND FIRE
The PV array voltage must never exceed 600 VOC, including the local
temperature correction factor required by the applicable electrical codes. The
PV array maximum circuit current must not exceed 35 A, including the
multiplier required by the applicable electrical codes. For example, the NEC
and the CEC require that the array STC Isc must not exceed 28 A (28 A x 125%
= 35 A).
Failure to follow these instructions can result in death or serious injury.

Mounting
The instructions in this chapter are applicable to a typical stand-alone
installation. Installation procedures will vary according to your specific
application. For special applications, consult a qualified Renewable Energy
System Installer or a Certified Dealer.

975-0540-01-01 F 2–3

This guide is for use by qualified personnel only.

Installation

Choosing a Location

WARNING
HAZARD OF ELECTRIC SHOCK, BURN, FIRE, AND EXPLOSION
RISK OF EQUIPMENT DAMAGE
The charge controller must be mounted vertically and installed indoors in a
dry, protected location away from flammable materials, sources of high
temperature, moisture, and vibration. The location must also be sheltered from
direct sunlight, dust, and wind-blown debris.
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.

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

WARNING
HAZARD OF EXPLOSION
Do not install the charge controller in a sealed compartment containing
batteries.
Failure to follow these instructions can result in death or serious injury.

NOTICE
CHARGE CONTROLLER DAMAGE
The charge controller can overheat if installed in a sealed, indoor enclosure.
Do not install the charge controller in a sealed compartment.
Failure to follow these instructions can result in equipment damage.

To help ensure optimal and safe operation, make sure there is adequate
clearance around the charge controller. See Table 2-1 and Figure 2-1. If
clearances are reduced below these minimums, charging performance might be
impaired.

2–4 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Mounting

Table 2-1 Minimum clearance requirements

Location Minimum Clearance
Above 6 inches (150 mm). Do not mount charge controllers in a vertical
and below stack.

One charge controller can be mounted on the side of the Conext

Power Distribution Panel (PDP) (Part Number 865-1015-01). For
more information, see the Conext XW+ Inverter/Charger Installation
Guide. Other installations must follow the guidelines in this Guide.
In front Sufficient room to allow for easy access to see the LEDs and to
perform maintenance.
Sides No clearance requirement.

6 inches (150 mm) above

Conext MPPT 80 600 Conext MPPT 80 600

Cha rg ing Cha rg ing

Event ! Event !
E q ualize E q ualize

6 inches (150 mm) below

Figure 2-1 Minimum Clearance Requirements

975-0540-01-01 F 2–5

This guide is for use by qualified personnel only.

Installation

Removing the Wiring Compartment Cover

DANGER
HAZARD OF ELECTRIC SHOCK AND ENERGY
Before removing the wiring compartment cover, make sure all electrical power
sources have been disconnected for at least two minutes. Before energizing
the charge controller, make sure the wiring compartment cover has been
replaced and all fasteners are in place.
Failure to follow these instructions will result in death or serious injury.

Before mounting, remove the wiring compartment cover to access the mounting
holes and the wiring terminals. The wiring compartment cover is secured with
two screws on the front of the charge controller (see Figure 2-2).

Remove two screws to

access the wiring terminals.

Figure 2-2 Removing the Wiring Compartment Cover

The wiring compartment (see Figure 2-3) contains a flexible Lexan™ barrier used
to segregate low voltage battery and high voltage PV wire routing. In some
instances, you must manipulate this barrier to provide a passage for the battery
or PV cables which run through the wiring compartment. In this scenario, you
must take care to avoid intermingling the high voltage PV and low voltage battery
wires.

Lexan barrier

Figure 2-3 Wiring Compartment with Lexan Barrier

2–6 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Mounting

Removing Knockouts
Fourteen knockouts are provided for conduit or cable entry into the charge
controller (see Figure 2-4 and Figure 2-5):

• Three single (one on each side and one on the back) for battery wires:
1.73 in. (44.0 mm).
• Two single on the back and six dual on the sides (three on each side) for PV
array wires: 1.38 in. (35.0 mm).
• Three dual (one on each side and one on the back) for routing BTS and
network cables: 1.11 in. (28.2 mm).

When removing knockouts, make sure no metal shavings or fragments fall into
the wiring compartment. Use bushings or conduits to help protect the wiring from
damage from the rough edges around the knockout holes.

NOTICE
CHARGE CONTROLLER DAMAGE
Do not drill, cut, or punch holes in the charge controller. Use only the
knockouts provided for conduit entry.
Failure to follow these instructions can result in equipment damage.

701.0 (2

150.0 (5.90)

35.0 (1.38) KNOCKOUT 2PL 44.0 (1.73) KNOCK

6.5 (0.25)
28.2 (1.11)/ 22.2(0.87)
DUAL KNOCKOUT

146.5 (5.18)
102.5 (4.03)

82.8 3.26)

26.4 (1.03)
35.0 (1.38)
29.0 (1.14)
22.8 (0.90)
62.3 (2.45)
22.8 (0.90)

45.4 (1.78) 85.0 (3.35)

55.2 (2.17)
110.0 (4.33)
85.5 (3.37)
169.0 (6.65)

Figure 2-4 Knockout Dimensions

975-0540-01-01 F 2–7

This guide is for use by qualified personnel only.

Installation

Conext MPPT 80 600

Charging

Event !
Equalize

673.4 (26.5)

764.0 (30.0)
44.0 (1.73) KNOCKOUT

35.0 (1.38)/ 28.2 (1.11)

DUAL KNOCKOUT 3PL

28.2 (1.11)/ 22.2(0.87)

DUAL KNOCKOUT
61.9 (2.44)

108.4 (4.27) 220.5 (8.68)

219.7 (8.65)

Figure 2-5 Dimensions and Knockout Locations

2–8 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Mounting

Mounting the Charge Controller

The charge controller must be vertically mounted to the wall using three ¼-inch ×
½-inch (6.35 mm × 12.5 mm) pan head screws. Alternatively, the it can also be
mounted on the side of the PDP (the hardware is provided with the charge
controller).

To mount the charge controller on the wall (see Figure 2-6):

1. Remove the wiring compartment cover (see page 2–6).

2. Mark the location of the keyhole slot on the wall.
3. Secure the top mounting screw in the location marked, but leave the screw
head backed out approximately ¼ inch (6 mm).
4. Place the charge controller onto the screw and pull it down into the keyhole
slot.
5. Insert two screws in the two mounting holes provided to secure the charge
controller to the wall.

¼"
(6 mm)

Place keyhole slot

over the mounting
screw.

Secure with two

more screws.

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

Figure 2-6 Mounting the Charge Controller

975-0540-01-01 F 2–9

This guide is for use by qualified personnel only.

Installation

PV Grounding
You can configure the charge controller to be compatible with either negative-
grounded, positive-grounded, or ungrounded (floating) PV arrays. For
information about routing the array ground connection, see Figure 2-9.

Chassis Grounding
For ground conductor requirements for your specific installation, consult your
local electrical code. The recommended size of the chassis ground conductor is
#8 AWG (10 mm2)1.

Internal Ground Fault Protection

The charge controller utilizes different ground fault protection for grounded and
ungrounded arrays. If the charge controller detects a ground fault, it ceases
operating and indicates a fault on the charge controller’s display and over the
Xanbus network. The charge controller is configured at the factory for an
ungrounded PV array.

Grounded Arrays For grounded arrays, the charge controller has two PV ground fault protection
fuse holders (rated 600 VDC, 1 A maximum) located inside the wiring
compartment.

Ungrounded For ungrounded (floating) arrays, the charge controller detects the impedance
(Floating) Arrays between the array and ground, and it indicates a fault if the resistance is too low.

DANGER
HAZARD OF ELECTRIC SHOCK AND FIRE
• Do not ground either PV conductor outside of the unit.
• Grounded arrays:
Install a fuse in the correct holder: (+) or (–). Replace the fuse with the
same type and rating (Littelfuse KLKD 1 or equivalent). Fuses must be
replaced by qualified service personnel only.
• Ungrounded (floating) arrays:
Leave both fuse holders empty.
Failure to follow these instructions will result in death or serious injury.

1.Based on the NEC (NFPA 70) Article 250 for 100 A maximum battery fuse.

2–10 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Wiring

This symbol identifies the

protective conductor
(grounding) connection.

Ground fault
protection fuse
holders

Chassis ground
terminals (4)

Figure 2-7 Chassis ground connector

Wiring
The following sections provide information about wiring.

Connector Locations
Terminal connectors for DC wiring are located inside the wiring compartment.
Labels above the DC wiring terminals identify all the connection points. See
Figure 2-8.

X ANB US X ANB US B TS AUX

COM NO NC

B_ATT E R Y
+ NE G. GND P V . P OS . G ND PV.
PV- PV+

T E R MIN AL T OR QU E T E R MIN AL T OR QU E
25 lbf.in ( 2.8 N m) 15 lbf.in ( 1.7 N m)

Figure 2-8 DC Terminal Connector Locations

A label providing details on each connector and torque requirements for each
terminal is affixed to the inside of the wiring compartment cover plate.

975-0540-01-01 F 2–11

This guide is for use by qualified personnel only.

Installation

Wire Size and Over-current Protection Requirements

WARNING
HAZARD OF ELECTRIC SHOCK, ENERGY, AND FIRE
The wiring, over-current protection devices (fuses and circuit breakers), and
installation methods used must conform to all applicable code requirements.
Wiring must be protected from physical damage with appropriate methods
such as the use of conduit and strain relief clamps.
To prevent intermingling with hazardous voltage-level wiring, the BTS, auxiliary
output, and network cables must pass through a different conduit than the PV
and battery cables.
Failure to follow these instructions can result in death or serious injury.

PV Current Rating

The maximum PV array input current specification is 28 A Isc at STC. The gauge
of PV wiring must comply with applicable electrical code requirements and the
total array short circuit current, based on the published ISC rating of the PV
panels installed in the system.

Minimum Wire Gauge

For installations where the PV array is specified at the 35 A maximum, the
recommended smallest wire size is #8 AWG (10 mm2)1 copper wire with a 75°C
(167°F) insulation rating. For details, consult the applicable electrical codes.

Over-current Protection

WARNING
HAZARD OF ELECTRIC SHOCK, ENERGY, AND FIRE
Over-current protection must be provided, external to the unit, to protect the
PV and battery wiring. External disconnecting means must also be provided
for the PV and battery circuits. Consult applicable electrical codes to establish
the correct fuse or circuit breaker ratings and for required locations of
protection and disconnecting means.
Failure to follow these instructions can result in death or serious injury.

If a fuse is used for over-current protection, a disconnect switch must also be

provided between the fuse and the source of supply (the PV array or the battery).
If a circuit breaker is used, it will serve both purposes of disconnection and over-
current protection.

1.Based on NEC Table 310-16.

2–12 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Wiring

Battery Circuit The DC-rated fuse or circuit breaker between the battery and the charge
controller must be rated—at minimum—100 A and must not exceed the
allowable over-current protection rating for the size of wire being used, in
accordance with applicable electrical codes.

PV Circuit

DANGER
HAZARD OF ELECTRIC SHOCK
The PV array will produce a hazardous voltage with even a small amount of
light. Appropriate measures must be taken to prevent electric shock.
Failure to follow these instructions will result in death or serious injury.

WARNING
HAZARD OF ELECTRIC SHOCK, ENERGY, AND FIRE
PV wiring must be done by qualified personnel and in accordance with local
electrical codes.
Failure to follow these instructions can result in death or serious injury.

A properly rated PV disconnect switch is mandatory between the PV array and

the charge controller, and it must be rated for 600 VDC and have a sufficient
current rating for your specific installation.

For the PV-disconnect, Schneider Electric recommends using the Square-D 3100
series safety switch (H361 Fusible and HU361 Non-fusible).

When three or more PV array strings connected to one charge controller, each
string must be fused before being combined at the PV input terminal connector
inside the wiring compartment. See “Connecting Multiple PV Array Strings to One
Unit” on page 2–17 for more information.

You can use separate disconnect switches for each PV string and combine these
in the charge controller, as long as the following conditions are met:

• Each PV string is fused.

• All disconnects are placed side by side, so that it is clear that all need to be
thrown for a complete and visible PV disconnect.

975-0540-01-01 F 2–13

This guide is for use by qualified personnel only.

Installation

Connecting the Charge Controller

The following procedure is illustrated in Figure 2-9.

DANGER
HAZARD OF ELECTRIC SHOCK
Whenever a PV array is exposed to light, a shock hazard exists at the output
wires or exposed terminals. Open the array disconnect switch before making
the connections.
Failure to follow these instructions will result in death or serious injury.

To connect the charge controller in a negative-grounded system:

1. Make sure the PV array disconnect and battery disconnect are turned off.
2. Install a cable clamp into each knockout being used.

NOTICE
REVERSE POLARITY DAMAGE
Before energizing the charge controller from either the PV array or from the
battery, check the polarity of all power connections. Positive (+) must be
connected to positive (+). Negative (–) must be connected to negative (–).
Failure to follow these instructions can result in equipment damage.

3. Ground the charge controller: connect a grounding conductor between a

charge controller ground lug and the grounding electrode (see Figure 2-9).
4. Connect the PV array’s negative (–) output to the charge controller terminal
marked PV –.
5. Connect the PV array’s positive (+) output to the PV array disconnect.
6. Route another positive (+) cable from the other end of the PV array
disconnect to the charge controller terminal marked PV +.
7. Connect the negative (–) battery cable to the charge controller terminal
marked BAT –.
8. Connect a positive (+) cable from the charge controller terminal marked
BAT + to the battery disconnect.

9. Connect a second positive (+) cable from the other side of the battery
disconnect to the positive (+) battery terminal.
10. Torque the charge controller’s battery terminals to 25 lbf.in (2.8 Nm) and the
PV terminals to 15 lbf.in (1.7 Nm). Allow some slack on the cables within the
charge controller and secure the wiring with strain reliefs or cable clamps.

2–14 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Wiring

To connect the charge controller in a positive-grounded or floating system:

◆ Follow the same steps described above for a negative-grounded charge

controller installation except modify the location of the PV array disconnect
switch as follows:

• For positive-grounded systems, the PV array disconnect switch must be

in the negative conductor.
• For floating systems, the PV array disconnect switch must be a 2-pole
type disconnect, connected in both the positive and negative
conductors as per applicable electrical code in the United States and
Canada.

In general, the same rules apply for disconnect switches as for battery circuits:
they must be located in all ungrounded conductors. Requirements vary so
consult applicable codes.

NOTICE
LIGHTNING PROTECTION
To protect the charge controller’s insulation and conductors from damage due
to a sudden over-voltage surge such as a lightning strike, install a DC-rated
lightning arrestor on the DC input line.
Failure to follow these instructions can damage the equipment.

975-0540-01-01 F 2–15

This guide is for use by qualified personnel only.

Installation

For negative-grounded
The positive or negative of the PV array, install fuse here.
battery can be grounded
independent of the array grounding. For positive-grounded PV
array, install fuse here.

4800 W STC array

(2 x 2400 W strings)

BAT

PV - PV +

CHASSIS
GROUND
To inverter

100 ADC
(typical)

Disconnect
(configuration will vary)

48 V battery bank
LEGEND
Ground Ground
DC Positive
DC Negative
Circuit Breaker
Grounding and disconnect locations will vary according to system design and local electrical codes.

Figure 2-9 Typical Wiring Diagram for a Negative-Grounded System (48 V Battery Bank Shown)

2–16 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Connecting Multiple PV Array Strings to One Unit

Connecting Multiple PV Array Strings to One Unit

The charge controller has two three-pole PV connectors, allowing up to three PV
array strings to be directly connected in the charge controller. These input
connectors can accept #6 to #14 AWG (13.5 to 2.5 mm2) solid or stranded wire.

WARNING
HAZARD OF FIRE
• As per applicable electrical codes, fuses are required when paralleling
(combining) more than two PV strings.
• Fuses must be installed in a combiner box or in a PV array disconnect
switch.
• These items are not provided with the charge controller.
Failure to follow these instructions can result in death or serious injury.

NOTICE
LIGHTNING PROTECTION
To protect the charge controller’s insulation and conductors from damage due
to a sudden over-voltage surge such as a lightning strike, install a DC-rated
lightning arrestor on the DC input line.
Failure to follow these instructions can damage the equipment.

975-0540-01-01 F 2–17

This guide is for use by qualified personnel only.

Installation

Connecting Multiple Units

In a multiple-unit installation, each charge controller must be connected to one or
more separate PV arrays. See Figure 2-10. For other multiple-unit installation
considerations, see “Network Installation” on page 2–20.

NOTICE
PV ARRAY AND CHARGE CONTROLLER DAMAGE
Make sure that each charge controller is correctly connected to its own PV
array(s) and that no wires are interconnected between charge controllers.
Failure to follow these instructions can result in equipment damage.

PV Array #1 PV Array #2 PV Array #1 PV Array #2

+ – + – + – + –

PV – PV + PV – PV + PV – PV + PV – PV +

 
Correct wiring—no Incorrect wiring—
interconnection systems are
between systems interconnected
Grounding not shown.

Figure 2-10 Multiple Unit DC Wiring

2–18 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Auxiliary Output Connections

Auxiliary Output Connections

The auxiliary output (dry relay contacts) provides a connector which can accept
wire sizes from #22 to #14 AWG (0.5 to 2.5 mm2), copper solid or stranded. As
shown in Figure 2-11, the auxiliary output can control 12 VDC power to a fan to
vent the battery compartment. See “Configuring the Auxiliary Output” in the
Conext MPPT 80 600 Solar Charge Controller Operation Guide.

WARNING
HAZARD OF ELECTRIC SHOCK AND FIRE
The auxiliary NO and NC dry contacts are rated up to 60 VDC and up to 8 A.
Do not expose the auxiliary contacts to voltages or currents higher than this
rating. Provide external over-current protection rated at 8 A maximum.
Failure to follow these instructions can result in death or serious injury.

In order from left:

+ - COMMON | NO | NC

XANBUS XANBUS BTS AUX

BATTERY
_
+ NEG. GND PV. POS. GND PV.
PV- PV+

TERMINAL TORQUE TERMINAL TORQUE

25 lbf.in (2.8 Nm) 15 lbf.in (1.7 Nm)

Figure 2-11 Auxiliary Output Vent Fan Application

975-0540-01-01 F 2–19

This guide is for use by qualified personnel only.

Installation

Network Installation
The charge controller is a Xanbus-enabled device. Xanbus is a network
communications system which allows the charge controller to communicate
settings and status information to other Xanbus-enabled devices.

Xanbus connections between multiple charge controllers allow information about

each charge controller and its associated PV array to be communicated among
all of the charge controllers in the system. Information about the entire system
can be viewed on the SCP or ComBox.

For example, in a two-charge controller system, if charge controller #1 is

producing 1500 W and charge controller #2 is producing 2000 W, the SCP
displays a total system power of 3500 W. The accumulated amp hours and
kilowatt hours produced by each charge controller for that day is also displayed.

Networked charge controllers can also share battery temperature information if a

single BTS is connected to a charge controller (or Conext XW+ inverter/charger)
in the system.

Network Components
A Xanbus network consists of the following components:

• Xanbus-enabled devices:
• Conext MPPT 80 600 Solar Charge Controller
• Conext XW+ inverter/charger
• Conext Automatic Generator Start
• Conext System Control Panel or Conext ComBox
• Xanbus power supply—an embedded power supply in the charge controller
provides up to 7 W of power to the Xanbus network to power one SCP and
AGS, not including the auxiliary supply.
To reduce tare losses at night, you can configure the charge controller to shut
off the Xanbus power supply after sunset. See “Disabling Power Supplies at
Night” in the Conext MPPT 80 600 Solar Charge Controller Operation Guide
for more information.
• Network cables—each Xanbus-enabled device is connected by a standard
Ethernet (CAT 5/CAT 5e) patch cable. Do not use crossover cable.

• Network terminators (see Figure 2-12)—the Xanbus network must be

properly terminated at each end to help ensure communication signal
quality.
Network terminators plug into network ports on Xanbus-enabled devices.
The charge controller ships with one terminator. Depending on your network
layout, this terminator might need to be inserted into another device
elsewhere in the network. Two network terminators are required for all
Xanbus network configurations.

2–20 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Network Installation

Figure 2-12 Network Terminator

Network Layout
Xanbus-enabled devices are connected with separate lengths of cable. The
devices at each end of the chain must have a terminator inserted into their open
network ports, as shown in Figure 2-13. Total cable length for the Xanbus network
must not exceed 131 feet (40 m).

XANBUS XANBUS BTS AUX XANBUS XANBUS BTS AUX

BATTERY
_ BATTERY
_
+ NEG. GND PV. POS. GND PV. + NEG. GND PV. POS. GND PV.
PV- PV+ PV- PV+

TERMINAL TORQUE TERMINAL TORQUE TERMINAL TORQUE TERMINAL TORQUE

25 lbf.in (2.8 Nm) 15 lbf.in (1.7 Nm) 25 lbf.in (2.8 Nm) 15 lbf.in (1.7 Nm)

Network
Cable to next device
terminator Conext MPPT 80 600
Solar Charge
Controller cable

Figure 2-13 Network Layout

Connecting Network Cables Between Multiple Units

WARNING
HAZARD OF ELECTRIC SHOCK
Do not route the network cables with the same conduit or panel as the PV or
battery input and output cables, and make sure the network cables are not
intermingled with other conductors in those systems.
Failure to follow these instructions can result in death or serious injury.

Dual knockouts on the back and sides of the charge controller are provided for
routing the Xanbus network cable (see Figure 2-4). See Figure 2-8 for the location
of the charge controller’s network ports.

975-0540-01-01 F 2–21

This guide is for use by qualified personnel only.

Installation

NOTE
• Connect only Xanbus-enabled devices. Although the cabling and
connectors used in this network system are the same as ethernet
connectors, this network is not an ethernet system.
• Do not connect one end of the network to the other to make a ring or loop.

To connect network cables between multiple charge controllers:

1. Remove the wiring compartment cover from each charge controller (see
“Removing the Wiring Compartment Cover” on page 2–6).
2. Remove a knockout from the back or either side of the unit, and then install
an appropriately sized strain relief bushing for the network cable.
3. Connect the network cable to a network port in charge controller #1.
4. Route the cable to charge controller #2.
5. Connect the network cable to a network port in charge controller #2.
6. Connect another network cable to charge controller #2, and then route the
cable to the next device in the network.
7. Make sure the factory-supplied network terminators are inserted into the
empty network ports in the devices at the beginning and end of the network.
There should be no empty network ports in any of the charge controllers.

2–22 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Installing the Battery Temperature Sensor

Installing the Battery Temperature Sensor

WARNING
BATTERY TEMPERATURE
The Battery Temperature Sensor provides necessary information for
performance and safety.
Always install and connect the Battery Temperature Sensor (BTS). See the
note directly below.
Failure to follow these instructions can result in death or serious injury.

Note: For all BTS compatible Xanbus-enabled devices in the system, at least one
BTS must be separately installed for each device type associated with a battery.

If there is a group of the same devices forming a multi-unit setup, only one BTS is
required per device type connected to the same battery (same DC association).

See the installation guide of each device for BTS installation instructions.

Installing a BTS is recommended for optimum charging performance and battery

life. If a BTS is not installed and the batteries must operate in hot or cold
conditions, manually adjust the temperature settings to suit the conditions. See
“Configuring Battery Characteristics and Battery Charging” in the Conext MPPT
80 600 Solar Charge Controller Operation Guide.

All networked Xanbus devices share battery temperature information. If there are
multiple battery banks and more than one BTS is used within the system, then the
highest reported temperature will be used as the battery temperature for the
temperature compensation value of the battery charge algorithm.

See Figure 2-8 for the location of the BTS port. Dual knockouts on the back and
sides of the charge controller are provided for routing the BTS cable (see Figure
2-4).

NOTE
If the sensor cable is damaged and the wires are shorted, the charge
controller registers a battery over temperature fault condition. If the BTS wires
have been cut, the charge controller assumes that the BTS is not connected. A
replacement BTS can be ordered from the manufacturer (part number
808-0232-02).

To install the BTS:

1. Remove the charge controller’s wiring compartment cover (see “Removing

the Wiring Compartment Cover” on page 2–6).
2. Remove a knockout from the back or either side of the charge controller, and
then install an appropriately-sized strain relief bushing for the BTS cable.

975-0540-01-01 F 2–23

This guide is for use by qualified personnel only.

Installation

3. Connect the ring terminal on the BTS directly to the negative battery terminal
or positive battery terminal, or use the adhesive backing on the sensor back
to attach the sensor to any side of the battery to be monitored. See
Figure 2-14.
If connecting to the battery terminal, make sure the BTS does not prevent the
power wiring from making the best possible contact with the battery terminal.
If using the adhesive backing, install the BTS on the side of the battery below
the electrolyte level. It is best to place the sensor between batteries and
place the batteries in an insulated box to reduce the influence of the ambient
temperature outside the battery enclosure.

Figure 2-14 Attaching the BTS to a battery terminal

WARNING
HAZARD OF ELECTRIC SHOCK
The BTS cable must not pass through the same conduit used for PV wiring and
battery cables.
Failure to follow these instructions can result in death or serious injury.

4. Pass the other end of the BTS cable through the knockout and strain relief
bushing on the charge controller, and then insert the BTS plug into the BTS
RJ-11 port. See Figure 2-15.

5. Replace the charge controller’s wiring compartment cover.

2–24 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Commissioning

Insert the BTS plug into

the charge controller’s
BTS port.

+ –

Attach the BTS to a

+
–
+
– battery terminal or to
the side of a battery.
+
–

Figure 2-15 Installing the BTS

Commissioning
Conext SCP
You must use the SCP to commission the charge controller. For information about
SCP navigation and menus, see the Conext MPPT 80 600 Solar Charge
Controller Operation Guide.

In place of the SCP, the Conext ComBox (ComBox) (Part Number 865-1055) can
also be used. The ComBox allows you to configure and monitor the charge
controller through a web interface on a PC or laptop. See the Conext ComBox
Owner’s Guide (Document Part Number 975-0679-01-01)

NOTE
You must use the SCP with firmware version 1.05.00 or higher for full compati-
bility with the charge controller. For information on updating your firmware,
contact customer service. The Conext Config Tool is required for upgrading.

Conext Config Tool

The Conext Config Tool (Part Number 865-1155) is a commissioning tool used for
configuring or upgrading a Conext system. The Config Tool is available to
installers only by request. Contact customer service for more information.

Before you begin, make sure you have all important system information such as
the nominal battery voltage, battery type, and battery bank capacity available.

975-0540-01-01 F 2–25

This guide is for use by qualified personnel only.

Installation

To commission one or more charge controllers:

1. “Setting the Device Number” on page 2–26

2. “Configuring Connections and Charger Settings” on page 2–27
3. If commissioning multiple charge controllers: “Copying Settings to Another
Charge Controller” on page 2–28
4. “Starting the Charge Controller” on page 2–29

When commissioning multiple charge controllers on the same Xanbus network,

make sure to set a unique device number and the correct battery connection.
The connection is important to define so that system totals and other related
information are displayed accurately.

Setting the Device Number

To set a device number for the charge controller:

1. Make sure an SCP is attached to the Xanbus network.

2. Close the DC disconnect. When a charge controller is powered up, it will
begin communicating with the SCP and be ready for configuration through
the SCP. Do not apply PV power at this point.
3. On the SCP System Status home screen, press Enter.
The Select Device menu opens.
4. Use the arrow buttons to scroll to the charge controller to configure, and then
press Enter. Each charge controller appears as XW MPPT80 xx, where xx is
its device number.
The Setup menu opens.
5. To display the Advanced Settings menu item press the Enter, up arrow,
and down arrow buttons simultaneously.

6. Press Enter to select Advanced Settings.

The Config menu opens.
7. Scroll to Multi Unit Config, and then press Enter.
The Multi menu opens. The LEDs on the charge controller you are
configuring will start to flash when you enter this menu, providing visual
confirmation of the charge controller you are configuring.
8. Scroll to Dev Number, and then press Enter. Scroll again to set it to a number
other than 00, and then press Enter to confirm the new device number.
The device number can be set to any number between 01 and 31. If you are
commissioning multiple charge controllers, the manufacturer recommends
using 01 for the first charge controller.
9. Press Exit until the Select Device menu is displayed.

2–26 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Commissioning

The charge controller appears as XW MPPT80 xx on the menu, where xx is the

device number you selected.
10. Repeat steps 3 through 9 if you are commissioning multiple charge controllers.

Configuring Connections and Charger Settings

WARNING
HAZARD OF FIRE AND EXPLOSION
Battery charging settings must be configured by qualified personnel in
accordance with the battery manufacturer's recommended charging
instructions.
This section covers basic default settings. See the Conext MPPT 80 600 Solar
Charge Controller Operation Guide for additional configuration information
and details including setting descriptions and value ranges.
Failure to follow these instructions can result in death or serious injury.

To configure connections and charger settings for a charge controller:

1. On the Select Device menu, select XW MPPT80 xx, where xx is the device
number.
The Setup menu opens.
2. Press Enter to select Advanced Settings.
The Config menu opens.
3. Scroll to Multi Unit Config, and then press Enter.
The Multi menu opens.
4. Scroll to Connections, and then press Enter.
The Conn menu opens.
5. Configure PV input (PV In) and DC output or the battery bank (DC Conn). If the
system only has one battery bank, leave DC Conn at the default setting. The PV In
setting allows you to differentiate which array is going to which charge controller.
This setting is used for status reporting only, not for any internal controls. Setting PV
In to a non-default value is optional.
6. Press Exit until the Config menu is displayed.
7. Scroll to Charger Settings, and then press Enter.
The Chgr menu opens.
8. Set the battery type (Batt Type), battery capacity (Batt Capacity), and any
other charger settings required for your system. If you select Custom for the battery
type, you can further configure bulk, absorption, float, and other settings for the
charge cycle in the Custom Settings menu that appears.
9. While in the Chgr menu, make sure the nominal battery voltage (Batt Voltage) is
set correctly. The default value is 48 V. If your system is a 24 V battery system, then
change it to 24 V.
10. Press Exit until the Select Device menu is displayed.

975-0540-01-01 F 2–27

This guide is for use by qualified personnel only.

Installation

Copying Settings to Another Charge Controller

WARNING
HAZARD OF FIRE AND EXPLOSION
• Do not copy settings from one charge controller to another unless the
battery banks are identical: same size, type, and so on.
• See the Conext MPPT 80 600 Solar Charge Controller Operation Guide for
additional configuration information and details including setting
descriptions and value ranges.
Failure to follow these instructions will result in death or serious injury.

Settings that are copied from one charge controller to another are:

• Batt Type
• Batt Capacity
• Max Chg Rate
• Charge Cycle
• ReCharge Volts
• Absorb Time
• Default Batt Temp
• Batt Voltage
• DC Conn
• Custom battery settings (if Custom battery type selected) including Eqlz
Support, Eqlz Voltage, Bulk Voltage, Absorb Voltage, Float
Voltage, and BattTempComp.
If you are commissioning multiple charge controllers, follow these steps to copy
the settings from the configured charge controller to the other charge controllers:

1. On the Select Device menu, select the next charge controller for
configuration.
The Setup menu opens.
2. Press Enter to select Advanced Settings.
The Config menu opens.
3. Scroll to Copy from, and then press Enter to select the charge controller
from which you want to copy. Scroll to select the charge controller with the
device number that matches the first charge controller you configured, and
then press Enter again.
The settings are automatically copied from the selected charge controller.

2–28 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Commissioning

NOTE
The Copy from command will not give you any indication that it has
completed its task. To check that the charger settings have been copied
properly, view some of the settings you originally configured.

4. Repeat steps 1 to 3 for the remaining charge controllers.

5. After you have finished configuring, press the Enter, up arrow, and down
arrow buttons simultaneously to hide the Advanced Settings menu item.

Starting the Charge Controller

To start the charge controller:

1. Turn on the charge controller battery breaker.

2. Close the PV array disconnect switch.

If the PV array voltage exceeds the minimum start voltage, the charge controller
begins charging and the On/Charging LED starts flashing.

If the PV array voltage is not above the start voltage, the charge controller is
powered but not charging. The On/Charging LED stays solid green.

975-0540-01-01 F 2–29

This guide is for use by qualified personnel only.

2–30
3 Troubleshooting

Chapter 3 provides information about

identifying and resolving problems that might
arise while using the charge controller.
It includes:
• Charge Controller Troubleshooting
• Replacing the Ground Fault Protection Fuse
• Ground Faults in a Normally Ungrounded
Array

975-0540-01-01 F 3–1

This guide is for use by qualified personnel only.

Troubleshooting

Charge Controller Troubleshooting

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS, FIRE, AND EXPLOSION
This chapter includes hazardous tasks that must be performed only by
qualified personnel equipped with appropriate personal protective equipment
and following safe electrical work practices. Review the “Important Safety
Instructions” beginning on page v before proceeding.
Failure to follow these instructions will result in death or serious injury.

Table 3-1 lists possible problems that could arise with the charge controller.

Table 3-1 Charge controller problems

Problem Possible Cause Solution

Uneven output current A. PV arrays are supplying different A. Check array output, but consider
between multiple amounts of current to each charge that this could be a normal operating
charge controllers. controller. condition if the arrays are located in
different locations or point in different
directions.
B. Charging set points are not all set B. Set charge controllers to the same
the same. settings.
C. Excess voltage drop in wiring is C. Check wiring. Upgrading or
causing charge controllers to measure shortening the wire run might be
the battery voltage differently and required.
regulate accordingly.
D. Charge controllers are in constant D. No need to intervene as this is a
voltage (absorption) mode and normal operating condition.
therefore are limiting their output
current to maintain the present battery
voltage. In this situation, some charge
controllers will produce more output
current than others.
The SCP LCD shows a A ground fault has caused the ground See “Replacing the Ground Fault
ground fault and the fault protection fuse to blow, or a Protection Fuse” on page 3–4 or
charge controller has normally ungrounded array contains a “Ground Faults in a Normally
stopped operating. ground fault. Ungrounded Array” on page 3–5.

3–2 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Charge Controller Troubleshooting

Table 3-1 Charge controller problems

Problem Possible Cause Solution

The charge An active fault, error, or warning is See “Viewing Active Faults, Errors,
controller’s Error/ present on the charge controller. and Warnings” in the Conext MPPT 80
Warning (red) LED is 600 Solar Charge Controller Operation
on or flashing. Guide to determine which alarm is
active on the charge controller. The
tables in this section provide detailed
information on why various alarms
could be occurring on the charge
controller.
The charge A ground fault has caused the ground See “Replacing the Ground Fault
controller’s Error/ fault protection fuse to blow, or a Protection Fuse” on page 3–4 or
Warning (red) LED is normally ungrounded array contains a “Ground Faults in a Normally
on, and the SCP ground fault. Ungrounded Array” on page 3–5.
indicates a ground
fault (F56) for the
charge controller.
The charge A. The default configuration for the A. Use the SCP to configure the
controller’s Error/ charge controller is a 48 V battery charge controller for 24 V operation.
Warning (red) LED is bank, and you have installed the See “Configuring Battery
on, and the SCP charge controller on a 24 V battery Characteristics and Battery Charging”
indicates an output bank. in the Conext MPPT 80 600 Solar
under voltage error Charge Controller Operation Guide for
(F11) for the charge more information.
controller.
B. The batteries are dead or B. Check the battery voltage to see if
undercharged. the batteries are within operating
specifications. If necessary, replace
them with new batteries, or use a
device capable of performing dead
battery charging.
The charge controller A. Network terminators have not been A. Install a terminator at each far end
does not show up on installed at both ends of the Xanbus of the network. See “Network
the SCP or it drops off network. Components” on page 2–20 for more
the network information.
periodically.
B. The total network length exceeds B. See “Network Layout” on
the maximum length specification. page 2–21 for specifications.
The charge controller A. No PV input voltage. A. Change the PV disconnect switch
does not produce any from the off position to the on position.
power.
B. PV input voltage is not within B. Make sure that the PV panels are
operating range. configured to provide voltages within
the charge controller’s operating
voltage window.

975-0540-01-01 F 3–3

This guide is for use by qualified personnel only.

Troubleshooting

Table 3-1 Charge controller problems

Problem Possible Cause Solution

All of the charge A. No battery connection to the charge A. Change the battery disconnect from
controller’s LEDs are controller. the off position to the on position.
off and the charge
controller does not B. The charge controller is wired B. Check all connections and correct
show up on the SCP. incorrectly. the wiring if voltage is not present on
the charge controller’s battery
terminals.

C. If you have verified there is at least

C. Failed charge controller. 20 V present on the charge controller’s
battery terminals yet the On/Charging
(green) LED remains off, contact
customer service.
The charge The charge controller is outputting No problem. This is intended
controller’s On/ charge current. operation. See “Viewing Status
Charging (green) LED Information on the Conext MPPT 80
is flashing. 600” in the Conext MPPT 80 600 Solar
Charge Controller Operation Guide for
LED status information.

Replacing the Ground Fault Protection Fuse

DANGER
HAZARD OF ELECTRIC SHOCK
If a ground fault is indicated, normally grounded PV conductors could be
ungrounded and energized. Before working on any portion of the array or
wiring, make sure that portion of the array is de-energized by blanketing, use
of disconnects, or other safe working procedures and by testing for voltage
before beginning work.
Failure to follow these instructions will result in death or serious injury.

The ground fault protection fuse blows when a significant leakage current flows
between the PV array and earth ground or when the system has been installed
with deficient wiring. Before replacing the fuse, it is important to have qualified
service personnel, such as a certified electrician or technician, determine the
cause of the ground fault and effect repair.

To replace the ground fault protection fuse:

1. Make sure the PV and battery disconnect switches are open and the charge
controller is de-energized.
2. Remove the wiring compartment cover, as described on page 2–6.
The ground fault protection fuse is located behind the wiring terminals.

3–4 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Ground Faults in a Normally Ungrounded Array

3. Remove the blown fuse and replace it with a new AC/DC midget cartridge,
DC-rated 600 VDC, 1 A (Littelfuse KLKD 1 or equivalent). Be careful not to
damage the fuse clips, circuit board, and surrounding components.
4. Replace the wiring compartment cover.
5. Clear the fault and reset the system by removing and then reapplying both
PV and battery power.

Ground Faults in a Normally Ungrounded Array

DANGER
HAZARD OF ELECTRIC SHOCK
Before working on any portion of the array or wiring, make sure that portion of
the array is de-energized by blanketing, use of disconnects, or other safe
working procedures and by testing for voltage before beginning work.
Failure to follow these instructions will result in death or serious injury.

On a normally ungrounded (floating) array, the ground fault protection system

indicates a fault when a short circuit or lower than normal resistance exists
between the array and ground. Before resetting the fault and attempting to restart
the system, it is important to have qualified service personnel, such as a certified
electrician or technician, determine the cause of the ground fault and effect
repair.

To mitigate a ground fault in a normally ungrounded array:

1. Make sure the PV and battery disconnect switches are open and the charge
controller is de-energized.
2. Search or troubleshoot for a ground fault on the PV array (for example, a
broken PV panel or pinched PV wire).
3. Clear the fault and reset the system by removing and then reapplying both
PV and battery power.

975-0540-01-01 F 3–5

This guide is for use by qualified personnel only.

3–6
A Specifications

Appendix A provides the specifications for the

charge controller.
It includes:
• Electrical Specifications
• Default Battery Charger Settings
• Mechanical Specifications
• Accessories
• Regulatory Approvals
All specifications are subject to change without
notice.

975-0540-01-01 F A–1

This guide is for use by qualified personnel only.

Specifications

Electrical Specifications
Maximum PV Array Open Circuit Voltage 600 VDC
PV Array Voltage Operating Range 195 to 550 VDC
a
PV Array Voltage Full Power Range 230 to 550 VDC
Maximum Power Point Tracking Range 195 to 510 VDC
PV Input Start Voltage 230 VDC
Maximum Operating Current 23 A
Maximum Array Short Circuit Current at STC 28 A
Absolute Maximum Array Short Circuit Current 35 A
Under Any Conditions (See the Notice on the next page for more
information)
Nominal Battery Voltages 24 and 48 VDC (Default is 48 V)
Battery Voltage Operating Range 16 to 67 VDC
Maximum Charging Current 80 A
Maximum Charging Power 2560 W (nominal 24 V battery bank)
4800 W (nominal 48 V battery bank)
Maximum Power Conversion Efficiency 94% (nominal 24 V battery bank)
96% (nominal 48 V battery bank)
Auxiliary Output Dry contact switching up to 60 VDC, 30 VAC, 8 A
Charger Regulation Method Three stage (bulk, absorption, float)
Two stage (bulk, absorption)
Manual equalization
Tare Lossesb Less than 1.0 W (Xanbus power supply on)
Less than 0.5 W (Xanbus power supply off)
a.Full power output below 230 V is not assured. See “Operating Below the PV Array Voltage Full Power Range” on
page A–3 for more information.
b.These values are based on the following specifications:
- The battery voltage is 48 V.
- The auxiliary power supply is shut off at night. See “Disabling Power Supplies at Night” in the Conext MPPT 80 600 Solar
Charge Controller Operation Guide for more information.

A–2 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Electrical Specifications

NOTE
• PV array voltages often exceed STC voltage specifications, especially
when the array is cold. A voltage temperature correction factor based on
the local code (i.e., NEC 690 or CEC Section 50), ambient temperature
conditions, and module manufacturer specifications must be applied to the
array STC VOC to keep array voltage within specifications listed above.
• PV array current might exceed STC current specifications, especially under
intense sunlight, certain atmospheric conditions, or from reflections (i.e,
water, snow, or ice). Local codes typically apply a multiplier to the PV array
Isc to determine “maximum current” for design purposes. The “Absolute
Maximum Array Short Circuit Current” specification above includes the
125% multiplier required by the NEC and the CEC. Accordingly, the PV
array STC Isc cannot exceed 28 A.

MPPT Voltage Range

The charge controller’s Maximum Power Point Tracking (MPPT) algorithm
maximizes the output energy of PV arrays as long as the operating voltage is
within the MPPT operational window. Make sure that the PV arrays used in the
system operate within the MPPT operational window. The operational window is
shown below.

Min. Operating Voltage Min. Starting Voltage Max. Operating Voltage

Note:
Max VOC 600 V
Input current limit 35 A (array Isc including 125% code multiplier)
Output current limit 80 A
Figure A-1 MPPT operational window

Operating Below the PV Array Voltage Full Power Range

When the charge controller is operating on a 48 V battery bank and a PV array
where the MPP is below 230 V, full output power is not assured. Figure A-2 and
Figure A-3 show the maximum output current and maximum output power that
can be produced when the charge controller is operating below 230 V. The
actual amount of current and power that your charge controller can produce
below 230 V will depend on the actual battery voltage and the amount of solar
power available from your panels. Full output current is available on 24 V battery
systems across the entire input voltage operating range.

975-0540-01-01 F A–3

This guide is for use by qualified personnel only.

Specifications

90

80

70

60

Output 50
Current BatteryVoltage=54V
(Amps) 40 BatteryVoltage=58V
Battery Voltage 64V
BatteryVoltage=64V

30

20

10

0
195 200 205 210 215 220 225 230 235 240
InputVoltage(Volts)

Figure A-2 Maximum expected output current versus input voltage

5000

4500

4000

3500

3000
Output
O
Power 2500
BatteryVoltage=54V
(Watts)
2000 BatteryVoltage=58V
BatteryVoltage=64V
1500

1000

500

0
195 200 205 210 215 220 225 230 235 240

InputVoltage(Volts)

Figure A-3 Maximum expected output power versus input voltage

A–4 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Default Battery Charger Settings

Default Battery Charger Settings

All settings in the following table are based on a 48 V nominal battery bank. For a
24 V nominal battery bank, divide the voltage values in this table by two.

Battery Type
Setting Floodeda Gel AGM
Equalize Voltage 64.0 V n/a n/a
ReCharge Voltage 50.0 V 50.0 V 50.0 V
Bulk Voltage 57.6 V 56.8 V 57.2 V
Absorption Voltage 57.6 V 56.8 V 57.2 V
Float Voltage 54.0 V 55.2 V 53.6 V
Absorption Time 360 min 360 min 360 min
Batt Temp Comp -108 mV/C -108 mV/C -84 mV/C
a.When Custom is selected for the battery type, the default settings are
based on the flooded battery type.

The Custom Settings menu item allows you to adjust charging and
equalization voltage for lithium ion and other specialty batteries whose
specifications fall outside of the default settings for the battery types that the
charge controller offers. For more information, see the Conext MPPT 80 600 Solar
Charge Controller Operation Guide.

Mechanical Specifications

Enclosure Type IP20, indoor, ventilated, aluminum sheet metal chassis with 7/8" and
1" (22.22 mm and 27.76 mm) knockouts and aluminum heat sink
Maximum and Minimum Wire Size #6 AWG to #14 AWG (13.5 to 2.5 mm2)
in Conduit
Maximum and Minimum Wire Size #6 AWG to #14 AWG (13.5 to 2.5 mm2)
Rating of PV Terminal Block
Maximum and Minimum Wire Size #2 AWG to #14 AWG (35 to 2.5 mm2)
Rating of Battery Terminal Block
Wire Size Rating of Auxiliary #16 AWG (1.5 mm2)
Output Connector
Operating Temperature Range -20 to +65°C (-4 to 149 °F)
(derate above 45°C) (output power to be derated linearly to zero at 65°C)
Pollution degree 2
Over voltage category CAT II
Storage Temperature -40 to +85°C (-40 to 185°F)

975-0540-01-01 F A–5

This guide is for use by qualified personnel only.

Specifications

Altitude Limit (operating) Sea level to 6,500 feet (approximately 2000 m)

Unit Dimensions (H × W × D) 30 × 8 5/8 × 8 5/8" (760 × 220 × 220 mm)
Mounting Vertical wall mount
Weight (charge controller only) 29.8 lb (13.5 kg)
Weight (shipping) 45 lb (20.4 kg)

Accessories
The SCP (Part Number 865-1050-01) is required for installation of the charge
controller and is strongly recommended for ongoing operation.

As the primary interface to the charge controller, the SCP is used for setup and
configuration. Once installation is complete, you can use the SCP for monitoring
and fault reporting. Only one SCP is required to monitor multiple charge
controllers.

In place of the SCP, the Conext ComBox (ComBox) (Part Number 865-1055) can
also be used. The ComBox allows you to configure and monitor the charge
controller through a web interface on a PC or laptop. See the Conext ComBox
Owner’s Guide (Document Part Number 975-0679-01-01)

NOTE
You must use the SCP with firmware version 1.05.00 or higher for full
compatibility with the charge controller. For information on updating your
firmware, contact customer service. To upgrade, use either the ComBox or
Conext Config Tool.

Conext Config Tool

The Conext Config Tool (Part Number 865-1155-01) is a commissioning tool used
for configuring or upgrading a Conext system.

A–6 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Regulatory Approvals

Regulatory Approvals
Certified to UL 1741 and to CSA 107.1 and carries the c(CSA)us mark.

EMC - North America:

• FCC Part-15 sub part B, Class B

• Industry Canada ICES-003, Class B

CE Marked and complies with the following:

Low Voltage Directive 2006/95/EC, per:

• EN50178 Electronic Equipment for Use in Power Installations.
EMC Directive 2004/108/EC, per:
• EN61000-6-3 Emission standard for residential, commercial, and light-
industrial environments
• EN61000-6-1 Immunity for residential, commercial, and light-industrial
environments

Australia:

• C-tick marked

975-0540-01-01 F A–7

This guide is for use by qualified personnel only.

A–8
Index

A connections 2–27
abbreviations iv connecting
accessories A–6 multiple PV array strings 2–17
acronyms iv multiple units 2–18
auxiliary output network cables between multiple units 2–21
connections 2–19 single unit, floating system 2–15
vent fan application 2–19 single unit, negative-grounded system 2–14
single unit, positive-grounded system 2–15
B connections, auxiliary output 2–19
batteries copying settings 2–28
charging current 1–3 current rating 2–12
default charger settings A–5
over-current protection 2–13 D
requirements 1–2 DC terminal connector locations 2–11
safety information ix device number, setting 2–26
sealed 2–4 disconnecting the unit 2–20
battery temperature sensor
attaching to battery terminal 2–24 E
installation diagram 2–25 electrical specifications A–2
installing 2–23
overview 2–23 F
Fast Sweep 1–2
C FCC information x
cables, network 2–20 features 1–2
charge controlling floating PV system 2–10
charging current 1–3 fuse holders, ground fault protection 2–10
overview 1–3 fuses, replacing 3–4
three-stage 1–3
two-stage 1–3 G
charger settings ground fault protection 3–4
configuring 2–27 fuse holders 2–10
default A–5 normally ungrounded array 3–5
chassis grounding 2–10 overview 2–10
clearance requirements 2–5 replacing fuse 3–4
ComBox. See Conext ComBox grounding
commissioning chassis 2–10
charger settings 2–27 PV. See PV grounding
connections 2–27
copying settings 2–28
I
multiple units 2–26
installing battery temperature sensor 2–23
overview 2–25
interference, radio and television reception x
setting device number 2–26
Conext ComBox 1–2
configuring K
knockouts
charger settings 2–27
dimensions 2–8

975-0540-01-01 F IX-1

This guide is for use by qualified personnel only.

Index

locations 2–8 PV array

overview 2–7 requirements 2–3
removing 2–7 PV disconnect switch 2–13
PV grounding
L floating 2–10
Lexan barrier 2–6 negative 2–10
limitations on use vii overview 2–10
location positive 2–10
choosing 2–4 ungrounded 2–10
minimum clearance requirements 2–5 PV input current rating 2–12

M Q
maximum power point tracking voltage range A–3 qualified personnel, requirements iii
mechanical specifications A–5
minimum R
clearance requirements 2–5 radio reception interference x
wire gauge 2–12 reception interference x
mounting regulatory approvals A–7
instructions 2–9 removing
orientation 2–4 knockouts 2–7
MPPT voltage range A–3 wiring compartment cover 2–6
multiple PV array strings 2–17 replacing the fuse 3–4
multiple units requirements, PV array 2–3
commissioning 2–26 reverse polarity damage 2–14
connecting 2–18
connecting network cables 2–21 S
copying settings 2–28 safety information
DC wiring diagram 2–18 batteries ix
sealed batteries, mounting with 2–4
N specifications
negative-grounded PV system 2–10 electrical A–2
network mechanical A–5
cables 2–20
components 2–20 T
diagram 2–21 television reception interference x
installation 2–20 terminators, network 2–20
layout 2–21 three-stage charge controlling 1–3
terminators 2–20 troubleshooting 3–2
normally ungrounded array, ground fault protection two-stage charge controlling 1–3
3–5
U
O ungrounded PV system 2–10
over-current protection
battery circuit 2–13 W
PV 2–13 wire gauge, minimum 2–12
requirements 2–12 wiring
DC terminal connector locations 2–11
P diagram 2–16
positive-grounded PV system 2–10 wiring compartment
power supply, Xanbus 2–20 Lexan barrier 2–6

IX–2 975-0540-01-01 F

This guide is for use by qualified personnel only.

 Index

removing cover 2–6

X
Xanbus
overview 2–20
power supply 2–20

975-0540-01-01 F IX–3

This guide is for use by qualified personnel only.

Index

IX–4 975-0540-01-01 F

This guide is for use by qualified personnel only.

Schneider Electric
http://solar.schneider-electric.com

As standards, specifications, and designs

change from time to time, please ask for
confirmation of the information given in this
publication.

© 2015 Schneider Electric. All rights reserved.

975-0540-01-01 Rev
975-0540-01-01 F F Printed in India